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Kawasaki Ninja 650 Service Manual

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Ninja 650
Ninja 650 ABS
ER-6f
ER-6f ABS
Motorcycle
Service Manual

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  Summary of Contents for Kawasaki Ninja 650

  • Page 1 Ninja 650 Ninja 650 ABS ER-6f ER-6f ABS Motorcycle Service Manual...
  • Page 3 Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 5 All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan.
  • Page 6 LIST OF ABBREVIATIONS ampere(s) Kawasaki Diagnostic System ABDC after bottom dead center km/h kilometers per hour alternating current liter(s) ampere hour pound(s) ATDC after top dead center Liquid Crystal Display BBDC before bottom dead center Light Emitting Diode bottom dead center...
  • Page 7: Emission Control Information

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi-...
  • Page 8 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
  • Page 9: How To Use This Manual

    Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. • venient operation. Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and • Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 11 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................1-10 Unit Conversion Table ......................1-13...
  • Page 12: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 13: General Information

    Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.
  • Page 14 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.
  • Page 15 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 16 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.
  • Page 17: Model Identification

    GENERAL INFORMATION 1-7 Model Identification EX650EC (EUR Models) Left Side View EX650EC (EUR Models) Right Side View...
  • Page 18 1-8 GENERAL INFORMATION Model Identification EX650EC (US, CA and CAL Models) Left Side View EX650EC (US, CA and CAL Models) Right Side View...
  • Page 19 GENERAL INFORMATION 1-9 Model Identification EX650FC Left Side View EX650FC Right Side View Frame Number Engine Number...
  • Page 20: General Specifications

    1-10 GENERAL INFORMATION General Specifications Items EX650EC/FC Dimensions Overall Length 2 110 mm (83.07 in.) Overall Width 770 mm (30.3 in.) Overall Height 1 180 mm (46.46 in.) Wheelbase 1 410 mm (55.51 in.) Road Clearance 130 mm (5.12 in.) Seat Height 805 mm (31.7 in.) Curb Mass:...
  • Page 21 GENERAL INFORMATION 1-11 General Specifications Items EX650EC/FC Valve Timing: Intake: Open 31° BTDC Close 61° ABDC Duration 272° Exhaust: Open 50° BBDC Close 30° ATDC Duration 260° Lubrication System Forced lubrication (semi-dry sump) Engine Oil: Grade API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity...
  • Page 22 1-12 GENERAL INFORMATION General Specifications Items EX650EC/FC Front Suspension: Type Telescopic fork Wheel Travel 125 mm (4.92 in.) Rear Suspension: Type Swingarm Wheel Travel 130 mm (5.12 in.) Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 10 Ah Headlight: Type Semi-sealed beam...
  • Page 23: Unit Conversion Table

    GENERAL INFORMATION 1-13 Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 N·m ×...
  • Page 25: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-12 Special Tools .......................... 2-14 Periodic Maintenance Procedures..................2-15 Fuel System (DFI)........................ 2-15 Throttle Control System Inspection................... 2-15 Engine Vacuum Synchronization Inspection..............2-15 Idle Speed Inspection .......................
  • Page 26 2-2 PERIODIC MAINTENANCE Headlight Aiming Inspection ..................... 2-41 Sidestand Switch Operation Inspection ................2-42 Engine Stop Switch Operation Inspection................. 2-43 Others ..........................2-44 Chassis Parts Lubrication ....................2-44 Bolts, Nuts and Fasteners Tightness Inspection............... 2-45 Replacement Parts ......................2-46 Air Cleaner Element Replacement..................2-46 Fuel Hose Replacement ....................
  • Page 27: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection FREQUENCY * ODOMETER READING Whichever ×...
  • Page 28 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY * ODOMETER READING Whichever × 1 000 km comes first (× 1 000 mile) Page (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) ITEM Every Final Drive Drive chain lubrication condition Every 600 km (400 mile) 2-28 - inspect # Drive chain slack - inspect #...
  • Page 29 PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY * ODOMETER Whichever READING comes × 1 000 km first (× 1 000 mile) Page (0.6) (7.5) (15) (22.5) (30) ITEM Every Air cleaner element # - replace every 18 000 km (11 250 mile) 2-46 •...
  • Page 30: Torque And Locking Agent

    2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. EO: Apply engine oil.
  • Page 31 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Rear Camshaft Chain Guide Bolt Throttle Body Assy Holder Bolts 106 in·lb Cylinder Bolt (M8) 27.5 MO, S Cylinder Nut MO, S Cylinder Bolts (M6) 106 in·lb L, S Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolts...
  • Page 32 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Ground Lead Terminal Bolt 87 in·lb Crankshaft/Transmission Breather Plate Bolts 87 in·lb Race Holder Screw 0.50 43 in·lb Connecting Rod Big End Nuts see Text ← ←...
  • Page 33 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Sprocket Cover Bolts 87 in·lb Brakes Caliper Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Brake Disc Mounting Bolts...
  • Page 34 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Sidestand Switch Bolt 0.90 78 in·lb Windshield Mounting Bolts 0.43 37 in·lb Upper Saree Guard Mounting Bolts (IN Model) Lower Saree Guard Mounting Bolt (IN Model) Saree Guard Bracket Bolts (IN Model) Electrical System License Plate Light Mounting Screws 0.12...
  • Page 35 PERIODIC MAINTENANCE 2-11 Torque and Locking Agent The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.
  • Page 36: Specifications

    2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 1 300 ±50 r/min (rpm) – – – 0 ∼ 2 1/2 (for reference) Bypass Screws (Turn out) –...
  • Page 37 PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Final Drive 25 ∼ 35 mm (1.0 ∼ 1.4 in.) Drive Chain Slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Chain 20-link Length 323 mm (12.7 in.) Standard Chain: Make DAIDO –...
  • Page 38: Special Tools

    2-14 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers: Vacuum Gauge: 57001-143 57001-1369 Steering Stem Nut Wrench: Throttle Sensor Setting Adapter: 57001-1100 57001-1538 Jack: Extension Tube: 57001-1238 57001-1578 Oil Filter Wrench: Pilot Screw Adjuster, E: 57001-1249 57001-1603...
  • Page 39: Periodic Maintenance Procedures

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Fuel System (DFI) Throttle Control System Inspection • Check that the throttle grip [A] moves smoothly from full open to close, and the throttle closes quickly and com- pletely by the return spring in all steering positions. If the throttle grip does not return properly, check the throt- tle cable routing, grip free play, and cable damage.
  • Page 40 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • For CAL, SEA-B1 and TH models, remove the tubes [A] from the fittings on the throttle body. • Connect a vacuum gauge (special tool) and hoses [A] to the fittings on the throttle body. Special Tool - Vacuum Gauge: 57001-1369 •...
  • Page 41 PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures If any one vacuum is not within the specification, turn in the bypass screws until it seats fully but not tightly. Special Tool - Pilot Screw Adjuster, E [A]: 57001-1603 NOTICE Do not over tighten them. They could be damaged, requiring replacement.
  • Page 42: Idle Speed Inspection

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Disconnect: Fuel Pump Lead Connector Extension Tube • Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter), take off the vacuum gauge hoses and install the rubber caps onto the fittings on the throttle body assy.
  • Page 43: Fuel Hose Inspection (Fuel Leak, Damage, Installation Condition)

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Fuel Hose Inspection (fuel leak, damage, installation condition) ○ If the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel Tank Re- moval in the Fuel System (DFI) chapter) and check the fuel hose.
  • Page 44: Evaporative Emission Control System Inspection (Cal, Sea-B1 And Th Models)

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Evaporative Emission Control System Inspection (CAL, SEA-B1 and TH Models) • Inspect the canister as follows. ○ Remove: Left Frame Cover (see Frame Cover Removal in the Frame chapter) Canister Bracket Bolts [A] ○ Unhook the band [B] to remove the canister [C], and dis- connect the tubes [D] from the canister.
  • Page 45: Water Hose Damage And Installation Condition Inspection

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Water Hose Damage and Installation Condition Inspection ○ The high pressure inside the water hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. • Visually inspect the hoses for signs of deterioration.
  • Page 46: Valve Clearance Adjustment

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Using the thickness gauge [A], measure the valve clear- ance between cam and valve lifter. Valve Clearance Standard: Exhaust 0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.) 0.15 ∼ 0.21 mm (0.0059 ∼ 0.0083 in.) Intake ○...
  • Page 47 PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INTAKE VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm.
  • Page 48 2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm.
  • Page 49: Air Suction System Damage Inspection

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Air Suction System Damage Inspection • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) • Take the air switching valve hose end [A] outside of the frame [B].
  • Page 50: Wheels/Tires

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch the engine or exhaust pipe during clutch adjustment. • Turn the adjuster [A] so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) [B] of threads are visible.
  • Page 51: Wheel/Tire Damage Inspection

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Wheel/Tire Damage Inspection • Remove any imbedded stones [A] or other foreign parti- cles [B] from tread. • Visually inspect the tire for cracks and cuts, and replace the tire if necessary. Swelling or high spots indicate inter- nal damage, requiring tire replacement.
  • Page 52: Wheel Bearing Damage Inspection

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel Bearing Damage Inspection • Raise the front wheel off the ground with the jack. Special Tool - Jack: 57001-1238 • Turn the handlebar all the way to the right or left. • Inspect the roughness of the front wheel bearing by push- ing and pulling [A] the wheel.
  • Page 53: Drive Chain Slack Inspection

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures • Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the O-rings so that the O-rings will be coated with oil. •...
  • Page 54: Wheel Alignment Inspection

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. ○...
  • Page 55: Drive Chain Wear Inspection

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Drive Chain Wear Inspection • Remove the chain cover (see Swingarm Removal in the Suspension chapter). • Rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain.
  • Page 56: Brake System

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake System Brake Fluid Leak (Brake Hose and Pipe) Inspection • For models equipped with an ABS, remove the right swingarm bracket (see ABS Hydraulic Unit Removal in the Brakes chapter). • Apply the brake lever or pedal, and inspect the brake fluid leak from the brake hoses [A], pipes (ABS equipped mod- els) [B] and fittings [C].
  • Page 57: Brake Fluid Level Inspection

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Brake Fluid Level Inspection • Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE ○ Hold the reservoir horizontal by turning the handlebar when checking brake fluid level.
  • Page 58: Brake Pad Wear Inspection

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Pad Wear Inspection • Check the lining thickness [A] of the pads in each caliper. Pad Lining Thickness Standard: Front [C] 4.5 mm (0.18 in.) Rear [D] 5.0 mm (0.20 in.) Service Limit: 1 mm (0.04 in.) If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set.
  • Page 59: Suspensions

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures If it does not go on, inspect or replace the following items. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Brake Light (see Tail/Brake Light (LED) Unit Removal in the Electrical System chapter) Main Fuse 30 A and Brake/Horn Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Front Brake Light Switch [A] (see Switch Inspection in...
  • Page 60: Rear Shock Absorber Oil Leak Inspection

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Shock Absorber Oil Leak Inspection • Visually inspect the shock absorber [A] for oil leakage. If the oil leakage is found on it, replace the shock absorber with a new one. Steering System Steering Play Inspection •...
  • Page 61 PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures • Bend the claws [A] of the claw washer straighten. • Remove the steering stem locknut [B] and claw washer. Special Tool - Steering Stem Nut Wrench: 57001-1100 • Adjust the steering. Special Tool - Steering Stem Nut Wrench [A]: 57001-1100 If the steering is too tight, loosen the stem nut [B] a fraction of a turn.
  • Page 62: Steering Stem Bearing Lubrication

