Page 1 Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.
Page 2 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch degree(s) Celsius revolution direct current r/min, rpm...
Page 3: Emission Control Information
EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only.
Page 4 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 5: How To Use This Manual
• Be alert for problems and non-scheduled maintenance. This note symbol indicates points of particular in- • Use proper tools and genuine Kawasaki Motorcycle terest for more efﬁcient and convenient operation. parts. Special tools, gauges, and testers that are •...
Page 7: Table Of Contents
GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing................................1-2 Model Identiﬁcation ................................1-4 General Speciﬁcations ..............................1-6 Torque and Locking Agent..............................1-8 Special Tools and Sealant...............................1-13 Cable, Wire, and Hose Routing ............................1-20...
Page 8: Before Servicing
1-2 GENERAL INFORMATION Before Servicing Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work.
Page 9 GENERAL INFORMATION 1-3 Before Servicing (14) Circlip, Retaining Ring, and Cotter Pin Replace any circlips and retaining rings, and cotter pins that were removed with new ones, as removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more.
Page 10: Model Identiﬁcation
1-4 GENERAL INFORMATION Model Identiﬁcation VN1500-P1 (US, and Canada) Left Side View: VN1500-P1 (US, and Canada) Right Side View:...
Page 11 GENERAL INFORMATION 1-5 Model Identiﬁcation VN1500-P1 (Europe) Left Side View: VN1500-P1 (Europe) Right Side View:...
Page 12: General Speciﬁcations
1-6 GENERAL INFORMATION General Speciﬁcations Items VN1500-P1 Dimensions: Overall length 2410 mm (94.9 in.) Overall width 850 mm (33.5 in.) Overall height 1100 mm (43.3 in.) Wheelbase 1705 mm (67.1 in.) Road clearance 125 mm (4.92 in.) Seat height 700 mm (27.6 in.) Dry mass 289 kg (637 lb) Curb mass:...
Page 13 GENERAL INFORMATION 1-7 General Speciﬁcations Items VN1500-P1 Transmission: Type 5-speed, constant mesh, return shift Gear ratios: (CA, CN, US) 2.500 (40/16) 1.750 (35/20) 1.333 (32/24) 1.074 (29/27) 0.867 (26/30) (other than CA, CN, US) 2.500 (40/16) 1.590 (35/22) 1.192 (31/26) 0.965 (28/29) 0.781 (25/32) Final drive system:...
Page 14: Torque And Locking Agent
1-8 GENERAL INFORMATION Torque and Locking Agent The following tables list the tightening torque for the The table below, relating tightening torque to thread major fasteners requiring use of a non-permanent locking diameter, lists the basic torque for the bolts and nuts. Use agent or liquid gasket.
Page 15 GENERAL INFORMATION 1-9 Torque and Locking Agent Torque Fastener Remarks Spark Plug Retainer 104 in Air Suction Valve Cover Bolts 0.75 65 in Chain Tensioner Mounting Bolts 95 in Chain Tensioner Cap Chain Tensioner Lockbolt 0.50 43 in Timing Inspection Cap 0.15 13 in Rotor Bolt Cap...
Page 16 1-10 GENERAL INFORMATION Torque and Locking Agent Torque Fastener Remarks Engine Mounting Bolts and Nuts Engine Mounting Bracket Bolts Engine Ground Terminal Bolt 0.80 69 in Crankshaft/Transmission: Crankcase Bolts 10 mm 8 mm 6 mm 95 in Jumper Cable Ground Bracket Bolt 87 in Left Crankcase Crankcase Bearing Retainer Bolts...
Page 17 GENERAL INFORMATION 1-11 Torque and Locking Agent Torque Fastener Remarks Final Gear Case Mounting Nuts Final Gear Case Studs – – – Final Gear Case Cover Bolts: 8 mm 10 mm Pinion Gear Nut (Final Gear) St, MO Bearing Retainer Bolt 61 in Brakes: Caliper Bleed Valves...
Page 18 1-12 GENERAL INFORMATION Torque and Locking Agent Torque Fastener Remarks Alternator Outer Cover Assembly Bolts 61 in Alternator Cover Bolts 95 in Alternator Inner Cover Bolts 95 in Alternator Rotor Bolt Alternator Stator Bolts 113 in Regulator/Rectiﬁer Bolts 0.66 58 in Timing Inspection Cap 0.15 13 in...
Page 19: Special Tools And Sealant
GENERAL INFORMATION 1-13 Special Tools and Sealant Oil Pressure Gauge, 5 kg/cm : 57001-125 Valve Guide Arbor, 7: 57001-163 Inside Circlip Pliers: 57001-143 Compression Gauge: 57001-221 Outside Circlip Pliers: 57001-144 Valve Spring Compressor Assembly: 57001-241 Bearing Puller: 57001-158 Valve Spring Compressor Adapter, 28.2: 57001-243 Valve Guide Reamer, 7: 57001-162 Bearing Puller Adapter: 57001-317...
Page 20 1-14 GENERAL INFORMATION Special Tools and Sealant Bearing Driver: 57001-382 Damper Cam Holder: 57001-1025 Piston Pin Puller Assembly: 57001-910 Driven Gear Holder: 57001-1027 Gear Holder: 57001-1015 Oil Pressure Gauge Adapter, PT 1/8: 57001-1033 Compression Gauge Adapter, M12 1.25: 57001-1018 Oil Seal & Bearing Remover: 57001-1058 Spark Plug Wrench, Hex 18: 57001-1024 Head Pipe Outer Race Press Shaft: 57001-1075...
Page 21 GENERAL INFORMATION 1-15 Special Tools and Sealant Head Pipe Outer Race Driver: 57001-1077 Valve Seat Cutter, 45 35: 57001-1116 Piston Ring Compressor Grip: 57001-1095 Valve Seat Cutter, 32 35: 57001-1121 Steering Stem Nut Wrench: 57001-1100 Valve Seat Cutter, 32 – 38.5 : 57001–1122 Head Pipe Outer Race Remover: 57001-1107 Valve Seat Cutter Holder, 7: 57001-1126...
Page 22 1-16 GENERAL INFORMATION Special Tools and Sealant Bearing Driver Set: 57001-1129 Jack: 57001-1238 Pinion Gear Holder: 57001-1165 Timing Light: 57001-1241 Hexagon Wrench, Hex 27: 57001-1210 Valve Seat Cutter, 55 - 35: 57001-1247 Piston Pin Puller Adapter: 57001-1211 Oil Filter Wrench: 57001-1249 Fork Outer Tube Weight: 57001-1218 Final Gear Case Holder: 57001-1250...
Page 23 GENERAL INFORMATION 1-17 Special Tools and Sealant Bearing Remover Shaft, 9: 57001-1265 Flywheel Holder : 57001–1313 Bearing Remover Head, 10 12: 57001-1266 Steering Stem Bearing Driver: 57001-1344 Fork Piston Rod Puller, M12 x 1.25 : 57001–1289 Steering Stem Bearing Driver Adapter: 57001-1345 Fork Oil Level Gauge: 57001-1290 Piston Ring Compressor Belt, 95 108: 57001-1358...
Page 24 1-18 GENERAL INFORMATION Special Tools and Sealant Hand Tester: 57001-1394 Driver-Filler Cap: 57001–1454 Needle Adapter Set: 57001–1457 Attachment Jack: 57001-1398 Valve Seat Cutter, 45 - 40: 57001-1496 Drive Shaft Holder: 57001-1407 Valve Seat Cutter, 55 - 38.5: 57001-1497 Flywheel Holder: 57001-1410 Fork Cylinder Holder: 57001-1502 Fuel Pressure Gauge Adapter: 57001-1417...
Page 25 GENERAL INFORMATION 1-19 Special Tools and Sealant Kawasaki Bond (Silicone Sealant): 56019–120 Kawasaki Bond (Liquid Gasket-Black): 92104-1003...
Page 26: Cable, Wire, And Hose Routing
1-20 GENERAL INFORMATION Cable, Wire, and Hose Routing F: Front 10. Indicator Light Connector : 13. Indicator Unit Bracket 1. Indicator Lights Insert the main harness side 14. Ignition Switch 2. Fuel Tank connector into the 15. Press each end of clamps by 3.
Page 27 GENERAL INFORMATION 1-21 Cable, Wire, and Hose Routing F: Front 11. Clutch Hose 1. Front Right Spark Plug Cap 12. Plastic Snap-on Clamps 2. Rear Right Spark Plug Cap 13. Strap 3. 2nd Lead from the left ignition coil lower side 14.
Page 28 1-22 GENERAL INFORMATION Cable, Wire, and Hose Routing : Inlet Air Flow 10. Right Air Cleaner Base 1. Rear View 11. Right Rubber Gasket 2. Air Inlet 12. Right Air Cleaner Cover 3. Left Rubber Gasket 13. Locate the glued joint of the gasket within the angle. 4.
Page 29 GENERAL INFORMATION 1-23 Cable, Wire, and Hose Routing : Bypass Air Flow 9. Vacuum Sensor and Pressure 18. ISC Valve #2 (rear cylinder) F: Front Regulator 19. ISC Valve Inlets 1. Rear View 10. Strap (holds [4], [6], and [11]) 20.
Page 30 1-24 GENERAL INFORMATION Cable, Wire, and Hose Routing : Vacuum Pulsation 5. Fuel Injector #1 13. Low Pressure (Return) Fuel Hose : Fuel Flow 6. Fuel Injector #2 14. Vacuum Hoses from Throttle Body #1: For Front Cylinder 7. Pressure Regulator 15.
Page 31 GENERAL INFORMATION 1-25 Cable, Wire, and Hose Routing F: Front 7. Fuel Injector #1 18. Choke Lever Stop Screw : Vacuum Pulsation 8. Vacuum Hoses from Throttle Body 19. Throttle Pulley : Bypass Air Flow 9. ISC Hose #1 (blue mark) 20.
Page 32 1-26 GENERAL INFORMATION Cable, Wire, and Hose Routing F: Front 6. Vacuum Switch Valve Hose 12. 112 ± 1 mm (4.409 ± 0.039 1. Clips (for rear air suction valve): in. the outside length of these 2. Vacuum Switch Valve (The air Run the hose under the vac- nuts) hole is faced downwards.)
Page 33 GENERAL INFORMATION 1-27 Cable, Wire, and Hose Routing F: Front 1. White Marks on the hose [2] and [7] :The marks faces forwards. 2. Front Coolant Hose 3. Reserve Tank Hose 4. Clip 5. Rear Coolant Hose 6. White Marks on the hose face backwards. 7.
Page 34 1-28 GENERAL INFORMATION Cable, Wire, and Hose Routing F: Front 8. Yellow Mark: 15. High Pressure Fuel Hose (sup- : Fuel Flow Face the yellow mark upwards ply) : Vacuum Pulsation and forwards, aligning with the 16. Fuel Filter 1. Atmospheric Pressure Sensor white mark.
Page 35 GENERAL INFORMATION 1-29 Cable, Wire, and Hose Routing : Fuel Flow 9. Fuel Reserve Switch BK/Y (–) Lead F: Front 10. Pump Base Plate 1. Fuel Pump Connector (outside the fuel tank) 11. Base Plate Gasket 2. Bottom of Fuel Tank 12.