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Stem Bearing Lubrication • Remove the steering stem (see Stem, Stem Bearing Re- moval in the Steering chapter). • Using a high flash-point solvent, wash the upper and lower ball bearings [A] in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt.
  • Page 63: Electrical System

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step • Set the gear position in the neutral position. • Turn the ignition switch to ON. • The following lights should go on according to the table below.
  • Page 64 2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures ECU (see ECU Power Supply Inspection in the Fuel Sys- tem (DFI) chapter) Ignition Switch (see Switch Inspection in the Electrical System chapter) Neutral Switch (see Switch Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter) •...
  • Page 65: Headlight Aiming Inspection

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Fourth Step • Set the dimmer switch [A] to low beam position. • Start the engine. • The low beam headlight should go on. If the low beam headlight does not go on, inspect or re- place the following item.
  • Page 66: Sidestand Switch Operation Inspection

    2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Headlight Beam Vertical Adjustment • Turn the vertical adjuster [A] on the headlight in or out to adjust the headlight vertically. NOTE ○ On high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated.
  • Page 67: Engine Stop Switch Operation Inspection

    PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures If the sidestand switch operation does not work, inspect or replace the following item. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Ignition Fuse 10 A (see Fuse Inspection in the Electrical System chapter)
  • Page 68: Others

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Others Chassis Parts Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○...
  • Page 69: Bolts, Nuts And Fasteners Tightness Inspection

    PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures Bolts, Nuts and Fasteners Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).
  • Page 70: Replacement Parts

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Replacement Parts Air Cleaner Element Replacement NOTE ○ In dusty areas, the element should be replaced more frequently than the recommended interval. WARNING If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident.
  • Page 71: Fuel Hose Replacement

    Install a new element so that the screen side faces up- ward. NOTICE Use only the recommended air cleaner element (Kawasaki part number 11013-0713). Using another air cleaner element will wear the engine prema- turely or lower the engine performance. •...
  • Page 72: Coolant Change

    2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Turn [A] the driver to unlock the joint lock [B]. • Pull the fuel hose joint [C] out of the delivery pipe. WARNING Fuel is flammable and explosive under certain con- ditions and can cause severe burns. Be prepared for fuel spillage;...
  • Page 73 PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures • Place a container under the water pump drain bolt [A], then remove the drain bolt. • Remove the radiator cap [A] in two steps. First turn the cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap.
  • Page 74: Radiator Hose And O-Ring Replacement

    2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Fill the reserve tank up to the “F” (full) level line [A] with coolant and install the cap [B]. • Start the engine, warm it up thoroughly until the radiator fan turns on, and then stop the engine. •...
  • Page 75: Oil Filter Replacement

    PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures • Place the oil pan beneath the engine. • Remove the engine oil drain plug [A] to drain the oil. ○ The oil in the oil filter can be drained by removing the filter (see Oil Filter Replacement).
  • Page 76: Brake Hose And Pipe Replacement

    2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the filter with a new one. • Apply grease to the O-ring [A] before installation. • Tighten the filter with the oil filter wrench. Torque - Oil Filter: 17.5 N·m (1.8 kgf·m, 13 ft·lb) NOTE ○...
  • Page 77 PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures • For models equipped with an ABS, note the following. NOTE ○ When removing the brake pipes and hoses on the hy- draulic unit, remove them according to each assembly of the exploded view in the Brakes chapter. •...
  • Page 78: Brake Fluid Change

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Change NOTE ○ The procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is the same as for the front brake. • Level the brake fluid reservoir. •...
  • Page 79: Master Cylinder Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). • Remove the reservoir cap and diaphragm, and pour the brake fluid into a container.
  • Page 80: Caliper Rubber Parts Replacement

    2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Apply brake fluid to the new parts and to the inner wall of the cylinder. • Take care not to scratch the piston or the inner wall of the cylinder. • Apply silicone grease to the brake lever pivot bolt and the push rod.
  • Page 81 PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures Front Caliper Assembly • Clean the caliper parts except for the pads. NOTICE For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • Install the bleed valve and rubber cap. Torque - Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) •...
  • Page 82 2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Using compressed air, remove the piston. ○ Cover the piston area with a clean, thick cloth [A]. ○ Blow compressed air [B] into the hole for the banjo bolt to remove the piston. WARNING The piston in the brake caliper can crush hands and fingers.
  • Page 83: Spark Plug Replacement

    PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures • Apply brake fluid to the outside of the piston, and push it into the cylinder by hand. • Replace the friction boot [A] and dust cover [B] with new ones if they are damaged. •...
  • Page 85 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................3-10 DFI Parts Location........................3-15 Specifications ......................... 3-17 Special Tools and Sealant ...................... 3-19 DFI Servicing Precautions ...................... 3-21 DFI Servicing Precautions ....................3-21 Troubleshooting the DFI System .................... 3-23 Outline..........................
  • Page 86 3-2 FUEL SYSTEM (DFI) Subthrottle Sensor Input Voltage Inspection..............3-63 Subthrottle Sensor Output Voltage Inspection ..............3-64 Subthrottle Sensor Resistance Inspection ................ 3-66 Oxygen Sensor-not activated (Service Code 33) (Equipped Models) ........3-67 Oxygen Sensor Removal/Installation................3-67 Oxygen Sensor Inspection....................3-67 Stick Coils #1, #2: (Service Code 51, 52) ................
  • Page 87 FUEL SYSTEM (DFI) 3-3 Fuel Injector Resistance Inspection .................. 3-97 Fuel Injector Power Source Voltage Inspection ..............3-98 Fuel Injector Output Voltage Inspection ................3-99 Fuel Injector Fuel Line Inspection ..................3-100 Throttle Grip and Cables ......................3-102 Throttle Grip Free Play Inspection ..................3-102 Throttle Grip Free Play Adjustment...................
  • Page 88: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 89: Exploded View

    FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Cleaner Element Screw 0.12 11 in·lb Air Cleaner Housing Cover Screws 0.12 11 in·lb Intake Air Temperature Sensor Screw 0.12 11 in·lb Air Cleaner Housing Clamp Bolt 0.20 18 in·lb Timing Rotor Bolt...
  • Page 90 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 91 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Switch Housing Screws 0.36 31 in·lb Fuel Pump Bolts 87 in·lb L, S 3. Other than CAL, SEA-B1 and TH Models 4. CAL, SEA-B1 and TH Models 5. AU LAMS Model 6.
  • Page 92 3-8 FUEL SYSTEM (DFI) Exploded View CAL, SEA-B1 and TH Models...
  • Page 93 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Purge Valve Mounting Nut 0.71 62 in·lb 2. Canister 3. Purge Valve...
  • Page 94: Dfi System

    3-10 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 95 FUEL SYSTEM (DFI) 3-11 DFI System 1. ECU (Electronic Control Unit) 2. Battery 3. Fuel Tank 4. Fuel Pump 5. Pressure Regulator 6. Delivery Pipe 7. Intake Air Temperature Sensor 8. Subthrottle Valve 9. Air Cleaner Housing 10. Subthrottle Sensor 11.
  • Page 96 3-12 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 97 FUEL SYSTEM (DFI) 3-13 DFI System Part Name 1. ECU 2. Joint Connector B 3. Kawasaki Diagnostic System Connector 4. Fuel Pump 5. Frame Ground 1 6. Frame Ground 2 7. Battery 12 V 10 Ah 8. Main Fuse 30 A 9.
  • Page 98 3-14 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Subthrottle Valve Actuator: BK/O 23. Oxygen Sensor Heater (Equipped Models): 2. Subthrottle Valve Actuator: G/Y P/BK 3. Unused 24. Crankshaft Sensor (–): Y/BK 4. Oxygen Sensor (Equipped Models): BL/Y 25.
  • Page 99: Dfi Parts Location

    FUEL SYSTEM (DFI) 3-15 DFI Parts Location Ignition Switch [A] Relay Box [B] (ECU Main Relay, Radiator Fan Relay, Fuel Pump Relay) ECU [C] Intake Air Temperature Sensor [D] Vehicle-down Sensor [E] Fuse Box [F] (Oxygen Sensor Heater Fuse 10 A, Radia- tor Fan Fuse 15 A, ECU Fuse 15 A, Ignition Fuse 10 A) Intake Air Pressure Sensor [G] Subthrottle Sensor [A]...
  • Page 100 3-16 FUEL SYSTEM (DFI) DFI Parts Location Battery 12 V 10 Ah [A] Kawasaki Diagnostic System Connector [B] Crankshaft Sensor [A] Speed Sensor [A] Neutral Switch [B] Oxygen Sensor [A] (Equipped Models) Purge Valve [A] (CAL, SEA-B1 and TH Models)
  • Page 101: Specifications

    FUEL SYSTEM (DFI) 3-17 Specifications Item Standard Digital Fuel Injection System Idle Speed 1 300 ±50 r/min (rpm) Throttle Body Assy: Throttle Valve Dual throttle valve Bore 38 mm (1.5 in.) 0 ∼ 2 1/2 (for reference) Bypass Screws (Turn out) ECU (Electronic Control Unit): Make DENSO...
  • Page 102 3-18 FUEL SYSTEM (DFI) Specifications Item Standard with the sensor tilted 60 ∼ 70° or more: 0.65 ∼ 1.35 V Output Voltage with the sensor arrow mark pointed up: 3.55 ∼ 4.45 V Subthrottle Sensor: Non-adjustable and non-removable DC 4.75 ∼ 5.25 V Input Voltage DC 0.6 ∼...
  • Page 103: Special Tools And Sealant

    FUEL SYSTEM (DFI) 3-19 Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Peak Voltage Adapter: 57001-125 57001-1415 Fork Oil Level Gauge: Needle Adapter Set: 57001-1290 57001-1457 Vacuum Gauge: Throttle Sensor Setting Adapter: 57001-1369 57001-1538 Hand Tester: Fuel Pressure Gauge Adapter: 57001-1394 57001-1593 Throttle Sensor Setting Adapter #1:...
  • Page 104 3-20 FUEL SYSTEM (DFI) Special Tools and Sealant Oxygen Sensor Measuring Adapter: Liquid Gasket, TB1211: 57001-1682 56019-120 Measuring Adapter: 57001-1700...
  • Page 105: Dfi Servicing Precautions

    FUEL SYSTEM (DFI) 3-21 DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 106 3-22 FUEL SYSTEM (DFI) DFI Servicing Precautions ○ If the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see Fuel Tank Removal) and check the fuel hose [A].
  • Page 107: Troubleshooting The Dfi System

    FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System Outline When a problem occurs with DFI system, the yellow en- gine warning indicator light (LED) [A] goes on or blinks to alert the rider. In addition, the condition of the problem is stored in the memory of the ECU.
  • Page 108 (LED) goes off. But the service codes stored in memory of the ECU are not erased to preserve the problem history. The problem history can be referred using the KDS (Kawasaki Diagnostic System) when solv- ing unstable problems. When the motorcycle is down, the vehicle-down sensor operates and the ECU shuts off the fuel pump relay, fuel in- jectors and ignition system.
  • Page 109 FUEL SYSTEM (DFI) 3-25 Troubleshooting the DFI System ○ After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Sealant - Liquid Gasket, TB1211: 56019-120 • Always check battery condition before replacing the DFI parts.
  • Page 110 3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○ When checking a harness [A] for short circuit, open one end [B] and check the continuity between the other end [C] and ground [D]. If there is continuity, the harness has a short circuit to ground, and it must be repaired or re- placed.
  • Page 111: Inquiries To Rider

    FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.
  • Page 112 3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ □ □ Poor running very low idle speed, very high idle speed, rough idle speed at low speed □ battery voltage is low (charge the battery) □ spark plug loose (tighten it) □...
  • Page 113: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-29 DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system.
  • Page 114 3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Intake air pressure sensor trouble Inspect (see chapter 3).
  • Page 115 FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Water temperature sensor trouble Inspect (see chapter 3). Intake air temperature sensor trouble Inspect (see chapter 3). Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 2). Stick coil trouble Inspect (see chapter 16).
  • Page 116: Poor Running Or No Power At High Speed

    3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Poor Running or No Power at High Speed Symptoms or Possible Causes Actions Firing incorrect: Stick coil shorted or not in good contact Inspect or Reinstall (see chapter 16). Stick coil trouble Inspect (see chapter 16).
  • Page 117 FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Engine overheating - Water temperature sensor, (see Overheating of Troubleshooting Guide in crankshaft sensor or speed sensor trouble chapter 17) Air switching valve trouble Inspect and replace (see chapter 16). Air suction valve trouble Inspect and replace (see chapter 5).
  • Page 118: Self-Diagnosis

    3-34 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has 2 modes and can be switched to another mode by operating the meter unit. User Mode The ECU notifies the rider of troubles in DFI system and ignition system by lighting the yellow engine warning indi- cator light (LED) [A] when DFI and ignition system parts are faulty, and initiates fail-safe function.
  • Page 119 FUEL SYSTEM (DFI) 3-35 Self-Diagnosis • Turn the ignition switch to ON. • Press the upper button [A] to display the odometer [B]. • Press the upper button [A] for more than 2 seconds. • The service code [B] is displayed on the LCD by the num- ber of two digits.
  • Page 120 3-36 FUEL SYSTEM (DFI) Self-Diagnosis...
  • Page 121: Service Code Reading

    FUEL SYSTEM (DFI) 3-37 Self-Diagnosis Service Code Reading ○ The service code(s) is displayed on the LCD by the number of two digits. ○ When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order.
  • Page 122: Service Code Table

    3-38 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Table Service Code Problems Main throttle sensor malfunction, wiring open or short Intake air pressure sensor malfunction, wiring open or short Intake air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Crankshaft sensor malfunction, wiring open or short Speed sensor malfunction, wiring open or short Vehicle-down sensor malfunction, wiring open or short...
  • Page 123: Backups

    FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the output voltage is out of the usable range, wiring short or open), the ECU locks ignition timing into the ignition timing at closed throttle...
  • Page 124 3-40 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria The ECU sends the data (for service code) — to the meter unit. The ECU must send If the stick coil #1 primary winding has failures signals continuously to (no signal, wiring short or open), the ECU Stick Coil #1*...
  • Page 125: Main Throttle Sensor (Service Code 11)

    FUEL SYSTEM (DFI) 3-41 Main Throttle Sensor (Service Code 11) Main Throttle Sensor Removal/Adjustment NOTICE Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface.
  • Page 126: Main Throttle Sensor Output Voltage Inspection

    3-42 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Output Voltage Inspection • Measure the output voltage at the main throttle sensor in the same way as input voltage inspection, noting the following. ○ Disconnect the main throttle sensor connector and con- nect the harness adapter [A] between these connectors.
  • Page 127: Main Throttle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-43 Main Throttle Sensor (Service Code 11) If the output voltage is normal, check the wiring for conti- nuity. ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→ Main Throttle Sensor Connector [B] Y/R lead (ECU terminal 6) [C] BR/BK lead (ECU terminal 22) [D] If the wiring is good, check the ECU for its ground and...
  • Page 128: Intake Air Pressure Sensor (Service Code 12)

    3-44 FUEL SYSTEM (DFI) Intake Air Pressure Sensor (Service Code 12) Intake Air Pressure Sensor Removal NOTICE Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. • Remove the fuel tank (see Fuel Tank Removal). •...
  • Page 129: Intake Air Pressure Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-45 Intake Air Pressure Sensor (Service Code 12) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 130 3-46 FUEL SYSTEM (DFI) Intake Air Pressure Sensor (Service Code 12) If the reading is within the usable range, remove the ECU and check the wiring for continuity between main harness connector. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 131 FUEL SYSTEM (DFI) 3-47 Intake Air Pressure Sensor (Service Code 12) Suppose: Pg: Vacuum Pressure (Gauge) to Sensor Pl: Local Atmospheric Pressure (Absolute) measured by a barometer Pv: Vacuum Pressure (Absolute) to Sensor Vv: Sensor Output Voltage (V) then Pv = Pl – Pg For example, suppose the following data is obtained: Pg = 8 cmHg (Vacuum Gauge Reading) Pl = 70 cmHg (Varometer Reading)
  • Page 132 3-48 FUEL SYSTEM (DFI) Intake Air Pressure Sensor (Service Code 12) Pv = 55 ∼ 86 cmHg ID: Idling Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle Vacuum Pressure (Absolute) ST: Standard of Sensor Output Voltage (V) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (V) Vv: Intake Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)
  • Page 133 FUEL SYSTEM (DFI) 3-49 Intake Air Pressure Sensor (Service Code 12) Intake Air Pressure Sensor Circuit 1. ECU 2. Intake Air Pressure Sensor 3. Joint Connector C...
  • Page 134: Intake Air Temperature Sensor (Service Code 13)

    3-50 FUEL SYSTEM (DFI) Intake Air Temperature Sensor (Service Code 13) Intake Air Temperature Sensor Removal/Instal- lation NOTICE Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal). •...
  • Page 135: Intake Air Temperature Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-51 Intake Air Temperature Sensor (Service Code 13) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness side connectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors.
  • Page 136 3-52 FUEL SYSTEM (DFI) Intake Air Temperature Sensor (Service Code 13) Intake Air Temperature Sensor Circuit 1. ECU 2. Intake Air Temperature Sensor 3. Joint Connector D...
  • Page 137: Water Temperature Sensor (Service Code 14)

    FUEL SYSTEM (DFI) 3-53 Water Temperature Sensor (Service Code 14) Water Temperature Sensor Removal/Installation NOTICE Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).
  • Page 138: Water Temperature Sensor Output Voltage Inspection

    3-54 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Water Temperature Sensor Output Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. • Remove the left middle fairing (see Middle Fairing Re- moval in the Frame chapter).
  • Page 139: Water Temperature Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-55 Water Temperature Sensor (Service Code 14) Water Temperature Sensor Resistance Inspection • Refer to the Water Temperature Sensor Inspection in the Electrical System chapter. If the reading is within the standard, but the problem still exists, replace the ECU (see ECU Removal/Installation). Water Temperature Sensor Circuit 1.
  • Page 140: Crankshaft Sensor (Service Code 21)

    3-56 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) The crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no sig- nals. Crankshaft Sensor Removal/Installation • Refer to the Crankshaft Sensor Removal/Installation in the Electrical System chapter. Crankshaft Sensor Resistance Inspection •...
  • Page 141: Speed Sensor (Service Code 24)

    FUEL SYSTEM (DFI) 3-57 Speed Sensor (Service Code 24) Speed Sensor Removal/Installation • Refer to the Speed Sensor Removal/Installation in the Electrical System chapter. Speed Sensor Inspection • Refer to the Speed Sensor Inspection in the Electrical System chapter. Speed Sensor Input Voltage Inspection NOTE ○...
  • Page 142: Speed Sensor Output Voltage Inspection

    3-58 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) Speed Sensor Output Voltage Inspection • Before this inspection, inspect the input voltage (see Speed Sensor Input Voltage Inspection). NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. •...
  • Page 143 FUEL SYSTEM (DFI) 3-59 Speed Sensor (Service Code 24) Speed Sensor Circuit 1. ECU 2. Joint Connector D 3. Joint Connector C 4. Speed Sensor 5. Meter Unit...
  • Page 144: Vehicle-Down Sensor (Service Code 31)

    3-60 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Removal/Installation NOTICE Never drop the vehicle-down sensor especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Tank Bracket (see Air Cleaner Element Replace- ment in the Periodic Maintenance chapter) Clamp [A]...
  • Page 145 FUEL SYSTEM (DFI) 3-61 Vehicle-down Sensor (Service Code 31) • Remove the vehicle-down sensor (see Vehicle-down Sensor Removal/Installation). ○ Do not disconnect the sensor connector. • Connect a digital meter [A] to the connector with needle adapter set [B]. Special Tool - Needle Adapter Set: 57001-1457 Vehicle-down Sensor Output Voltage Connections to Sensor Connector: Meter (+) →...
  • Page 146 3-62 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Circuit 1. ECU 2. Vehicle-down Sensor 3. Joint Connector C...
  • Page 147: Subthrottle Sensor (Service Code 32)

    FUEL SYSTEM (DFI) 3-63 Subthrottle Sensor (Service Code 32) Subthrottle Sensor Removal/Adjustment NOTICE Do not remove or adjust the subthrottle sensor since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface.
  • Page 148: Subthrottle Sensor Output Voltage Inspection

    3-64 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 149 FUEL SYSTEM (DFI) 3-65 Subthrottle Sensor (Service Code 32) Subthrottle Sensor Output Voltage Connections to Adapter: Digital Meter (+) → Y/W (sensor BR) lead Digital Meter (–) → BK/BL (sensor BR/BK) lead • Turn the ignition switch to ON. • Measure the output voltage when the subthrottle valve is fully opened or completely closed by hand.
  • Page 150: Subthrottle Sensor Resistance Inspection

    3-66 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Subthrottle Sensor Resistance Inspection • Turn the ignition switch to OFF. • Disconnect the subthrottle sensor connector. • Connect a digital meter [A] to the subthrottle sensor con- nector [B]. • Measure the subthrottle sensor resistance.
  • Page 151: Oxygen Sensor-Not Activated (Service Code 33) (Equipped Models)

    FUEL SYSTEM (DFI) 3-67 Oxygen Sensor-not activated (Service Code 33) (Equipped Models) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection • Turn the ignition switch to OFF. • Remove the engine sprocket cover (see Engine Sprocket Removal in the Final Drive chapter).
  • Page 152 3-68 FUEL SYSTEM (DFI) Oxygen Sensor-not activated (Service Code 33) (Equipped Models) If the reading is out of the standard (with plug: DC 0.7 V or more, without plug: DC 0.2 V or less), remove the ECU and check the wiring for continuity between main harness connectors.
  • Page 153 FUEL SYSTEM (DFI) 3-69 Oxygen Sensor-not activated (Service Code 33) (Equipped Models) Oxygen Sensor Circuit 1. Ignition Switch 2. Oxygen Sensor 3. ECU 4. Frame Ground 2 5. Battery 12 V 10 Ah 6. Main Fuse 30 A 7. Relay Box 8.
  • Page 154: Stick Coils #1, #2: (Service Code 51, 52)

    3-70 FUEL SYSTEM (DFI) Stick Coils #1, #2: (Service Code 51, 52) Stick Coil #1: Service Code 51 Stick Coil #2: Service Code 52 Stick Coil Removal/Installation • Refer to the Stick Coil Removal/Installation in the Electri- cal System chapter. Stick Coil Primary Winding Resistance Inspection •...
  • Page 155 FUEL SYSTEM (DFI) 3-71 Stick Coils #1, #2: (Service Code 51, 52) Stick Coil Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Stick Coils 4. ECU 5. Frame Ground 6. Battery 12 V 10 Ah 7. Main Fuse 30 A 8.
  • Page 156: Radiator Fan Relay (Service Code 56)