Page 36 1-30 GENERAL INFORMATION Cable, Wire, and Hose Routing...
Page 37 GENERAL INFORMATION 1-31 Cable, Wire, and Hose Routing F: Front 1. Rubber Boot 2. Starter Motor Lead 3. Clutch Hose 4. Upper Washer ( 8.2 mm) 5. Lower Washer ( 8.2 mm) 6. Engine Oil Pipe 7. Clamp 8. Clutch Slave Cylinder Bleed Valve 9.
Page 38 1-32 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Fuel Tank Fill Opening (top view) 10. Holder (hose [7], [5], coolant reserve 2. Fuel Tank tank hose, clutch hose) 3. Fuel Tank Breather Pipe 11. Swingarm Pivot 4. Filler Drainpipe 12.
Page 39 GENERAL INFORMATION 1-33 Cable, Wire, and Hose Routing F: Front 9. License Plate Light Lead (Run 16. Connector of [13] ﬁtted into 1. Rear View this lead between the ribs of [15] 2. Rear Fender the ﬂap [18].) 17. Connector of [14] ﬁtted into 3.
Page 40 1-34 GENERAL INFORMATION Cable, Wire, and Hose Routing F: Front 8. Coolant Reserve Tank Hose 1. Clamps 9. Main Harness 2. Rear Coolant Hose 10. Vacuum Switch Valve Hose 3. Choke Cable: (for front air suction valve) Starting with the choke knob, run the choke cable 11.
Page 41 GENERAL INFORMATION 1-35 Cable, Wire, and Hose Routing 15. Vacuum Hose (for vacuum sensor) 25. Coolant Reserve Tank 16. Vacuum Hose (for pressure regulator) 26. Throttle Cables: 17. High Pressure Fuel Hose (supply from fuel tank) Install the lower end of the accelerator 18.
Page 42 1-36 GENERAL INFORMATION Cable, Wire, and Hose Routing F: Front 10. Indicator Unit and Ignition Switch Harness T: Top 11. Plastic Snap-on Clamp ( 10 mm) Install the plastic: snap-on clamps [11] [16] [26], 12. Left Frame Pipe 13. Band (clutch hose [8]): Run the clutch hose outside the nothing the position of the opening as shown.
Page 43 GENERAL INFORMATION 1-37 Cable, Wire, and Hose Routing 21. Run the leads through the cuts of the radiator 33. Sidestand Switch Leads: cover. Run the leads through the front and rear 22. Choke Knob hooks and hold them with the clamp [11] a 23.
Page 44 1-38 GENERAL INFORMATION Cable, Wire, and Hose Routing F: Front 11. Primary Leads for Ignition Coil 24. Water Temperature Sensor 1. Ignition Coil #2 (for rear cylin- Connector (on the bottom of der) 12. Rear Coolant Hose the thermostat housing) 2.
Page 45 GENERAL INFORMATION 1-39 Cable, Wire, and Hose Routing F: Front 51. Starter Motor Lead 37. Fit the clamp pin of the harness into the frame. 52. Branch of Main Harness 38. Plastic Snap-on Clamp (intank-fuel pump harness) 53. Intank Fuel Pump Connector 39.
Page 46 1-40 GENERAL INFORMATION Cable, Wire, and Hose Routing F: Front 8. Through alternator outer 17. Rear Coolant Hose T: Top 18. Right Handlebar Switch Con- cover to the starter motor 1 Fuel Tank Filler Drain Hose 9. Clutch Hose nector 2.
Page 47 GENERAL INFORMATION 1-41 Cable, Wire, and Hose Routing F: Front 37. Battery (+) Lead 44. Right Spark Plug Leads T: Top 38. Plastic Snap-on Clamps ( 45. Fit the pin of the harness 27. Throttle Assy mm, rear brake light switch and clamp into the bracket.
Page 48 1-42 GENERAL INFORMATION Cable, Wire, and Hose Routing F: Front 5. Hose Clamps 1. Rear Brake Caliper 6. Run the brake hose between the engine mounting 2. Hose Holders bracket bosses and the oil ﬁlter, and then along 3. Rear Brake Hose the downtube towards the front.
Page 49 GENERAL INFORMATION 1-43 Cable, Wire, and Hose Routing 8. Rear Brake Reservoir 13. Rear Brake Reservoir Cover 9. Rear Master Cylinder 14. Downtube 10. Brake Pedal 15. Swingarm 11. Bend both ends of the cotter pin [16] as shown. 16. Cotter Pin 12.
Page 50 1-44 GENERAL INFORMATION Cable, Wire, and Hose Routing F: Front 9. Clutch Hose 16. Apply adhesive to the grip cap 1. Throttle Cable (accelerator) 10. Clamps (leads [8]) inside and screw the cap in 2. Throttle Cable (decelerator) 11. Plastic Snap-on Strap (har- counterclockwise to the grip 3.
Page 51 GENERAL INFORMATION 1-45 Cable, Wire, and Hose Routing Evaporative Emission Control System (California Model) with fuel line : Vapor Flow : Fuel Flow : Vacuum Pulsation 1. Fuel Return Hose 2. Fuel Tank Breather Hose 3. Separator Breather Hose 4. Canister Purge Hose 5.
Page 52 1-46 GENERAL INFORMATION Cable, Wire, and Hose Routing Evaporative Emission Control System (California Model) F: Front 8. Fitting of the hose [6] 15. Fuel Tank Breather Hose (blue, 1. Fuel Tank 9. Radiator Cap right): Run the hose between 2. Filler Drainpipe 10.
Page 53 GENERAL INFORMATION 1-47 Cable, Wire, and Hose Routing R: Rear View 26. Right Main Harness 32. Rubber Plug 19. Separator 27. Face the white mark left. 33. Choke Cable: Run this over 20. Canister 28. Run hoses [15] [16] the hose [35] and under the 21.
Page 54 1-48 GENERAL INFORMATION Cable, Wire, and Hose Routing Evaporative Emission Control System (California Model) F: Front 7. Throttle Assy 1. Fuel Tank 8. Fuel Tank Return Hose (red, left) 2. Left Air Cleaner Base 9. Separator 3. Canister Purge Hose (Green) 10.
Page 55 PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart..............................2-3 Speciﬁcations ..................................2-4 Periodic Maintenance Procedures............................ 2-6 Fuel System (DFI) ................................. 2-6 Fuel Hose and Connection Check..........................2-6 Throttle Control System Check..........................2-6 Idle Speed Check...............................2-7 Air Cleaner Element Cleaning............................2-8 Evaporative Emission Control System Check (CA) ....................2-8 Cooling System................................2-9 Radiator Hose and Connection Check........................2-9 Coolant Change .................................
Page 56 2-2 PERIODIC MAINTENANCE Steering Adjustment..............................2-28 Electrical System .................................2-28 Spark Plug Cleaning/Inspection..........................2-28 General Lubrication ..............................2-28 Lubrication................................2-28 Nut, Bolt, and Fastener Tightness..........................2-30 Tightness Inspection ..............................2-30...
Page 57: 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. Whichever 1 000 km * ODOMETER READING comes (600 mile)
Page 58: Speciﬁcations
2-4 PERIODIC MAINTENANCE Speciﬁcations Item Standard Service Limit Fuel System (DFI): — — — Throttle grip free play 2 ~ 3 mm Idle speed 950 ± 50 r/min (rpm) Air cleaner element Paper ﬁlter Cooling System: — — — Coolant: Type (recommended) Permanent type antifreeze Color...
Page 59 PERIODIC MAINTENANCE 2-5 Speciﬁcations Item Standard Service Limit Final Drive: Final gear case oil: Grade API Service Classiﬁcation : GL-5 hy- — — — poid gear oil Viscosity when above 5 C (41 F) SAE 90 — — — when below 5 C (41 F) SAE80 —...
Page 60: Periodic Maintenance Procedures
2-6 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Fuel Hose and Connection Check The fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst.
Page 61: Idle Speed Check
PERIODIC MAINTENANCE 2-7 Periodic Maintenance Procedures • If necessary, adjust the throttle cable as follows: Loosen the locknuts [A] and screw the adjusters [B] all the way in so as to give the throttle grip plenty of play (front view). Turn out the adjuster of the decelerator cable [C] until there is no play.
Page 62: Air Cleaner Element Cleaning
2-8 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the idle speed is out of the speciﬁed range, adjust it. • Start the engine and warm it up thoroughly. Wait until fast idle speed lowers to a certain value. • Turn the adjusting screw [A] until the idle speed is correct. Open and close the throttle a few times to make sure that the idle speed is within the speciﬁed range.
Page 63: Cooling System
PERIODIC MAINTENANCE 2-9 Periodic Maintenance Procedures Run the purge hose (green) [A] above the canister breather hose (blue) [B] through the hole [C] into the tool case [D]. Do not run these hoses side by side on the battery side of the canister. This prevents hoses from being ﬂattened when installing the left side cover.
Page 64 2-10 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the fuel tank (see Fuel System chapter). • 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 65 PERIODIC MAINTENANCE 2-11 Periodic Maintenance Procedures Water and Coolant Mixture Ratio (when shipping) Soft Water 50 % Coolant 50 % − 35 Freezing Point C (− 31 Total Amount 2.3 L (2.4 US gt.) • Tighten the drain bolts. Torque - Radiator Drain Bolt: 7.4 N m (0.75 kg m, 65 in...
Page 66: Engine Top End
2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Top End Air Suction Valve Inspection • Remove the air suction valve (see Air Suction Valve Removal in the 5. Engine Top End chapter). • Visually inspect the reeds for cracks, folds, warps, heat damage or other damage.
Page 67: Clutch Fluid Change
PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Clutch Fluid Change • Level the clutch ﬂuid reservoir and remove the reservoir cap. • Remove the alternator outer cover (see Alternator Outer Cover Removal in the Electrical System chapter.) and the rubber cap from the bleed valve on the clutch slave cylinder.
Page 68: Clutch Slave Cylinder Piston Seal Replacement
2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Before assembly, clean all parts including the master cylinder with clutch ﬂuid or alcohol. CAUTION Use only disc brake ﬂuid, isopropyl alcohol or ethyl alcohol, for cleaning parts. Do not use any other ﬂuid for cleaning these parts.
Page 69: Engine Lubrication System
PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Engine Lubrication System Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the engine oil drain plug [A] and drain the oil. Front [B] •...
Page 70: Oil Filter Replacement
2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the oil ﬁller cap [A] with the driver-ﬁller cap [B] and pour in the speciﬁed type and amount of oil. Clutch Cover [C] Front [D] Special Tool - Driver-Filler Cap: 57001–1454 Torque - Oil Filler Cap: 1.5 N m (0.15 kg m, 13 in...
Page 71: Wheel/Tires
PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Wheel/Tires Tire Inspection As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn). So it is false economy and unsafe to use the tires until they are bald.