    3-72 FUEL SYSTEM (DFI) Radiator Fan Relay (Service Code 56) Radiator Fan Relay Removal/Installation ○ The radiator fan relay is built in the relay box [A]. • Refer to the Relay Box Removal in the Electrical System chapter. Radiator Fan Relay Inspection •...
  • Page 157: Subthrottle Valve Actuator (Service Code 62)

    FUEL SYSTEM (DFI) 3-73 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal NOTICE Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface.
  • Page 158: Subthrottle Valve Actuator Input Voltage Inspection

    3-74 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove the air cleaner housing (see Air Cleaner Housing Removal). • Turn the ignition switch to OFF. •...
  • Page 159 FUEL SYSTEM (DFI) 3-75 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Circuit 1. ECU 2. Subthrottle Valve Actuator...
  • Page 160: Air Switching Valve (Service Code 64)

    3-76 FUEL SYSTEM (DFI) Air Switching Valve (Service Code 64) Air Switching Valve Removal/Installation • Refer to the Air Switching Valve Removal/Installation in the Engine Top End chapter. Air Switching Valve Inspection • Refer to the Air Switching Valve Operation Test/Unit Test in the Electrical System chapter.
  • Page 161: Oxygen Sensor Heater (Service Code 67) (Equipped Models)

    FUEL SYSTEM (DFI) 3-77 Oxygen Sensor Heater (Service Code 67) (Equipped Models) Oxygen Sensor Heater Removal/Installation The oxygen sensor heater is bult in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see Oxygen Sensor Removal in the Electrical System chapter).
  • Page 162: Oxygen Sensor Heater Power Source Voltage Inspection

    3-78 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67) (Equipped Models) Oxygen Sensor Heater Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. • Remove the engine sprocket cover (see Engine Sprocket Removal in the Final Drive chapter).
  • Page 163 FUEL SYSTEM (DFI) 3-79 Oxygen Sensor Heater (Service Code 67) (Equipped Models) Oxygen Sensor Circuit 1. Ignition Switch 2. Oxygen Sensor 3. ECU 4. Frame Ground 2 5. Battery 12 V 10 Ah 6. Main Fuse 30 A 7. Relay Box 8.
  • Page 164: Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Equipped Models)

    3-80 FUEL SYSTEM (DFI) Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Equipped Models) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection • Turn the ignition switch to OFF. • Remove the engine sprocket cover (see Engine Sprocket Removal in the Final Drive chapter).
  • Page 165 FUEL SYSTEM (DFI) 3-81 Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Equipped Models) • Next, remove the plug from the fitting [A] with idling. WARNING The engine gets extremely hot during normal oper- ation and can cause serious burns. Never touch a hot engine.
  • Page 166 3-82 FUEL SYSTEM (DFI) Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Equipped Models) Oxygen Sensor Circuit 1. Ignition Switch 2. Oxygen Sensor 3. ECU 4. Frame Ground 2 5. Battery 12 V 10 Ah 6. Main Fuse 30 A 7. Relay Box 8.
  • Page 167: Purge Valve (Service Code 3A) (Cal, Sea-B1 And Th Models)

    FUEL SYSTEM (DFI) 3-83 Purge Valve (Service Code 3A) (CAL, SEA-B1 and TH Models) Purge Valve Removal/Installation • Remove: Left Frame Cover (see Frame Cover Removal in the Frame chapter) Purge Valve Connector [A] (Disconnect) Tubes [B] (Disconnect) Purge Valve Mounting Nut [C] Purge Valve [D] •...
  • Page 168 3-84 FUEL SYSTEM (DFI) Purge Valve (Service Code 3A) (CAL, SEA-B1 and TH Models) • Disconnect the 12 V battery. • Blow the air to the intake air duct [A] again, and make sure that the air does not flow from the outlet air duct [B]. If the purge valve dose not operate as described, replace it with a new one.
  • Page 169: Yellow Engine Warning Indicator Light (Led)

    FUEL SYSTEM (DFI) 3-85 Yellow Engine Warning Indicator Light (LED) Yellow Engine Warning Indicator Light (LED) Inspection • Refer to the Meter Unit Inspection in the Electrical System chapter. Yellow Engine Warning Indicator Light (LED) Circuit for DFI System 1. ECU 2.
  • Page 170: Ecu

    3-86 FUEL SYSTEM (DFI) ECU Identification ○ Most countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU with each other and use only the ECU for your model. Other- wise, the motorcycle can not clear the regulation. ECU Identification Part Number [A] Specification...
  • Page 171 FUEL SYSTEM (DFI) 3-87 • Turn the ignition switch to OFF. • Disconnect the ECU connectors [A]. • Set the hand tester [B] to the × 1 Ω range and check the following wiring for continuity. Special Tool - Hand Tester: 57001-1394 ECU Grounding Continuity Inspection Connections: (I) BK lead (ECU terminal...
  • Page 172 3-88 FUEL SYSTEM (DFI) ECU Power Source Circuit 1. ECU 2. Frame Ground 1 3. Frame Ground 2 4. Battery 12 V 10 Ah 5. Main Fuse 30 A 6. Relay Box 7. ECU Main Relay 8. Fuse Box 1 9.
  • Page 173: Dfi Power Source

    FUEL SYSTEM (DFI) 3-89 DFI Power Source ECU Fuse Removal • Refer to the 15 A ECU Fuse Removal in the Electrical System chapter. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 174: Fuel Line

    3-90 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) ○ Be sure to place a piece of cloth around the fuel supply pipes of the fuel pump and the throttle body assy.
  • Page 175: Fuel Flow Rate Inspection

    FUEL SYSTEM (DFI) 3-91 Fuel Line NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. • Turn the ignition switch to OFF. If the fuel pressure is much higher than specified, the fuel pressure regulator in the fuel pump have been clogged or stuck.
  • Page 176 3-92 FUEL SYSTEM (DFI) Fuel Line • Open the fuel tank cap [A] to lower the pressure in the tank. • Remove the fuel hose from the fuel pump (see Fuel Tank Removal). ○ Be sure to place a piece of cloth around the fuel supply pipe of the fuel pump.
  • Page 177: Fuel Pump

    FUEL SYSTEM (DFI) 3-93 Fuel Pump Fuel Pump Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 178: Fuel Pump Operation Inspection

    3-94 FUEL SYSTEM (DFI) Fuel Pump • Replace the fuel pump gasket [A] with a new one and apply grease to it. • Apply a non-permanent locking agent to the threads of the fuel pump bolts. • Tighten the fuel pump bolts to a snug fit, and tighten them alternating diagonally.
  • Page 179: Fuel Pump Operating Voltage Inspection

    FUEL SYSTEM (DFI) 3-95 Fuel Pump Fuel Pump Operating Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. • Remove the left side cover (see Side Cover Removal in the Frame chapter). •...
  • Page 180: Pressure Regulator Removal

    3-96 FUEL SYSTEM (DFI) Fuel Pump Pressure Regulator Removal ○ The pressure regulator [A] is built into the fuel pump [B] and cannot be removed. Fuel Filter Cleaning ○ The fuel filter [A] is built into the pump and cannot be cleaned or checked.
  • Page 181: Fuel Injectors

    FUEL SYSTEM (DFI) 3-97 Fuel Injectors Fuel Injector Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Fuel Injector Audible Inspection • Start the engine, and let it to idle. • Apply the tip of a screwdriver [A] to the fuel injector [B]. Put the grip end onto your ear, and listen whether the fuel injector is clicking or not.
  • Page 182: Fuel Injector Power Source Voltage Inspection

    3-98 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. • Remove the air cleaner housing (see Air Cleaner Housing Removal). • Disconnect the injector connector and connect the har- ness adapter [A] between these connectors as shown in the figure.
  • Page 183: Fuel Injector Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-99 Fuel Injectors Fuel Injector Output Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. • Remove the ECU (see ECU Removal). ○ Do not disconnect the ECU connector. •...
  • Page 184: Fuel Injector Fuel Line Inspection

    3-100 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Fuel Line Inspection • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) ○ Be sure to place a piece of cloth around the fuel supply pipes of the fuel pump and the throttle body assy.
  • Page 185 FUEL SYSTEM (DFI) 3-101 Fuel Injectors Fuel Injector Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Fuel Injectors 4. ECU 5. Frame Ground 1 6. Frame Ground 2 7. Battery 12 V 10 Ah 8. Main Fuse 30 A 9.
  • Page 186: Throttle Grip And Cables

    3-102 FUEL SYSTEM (DFI) Throttle Grip and Cables Throttle Grip Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Throttle Grip Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter.
  • Page 187: Throttle Body Assy

    FUEL SYSTEM (DFI) 3-103 Throttle Body Assy Idle Speed Inspection/Adjustment • Refer to the Idle Speed Inspection/Adjustment in the Pe- riodic Maintenance chapter. Synchronization Inspection/Adjustment • Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter. Throttle Body Assy Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the...
  • Page 188: Throttle Body Assy Installation

    3-104 FUEL SYSTEM (DFI) Throttle Body Assy • Pull the throttle body assy [A] out of the holder. • Disconnect the subthrottle sensor connector [B]. • Loosen the locknut [A] and screw the adjuster [B] to give the throttle grip plenty of play. •...
  • Page 189: Throttle Body Assy Disassembly

    FUEL SYSTEM (DFI) 3-105 Throttle Body Assy • Install the throttle body assy holder clamp bolts [A] so that their bolt heads [B] face outward. • Install the throttle body assy onto the holder securely. • Tighten: Torque - Throttle Body Assy Holder Clamp Bolts: 2.0 N·m (0.20 kgf·m, 18 in·lb) •...
  • Page 190: Throttle Body Assy Assembly

    3-106 FUEL SYSTEM (DFI) Throttle Body Assy • Remove: Throttle Body Assy (see Throttle Body Assy Removal) Screws [A] • Pull out the fuel injectors [B] from the throttle body assy together with the delivery pipe [C]. • Pull out the fuel injectors from the delivery pipe. Throttle Body Assy Assembly •...
  • Page 191: Air Cleaner

    FUEL SYSTEM (DFI) 3-107 Air Cleaner Air Cleaner Element Removal/Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Element Inspection • Remove the air cleaner element (see Air Cleaner Element Replacement in the Periodic Maintenance chapter). •...
  • Page 192: Air Cleaner Housing Installation

    3-108 FUEL SYSTEM (DFI) Air Cleaner • Pull out the air cleaner housing [A] from the throttle body assy. • Disconnect the air switching valve hose [B] from the hous- ing. Air Cleaner Housing Installation • Installation is the reverse of removal. ○...
  • Page 193: Fuel Tank

    FUEL SYSTEM (DFI) 3-109 Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 194 3-110 FUEL SYSTEM (DFI) Fuel Tank • Remove the fuel tank bolts [A] and washers. • Draw the fuel out from the fuel tank with a commercially available pump [A]. ○ Use a soft plastic hose [B] as a pump intake hose in order to insert the hose smoothly.
  • Page 195: Fuel Tank Installation

    FUEL SYSTEM (DFI) 3-111 Fuel Tank • Turn the driver [A] to disconnect the joint lock [B]. • Pull the fuel hose joint [C] out of the outlet pipe [D]. WARNING Fuel is flammable and explosive under certain con- ditions and can cause severe burns. Be prepared for fuel spillage;...
  • Page 196: Fuel Tank And Cap Inspection

    3-112 FUEL SYSTEM (DFI) Fuel Tank • Push and pull [A] the hose joint [B] back and forth more than 2 times and make sure it is locked and does not come off. WARNING Leaking fuel can cause a fire or explosion resulting in serious burns.
  • Page 197: Fuel Tank Cleaning

    FUEL SYSTEM (DFI) 3-113 Fuel Tank Fuel Tank Cleaning WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the tank in a well-ventilated area, and take care that there are no sparks or flame any- where near the working area.
  • Page 198: Evaporative Emission Control System (Cal, Sea-B1 And Th Models)

    3-114 FUEL SYSTEM (DFI) Evaporative Emission Control System (CAL, SEA-B1 and TH Models) The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.
  • Page 199 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Special Tools .......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal/Installation ..............Water Pump..........................
  • Page 200: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 201 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Radiator Bolt 0.81 70 in·lb Coolant Reserve Tank Mounting Bolts 0.81 70 in·lb Water Temperature Sensor 106 in·lb Water Hose Clamp Screws 0.31 27 in·lb Thermostat Housing Bolts 87 in·lb Water Pump Cover Bolts 87 in·lb Water Pump Drain Bolt...
  • Page 202: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart...
  • Page 203 COOLING SYSTEM 4-5 Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 204: Specifications

    4-6 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type (Recommended) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point −35°C (−31°F) Total Amount...
  • Page 205: Special Tools

    COOLING SYSTEM 4-7 Special Tools Bearing Driver Set: Oil Seal Driver: 57001-1129 57001-1660...
  • Page 206: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the right middle fairing (see Middle Fairing Re- moval in the Frame chapter). • Visually inspect the coolant [A] in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded.
  • Page 207: Cooling System Flushing

    COOLING SYSTEM 4-9 Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the effi- ciency of the cooling system.
  • Page 208: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Water Hose [A] Water Pump Cover Bolts [B] Water Pump Cover [C] • Shift the transmission into 1st gear. •...
  • Page 209: Water Pump Inspection

    COOLING SYSTEM 4-11 Water Pump • Be sure that the dowel pins [A] are in position. • Install the water pump cover and the bolts. [A] L = 40 mm (1.6 in.) [B] L = 30 mm (1.2 in.) • Tighten: Torque - Water Pump Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
  • Page 210: Water Pump Housing Disassembly

    4-12 COOLING SYSTEM Water Pump Water Pump Housing Disassembly NOTICE Be careful not to damage the sealing surface of the mechanical seal. • Remove the water pump housing (see Water Pump Re- moval). • Take the oil seal [A] out of the housing [B] with a hook [C]. •...
  • Page 211: Radiator

    COOLING SYSTEM 4-13 Radiator Radiator and Radiator Fan Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove the left middle fairing (see Middle Fairing Re- moval in the Frame chapter). • Disconnect the radiator fan lead connector [A]. •...
  • Page 212: Radiator And Radiator Fan Installation

    4-14 COOLING SYSTEM Radiator Radiator and Radiator Fan Installation • Install the radiator fan [A] and tighten the bolts. • Install the rubber dampers [B] and collar [C] to the radiator and frame. • Install the radiator so that the projections [D] on the frame fit into the holes [E] on the dampers.
  • Page 213: Radiator Inspection

    COOLING SYSTEM 4-15 Radiator Radiator Inspection • Remove the radiator (see Radiator and Radiator Fan Re- moval). • Inspect the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably de- formed fins, replace the radiator with a new one.
  • Page 214: Radiator Filler Neck Inspection

    4-16 COOLING SYSTEM Radiator Radiator Filler Neck Inspection • Remove the radiator cap (see Coolant Change in the Pe- riodic Maintenance chapter). • Inspect the radiator filler neck for signs of damage. • Inspect the condition of the top and bottom sealing seats [A] in the filler neck.
  • Page 215: Thermostat

    COOLING SYSTEM 4-17 Thermostat Thermostat Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Left Middle Fairing (see Middle Fairing Removal in the Frame chapter) Water Hose [A] Thermostat Housing Bolts [B] Thermostat Housing [C] •...
  • Page 216: Thermostat Inspection

    4-18 COOLING SYSTEM Thermostat Thermostat Inspection • Remove the thermostat (see Thermostat Removal), and inspect the thermostat valve [A] at room temperature. If the valve is open, replace the thermostat with a new one. • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water.
  • Page 217: Hose And Pipes

    COOLING SYSTEM 4-19 Hose and Pipes Hose Installation • Install the hoses, being careful to follow bending direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses correctly (see Cable, Wire, and Hose Rout- ing section in the Appendix chapter). •...
  • Page 218: Water Temperature Sensor

    4-20 COOLING SYSTEM Water Temperature Sensor Water Temperature Sensor Removal/Installation • Refer to the Water Temperature Sensor Removal/Instal- lation in the Fuel System (DFI) chapter. Water Temperature Sensor Inspection • Refer to the Water Temperature Sensor Inspection in the Electrical System chapter.
  • Page 219 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Cylinder Head Installation .... 5-27 Exhaust System Identification ... Cylinder Head Warp Inspection ... 5-29 Specifications ........Valves ..........5-30 Special Tools and Sealant ....Valve Clearance Inspection ..5-30 Clean Air System.......
  • Page 220: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 221 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Baffle Plate Bolts 0.60 52 in·lb Air Suction Valve Cover Bolts 87 in·lb Cylinder Head Cover Bolts 87 in·lb Camshaft Cap Bolts 106 in·lb Throttle Body Assy Holder Clamp Bolts 0.20 18 in·lb Throttle Body Assy Holder Bolts...
  • Page 222 5-4 ENGINE TOP END Exploded View...
  • Page 223 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Bolt (M8) 27.5 MO,S Cylinder Bolts (M6) 106 in·lb L, S Cylinder Nut MO, S Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolts L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil solution.
  • Page 224: Exhaust System Identification

    5-6 ENGINE TOP END Exhaust System Identification Exhaust System Muffler Mark Position [A] Honeycomb Type Catalyst Position [A] Muffler with Hole [A] for Oxygen Sensor [B]...
  • Page 225: Specifications

    ENGINE TOP END 5-7 Specifications Item Standard Service Limit Camshafts Cam Height: 35.843 ∼ 35.957 mm Exhaust 35.74 mm (1.407 in.) (1.4111 ∼ 1.4156 in.) 36.543 ∼ 36.657 mm Intake 36.44 mm (1.435 in.) (1.4387 ∼ 1.4432 in.) 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.) Camshaft Journal, Camshaft 0.16 mm (0.0063 in.) Cap Clearance...
  • Page 226 5-8 ENGINE TOP END Specifications Item Standard Service Limit Valve Spring Free Length: Exhaust 41.91 mm (1.650 in.) 40.3 mm (1.59 in.) Intake 41.91 mm (1.650 in.) 40.3 mm (1.59 in.) Cylinder, Pistons 82.994 ∼ 83.006 mm Cylinder Inside Diameter 83.09 mm (3.271 in.) (3.2675 ∼...
  • Page 227: Special Tools And Sealant

    ENGINE TOP END 5-9 Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 60° - 30: 57001-221 57001-1123 Valve Spring Compressor Assembly: Valve Seat Cutter Holder Bar: 57001-241 57001-1128 Valve Seat Cutter, 45° - 35: Valve Seat Cutter, 45° - 30: 57001-1116 57001-1187 Valve Seat Cutter, 32°...
  • Page 228 5-10 ENGINE TOP END Special Tools and Sealant Compression Gauge Adapter, M10 × 1.0: Filler Cap Driver: 57001-1317 57001-1454 Valve Seat Cutter Holder, 4.5: Piston Pin Puller: 57001-1330 57001-1568 Valve Guide Arbor, 4.5: Piston Pin Puller Adapter, 12: 57001-1331 57001-1657 Valve Guide Reamer, 4.5: Liquid Gasket, TB1216B: 57001-1333...
  • Page 229: Clean Air System

    ENGINE TOP END 5-11 Clean Air System Air Suction Valve Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Air Switching Valve (see Air Switching Valve Removal) Air Suction Valve Cover Bolts [A] Clamp [B] Air Suction Valve Cover [C]...
  • Page 230: Air Suction Valve Inspection

    5-12 ENGINE TOP END Clean Air System Air Suction Valve Inspection • Remove the air suction valve (see Air Suction Valve Re- moval). • Visually inspect the reeds [A] for cracks, folds, warps, heat damage or other damage. If there is any doubt as to the condition of the reeds, re- place the air suction valve as an assembly.
  • Page 231: Clean Air System Hose Inspection

    ENGINE TOP END 5-13 Clean Air System Clean Air System Hose Inspection • Be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the air cleaner housing, air switching valve and air suction valve cover.
  • Page 232: Cylinder Head Cover

    5-14 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal • Remove the right middle fairing (see Middle Fairing Re- moval in the Frame chapter). • Clear the rubber cover [A] from the filler neck. • Remove the radiator bolt [B] and lower the radiator [C] for extra clearance.
  • Page 233: Cylinder Head Cover Installation

    ENGINE TOP END 5-15 Cylinder Head Cover Cylinder Head Cover Installation • Replace the head cover gasket [A] with a new one. • Clean off any oil or dirt and apply liquid gasket to the areas [B] on the cylinder. Sealant - Liquid Gasket, TB1216B: 92104-1064 •...
  • Page 234 5-16 ENGINE TOP END Cylinder Head Cover • Be sure that the dampers [A] of the baffle plate are in position. • Tighten: Torque - Baffle Plate Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) • Install the other removed parts (see appropriate chap- ters).
  • Page 235: Camshaft Chain Tensioner

    ENGINE TOP END 5-17 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal NOTICE This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 236 5-18 ENGINE TOP END Camshaft Chain Tensioner • Install the tensioner body so that the stopper [A] faces upward. • Apply a non-permanent locking agent to the camshaft chain tensioner mounting bolts and tighten them. Torque - Camshaft Chain Tensioner Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 237: Camshaft, Camshaft Chain

    ENGINE TOP END 5-19 Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Timing Inspection Cap [A] Timing Rotor Bolt Cap [B] Special Tool - Filler Cap Driver [C]: 57001-1454 • Using a wrench on the timing rotor bolt [A], turn the crank- shaft clockwise until the 2/T mark line [B] on the timing rotor is aligned with the notch [C] in the edge of the timing inspection hole in the clutch cover.
  • Page 238 5-20 ENGINE TOP END Camshaft, Camshaft Chain • Remove the camshaft chain tensioner (see Camshaft Chain Tensioner Removal). • Loosen the camshaft cap bolts following the sequence [1 ∼ 12 ] shown in the figure, and remove them. • Remove: Camshaft Caps [A] Camshafts [B] NOTICE...
  • Page 239: Camshaft Installation

    ENGINE TOP END 5-21 Camshaft, Camshaft Chain Camshaft Installation • Replace the plug hole gaskets [A] with new ones. • Be sure to install the following parts. Dowel Pins [B] Plug Hole Gaskets • Install the camshaft sprockets so that the marked (“IN" and “EX”) side faces outward.
  • Page 240 5-22 ENGINE TOP END Camshaft, Camshaft Chain • Using a wrench on the timing rotor bolt [A], turn the crank- shaft clockwise until the 2/T mark line [B] on the timing rotor is aligned with the notch [C] in the edge of the timing inspection hole in the clutch cover.
  • Page 241 ENGINE TOP END 5-23 Camshaft, Camshaft Chain • Before installing the camshaft caps, install the camshaft chain tensioner body temporarily (see Camshaft Chain Tensioner Installation). • Install the camshaft caps as shown. NOTE ○ The exhaust cap has an “EX” mark [A] and the intake cap has an “IN”...
  • Page 242: Camshaft, Camshaft Cap Wear Inspection