Page 72: Final Drive
2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Final Drive Oil Level Inspection Motorcycle operation with insufﬁcient, deteriorated, or con- taminated oil causes accelerated wear and may result in seizure of the pinion and ring gears. Seizure can lock the rear wheel and skid the rear tire, with consequent less of control. •...
Page 73: Propeller Shaft Joint Lubrication
PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Propeller Shaft Joint Lubrication • Remove the ﬁnal gear case and propeller shaft joint (see Final Drive chapter). • Wipe the old grease off the propeller shaft sliding joint and pinion joint. • Pack the propeller shaft sliding joint with 20 mL (16 grams) of high temperature grease [A].
Page 74: Brake Hose And Connection Check
2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Connection Check • Inspect the brake hose and ﬁttings for deterioration, cracks and signs of leakage. The high pressure inside the brake line can cause ﬂuid to leak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining it.
Page 75: Brake Fluid Change
PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Brake Fluid Change NOTE The procedure to change the front brake ﬂuid is as follows. Changing the rear brake ﬂuid is almost the same as for the front brake. • Level the brake ﬂuid reservoir. •...
Page 76: Brake/Master Cylinder Cup And Dust Seal Replacement
2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the clear plastic hose. • Install the reservoir cap. • Tighten the bleed valve, and install the rubber cap. Torque - Caliper Bleed Valve: 7.8 N m (0.8 kg m, 69 in Front Brake Reservoir Cap Screws: 1.5 N m (0.15 kg m, 13...
Page 77: Suspension
PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Suspension Fork Oil Change • Remove the front fork (see Suspension chapter) • Unscrew the top plug out of the outer tube. Right Fork Leg: • Use the wrenches on the top plug [A] and piston rod nut [B] loosen the piston rod nut.
Page 78 2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Pull out the joint rod assy [A] together with the spring [B]. • Compress and extend [B] the fork [A] upside down to draw out the fork oil into a suitable container [C], then drop out the collar [D], washer [E] and fork spring [F].
Page 79 PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Pump the outer tube several times to expel air bubbles. Wait until the oil level settles. With the fork fully compressed and the piston rod fully pushed in (Right Fork Leg), insert a tape measure or rod into the inner tube, and measure the distance from the top of the outer tube to the oil.
Page 80: Front Fork Oil Leak Inspection
2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Left Fork Leg: • Install the fork spring [A] with the smaller end facing upward [B]. • Install: Washer Collar Joint Rod Assy together with the spring • Install the inner fork bolt using the fork cylinder holder. Special Tool - Fork Cylinder Holder: 57001–1502 Torque -...
Page 81: Swingarm Pivot Lubrication
PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Swingarm Pivot Lubrication • Remove the swingarm (see Suspension chapter). • Clean the old grease out of the bearings. • Apply grease to the inner surface of the needle bearings [A]. • Apply a thin coat of grease to the lips [B] of the grease seals. •...
Page 82: Steering Adjustment
2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Adjustment Adjust the steering, if necessary. • Loosen the upper fork clamp bolt [A] on both side and unscrew the stem head nut [B]. • Remove the O-ring (see Steering chapter). • Remove the steering stem head [C] together with the handlebar installed.
Page 83 PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Pivots: Lubricate with Motor Oil. Rear Brake Rod Joint Points: Lubricate with Grease. Throttle Inner Cable Upper Ends [A] Clutch Lever Pivot (Apply silicone grease) Brake Lever Pivot (Apply silicone grease) Brake Pedal Pivot Side Stand Cable: Lubricate with Cable Lubricant.
Page 84: Nut, Bolt, And Fastener Tightness
2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Nut, Bolt, and Fastener Tightness 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 85 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View............3-3 ECU Identiﬁcation..........3-43 DFI Parts Location ............. 3-6 ECU Removal............3-43 DFI System..............3-8 ECU Installation..........3-43 DFI Wiring Diagram..........3-10 ECU Power Supply Inspection ......3-44 Speciﬁcations ............3-12 DFI Power Source............3-45 DFI Servicing Precautions ........
Page 86 3-2 FUEL SYSTEM (DFI) Output Voltage Inspection ......... 3-70 Injector Signal Test..........3-79 Pickup Coils (#1, #2: Fault Code 21, 22) ....3-72 Injector Resistance Inspection ......3-80 Pickup Coil Removal/Installation....... 3-72 Injector Unit Test..........3-80 Pickup Coil Inspection........3-72 In-tank Fuel Pump (Fault Code 45) ......3-82 Vehicle-down Sensor (Fault Code 31) .....
Page 87: Exploded View
15. Fuel Tank Filler Drain Hose SS: Apply silicone sealant 8. Left Air Cleaner Base 16. Fuel Tank Breather Hose (ex- (Kawasaki Bond: 56019–120). 9. Right Air Cleaner Base cept CA) CA: California Model 10. Air Cleaner Drain Hose 17. Fuel Tank Breather Hose (CA) 1.
Page 88 3-4 FUEL SYSTEM (DFI) Exploded View...
Page 89 FUEL SYSTEM (DFI) 3-5 Exploded View CL: Apply cable lubricant. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the speciﬁed tightening sequence. T1: 9.8 N m (1.0 kg m, 87 in T2: 2.9 N m (0.30 kg m, 26 in T3: 12 N...
Page 90: Dfi Parts Location
3-6 FUEL SYSTEM (DFI) DFI Parts Location DFI: DFI Parts (this chapter) 11. Neutral Switch 24. ISC Valve #2 (DFI, for Rear Cylinder) F: Front 12. Oil Pressure Switch 25. Inlet Air Temperature Sensor (DFI) 1. Atmospheric Pressure 13. In-tank Fuel Pump (DFI) 26.
Page 91 FUEL SYSTEM (DFI) 3-7 DFI Parts Location...
Page 92: Dfi System
3-8 FUEL SYSTEM (DFI) DFI System...
Page 93 FUEL SYSTEM (DFI) 3-9 DFI System #1: For Front Cylinder #2: For Rear Cylinder 1. ECU (Electronic Control Unit) 2. Pickup Coil #1 3. Pickup Coil #2 4. Pressure Regulator 5. Throttle Sensor (front view) 6. Atmospheric Pressure Sensor 7. Vacuum Sensor 8.
Page 94: Dfi Wiring Diagram
3-10 FUEL SYSTEM (DFI) DFI Wiring Diagram...
Page 95 FUEL SYSTEM (DFI) 3-11 DFI Wiring Diagram Terminal Numbers of ECU Connectors Terminal Names DFI and Electrical Parts DFI: DFI Parts #1: Front Cylinder, #2: Rear Cylinder ECU [A]: Electronic Control Unit (DFI) 1. — Engine Stop Switch [B] 2. Interlock Circuit Signal Starter Button [C] 3.
Page 96: Speciﬁcations
ﬁlter installed at 12 V atmospheric pressure Special Tools - Oil Pressure Gauge: 57001–125 Hand Tester: 57001–1394 Driver-Filler Cap: 57001–1454 Needle Adapter Set - Hand Tester: 57001–1457 Fuel Pressure Gauge Adapter: 57001–1417 Fork Oil Level Gauge: 57001–1290 Sealant - Kawasaki Bond (Silicone Sealant): 56019–120...
Page 97: Dfi Servicing Precautions
FUEL SYSTEM (DFI) 3-13 DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. To maintain the correct fuel-air mixture (F/A), there must be no inlet air leaks in the DFI system. Be sure to install the oil ﬁller cap [A] after ﬁlling the engine oil, using the driver-ﬁller cap [B].
Page 98 3-14 FUEL SYSTEM (DFI) DFI Servicing Precautions The fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Replace the fuel hose if any cracks [B] or bulges [C] are noticed.
Page 99: Throttle Grip And Cables
FUEL SYSTEM (DFI) 3-15 Throttle Grip and Cables Throttle Grip Free Play Inspection Refer to Throttle Control System Check in the Periodic Maintenance Chapter (2nd chapter). Throttle Grip Free Play Adjustment • Loosen the locknuts [A] and screw the adjusters [B] all the way in so as to give the throttle grip plenty of play.
Page 100: Throttle Assy
ECU compensates the change. (For reference: Mostly, Kawasaki recommends US carburetor models operated above 4000 feet, EPA - approved modiﬁcation to improve the EMISSION CONTROL PERFORMANCE). Throttle Assy Removal •...
Page 101 FUEL SYSTEM (DFI) 3-17 Throttle Assy • Remove the following from the choke cable holder [A] (left-behind view). Screw [B] Choke Cable Plate [C] • While pushing the choke lever [A] forward, remove the cable housing from the choke cable holder [B] and the inner cable out of the holder slit [C].
Page 102 3-18 FUEL SYSTEM (DFI) Throttle Assy • Remove the decelerator cable end [A] from the throttle pulley [B]. • Using needle nose pliers, move the accelerator inner cable outside the engine, and remove the cable end [C] from the pulley. Front [D] •...
Page 103: Throttle Assy Installation
FUEL SYSTEM (DFI) 3-19 Throttle Assy • Stuff a piece of lint-free, clean cloth into the throttle assy, and the inlet ports of the cylinder heads to keep dirt out of the engine. If dirt or dust is allowed to pass through into the throttle bore, the throttle may become stuck, possibly causing an accident.
Page 104: Throttle Assy Disassembly/Assembly
3-20 FUEL SYSTEM (DFI) Throttle Assy • Fit the fuel hose joint #2 [A] onto the pipe (for delivery joint) until the joint clicks [B]. Insert the hose joint straight along the pipe. Front [C] • Pull the hose joint #2 [A] up [B] and make sure it is locked and doesn’t come off.
Page 105 FUEL SYSTEM (DFI) 3-21 Throttle Assy Do not remove or adjust the following parts. These parts are set at the factory and cannot be readjusted. CAUTION Adjustment of some of these parts could result in poor performance, requiring replacement of the throttle body. Throttle Sensor [A]: Turning the sensor body could spoil the ignition timing and injection quantity.
Page 106 3-22 FUEL SYSTEM (DFI) Throttle Assy • Before assembly, visually inspect the mating surfaces [A] for any damage, like dent, nick, rust, ﬂaw, and crack. • Nick or rust damage can sometimes be repaired by using emery paper (ﬁrst No. 200, then 400) to remove sharp edges or raised areas. If the damage is not repairable, replace the throttle body and/or the inlet manifold to prevent leakage.
Page 107: Air Cleaner
FUEL SYSTEM (DFI) 3-23 Air Cleaner Element Removal • Remove: Allen Bolt and Washer [A] Left Air Cleaner Cover [B] Front [C] • Remove the element [A]. • Push a clean, lint-free towel into the lower air cleaner duct to keep dirt or other foreign material from entering.
Page 108: Right Air Cleaner Housing Removal
3-24 FUEL SYSTEM (DFI) Air Cleaner Right Air Cleaner Housing Removal • Remove: Allen Bolt and Washer [A] Right Air Cleaner Cover [B] Front [C] • Remove: ISC Valve Hoses [A] ISC Valve Lead Connectors [B] Air Cleaner Allen Bolts [C] and Screws [D] Air Cleaner Base Bolt [E] •...
Page 109: Lower Air Cleaner Duct Removal/Installation
FUEL SYSTEM (DFI) 3-25 Air Cleaner • Install the inlet air temperature sensor [A], the ISC valve #2 [B], ISC valve #1 [C], and the crankcase breather hose [D]. Torque - Inlet Air Temperature Sensor Nut [E]: 7.8 N m (0.80 kg m, 69 The ISC valve #2 is connected to W/R and G/Y leads, and the hose [F] marked red.
Page 110: Fuel Tank
3-26 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Removal Gasoline is extremely ﬂammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of ﬂame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF and disconnect the battery (–) terminal.
Page 111 FUEL SYSTEM (DFI) 3-27 Fuel Tank • Remove the seat (see Frame chapter). • Disconnect the battery (–) terminal [A]. • Raise the lock [B] and disconnect the fuel pump connector [C] (black, 4p). The fuel pump connector has fuel pump leads and fuel reserve switch leads.
Page 112: Fuel Tank Installation
3-28 FUEL SYSTEM (DFI) Fuel Tank • Raise the fuel tank [A] up, and make sure that the shop towel [B] is around the fuel outlet hose joint #1 [C]. • While pinching the hose joint locks [D] with ﬁngers, pull [E] the joint out along the fuel outlet pipe, and quickly plug the tank outlet pipe with the plug hose.
Page 113: Fuel Tank And Cap Inspection
FUEL SYSTEM (DFI) 3-29 Fuel Tank • Fit the outlet hose joint #1 [A] onto the outlet pipe until the joint clicks [B]. Insert the hose joint straight along the outlet pipe. • Pull the hose joint #1 [A] down [B] and make sure it is locked and doesn’t come off.
Page 114: Fuel Tank Cleaning
3-30 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Cleaning Clean the tank in a well-ventilated area, and take care that there are no sparks or ﬂame anywhere near the working area. Because of the danger of highly ﬂammable liquids, do not use gasoline or low-ﬂash point solvent to clean the tank.
Page 115: Evaporative Emission Control System
FUEL SYSTEM (DFI) 3-31 Evaporative Emission Control System The Evaporative Emission Control System for California Model routes fuel vapors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the intervals speciﬁed by the Periodic Maintenance Chart.
Page 116: Separator Operation Test
3-32 FUEL SYSTEM (DFI) Evaporative Emission Control System Separator Operation Test Gasoline is extremely ﬂammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of ﬂame or sparks; this includes any appliance with a pilot light.
Page 117: Troubleshooting The Dfi System
FUEL SYSTEM (DFI) 3-33 Troubleshooting the DFI System Outline When an abnormality in the system occurs, the FI indicator LED light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit).
Page 118 After measurement, remove the needle adapters and apply silicone sealant to the seals [A] of the connector [B] for waterprooﬁng. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Connector • Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system.
Page 119 FUEL SYSTEM (DFI) 3-35 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 replaced.
Page 120 3-36 FUEL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart...
Page 121 FUEL SYSTEM (DFI) 3-37 Troubleshooting the DFI System Notes: OK: No problem. NG: Problem exists. 1. Inspection starts. • An abnormality occurs in the DFI system, and the FI indicator LED light goes on to alert the rider. • Bring the motorcycle into the shop. 2.
Page 122: Problems And Inspection Order
3-38 FUEL SYSTEM (DFI) Troubleshooting the DFI System Problems and Inspection Order Problems Startability Idling stability Driveability Inspection items ECU ground and power supply Ignition SW, C3*, engine stop SW C16* Spark plug #1, #2 ISC valve #1, #2 In-tank fuel pump Fuel pressure Fuel injector #1, #2 Water temperature...
Page 123 FUEL SYSTEM (DFI) 3-39 Troubleshooting the DFI System Startability: (A): The starter motor rotates the engine but there is no combustion and the engine doesn’t start. (B): •There is combustion, but the engine stops immediately. •You need to push the starter button long to start the engine. When the engine is cold, this problem may be caused by too lean fuel-air mixture (due to poor fuel supply, ISC valve malfunction, water or air temperature sensor short, pressure...
Page 124 3-40 FUEL SYSTEM (DFI) Troubleshooting the DFI System (H): Stumble (due to temporal power drop probably caused by too lean fuel-air mixture.) When the motorcycle is about to accelerate, the engine speed cannot increase in response to throttle opening, and increases with a lag (longer lag than in hesitation) [B] at opening [C] the throttle.
Page 125: Inquiries To Rider
FUEL SYSTEM (DFI) 3-41 Troubleshooting the DFI System Inquiries to Rider • Refer to the next diagnosis chart. 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;...
Page 126 3-42 FUEL SYSTEM (DFI) Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. Weather ﬁne, cloudy, rain, snow, always, other: Temperature...
Page 127: Ecu
FUEL SYSTEM (DFI) 3-43 ECU Identiﬁcation Most countries have their own regulations, so each ECU has different characteristic of fuel injection according to each country. So, do not confuse ECU’s with each other and use only the ECU’s for your country.
Page 128: Ecu Power Supply Inspection
3-44 FUEL SYSTEM (DFI) ECU Power Supply Inspection • Visually inspect the terminals of the ECU connector. If the connector is clogged with mud or dust, blow it off with compressed air. Replace the main harness if the terminals [A] of the main harness connectors are cracked, bent, or otherwise damaged.
Page 129: Dfi Power Source
FUEL SYSTEM (DFI) 3-45 DFI Power Source DFI Fuse Removal • Remove the seat (see Frame chapter). • Pull the lock [A] and open the lid [B]. • Pull out the DFI fuse [C] from the case with needle nose pliers. Front [D] 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 130 3-46 FUEL SYSTEM (DFI) DFI Power Source DFI Power Source Circuit ECU [A] MF Battery [Q] ISC Valve #1 [W] Junction Box [F] Fuel Injector #1 [R] ISC Valve #2 [X] Ignition SW [N] Fuel Injector #2 [S] DFI Main Relay [e] Starter Relay [O] In-tank Fuel Pump [U] Ignition Fuse 10 A [f]...
Page 131: Fi Indicator Led Light
FUEL SYSTEM (DFI) 3-47 FI Indicator LED Light Inspection Flow Chart...
Page 132: Led Light Inspection
3-48 FUEL SYSTEM (DFI) FI Indicator LED Light The FI indicator LED light [A] goes ON when the ignition SW is turned ON and the LED light goes OFF 2 seconds later. This is to ensure that the FI indicator LED light has not burned out and the DFI system and the ignition system function properly.
Page 133: Isc Valves
FUEL SYSTEM (DFI) 3-49 ISC Valves Removal/Installation CAUTION Never drop the ISC valves, especially on a hard surface. Such a shock to the valve can damage it. The ISC valves are removed during right air cleaner housing removal (see this chapter). The ISC valve itself is the same for front and rear, but wiring is different.
Page 134: Resistance Inspection
3-50 FUEL SYSTEM (DFI) ISC Valves Output Voltage of ISC Valves Connections for ISC Valve #2 [C] Tester (+) W/R lead Tester (–) G/Y lead Connections for ISC Valve #1 [D] Tester (+) W/R lead Tester (–) G/BL lead Reading: The needle points battery voltage (12.5 V or more) and 11 seconds later 0 V.
Page 135: Fuel Line
FUEL SYSTEM (DFI) 3-51 Fuel Line Fuel Pressure Inspection NOTE This inspection can detect the faults of the DFI fuel line other than the DFI electronic system. It is preferable to measure the fuel pressure while running the motorcycle when the trouble has occurred in order to know symptom well.
Page 136: Pressure Regulator Removal
3-52 FUEL SYSTEM (DFI) Fuel Line • Measure the fuel pressure with the throttle fully opened a moment. Fuel Pressure (with throttle fully opened) Standard: 280 kPa (2.7 2.9 kg/cm , 38 41 psi) NOTE The gauge needle will ﬂuctuate. Read the pressure at the average of the maximum and minimum indications.
Page 137: Fuel Flow Rate Inspection
FUEL SYSTEM (DFI) 3-53 Fuel Line Fuel Flow Rate Inspection NOTE Be sure the battery is fully charged. Gasoline is extremely ﬂammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of ﬂame or sparks; this includes any appliance with a pilot light.
Page 138: Self-Diagnosis
3-54 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Conducting When a problem occurs with the DFI system, the DFI indicator LED light [A] goes on. • Remove the seat (see Frame chapter) and take the ECU [B] out. • Enter the self-diagnosis mode by grounding the self-diagnosis check female connector [C] to the battery (–) connector [D], using a wire [E].
Page 139 FUEL SYSTEM (DFI) 3-55 Self-Diagnosis...
Page 140: Fault Code Reading
3-56 FUEL SYSTEM (DFI) Self-Diagnosis Fault Code Reading Fault codes are shown by a series of long and short blinks of the FI indicator LED light as shown below. Read 10th digit and unit digit as the FI indicator LED light blinks. When there are a number of problems, all the fault codes can be stored and the display will begin starting from the lowest number fault code in the numerical order.
Page 141 FUEL SYSTEM (DFI) 3-57 Self-Diagnosis Fault Code Table Fault FI Indicator LED Light Problems (1) Code Throttle sensor malfunction, wiring open or short Vacuum sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Atmospheric pressure sensor malfunction, wiring open or short Pickup coil #1 malfunction, wiring open or short Pickup coil #2 malfunction, wiring open or short...
Page 142 3-58 FUEL SYSTEM (DFI) Self-Diagnosis Backups The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Fault Output Signal Usable Parts Backups by ECU Range or Criteria Codes Throttle Throttle Valve Opening If the throttle sensor system fails (the signal is out of Sensor Angle...
Page 143: Throttle Sensor (Fault Code 11)
FUEL SYSTEM (DFI) 3-59 Throttle Sensor (Fault Code 11) Throttle Sensor Removal/Adjustment CAUTION Do not remove or adjust the throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it.
Page 144: Resistance Inspection
• After throttle sensor inspection, remove the needle adapters, and apply silicone sealant to the seals [A] of the connector [B] for waterprooﬁng. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Connectors Resistance Inspection • Turn the ignition switch OFF.
Page 145: Vacuum Sensor (Fault Code 12)
FUEL SYSTEM (DFI) 3-61 Vacuum Sensor (Fault Code 12) Removal CAUTION 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 section in this chapter). •...
Page 146: Output Voltage Inspection
Turn the ignition SW OFF and remove the needle adapters. • Apply silicone sealant to the seals of the connector for waterprooﬁng. Silicone Sealant (Kawasaki Bond: 56019-120) - Connector Seals If the output voltage is normal, check the vacuum sensor output voltage for vacuum other than 76 cmHg (abs) as follows.
Page 147 FUEL SYSTEM (DFI) 3-63 Vacuum Sensor (Fault Code 12) Suppose: Pg : Vacuum (gauge) of Throttle Assy Pl : Local Atmospheric Pressure (absolute) measured by a barome- Pv : Vacuum (absolute) of Throttle Assy Vv : Sensor Output Voltage (v) then Pv = Pl –...