    5-24 ENGINE TOP END Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear Inspection • Remove the camshaft caps (see Camshaft Removal). • Cut strips of plastigage (press gauge) to journal width. Place a strip on each journal parallel to the camshaft in- stalled in the correct position.
  • Page 243: Camshaft Chain Removal

    ENGINE TOP END 5-25 Camshaft, Camshaft Chain Camshaft Chain Removal • Split the crankcase (see Crankcase Splitting in the Crank- shaft/Transmission chapter). • Remove the camshaft chain [A] from the crankshaft sprocket.
  • Page 244: Cylinder Head

    5-26 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Be sure the battery is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter)
  • Page 245: Cylinder Head Removal

    ENGINE TOP END 5-27 Cylinder Head Cylinder Head Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Muffler (see Muffler Removal) Cylinder Head Cover (see Cylinder Head Cover Re- moval) Camshafts (see Camshaft Removal) Throttle Body Assy (see Throttle Body Assy Removal in...
  • Page 246 5-28 ENGINE TOP END Cylinder Head • Apply molybdenum disulfide oil solution [A] to both sides of washers and the threads of bolts and nut. M10 Cylinder Head Bolts [B] M10 Cylinder Nut [C] M8 Cylinder Bolt [D] • Tighten the all bolts and nut following the tightening se- quence [1 ∼...
  • Page 247: Cylinder Head Warp Inspection

    ENGINE TOP END 5-29 Cylinder Head • Install the front camshaft chain guide [A]. ○ Insert the end [B] of front camshaft chain guide into the hollow on the lower crankcase half. • Install the other removed parts (see appropriate chap- ters).
  • Page 248: Valves

    5-30 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove cylinder head (see Cylinder Head Removal). •...
  • Page 249: Valve Guide Installation

    ENGINE TOP END 5-31 Valves Valve Guide Installation • Apply engine oil to the valve guide outer surface before installation. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). • Drive the valve guide in from the top of the head using the valve guide arbor.
  • Page 250: Valve Seat Inspection

    5-32 ENGINE TOP END Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
  • Page 251 ENGINE TOP END 5-33 Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
  • Page 252 5-34 ENGINE TOP END Valves • Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range.
  • Page 253 ENGINE TOP END 5-35 Valves If the seat width is too wide, make the 60° or 55° [A] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 60°...
  • Page 254 5-36 ENGINE TOP END Valves...
  • Page 255: Cylinder, Pistons

    ENGINE TOP END 5-37 Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Front Engine Mounting Bolts [A] and Nuts (Left and Right) Collar [B] Cylinder [C] Cylinder Installation NOTE ○ If a new cylinder is used, use new piston ring. •...
  • Page 256: Piston Removal

    5-38 ENGINE TOP END Cylinder, Pistons Piston Removal • Remove the cylinder (see Cylinder Removal). • Place a clean cloth under the pistons. • Remove the piston pin snap ring [A] by using the pliers [B] from the outside of each piston. •...
  • Page 257: Cylinder Wear Inspection

    ENGINE TOP END 5-39 Cylinder, Pistons • Apply molybdenum disulfide oil solution to the top and second rings. • Do not mix up the top and second ring. • Install the top ring [A] so that the "R" mark [B] faces up. •...
  • Page 258: Piston Wear Inspection

    5-40 ENGINE TOP END Cylinder, Pistons Piston Wear Inspection • Measure the outside diameter [A] of each piston 18 mm (0.7087 in.) [B] up from the bottom of the piston at a right angle to the direction of the piston pin. If the measurement is under service limit, replace the pis- ton.
  • Page 259: Piston Ring Thickness Inspection

    ENGINE TOP END 5-41 Cylinder, Pistons Piston Ring Thickness Inspection • Measure the piston ring thickness. ○ Use the micrometer to measure at several points around the ring. Piston Ring Thickness Standard: 0.87 ∼ 0.89 mm (0.0343 ∼ 0.0350 in.) Top [A] 0.97 ∼...
  • Page 260: Throttle Body Assy Holder

    5-42 ENGINE TOP END Throttle Body Assy Holder Throttle Body Assy Holder Removal • Remove: Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Clamps [A] Bolts [B] Throttle Body Assy Holders [C] Throttle Body Assy Holder Installation •...
  • Page 261: Muffler

    ENGINE TOP END 5-43 Muffler Muffler Removal WARNING The muffler can become extremely hot during nor- mal operation and cause severe burns. Do not re- move the muffler while it is hot. • Remove: Frame Covers (see Frame Cover Removal in the Frame chapter) Right Footpeg Stay (see Footpeg Stay Removal in the Frame chapter)
  • Page 262: Muffler Installation

    5-44 ENGINE TOP END Muffler Muffler Installation • Installation is the reverse of removal. ○ Replace the exhaust pipe gaskets [A] with new ones. ○ Tighten: Torque - Exhaust Pipe Manifold Holder Nuts: 17 N·m (1.7 kgf·m, 13 ft·lb) Muffler Body Mounting Bolts [B]: 20 N·m (2.0 kgf·m, 15 ft·lb) ○...
  • Page 263 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Clutch Cable Removal ...................... Clutch Cable Installation ....................Clutch Cable Lubrication....................
  • Page 264: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 265 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Cable Clamp Bracket Bolt 87 in·lb Clutch Cable Holder Bolts 87 in·lb Clutch Cover Bolts 87 in·lb Clutch Hub Nut 13.3 Clutch Spring Bolts 87 in·lb Timing Inspection Cap 0.40 35 in·lb Timing Rotor Bolt Cap...
  • Page 266: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) Friction Plate Thickness 2.7 mm (0.106 in.) Friction Plate Warp 0.15 mm (0.059 in.) or less 0.3 mm (0.012 in.)
  • Page 267: Special Tools And Sealant

    CLUTCH 6-5 Special Tools and Sealant Clutch Holder: Liquid Gasket, TB1211F: 57001-1243 92104-0004 Filler Cap Driver: 57001-1454...
  • Page 268: Clutch Lever And Cable

    6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Cable Removal •...
  • Page 269: Clutch Cable Lubrication

    CLUTCH 6-7 Clutch Lever and Cable Clutch Cable Lubrication • Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter. Clutch Lever Installation • Install the clutch lever so that the mating surface [A] of the clutch lever clamp is aligned with the punch mark [B]. •...
  • Page 270: Clutch Cover

    6-8 CLUTCH Clutch Cover Clutch Cover Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Right Frame Cover (see Frame Cover Removal in the Frame chapter) Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Bolt [A] Idle Speed Adjusting Screw Holder [B]...
  • Page 271: Release Shaft Removal

    CLUTCH 6-9 Clutch Cover Release Shaft Removal NOTICE Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary. If re- moved, the oil seal replacement may be required. • Remove the clutch cover (see Clutch Cover Removal). •...
  • Page 272: Clutch Cover Assembly

    6-10 CLUTCH Clutch Cover Clutch Cover Assembly • Replace the needle bearings [A] and oil seal [B] with new ones. NOTE ○ Install the needle bearings so that the manufacture’s mark face out. • Install the needle bearings and oil seal as shown. ○...
  • Page 273: Clutch Removal

    CLUTCH 6-11 Clutch Clutch Removal • Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts and Washers [A] Clutch Springs Clutch Spring Plate [B] (with Bearing) Pusher [C] Friction Plates Steel Plates • Hold the clutch hub [A] steady with the clutch holder [B], and remove the clutch hub nut [C] and washer [D].
  • Page 274: Clutch Installation

    6-12 CLUTCH Clutch Clutch Installation • Install the oil pump chain guide [A]. • Apply a non-permanent locking agent to the upper chain guide bolts [B]. • Tighten: Torque - Oil Pump Chain Guide Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) •...
  • Page 275 CLUTCH 6-13 Clutch • Install the washer so that the OUT SIDE mark [A] faces outward. • Replace the clutch hub nut [A] with a new one. • Hold the clutch hub [B] steady with the clutch holder [C], and tighten the clutch hub nut. Special Tool - Clutch Holder: 57001-1243 Torque - Clutch Hub Nut: 130 N·m (13.3 kgf·m, 96 ft·lb) •...
  • Page 276: Clutch Plate, Wear, Damage Inspection

    6-14 CLUTCH Clutch Clutch Plate, Wear, Damage Inspection • Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. • Measure the thickness of each friction plate [A] at several points. If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones.
  • Page 277: Clutch Housing Spline Inspection

    CLUTCH 6-15 Clutch Clutch Housing Spline Inspection • Visually inspect where the teeth [A] on the steel plates wear against the clutch hub splines [B]. If there are notches worn into the splines, replace the clutch hub. Also, replace the steel plates if their teeth are damaged.
  • Page 279 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealant ...................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ Oil Pan Removal .......................
  • Page 280: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 281 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Filter 17.5 EO, R Holder Mounting Bolt Oil Passage Plug (M6) 0.36 31 in·lb Oil Passage Plug Oil Pressure Switch Oil Plate Bolts 87 in·lb Oil Pressure Relief Valve Oil Pipe Plate Bolt 87 in·lb Filter Plate Bolts...
  • Page 282: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 283 ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart...
  • Page 284: Specifications

    7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity: 1.6 L (1.7 US gt) (when filter is not removed) 1.8 L (1.9 US gt) (when filter is removed) 2.3 L (2.4 US gt) (when engine is completely dry) Level Between upper and lower level lines...
  • Page 285: Special Tools And Sealant

    ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: Liquid Gasket, TB1211: 57001-164 56019-120 Oil Pressure Gauge Adapter, PT3/8: 57001-1233...
  • Page 286: Engine Oil And Oil Filter

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter according to the periodic maintenance chart.
  • Page 287: Oil Pan

    ENGINE LUBRICATION SYSTEM 7-9 Oil Pan Oil Pan Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Lower Fairing Brackets (see Lower Fairing Bracket Re- moval in the Frame chapter) Muffler (see Muffler Removal in the Engine Top End chapter)
  • Page 288: Oil Pan Installation

    7-10 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Installation If the following parts were removed, install them in the following procedure. Oil Pipes Oil Pipe Plate Dampers Oil Screen Filter Filter Plate ○ Replace the O-rings with new ones. ○ Apply grease to the O-rings on the oil pipes [A].
  • Page 289 ENGINE LUBRICATION SYSTEM 7-11 Oil Pan • Tighten the oil pan bolts following the specified tightening sequence. Torque - Oil Pan Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
  • Page 290: Oil Pressure Relief Valve

    7-12 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Pressure Relief Valve [A] Oil Pressure Relief Valve Installation • Apply a non-permanent locking agent to the threads of the oil pressure relief valve, and tighten it.
  • Page 291: Oil Pump

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump Oil Pump Removal • Remove: Clutch (see Clutch Removal in the Clutch chapter) Oil Pump Cover Bolts [A] • Temporarily install the oil pump sprocket bolt [A]. NOTE ○ The oil pump sprocket bolt has a left-hand threads. •...
  • Page 292: Oil Pump Installation