Page 148 3-64 FUEL SYSTEM (DFI) Vacuum Sensor (Fault Code 12) Pv = 55 86 cm Hg Vv: Vacuum Sensor Output Voltage (V) ID: Idling (Digital Meter Reading) TO: Throttle Full Open Pv: Throttle Vacuum (absolute) ST: Standard of Sensor Output Voltage (v) Ps: Standard Atmospheric Pressure (absolute) UR: Usable Range of Sensor Output Voltage (v) ECU [A]...
Page 149: Inlet Air Temperature Sensor (Fault Code 13)
ECU and the inlet air temperature sensor. If the wiring is good, check the sensor resistance. • Remove the needle adapters, and apply silicone sealant to the seals of the connector for waterprooﬁng. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Connector...
Page 150: Sensor Resistance Inspection
3-66 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Fault Code 13) Sensor Resistance Inspection • Remove the inlet air temperature sensor (see this section). • Suspend the sensor [A] in a container of machine oil so that the heat- sensitive portion and threaded portion are submerged. •...
Page 151: Water Temperature Sensor (Fault Code 14)
Cooling System chapter). • Disconnect the sensor connector, and unscrew the water temperature sensor [B]. Top [C] Silicone Sealant (Kawasaki Bond: 56019-120) - Threads of Water Temperature Sensor Torque - Water Temperature Sensor: 18 N m (1.8 kg m, 13 ft •...
Page 152: Sensor Resistance Inspection
3-68 FUEL SYSTEM (DFI) Water Temperature Sensor (Fault Code 14) Sensor Resistance Inspection • Remove the water temperature sensor (see this section). • Suspend the sensor [A] in a container of machine oil so that the heat- sensitive portion and threaded portion are submerged. •...
Page 153: Atmospheric Pressure Sensor (Fault Code 15)
ECU and the atmospheric pressure sensor for continuity. If the wiring is good, check the output voltage. • Remove the needle adapters. • Apply silicone sealant to the seals of the connector for waterprooﬁng. Silicone Sealant (Kawasaki Bond: 56019-120) - ECU Connector Seals...
Page 154 If the output voltage is out of the usable range, replace the sensor. • Turn the ignition SW OFF and remove the needle adapters. • Apply silicone sealant the seals of the connector for waterprooﬁng. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Sensor Connector ECU [A] Atmospheric Pressure Sensor [b]...
Page 155 FUEL SYSTEM (DFI) 3-71 Atmospheric Pressure Sensor (Fault Code 15) If you need to check the atmospheric pressure sensor for various altitudes other than sea level, check the output voltage as follows: Determine the local altitude (elevation). If you know the local atmospheric pressure using a barometer, substitute the atmospheric pressure for Pv (Throttle Vacuum) in the vacuum sensor chart (see Vacuum Sensor section in this chapter).
Page 156 3-72 FUEL SYSTEM (DFI) Pickup Coils (#1, #2: Fault Code 21, 22) Pickup Coil #1: for Front Cylinder (Fault Code 21) Pickup Coil #2: for Rear Cylinder (Fault Code 22) Pickup Coil Removal/Installation • See Ignition System section in the Electrical System chapter. Pickup Coil Inspection The pickup coils have no power source, and when the engine stops, the pickup coils generates no signals.
Page 157 FUEL SYSTEM (DFI) 3-73 Vehicle-down Sensor (Fault Code 31) Removal CAUTION Never drop the down-sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the seat (see Frame chapter). • Remove the bolt [A] and take out the vehicle-down sensor [B]. •...
Page 158 • Remove the needle adapters, and apply silicone sealant to the seals of the connector for waterprooﬁng. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Vehicle-down Sensor Connector If the output voltage is out of the speciﬁed, replace the vehicle-down sensor.
Page 159 FUEL SYSTEM (DFI) 3-75 Fuel Injectors (#1, #2: Fault Code 41, 42) Fuel Injector #1: Front Fuel Injector for Front Cylinder (Fault Code Fuel Injector #2: Rear Fuel Injector for Rear Cylinder (Fault Code CAUTION Never drop the injector, especially on a hard surface. Such a shock to the injector can damage it.
Page 160 3-76 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Fault Code 41, 42) The screen [A] comes off from the pressure regulator [B]. Delivery Joint [C] Front [D] • Clean the screen with a high-ﬂash point solvent to remove any particles. Clean the screen in a well-ventilated area, and take care that there is no spark or ﬂame anywhere near the working area.
Page 161 FUEL SYSTEM (DFI) 3-77 Fuel Injectors (#1, #2: Fault Code 41, 42) • Check the injector fuel line for leakage as follows: Connect a commercially available vacuum/pressure pump [C] and a rubber hose [I] to the fuel hose [B] of the delivery joint [A] as shown. Plug the outlet of the pressure regulator [G] with a rubber plug [J] (e.g.
Page 162 3-78 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Fault Code 41, 42) • Pull the hose joint #2 [A] up [B] and make sure it is locked and doesn’t come off. • Install the fuel tank (see this chapter) and connect the battery (–) terminal.
Page 163 FUEL SYSTEM (DFI) 3-79 Fuel Injectors (#1, #2: Fault Code 41, 42) If the power source voltage is incorrect, check the DFI power source (see DFI Power Source in this chapter). If the DFI power source is good, check the ECU for its ground and power supply. If the ground and power supply of the ECU are good, the ECU is suspect.
Page 164 3-80 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Fault Code 41, 42) • Remove the fuel tank (see this chapter). • Plug the fuel hose ends. • Remove connectors for injector [A]. • Connect each test light set [B] to the injector main harness connector [C].
Page 165 FUEL SYSTEM (DFI) 3-81 Fuel Injectors (#1, #2: Fault Code 41, 42) • Connect the test light set to the injector [E] as shown. • Open and connect [F] the end of the wire to the battery (–) terminal repeatedly. The injector should click. If the injector does not click, replace the injector.
Page 166 3-82 FUEL SYSTEM (DFI) In-tank Fuel Pump (Fault Code 45) Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard surface. Such a shock to the pump can damage it. Gasoline is extremely ﬂammable and can be explosive under certain conditions.
Page 167 FUEL SYSTEM (DFI) 3-83 In-tank Fuel Pump (Fault Code 45) Fuel Pump Installation • Clean the pump screen (see Pump Filter Cleaning). • Remove dirt or dust from the fuel pump by lightly applying com- pressed air. • Replace the fuel pump gasket with a new one. •...
Page 168 3-84 FUEL SYSTEM (DFI) In-tank Fuel Pump (Fault Code 45) Operation Inspection NOTE Be sure the battery is fully charged. Just listen to the pump sound in the fuel tank to conﬁrm pump operation. • Turn the ignition SW ON and make sure that the fuel pump operates (make light sounds) for 3 seconds, and then stops.
Page 169 ECU is suspect. Replace the ECU. • After inspection, remove the needle adapter, and apply silicone sealant to the seal of the connector for waterprooﬁng. Silicone Sealant (Kawasaki Bond: 56019-120) - Sealing of Fuel Pump Connector ECU [A] Starter Relay [O]...
Page 170 (see Electrical System chapter) in order to check the primary coils. • Remove the needle adapters. • Apply silicone sealant to the seals of the connector for waterprooﬁng. Silicone Sealant (Kawasaki Bond: 56019-120) - ECU Connector Seals...
Page 171 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View...................................4-2 Coolant Flow Chart................................4-4 Speciﬁcations ..................................4-6 Coolant....................................4-7 Coolant Deterioration Inspection..........................4-7 Coolant Level Inspection............................4-7 Coolant Draining.................................4-7 Coolant Filling................................4-7 Pressure Testing.................................4-8 Cooling System Flushing ............................4-8 Water Pump ..................................4-9 Water Pump Removal ..............................4-9 Water Pump Installation .............................
Page 172: Exploded View
4-2 COOLING SYSTEM Exploded View...
Page 173 14. Ball Bearing 15. Water Pump Air Bleeder Bolt G: Apply grease. Lh: Left-hand Threads R: Replacement Parts SS: Apply silicone sealant (Kawasaki Bond: 56019-120). T1: 2.5 N m (0.25 kg m, 22 in T2: 7.8 N m (0.80 kg...
Page 174: Coolant Flow Chart
4-4 COOLING SYSTEM 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 as coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
Page 175 COOLING SYSTEM 4-5 Coolant Flow Chart 1. Water Pump 9. Radiator 2. Water Jacket 10. Radiator Fan 3. Cylinder Head 11. Throttle Assy 4. Water Pipe 12. Front 5. Water Hose 13. Cold Coolant 6. Radiator Cap 14. Hot Coolant 7.
Page 176: Speciﬁcations
Valve opening temperature C (136 Valve full opening lift 8 mm (0.3 in) or more @75 C (167 Special Tools - Bearing Driver Set: 57001-1129 Bearing Remover Shaft: 57001-1265 Bearing Remover Head, 12: 57001-1266 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
Page 177: Coolant
COOLING SYSTEM 4-7 Coolant Coolant Deterioration Inspection • Remove the right side cover (see 15. 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. If the coolant is brown, iron or steel parts are rusting.
Page 178: Pressure Testing
4-8 COOLING SYSTEM Coolant Pressure Testing • Remove the fuel tank (see 3. Fuel System chapter). • Remove the radiator cap, and install a cooling system pressure tester [A] on the radiator ﬁller neck [B]. NOTE Wet the cap sealing surfaces with water or coolant to prevent pressure leakage.
Page 179: Water Pump
COOLING SYSTEM 4-9 Water Pump Water Pump Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance Chapter - 2nd chapter). • Remove: Water Hose Clamp [A] Water Hose [B] Front [C] • Remove: Water Pump Cover Bolts [A] Water Pump Cover [B] •...
Page 180: Water Pump Inspection
4-10 COOLING SYSTEM Water Pump Water Pump Inspection • Check the water pump drainage outlet hose [A] at the bottom of the water pump for coolant leakage. If the mechanical seal is damaged, the coolant leaks through the seal and drain through the passage. Replace the mechanical seal. •...
Page 181 COOLING SYSTEM 4-11 Water Pump • Using a thin-bladed screwdriver, pry out the oil seal. • Press out the mechanical seal [A] and ball bearing [B] from the inside of the right crankcase with the bearing driver set [C]. Special Tool - Bearing Driver Set: 57001-1129 Be sure to replace the mechanical seal, oil seal, O-ring, and ball bearings with new ones because these parts will be damaged by...
Page 182: Radiator
4-12 COOLING SYSTEM Radiator The radiator fan is connected directly to the battery. The ra- diator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CON- NECTOR IS DISCONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES.
Page 183: Radiator Inspection
COOLING SYSTEM 4-13 Radiator • Fit the radiator stoppers [A] into the right and left grommets. • Install the pump inlet hose and position the hose clamp (see Water Pump Installation in this chapter). • Tighten: Torque - Hose Clamp Screws: 2.5 N m (0.25 kg m, 22 in Radiator Inspection...
Page 184: Radiator Filler Neck Inspection
4-14 COOLING SYSTEM Radiator • Install the cap [A] on a cooling system pressure tester [B]. NOTE Wet the cap sealing surfaces with water or coolant to prevent pressure leakage. • Watching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gauge needle ﬂicks downward.
Page 185: Thermostat
COOLING SYSTEM 4-15 Thermostat Thermostat Removal • Remove: Coolant : Drain about 200 mL Fuel Tank (see Fuel System chapter - 3rd chapter) Four Water Hoses [A] Bracket Bolts [B] Water Temperature Sensor Connector • Remove the thermostat housing [C] along with the bracket. Front [D] •...
Page 186: Hoses And Pipes
4-16 COOLING SYSTEM Hoses and Pipes Hose Installation • Install the hoses and pipes being careful to follow bending direction. Avoid sharp bending, kinking, ﬂattening, or twisting. • Install the clamps [A] as near as possible to the hose end to clear the raised rib on the ﬁtting.
Page 187 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View............5-2 Cylinder Head............5-21 Speciﬁcations ............. 5-5 Cylinder Compression Measurement....5-21 Clean Air System ............5-8 Removal.............5-22 Air Suction Valve Removal........5-8 Installation............5-22 Air Suction Valve Installation.......5-8 Cylinder Head Warp..........5-23 Air Suction Valve Check........5-8 Valve Clearance Adjustment ......
Page 188 8 mm, 25 N m (2.5 kg m, 18.0 ft S: Follow the speciﬁc tightening sequence. T5: 7.4 N m (0.75 kg m, 65 in SS: Apply silicone sealant (Kawasaki Bond: 56019-120). T6: 20 N m (2.0 kg m, 15 ft...
Page 189 ENGINE TOP END 5-3 Exploded View 1. Rear Exhaust Pipe PN: Spray a penetrating oil on the nuts and studs 2. Front Exhaust Pipe if the nuts are difﬁcult to remove. 3. Upper Mufﬂer M: Apply molybdenum disulﬁde grease. 4. Lower Mufﬂer R: Replacement Parts 5.
Page 190 5-4 ENGINE TOP END Exploded View 1. Coolant Drain Bolts R: Replacement Parts 2. KACR Unit S: Follow the speciﬁc tightening sequence. 3. “R” marked side faces up. T1: 11 N m (1.1 kg m, 95 in 4. “RN” marked side faces up. T2: 20 N m (2.0 kg m, 15 ft...
Page 191 ENGINE TOP END 5-5 Speciﬁcations Item Standard Service Limit Clean Air System: Vacuum switch valve closing pressure: Open Close 42.7 50.7 kPa – – – (320 380 mm Hg) Camshafts: 33.741 33.857 mm Cam height: Exhaust 33.64 mm (1.32839 1.33295 in) (1.3244 in) Inlet 33.928...
Page 192 5-6 ENGINE TOP END Speciﬁcations Item Standard Service Limit Valve seat surface: Valve seat cutting angle , 32 , 55 – – – Outside diameter: Exhaust 31.9 32.1 mm (1.256 1.264 in) – – – Inlet 36.4 36.6 mm (1.433 1.441 in) –...
Page 193 Hexagon Wrench, Hex 27: 57001-1210 Compression Gauge Adapter: 57001-1183 can also be used. Valve Seat Cutter, 32 – 33: 57001-1199 can also be used instead of Valve Seat Cutter, 32 – 35: 57001-1121 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
Page 194 5-8 ENGINE TOP END Clean Air System Air Suction Valve Removal • For rear air suction valve removal, remove the rear exhaust pipe (see this chapter). • Remove the hose [A]. • Unscrew the mounting bolts [B] and remove the rear air suction valve cover [C].
Page 195: Clean Air System
ENGINE TOP END 5-9 Clean Air System Vacuum Switch Valve Installation • Install the vacuum switch valve [A] so that the air hole [B] faces downwards. • Route the hoses correctly (see General Information chapter). Front [C] Vacuum Switch Valve Operation Test •...
Page 196 5-10 ENGINE TOP END Clean Air System If the vacuum switch valve does not operate as described, replace it with a new one. NOTE To check air ﬂow through the vacuum switch valve, just blow through the air cleaner hose [C]. Vacuum Switch Valve Closing Pressure (Open Close) Standard:...
Page 197: Camshaft Chain Tensioner
ENGINE TOP END 5-11 Camshaft Chain Tensioner Removal CAUTION This is a non-return type cam 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 198 5-12 ENGINE TOP END Camshaft Chain Tensioner • Install the larger spring [A], and then the ball bearing assy [B]. Fit the ball bearing assy into the body until it bottoms out, using a thin-bladed screwdriver. • Screw in the lockbolt [A] ﬁnger-tight to hold the ball bearing assy temporarily.
Page 199 ENGINE TOP END 5-13 Rocker Case Cover Removal • Remove the engine (see Engine Removal/Installation chapter). • Remove the bolts [A] and take off the cover [B] from the rocker case. • Take out the oil ﬁlter springs [A] and HLA oil ﬁlters [B]. Installation •...
Page 200 18 ft • Apply silicone sealant [A] to the rocker case mating surface and the outer circumference of the plugs as shown. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Do not apply silicone sealant around the camshaft bearing. Inlet Side [B]...
Page 201 ENGINE TOP END 5-15 Rocker Case • Apply molybdenum disulﬁde oil to the threads and seating surface of 12 mm nuts and both sides of washers. • Tighten the rocker case nuts and bolts temporarily following the tightening sequence shown, and then tighten them to the speciﬁed torque.
Page 202 5-16 ENGINE TOP END Rocker Case HLA Removal • Remove the rocker case (see this chapter). • Remove the rocker arms. • Pull the HLA (hydraulic lash adjuster) [B] out of the rocker arm [A] with your ﬁngers. CAUTION Be careful not to damage or deform an HLA by tapping it during removal or installation.
Page 203 ENGINE TOP END 5-17 Camshafts Removal • Remove the timing inspection cap and rotor bolt cap. Special Tool - Driver-Filler Cap: 57001–1454 • Turn the crankshaft counterclockwise [A] and align the “F” mark [B] (TDC mark for the front piston) with the middle of the notch [C]. •...
Page 204 5-18 ENGINE TOP END Camshafts • First, install the front camshaft. Engage the front camshaft sprocket with the camshaft chain as shown. Timing Marks [A] F mark [B] Cylinder Head Upper Surface [C] Front [D] Pull the front side (exhaust side) of the chain taut to install the camshaft.
Page 205 ENGINE TOP END 5-19 Camshafts Camshaft/Rocker Case Wear • Cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position. • Measure each clearance between the camshaft and the rocker case using plastigage.
Page 206 128.9 mm (5.0748 in) Limit: KACR Inspection Due to the simplicity of the KACR (Kawasaki Automatic Compression Release), no periodic maintenance is needed. There are only two symptoms of problems with the KACR mechanism compression is not released during starting, and compression is released during running.
Page 207: Cylinder Head
ENGINE TOP END 5-21 Cylinder Head Cylinder Compression Measurement NOTE Be sure the battery is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove one spark plug and attach the compression gauge and adapter ﬁrmly into the spark plug hole. Do not remove the other spark plug, only the plug lead.
Page 208: Spark Plug Retainer
5-22 ENGINE TOP END Cylinder Head Removal • Remove: Engine (see Engine Removal/Installation chapter) Rocker Cases (see this chapter) Camshafts (see this chapter) Spark Plugs [A] Spark Plug Retainers [B] Special Tool - Hexagon Wrench, Hex 27 [C]: 57001-1210 The camshaft chain comes off. •...
Page 209 ENGINE TOP END 5-23 Cylinder Head Cylinder Head Warp • Lay a straightedge across the lower surface of the cylinder head at several positions. • Use a thickness gauge [A] to measure the space between the straight edge [B] and the head. Cylinder Head Warp Standard: - - -...
Page 210 5-24 ENGINE TOP END Cylinder Head 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 C (248 F) in the engine oil. •...
Page 211 ENGINE TOP END 5-25 Cylinder Head Valve Seat Repair • Repair the valve seat with the valve seat cutters [A]. Special Tools - Valve Seat Cutter Holder, 7: 57001-1126 [B] Valve Seat Cutter Holder Bar: 57001-1128 [C] [For Exhaust Valve Seat] Valve Seat Cutter, 45 –...
Page 212 5-26 ENGINE TOP END Cylinder Head Operating Procedures: • Clean the seat area carefully. • Coat the seat with machinist’s dye. • Fit a 45 cutter [A] into the holder [B] and slide it into the valve guide. • Press down lightly on the handle and turn it right or left [C]. Grind the seat surface only until it is smooth.
Page 213 ENGINE TOP END 5-27 Cylinder Head • Lap the valve to the seat, once the seat width and O.D. are within the ranges speciﬁed above. Put a little coarse grinding compound on the face of the valve in a number of places around the valve head. Spin the valve against the seat until the grinding compound produces a smooth, matched surface on both the seat and the valve.
Page 214 5-28 ENGINE TOP END Cylinder Head...
Page 215 ENGINE TOP END 5-29 Cylinders, Piston Cylinder Removal • Remove the cylinder head (see this chapter). • Remove the coolant drain plug [A] and drain the coolant from the cylinder. • Pull out the front camshaft chain guide [B]. • Remove the cylinder nuts [C].
Page 216 5-30 ENGINE TOP END Cylinders, Piston The front chain guide for the front cylinder has an F mark [A] and the front chain guide for the rear cylinder has an R mark [B]. Be careful not to mix up these chain guides since the front chain guide for the rear cylinder is longer.
Page 217 ENGINE TOP END 5-31 Cylinders, Piston • Face the arrow mark [A] on each piston toward the front side [B]. The front and rear pistons are the same, but they should be installed in their original positions. CAUTION Incorrect installation of the piston could cause piston seizure and result in severe engine damage.
Page 218 5-32 ENGINE TOP END Cylinders, Piston Piston Wear • Measure the outside diameter [A] of each piston 5 mm [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 piston. Piston Diameter Standard: 101.937 ~ 101.952 mm (4.013268 ~ 4.013858 in)
Page 219 ENGINE TOP END 5-33 Cylinders, Piston If the piston ring groove clearance is greater than the service limit, measure the ring thickness and groove width as follows to decide whether to replace the rings, the piston or both. Piston Ring Groove Width •...
Page 220 5-34 ENGINE TOP END Mufﬂers Exhaust Pipe Removal To avoid a serious burn, do not remove the exhaust pipe or mufﬂer when the engine is still hot. Wait until the mufﬂer cools down. • Loosen the upper mufﬂer bracket bolt [A] for easy removal or installation of exhaust pipes.
Page 221 ENGINE TOP END 5-35 Mufﬂers Lower Mufﬂer Removal • Remove: Front and Rear Exhaust Pipe Covers (see above) Chamber Flange Nuts [A] Mufﬂer Bracket Bolts [B] • Remove the lower mufﬂer [C]. NOTE If the chamber ﬂange nuts are difﬁcult to remove, spray a penetrat- ing oil on the studs and nuts.