    7-14 ENGINE LUBRICATION SYSTEM Oil Pump • Remove the pin [A]. • Remove: Pin [A] Inner Rotor for Feed Pump [B] Oil Pump Shaft [C] Oil Pump Installation • Apply molybdenum disulfide oil solution to the portion [A] of the oil pump shaft as shown in the figure. •...
  • Page 293 ENGINE LUBRICATION SYSTEM 7-15 Oil Pump • Be sure that the dowel pin [A] is in position. • Fit the dowel pin into the hole [B] on the oil pump cover [C]. • Apply a non-permanent locking agent to the oil pump cover bolts and tighten them.
  • Page 294: Oil Pressure Measurement

    7-16 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Right Lower Fairing Bracket (see Lower Fairing Bracket Removal in the Frame chapter) Oil Passage Plug [A] NOTE ○...
  • Page 295: Oil Pressure Switch

    ENGINE LUBRICATION SYSTEM 7-17 Oil Pressure Switch Oil Pressure Switch Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Right Lower Fairing Bracket (see Lower Fairing Bracket Removal in the Frame chapter) Switch Cover [A] Switch Terminal Bolt [B]...
  • Page 297 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 298: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 299 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Engine Bracket Bolts (Left) Front Engine Bracket Bolts (Right) Front Engine Mounting Bolt (Right) Front Engine Mounting Bolt (Left) Rear Engine Mounting Bolts Rear Engine Mounting Nuts R, S Rear Engine Bracket Bolts Engine Ground Lead Terminal Bolt 87 in·lb...
  • Page 300: Engine Removal/Installation

    8-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Support the rear part of the swingarm with a stand. • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Motorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to hold the front brake when removing the engine.
  • Page 301: Front Engine Bracket Bolts (Left)

    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation • Disconnect: Crankshaft Sensor Lead Connector [A] Starter Motor Cable Terminal [B] Engine Ground Lead Terminal [C] Water Temperature Sensor Lead Connector [D] • Disconnect the alternator lead connector [A]. • Disconnect the neutral switch lead terminal [A]. •...
  • Page 302: Engine Installation

    8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Front Engine Mounting Bolt [A] and Nut (Right) Front Engine Bracket Bolts (Right) [B] Front Engine Bracket (Right) [C] • Remove the rear engine mounting bolt and nut (upper) [A]. • Remove: Rear Engine Mounting Bolt and Nut (Lower) [A] Rear Engine Bracket Bolts [B] Rear Engine Bracket [C] •...
  • Page 303: Front Engine Mounting Bolt (Right)

    ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Install the following temporarily: Front Engine Bracket (Right) [A] Front Engine Bracket Bolts (Right) [B] • Replace the front engine mounting nut (right) [C] with a new one. • Install the following temporarily: Front Engine Mounting Bolt (Right) [D] Front Engine Mounting Nut (Right) Front Engine Bracket (Left) [E] Front Engine Bracket Bolts (Left) [F]...
  • Page 304 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation ○ Tighten: Torque - Front Engine Bracket Bolts (Left) [G]: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Engine Mounting Bolt [H] (Left): 44 N·m (4.5 kgf·m, 32 ft·lb) • Run the leads, cables, and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
  • Page 305 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealants ....................Crankcase Splitting......................... 9-10 Crankcase Splitting ......................9-10 Crankcase Assembly ......................9-12 Crankshaft and Connecting Rods................... 9-19 Crankshaft Removal ......................9-19 Crankshaft Installation ...................... 9-19 Connecting Rod Removal ....................9-19 Connecting Rod Installation ....................
  • Page 306: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 307 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Connecting Rod Big End Nuts see Text ← ← Timing Rotor Bolt Oil Plate Bolts 87 in·lb Oil Pipe Bolts 87 in·lb Breather Plate Bolts 87 in·lb Shift Shaft Return Spring Pin Crankcase Bolt (M6, L = 32 mm) 19.6 Crankcase Bolts (M6, L = 38 mm)
  • Page 308 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 309 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Transmission Case Bolts Gear Positioning Lever Bolt 106 in·lb Trasnmission Case Oil Nozzle 0.30 26 in·lb Shift Drum Cam Bolt 106 in·lb Shift Drum Bearing Holder Screws 0.50 43 in·lb Shift Rod Plate Bolt 87 in·lb Neutral Switch Holder Screw...
  • Page 310: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Bend – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.2/100 mm (0.008/3.94 in.) 0.13 ∼ 0.38 mm Connecting Rod Big End Side Clearance 0.58 mm (0.0051 ∼...
  • Page 311 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankshaft Runout TIR 0.02 mm (0.0008 in.) TIR 0.05 mm or less (0.002 in.) 0.017 ∼ 0.041 mm Crankshaft Main Bearing Insert/Journal Clearance 0.07 mm (0.0007 ∼ 0.0016 in.) (0.003 in.) 37.984 ∼ 38.000 mm Crankshaft Main Journal Diameter: 37.96 mm (1.4954 ∼...
  • Page 312 9-8 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit 31.000 ∼ 31.016 mm Crankcase Bearing Bore Diameter: – – – (1.2205 ∼ 1.2211 in.) Marking: ○ 31.000 ∼ 31.008 mm – – – (1.2205 ∼ 1.2208 in.) 31.009 ∼ 31.016 mm None –...
  • Page 313: Special Tools And Sealants

    CRANKSHAFT/TRANSMISSION 9-9 Special Tools and Sealants Outside Circlip Pliers: Liquid Gasket, TB1216B: 57001-144 92104-1064 Bearing Driver Set: Liquid Gasket, TB1207B: 57001-1129 92104-2068 Liquid Gasket, TB1211F: 92104-0004...
  • Page 314: Crankcase Splitting

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter) • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval in the Engine Top End chapter) Cylinder Head (see Cylinder Head Removal in the En- gine Top End chapter)
  • Page 315 CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting • Remove the upper crankcase bolts [A] and the copper plated washers. • Remove: Oil Pan (see Oil Pan Removal in the Engine Lubrication System chapter) Oil Screen (see Oil Pan Removal in the Engine Lubrica- tion System chapter) Oil Pipes (see Oil Pan Removal in the Engine Lubrication System chapter)
  • Page 316: Crankcase Assembly

    9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting ○ Prepare a 5 mm rod [A], and insert it to the hole of the upper crankcase half. ○ Remove the oil pipe [B], tapping [C] the rod as shown. If the breather plate [A] is to be removed, follow the next procedure.
  • Page 317 CRANKSHAFT/TRANSMISSION 9-13 Crankcase Splitting • When the new needle bearing [A] for the shift drum is installed in the lower crankcase half [B], press and insert [C] the new needle bearing until it is bottomed. Special Tool - Bearing Driver Set: 57001-1129 •...
  • Page 318 9-14 CRANKSHAFT/TRANSMISSION Crankcase Splitting ○ Apply a non-permanent locking agent to the threads of the breather plate bolts [A] and tighten them. Torque - Breather Plate Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) ○ Install the breather pipe [A]. ○ Align the white mark [B] on the pipe with the white mark [C] on the breather fitting.
  • Page 319 CRANKSHAFT/TRANSMISSION 9-15 Crankcase Splitting • Install the crankshaft and the balancer shaft on the upper crankcase half. ○ Apply molybdenum disulfide oil solution to the following items. Crankshaft Main Bearing Insert Balancer Shaft Bearing Insert ○ Align [A] the timing mark on the balancer gear [B] with the timing mark on the balancer drive gear [C] of the crank- shaft.
  • Page 320 9-16 CRANKSHAFT/TRANSMISSION Crankcase Splitting • With a high flash-point solvent, clean off the mating sur- faces of the crankcases halves and wipe dry. • Using compressed air, blow out the oil passages in the crankcase halves. • Apply liquid gasket [A] to the mating surface of the lower crankcase half.
  • Page 321 CRANKSHAFT/TRANSMISSION 9-17 Crankcase Splitting • Fit the lower crankcase half to the upper crankcase half. ○ Insert [A] the breather pipe [B] on the upper crankcase half through the hole [C] on the lower crankcase half. NOTE ○ Make the application finish within 20 minutes when the liquid gasket to the mating surface of the lower crankcase half is applied.
  • Page 322 9-18 CRANKSHAFT/TRANSMISSION Crankcase Splitting • The upper crankcase bolts [A] have copper plated wash- ers, replace them with new ones. • Tighten the upper crankcase bolts with copper plated washers. Torque - Upper Crankcase Bolts: 27.5 N·m (2.8 kgf·m, 20 ft·lb) •...
  • Page 323: Crankshaft And Connecting Rods

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove: Camshaft Chain [A] Crankshaft [B] Crankshaft Installation NOTE ○ If the crankshaft is replaced with a new one, refer to the Connecting Rod Big End Bearing/Crankshaft Main Bearing Insert Selection in the Specifications.
  • Page 324: Connecting Rod Installation

    9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Installation NOTICE To minimize vibration, the connecting rods should have the same weight mark. Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] ○ Diameter Mark [D]: “ ” or no mark NOTICE If the connecting rods, big end bearing inserts, or crankshaft are replaced with new ones, select the...
  • Page 325 CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods ○ The connecting rod big end is bolted using the “plastic region fastening method”. ○ This method precisely achieves the needed clamping force without exceeding it unnecessarily, allowing the use of thinner, lighter bolts further decreasing connecting rod weight.
  • Page 326 9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Dent both bolt head and bolt tip with a punch as shown. • Before tightening, use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt stretch.
  • Page 327: Crankshaft/Connecting Rod Cleaning

    CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Apply a small amount of molybdenum disulfide oil solution to the following. Threads [A] of Nuts and Bolts Seating Surfaces [B] of Nuts and Connecting Rods •...
  • Page 328: Connecting Rod Twist Inspection

    9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Twist Inspection • With the big-end arbor [A] still on V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being paralleled with the surface plate over a 100 mm (3.94 in.) length of the arbor to de- termine the amount of connecting rod twist.
  • Page 329 CRANKSHAFT/TRANSMISSION 9-25 Crankshaft and Connecting Rods If the clearance is within the standard, no bearing replace- ment is required. If the clearance is between 0.042 mm (0.00165 in.) and the service limit (0.08 mm, 0.003 in.), replace the bear- ing inserts [A] with inserts painted blue [B]. Check in- sert/crankpin clearance with the plastigage.
  • Page 330: Crankshaft Side Clearance Inspection

    9-26 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Select the proper bearing insert [A] in accordance with the combination of the connecting rod and crankshaft coding. Size Color [B] Bearing Insert Connecting Rod Big End Crankpin Diameter Inside Diameter Marking Marking Size Color Part Number ○...
  • Page 331: Crankshaft Main Bearing Insert/Journal Wear Inspection

    CRANKSHAFT/TRANSMISSION 9-27 Crankshaft and Connecting Rods Crankshaft Main Bearing Insert/Journal Wear Inspection • Using a plastigage (press gauge) [A], measure the bear- ing insert/journal [B] clearance. NOTE ○ Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). ○ Do not turn the crankshaft during clearance measure- ment.
  • Page 332 9-28 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. ○ Crankcase Main Bearing Inside Diameter Marks: “ ” or no mark. • Tighten the crankcase bolts to the specified torque (see Crankcase Assembly).
  • Page 333: Balancer

    CRANKSHAFT/TRANSMISSION 9-29 Balancer Balancer Removal • Split the crankcase (see Crankcase Splitting). • Pull the balancer shaft [A] with the balancer gear out of the crankcase. Balancer Installation • Apply molybdenum disulfide oil solution to the inside of the balancer shaft bearing insert. •...
  • Page 334 9-30 CRANKSHAFT/TRANSMISSION Balancer NOTE ○ Do not turn the balancer shaft during clearance mea- surement. ○ Remove the lower crankcase half and measure the plas- tigage width [A] to determine the bearing insert/journal [B] clearance. Balancer Shaft Bearing Insert/Journal Clearance 0.011 ∼...
  • Page 335 CRANKSHAFT/TRANSMISSION 9-31 Balancer • Put the lower crankcase half on the upper crankcase half without bearing inserts, and tighten the case bolts to the specified torque and sequence (see Crankcase Assem- bly). • Measure the crankcase bearing bore diameter for the bal- ancer shaft, and mark the upper crankcase half in accor- dance with the bore diameter.
  • Page 336: External Shift Mechanism

    9-32 CRANKSHAFT/TRANSMISSION External Shift Mechanism Shift Pedal Removal • Remove: Shift Pedal Bolt [A] Shift Pedal [B] Shift Pedal Installation • Install the shift pedal [A] to the shift shaft. ○ Align the punch mark [B] on the shift shaft with the punch mark [C] on the shift pedal.
  • Page 337: External Shift Mechanism Installation

    CRANKSHAFT/TRANSMISSION 9-33 External Shift Mechanism • Remove: Clutch (see Clutch Removal in the Clutch chapter) Gear Positioning Lever Bolt [A] Spacer [B] Gear Positioning Lever [C] Washer and Spring External Shift Mechanism Installation • Install the gear positioning lever [A] as shown in the figure. Spring [B] Washer [C] Spacer [D]...
  • Page 338: External Shift Mechanism Inspection

    9-34 CRANKSHAFT/TRANSMISSION External Shift Mechanism • Replace the shift shaft cover gasket with a new one. • Install the shift shaft cover. • Apply a non-permanent locking agent to the shift shaft cover screw [A]. • Apply a non-permanent locking agent to the shift shaft cover bolts [B, C].
  • Page 339: Transmission

    CRANKSHAFT/TRANSMISSION 9-35 Transmission Transmission Assy Removal • Remove: Shift Shaft Assembly (see External Shift Mechanism Re- moval) Neutral Switch Holder Screw [A] Neutral Switch Holder [B] and Pin Shift Drum Holder [C] and Pin • Remove the collar [A] and the O-ring [B] from the output shaft [C].
  • Page 340: Transmission Assy Disassembly

    9-36 CRANKSHAFT/TRANSMISSION Transmission • Install: Pin [A] Shift Drum Holder [B] Pin [C] Neutral Switch Holder [D] • Apply a non-permanent locking agent to the neutral switch holder screw [E] and tighten it. Torque - Neutral Switch Holder Screw: 4.9 N·m (0.50 kgf·m, 43 in·lb) •...
  • Page 341: Transmission Assy Assembly

    CRANKSHAFT/TRANSMISSION 9-37 Transmission • Remove the following from the transmission case as nec- essary. Shift Drum Bearing Holder Screws [A] Shift Drum Bearing Holder [B] • Remove the following from the transmission case as nec- essary. Drive Shaft Bearing Holder Screw [A] Drive Shaft Bearing Holder [B] Transmission Assy Assembly •...
  • Page 342 9-38 CRANKSHAFT/TRANSMISSION Transmission If the drive shaft bearing holder [A] is to be removed, fol- low the next procedure. ○ Apply a non-permanent locking agent to the threads of the drive shaft bearing holder screw [B] and tighten it. Torque - Drive Shaft Bearing Holder Screw: 4.9 N·m (0.50 kgf·m, 43 in·lb)
  • Page 343: Transmission Shaft Removal

    CRANKSHAFT/TRANSMISSION 9-39 Transmission • Apply engine oil to the shift drum groove. • Install the following on the transmission case [A]. Shift Drum [B] Pin [C] Shift Drum Cam [D] ○ Align the pin with the hole on the shift drum cam. •...
  • Page 344: Transmission Shaft Disassembly

    9-40 CRANKSHAFT/TRANSMISSION Transmission Transmission Shaft Disassembly • Remove the transmission shafts (see Transmission Assy Disassembly). • Remove the circlips, disassemble the transmission shafts. Special Tool - Outside Circlip Pliers: 57001-144 • The 5th gear [A] on the output shaft has three steel balls assembled into it for the positive neutral finder mecha- nism.
  • Page 345 CRANKSHAFT/TRANSMISSION 9-41 Transmission • Fit the steel balls into the 5th gear holes in the output shaft, aligning oil hole as shown in the figure. 5th Gear [A] Output Shaft [B] Steel Balls [C] Oil Holes [D] NOTICE Do not apply grease to the balls to hold them in place.
  • Page 346 9-42 CRANKSHAFT/TRANSMISSION Transmission 1. Drive Shaft 2. 1st Gear 3. 2nd Gear 4. 3rd Gear 5. 4th Gear 6. 5th Gear 7. 6th (Top) Gear 8. Bushing 9. Toothed Washer, 34 mm (1.34 in.) 10. Circlip 11. Bushing 12. Thrust Washer, 30 mm (1.18 in.) 13.
  • Page 347: Shift Drum And Fork Removal

    CRANKSHAFT/TRANSMISSION 9-43 Transmission Shift Drum and Fork Removal • Refer to the Transmission Assy Disassembly. Shift Drum and Fork Installation • Refer to the Transmission Assy Assembly. Shift Drum Disassembly • Refer to the Transmission Assy Disassembly. Shift Drum Assembly •...
  • Page 348: Gear Dog And Gear Dog Hole Damage Inspection

    9-44 CRANKSHAFT/TRANSMISSION Transmission Gear Dog and Gear Dog Hole Damage Inspection • Visually inspect the gear dogs [A] and gear dog holes [B]. Replace any damaged gears or gears with excessively worn dogs or dog holes.
  • Page 349: Ball Bearing, Needle Bearing, And Oil Seal

    CRANKSHAFT/TRANSMISSION 9-45 Ball Bearing, Needle Bearing, and Oil Seal Ball and Needle Bearing Replacement NOTICE Do not remove the ball or needle bearings unless it is necessary. Removal may damage them. • Using a press or puller, remove the ball bearing and/or needle bearings.
  • Page 351 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-7 Rear Wheel Installation..................... 10-8 Wheel Inspection ......................10-10 Axle Inspection........................
  • Page 352: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 353 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle 11.0 Front Axle Clamp Bolt Rear Axle Nut 11.0 4. EX650F Model G: Apply grease. HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 354: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 1.0 mm (0.04 in.) Axle Runout/100 mm (3.94 in.) TIR 0.03 mm (0.001 in.) or less TIR 0.2 mm (0.008 in.) Wheel Balance...
  • Page 355: Special Tools

    WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: Bearing Remover Head, 20 × 22: 57001-1129 57001-1293 Jack: Bearing Remover Shaft, 13: 57001-1238 57001-1377...
  • Page 356: Wheels (Rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Front Caliper Mounting Bolts [A] (Both Sides) Front Calipers [B] (Both Sides) • Loosen: Front Axle Clamp Bolt [A] Front Axle [B] • Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Lower Fairing Brackets (see Lower Fairing Bracket Re- moval in the Frame chapter)
  • Page 357: Rear Wheel Removal

    WHEELS/TIRES 10-7 Wheels (Rims) • Apply high-temperature grease to the grease seal lips. • Fit the collars [A] on the both sides of the hub. ○ The collars are identical. • Insert the front axle. • Remove the jack. • Tighten: Torque - Front Axle: 108 N·m (11.0 kgf·m, 80 ft·lb) •...
  • Page 358: Rear Wheel Installation

    10-8 WHEELS/TIRES Wheels (Rims) • Remove: Cotter Pin [A] Rear Axle Nut [B] Washer [C] Rear Axle [D] (from Right Side) • Remove the drive chain [A] from the rear sprocket toward the left. • Move the rear wheel back and remove it. NOTICE Do not lay the wheel on the ground with the disc facing down.
  • Page 359 WHEELS/TIRES 10-9 Wheels (Rims) • Bend the cotter pin [A] over the nut [B]. WARNING A loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper torque and install a new cotter pin. •...
  • Page 360: Wheel Inspection

    10-10 WHEELS/TIRES Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground. Special Tool - Jack: 57001-1238 • Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings (see Hub Bearing Removal/Installation).
  • Page 361: Balance Inspection

    WHEELS/TIRES 10-11 Wheels (Rims) Balance Inspection • Remove the front and rear wheels (see Front/Rear Wheel Removal). • Support the wheel so that it can be spun freely. • Spin the wheel lightly, and mark [A] the wheel at the top when the wheel stops.
  • Page 362 30 g (1.06 oz.) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20 and 30 grams (0.35, 0.71 and 1.06 oz.) sizes. An imbalance of less than 10 grams (0.35 oz.) will not usually affect running stability.
  • Page 363: Tires

    WHEELS/TIRES 10-13 Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove: Wheels (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...
  • Page 364 10-14 WHEELS/TIRES Tires • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull [B] the valve stem through the rim from the inside out until it snaps into place.
  • Page 365: Tire Repair

    Also, permanent (internal) repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire. For these reasons, Kawasaki does not recommend temporary (exter- nal) repair. Only appropriate permanent (internal) repairs are recommended. Repair methods may vary slightly from make to make.
  • Page 366: Hub Bearing

    10-16 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheels (see Front/Rear Wheel Removal), and take out the following. Collars Coupling (Out of rear hub) Grease Seals • Use the bearing remover to remove the hub bearings [A]. NOTICE Do not lay the wheel on the ground with the disc facing down.
  • Page 367: Hub Bearing Lubrication

    WHEELS/TIRES 10-17 Hub Bearing Hub Bearing Lubrication NOTE ○ Since the hub bearings are packed with grease and sealed, lubrication is not required.
  • Page 369 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................11-2 Specifications ......................... 11-4 Special Tools .......................... 11-5 Drive Chain..........................11-6 Drive Chain Slack Inspection .................... 11-6 Drive Chain Slack Adjustment ..................11-6 Wheel Alignment Inspection/Adjustment ................11-6 Drive Chain Wear Inspection .................... 11-6 Drive Chain Lubrication.....................
  • Page 370: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 371 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Speed Sensor Bracket Bolts 87 in·lb Speed Sensor Bolt 0.80 69 in·lb Engine Sprocket Nut 12.7 Engine Sprocket Cover Bolts 87 in·lb Rear Sprocket Nuts Rear Axle Nut 11.0 G: Apply grease.
  • Page 372: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain 25 ∼ 35 mm (1.0 ∼ 1.4 in.) Drive Chain Slack – – – Drive Chain Wear (20-link Length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) Standard Chain: Make DAIDO...
  • Page 373: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...
  • Page 374: Drive Chain

    11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection/Adjustment •...
  • Page 375: Drive Chain Installation

    FINAL DRIVE 11-7 Drive Chain • Grind [A] the heads of the link pin to make it flat. • Set the cutting and riveting pin [C] in the pin holder [B] as shown in the figure. • Set the “U” holder and body, align the positioning pin [A] with the “A”...
  • Page 376 11-8 FINAL DRIVE Drive Chain • Set the “U” holder and body, align the positioning pin [A] with the “A” mark [B]. • Hold the body with a wrench [C]. • Turn the pin holder clockwise [D] with another wrench and press in the link plate on the link pin.
  • Page 377 FINAL DRIVE 11-9 Drive Chain • After riveting, check the ends of the riveted pins for cracks. • Measure the outside diameter [A] and the length [B] of the link pin. Link Pin Outside Diameter 5.5 ∼ 5.8 mm (0.22 ∼ 0.23 in.) Standard: Link Pin Len