Page 222 5-36 ENGINE TOP END Mufﬂers Chamber Removal • Remove: Front Exhaust Pipe [A] Rear Exhaust Pipe [B] Lower and Upper Mufﬂers [C] Right and Left Chamber Bolts [D] • Take out the premufﬂer chamber [E]. Front [F] Chamber Installation • Replace the mufﬂer ﬂange gasket with new ones.
Page 223 CLUTCH 6-1 Clutch Table of Contents Exploded View...................................6-2 Speciﬁcations ..................................6-3 Clutch Fluid ..................................6-4 Clutch Fluid Level Check............................6-4 Clutch Fluid Change..............................6-4 Clutch Line Bleeding ..............................6-4 Clutch Hose Removal/Installation ..........................6-4 Clutch Hose and Connection Check..........................6-4 Clutch Master Cylinder..............................6-5 Clutch Lever Adjustment ............................
Page 224: Exploded View
6-2 CLUTCH Exploded View T1: 1.0 N m (0.10 kg m, 8.7 in EO: Apply engine oil. T2: 5.9 N m (0.60 kg m, 52 in L: Apply a non-permanent locking agent. T3: 1.5 N m (0.15 kg m, 13 in M: Apply molybdenum disulﬁde grease.
Page 225: Speciﬁcations
CLUTCH 6-3 Speciﬁcations Item Standard Service Limit Clutch Fluid Grade DOT4 (provided when shipping) – – – Clutch Lever Position No. 1 (to suit rider) 5-way adjustable Clutch Lever Free Play Non-adjustable – – – Clutch Clutch spring free height 5.98 mm (0.235 in) 5.6 mm (0.22in) Spring plate gap (usable range)
Page 226: Clutch Fluid
6-4 CLUTCH Clutch Fluid Clutch Fluid Level Check Refer to Clutch Fluid Level Check in the Periodic Maintenance Chapter (2nd chapter). Clutch Fluid Change Refer to Clutch Fluid Change in the Periodic Maintenance Chapter (2nd chapter). Clutch Line Bleeding • With the reservoir cap off, slowly pump the clutch lever several times until no air bubbles can be seen rising up through the ﬂuid from the holes at the bottom of the reservoir.
Page 227: Clutch Master Cylinder
CLUTCH 6-5 Clutch Master Cylinder Clutch Lever Adjustment The adjuster has 5 positions so that the clutch lever position can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder (front view).
Page 228: Clutch Master Cylinder Inspection
6-6 CLUTCH Clutch Master Cylinder Clutch Master Cylinder Inspection • Disassemble the clutch master cylinder. • Check that there are no scratches, rust or pitting on the inside of the master cylinder [A] and on the outside of the piston [B]. If the master cylinder or piston shows any damage, replace them.
Page 229: Clutch Slave Cylinder
CLUTCH 6-7 Clutch Slave Cylinder Removal • Remove: Alternator Outer Cover (see Electrical System chapter) Banjo Bolt [A] Clutch Slave Cylinder Bolts [B] Slave Cylinder [C] CAUTION Immediately wash away any clutch ﬂuid that spills. It may damage painted surfaces. •...
Page 230: Disassembly/Assembly
6-8 CLUTCH Clutch Slave Cylinder Disassembly/Assembly Refer to Clutch Slave Cylinder Piston Seal Replacement in the Periodic Maintenance Chapter (2nd chapter).
Page 231: Clutch Cover Removal
CLUTCH 6-9 Clutch Clutch Cover Removal • Drain the engine oil (see 2. Periodic Maintenance chapter). • Remove: Front Exhaust Pipe [A] (see Engine Top End chapter) Downtube [B] (see Frame chapter, but remove the downtube with the right footpeg and rear master cylinder left installed) •...
Page 232: Clutch Installation
6-10 CLUTCH Clutch • Take the inner clutch hub [A], collar [B], washer [C] and clutch housing [D] out of the crankcase. • Pull the needle bearing [A], sleeve [B], and thrust washer [C] off the drive shaft. Clutch Installation When replacing any one of the following parts, check the spring plate free play (see Spring Plate Free Play Measurement).
Page 233: Inner Clutch Hub Disassembly
CLUTCH 6-11 Clutch • Install the clutch spring [A] on the spring holder [B], nothing the direction. • Apply grease to the back torque limiter springs [C] and install them on the spring holder as shown. Clutch Hub Nut [D] (for reference) •...
Page 234: Spring Plate Gap Measurement
6-12 CLUTCH Clutch Spring Plate Gap Measurement Insufﬁcient spring plate gap will cause the engine braking effect to be more sudden, resulting in rear wheel hop. On the other hand, if the spring plate gap is excessive, the clutch may slip or the clutch lever may feel “spongy”...
Page 235: Spring Plate Gap Adjustment
CLUTCH 6-13 Clutch • Remove the clutch spring plate. • Peel off these strips with a thin-bladed screwdriver. • Measure the pressed thickness [A] of each strip with vernier calipers. The thickness represents the spring plate gap. Spring Plate Gap Usable Range: 1.95 ~ 2.45 mm (0.0768 ~ 0.0965 in) NOTE In case of rear wheel hop, adjust the spring plate gap a bit larger,...
Page 236: Clutch Spring Height Measurement
6-14 CLUTCH Clutch Clutch Spring Height Measurement • Measure the height [B] of the clutch spring [A]. If the spring height is less than the service limit, it must be replaced. Clutch Spring Height Standard: 5.98 mm (0.235 in) Service Limit: 5.6 mm (0.22 in) Clutch Housing Finger Inspection •...
Page 237 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Engine Oil Flow Chart...............................7-2 Exploded View...................................7-4 Speciﬁcations ..................................7-5 Engine Oil and Oil Filter..............................7-6 Oil Level Inspection..............................7-6 Engine Oil Change..............................7-6 Oil Filter Replacement..............................7-6 Oil Pump and Oil Line...............................7-7 Oil Pump Removal ..............................7-7 Oil Pump Installation ..............................
Page 238: Engine Oil Flow Chart
7-2 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
Page 239 ENGINE LUBRICATION SYSTEM 7-3 Engine Oil Flow Chart : Oil Flow (1 ~ 30) : Blowby Gas 1. Oil Screen 2. Oil Pump 3. Relief Valve 4. Oil Filter 5. Bypass Valve 6. Oil Pressure Switch 7. Inside Oil Pipe 8.
Page 240: Exploded View
3. Rear Rocker Case Lh: Left-hand Threads 4. Oil Separator (smaller side goes ﬁrst.) R: Replacement Parts 5. Oil Nozzle ( SS: Apply silicone sealant (Kawasaki Bond: 56019-120). 3), right-hand threads 6. Oil Return Pipes T1: 20 N m (2.0 kg m, 14 ft 7.
Page 241: Speciﬁcations
440 kPa (3.5 4.5 kg/cm , 50 64 psi) Special Tools - Driver-Filler Cap: 57001–1454 Oil Pressure Gauge, 5 kg/cm : 57001-125 Oil Pressure Gauge Adapter, PT 1/8: 57001-1033 Oil Filter Wrench: 57001-1249 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
Page 242: Engine Oil And Oil Filter
7-6 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Motorcycle operation with insufﬁcient, deteriorated, or con- taminated engine oil will cause accelerated wear and may re- sult in engine or transmission seizure, accident, and injury. Oil Level Inspection • Situate the motorcycle so that it is vertical. •...
Page 243: Oil Pump And Oil Line
ENGINE LUBRICATION SYSTEM 7-7 Oil Pump and Oil Line Oil Pump Removal • Remove the engine (see 8. Engine Removal/Installation chapter). • Split the crankcase (see 9. Crankshaft/Transmission chapter). • Remove the oil pump mounting bolts, and take off the pump [A] out of the right crankcase.
Page 244: Inside Oil Pipe Removal
7-8 ENGINE LUBRICATION SYSTEM Oil Pump and Oil Line • Install each bottom end of the oil hoses on the right crankcase behind the rear cylinder as shown. Front Oil Hose [A] Rear Oil Hose [B] Face the paint marks [C] rearward. •...
Page 245: Blowby Gas System Inspection
ENGINE LUBRICATION SYSTEM 7-9 Oil Pump and Oil Line • Install the oil return pipes as shown. Do not apply silicone sealant to the groove of the grommet and the mating surface of the grommet. Left Crankcase [A] Right Oil Return Pipe [D] Right Crankcase [B] Front [E] Left Oil Return Pipe [C]...
Page 246: Oil Pressure
7-10 ENGINE LUBRICATION SYSTEM Oil Pressure Oil Pressure Measurement NOTE Measure the oil pressure after the engine is warmed up. • Remove the oil pressure switch lead and unscrew the oil pressure switch [A] from the left crankcase. • Attach the oil pressure gauge [B] and adapter [C] to the switch hole. Special Tools - Oil Pressure Gauge, 5 kg/cm : 57001-125 Oil Pressure Gauge Adapter, PT 1/8: 57001-1033...
Page 247 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View...................................8-2 Speciﬁcations ..................................8-3 Engine Removal/Installation..............................8-4 Engine Removal ................................. 8-4 Engine Installation..............................8-7...
Page 248: Exploded View
8-2 ENGINE REMOVAL/INSTALLATION Exploded View WL: Apply a soap and water solution or rubber lubricant. T1: 44 N m (4.5 kg m, 32 ft T2: 25 N m (2.5 kg m, 18 ft...
Page 249: Speciﬁcations
ENGINE REMOVAL/INSTALLATION 8-3 Speciﬁcations Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398...
Page 250: Engine Removal/Installation
8-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Support the rear part of the frame on the jack [A], and the attachment jack [C]. Front [B] Fit the ribs of the frame into the groove of the attachments. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398 •...
Page 251 ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation • Disconnect: Snap-on Clamps [A] (pry open) Radiator Fan Motor Connector [B] Rear Brake Light Switch Connector [C] Spark Plug Leads [D] Front [E] • Remove: Shift Pedal (see Crankshaft/Transmission chapter) Alternator Outer Cover (see Electrical System chapter) •...
Page 252 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Support the engine with a commercially available stand [A]. • Remove: Right Spark Plug Lead Holder Front and Rear Exhaust Pipes (see Engine Top End chapter) Engine Mounting Bracket Bolts [B] Downtube Bolts [C] •...
Page 253: Engine Installation
ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation Engine Installation • Support the engine with a commercially available stand and move them inside the frame in the reverse order of removal. • Install the rubber boot [A] on the rear end of the front bevel gear case. •...
Page 254 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Install the removed parts (see appropriate chapters). • Adjust the throttle cables (see Fuel System chapter). • Fill the engine with engine oil (see 2. Periodic Maintenance chapter). • Fill the engine with coolant and bleed the air from the cooling system (see 2.
Page 255 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View...................................9-2 Speciﬁcations ..................................9-5 Crankcase ..................................9-6 Disassembly ................................9-6 Assembly ..................................9-9 Starter Clutch Disassembly............................9-15 Starter Clutch Assembly............................9-15 Starter Clutch Inspection............................9-16 Starter Torque Limiter Check........................... 9-16 Crankshaft/Connecting Rods ............................9-17 Connecting Rod Removal ............................9-17 Connecting Rod Installation .............................
Page 256: Exploded View
9-2 CRANKSHAFT/TRANSMISSION Exploded View...
Page 257 8. Oil Bafﬂe EO: Apply engine oil. L: Apply a non-permanent locking agent. LG: Apply liquid gasket (Kawasaki Bond: 92104-1003). Lh: Left-hand Threads MO: Apply molybdenum disulﬁde oil to the threads and the seating surface. The molybdenum disulﬁde oil is a mixture of engine oil and molybdenum disulﬁde grease with a weight ratio (10 : 1).
Page 258 9-4 CRANKSHAFT/TRANSMISSION Exploded View 1. The bolt head is numbered 10. R: Replacement Parts 2. Align the punch marks. T1: 8.8 N m (0.90 kg m, 78 in 3. Align the punch mark with the slit. T2: 17 N m (1.7 kg m, 12 ft 4.
Page 259: Speciﬁcations
0.323 in) (0.327 in) Special Tools - Damper Cam Holder: 57001-1025 Flywheel Holder: 57001-1410 Bearing Driver Set: 57001-1129 Flywheel Holder: 57001-1313 Gear Holder: 57001-1015 Outside Circlip Pliers: 57001-144 Sealant - Kawasaki Bond (Liquid Gasket-Black): 92104-1003 Kawasaki Bond (Silicone Sealant): 56019-120...
Page 260: Crankcase
9-6 CRANKSHAFT/TRANSMISSION Crankcase Disassembly • Remove: Engine (see Engine Removal/Installation chapter) Cylinder Blocks (see Engine Top End chapter) Pistons Clutch (see Clutch chapter) Front Gear Case (see Final Drive chapter) Alternator Inner Cover (see Electrical System chapter) • Remove the shift shaft [A] while pushing [B] the shift mechanism arm [C] towards the shift shaft.
Page 261 CRANKSHAFT/TRANSMISSION 9-7 Crankcase • Loosen the primary gear bolt [A] while holding the alternator rotor steady with the ﬂywheel holder (special tool) (The primary gear can be removed with the engine in the frame). Primary Gear [B] Special Tool - Flywheel Holder: 57001-1410 •...
Page 262 9-8 CRANKSHAFT/TRANSMISSION Crankcase • Remove the primary gear bolt [A] and take out the water pump drive sprocket [B] and idle shaft sprocket [C] as a set. Chain [D] • Pull the primary gear [A] out of the crankshaft, and take the idle shaft [B] out of the crankcase.
Page 263: Assembly
CRANKSHAFT/TRANSMISSION 9-9 Crankcase • Remove all the left crankcase bolts in the order listed. 6 mm Bolts (14) [A] 8 mm Bolt (1) [B] 10 mm Bolts (3) [C] • Using the pry points, split the crankcase halves. Pry Point (Front) [A] Pry Point (Rear) [B] •...
Page 264: Engine Oil Drain Plug
9-10 CRANKSHAFT/TRANSMISSION Crankcase • Install the bearing retainers. Special Tool - Bearing Driver Set: 57001-1129 Bearings [A] Bearing Retainer [B] Left Crankcase [C] Non-permanent Locking Agent - Bearing Retainer Bolts Torque - Bearing Retainer Bolts: 11 N m (1.1 kg m, 95 in •...
Page 265 Apply liquid gasket [A] to the mating surface of the right crankcase [B]. Sealant - Kawasaki Bond (Liquid Gasket-Black): 92104-1003 Do not apply liquid gasket to the area [C] around the hole of the oil screen. Do not drop liquid gasket into the oil passage [D].
Page 266 9-12 CRANKSHAFT/TRANSMISSION Crankcase • Tighten the crankcase bolts as follows. Lightly tighten all the bolts to a snug ﬁt. Tighten the 8 mm and 10 mm bolts in the order shown, and then tighten the 6 mm bolts to the speciﬁed torque. Torque - 8 mm Crankcase Bolts (1 6): 21 N...
Page 267 CRANKSHAFT/TRANSMISSION 9-13 Crankcase • Install the camshaft chain and chain guide in the engine left side. • Install the left balancer [A]. • Turn the crankshaft counterclockwise [B] and align the alignment tooth [C] with the middle of the crankcase rib [D]. This makes the front piston set to its top dead center.
Page 268 9-14 CRANKSHAFT/TRANSMISSION Crankcase Install: Idle Shaft Sprocket [A] and Pin Water Pump Drive Sprocket [B] and Chain [C] Washer [D] Dowel Pins [E] Install: Idle Shaft Holder [A] and Water Pump Chain Guide [B]. Torque - Water Pump Chain Guide Bolt, Idle Shaft Holder Bolts: 8.3 N m (0.85 kg m, 73 in...
Page 269: Starter Clutch Disassembly
CRANKSHAFT/TRANSMISSION 9-15 Crankcase • Install: Shift Mechanism (see this chapter) Damper Cam and Front Gear Case (see Final Drive chapter) Clutch (see Clutch chapter) Water Pump (see Cooling System chapter) Clutch Cover Engine Top End (see Engine Top End chapter) Alternator Inner Cover, Alternator Cover, Alternator Outer Cover (see Electrical System chapter) Molybdenum Disulﬁde Oil -...
Page 270: Starter Clutch Inspection
9-16 CRANKSHAFT/TRANSMISSION Crankcase Starter Clutch Inspection • Remove the starter clutch gear [A] and torque limiter, then reinstall the starter clutch gear into the starter clutch. • Turn the starter clutch to both side. When viewed from the right side of the engine, the clutch should turn clockwise [B] freely, but should not turn counterclockwise [C].
Page 271: Crankshaft/Connecting Rods
CRANKSHAFT/TRANSMISSION 9-17 Crankshaft/Connecting Rods Connecting Rod Removal • Remove the crankshaft. • Remove the connecting rod big end nuts, and take off the rod and cap along with the bearing inserts from the crankshaft [A]. NOTE Mark and record the locations of the connecting rods [B] and their big end caps [C] with the bearing inserts left attached so that they can be installed in their original positions.
Page 272: Crankshaft/Connecting Rod Cleaning
9-18 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods Crankshaft/Connecting Rod Cleaning • After removing the connecting rods from the crankshaft, clean them with a high-ﬂash point solvent. • Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages.
Page 273: Connecting Rod Big End Bearing Wear
CRANKSHAFT/TRANSMISSION 9-19 Crankshaft/Connecting Rods Connecting Rod Big End Bearing Wear • Remove the big end cap and place a strip of plastigage on the crankpin [A]. • Tighten the big end nuts to the speciﬁed torque to compress the plastigage and measure the plastigage width [B] to determine the bearing insert/crankpin clearance (see Camshaft/Rocker Case Wear in the Engine Top End chapter).
Page 274: Crankshaft Runout
9-20 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods • Temporarily, install the big end cap and tighten the big end nuts to the speciﬁed torque. Molybdenum Disulﬁde Oil - Threads and Seating Surface of Big End Nuts Torque - Connecting Rod Big End Nuts: 59 N m (6.0 kg m, 43 ft •...
Page 275: Crankshaft Side Clearance
CRANKSHAFT/TRANSMISSION 9-21 Crankshaft/Connecting Rods • Measure the main bearing bore diameter [A] in the crankcase halves. Crankcase Main Bearing Bore Diameter Standard: 55.025 55.038 mm (2.1663 ~ 2.1669 in) Service Limit: 55.07 mm (2.1681 in) If they are any signs of seizure, damage, or excessive wear, replace the crankcase halves as a set.
Page 276: Primary Gear
9-22 CRANKSHAFT/TRANSMISSION Primary Gear Removal • Remove: Clutch Cover (see Clutch chapter) Starter Clutch Gear (see this chapter) Starter Torque Limiter (see this chapter) Clutch (see Clutch chapter) • Remove the water pump chain guide [A] and water pump idle shaft holder [B] from the right crankcase.
Page 277: Transmission
CRANKSHAFT/TRANSMISSION 9-23 Transmission Shift Pedal Removal • Unscrew the footpeg bracket bolts [A] and take off the left front footpeg [B]. Front [C] • Unscrew the clamp bolt [B] and pull out the shift pedal [A]. Shift Pedal Installation • Install the shift pedal [A] so that the punched mark on the shaft is aligned [B] with the punched mark on the pedal.
Page 278: External Shift Mechanism Installation
9-24 CRANKSHAFT/TRANSMISSION Transmission External Shift Mechanism Installation • Install the gear set lever [A] and the spring [B] in the crankcase and tighten the bolt [C]. Torque - Gear Set Lever Bolt: 11 N m (1.1 kg m, 95 in •...
Page 279: Transmission Installation
CRANKSHAFT/TRANSMISSION 9-25 Transmission • Align the shift drum cam [A] with the cutoff [B] of the left crankcase by turning the shift drum. • Take out the transmission shafts [A] and shift drum [B] as a set. • Separate the drive and output shafts, shift drum, and shift forks. Transmission Installation •...
Page 280: Shift Drum Disassembly/Assembly
9-26 CRANKSHAFT/TRANSMISSION Transmission • Install: Shift Fork (No. 293 output shaft, 4th gear) [A] Shift Rod [B] Shift Drum Disassembly/Assembly • Remove the shift drum assy [A] (see this chapter). • Remove: Drive Shaft Shift Fork (No. 292, drive shaft) [B] Cotter Pin [C] •...
Page 281: Shift Fork Bending
CRANKSHAFT/TRANSMISSION 9-27 Transmission CAUTION Do not apply grease to the steel balls to hold them in place. This will cause the positive neutral ﬁnder mechanism to malfunction. • Fit the three steel balls [A] into the holes [B] of the output 4th gear [C], and then install the gear on the output shaft so that the steel balls align with the recesses [D] in the shaft.
Page 282: Shift Fork Guide Pin/Drum Groove Wear
9-28 CRANKSHAFT/TRANSMISSION Transmission Shift Fork Guide Pin/Drum Groove Wear • Measure the diameter of each shift fork guide pin [B], and measure the width [A] of each shift drum groove. If the guide pin on any shift fork is less than the service limit, the fork must be replaced.
Page 283 CRANKSHAFT/TRANSMISSION 9-29 Transmission 1. Circlip ( 25.5 t 1.2) 10. 4th Gear 19. Steel Balls 2. Needle Bearing 11. 1st Gear (drive shaft) 20. 4th Gear 3. Thrust Washer 12. Output Shaft 21. Washer 22.3 t 1.6) 13. 2nd Gear 25.5 t 1.0) 4.
Page 284: Ball Bearing, Needle Bearing, And Oil Seal
9-30 CRANKSHAFT/TRANSMISSION Ball Bearing, Needle Bearing, and Oil Seal Ball Bearing and Outer Race Replacement CAUTION Do not remove the ball bearing or needle bearing outer race unless it is necessary. Removal may damage them. • Using a press or puller, remove the ball bearing and/or needle bearing outer race.
Page 285 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View.................................10-2 Speciﬁcations .................................. 10-3 Wheels (Rims).................................10-4 Front Wheel Removal...............................10-4 Front Wheel Installation............................10-5 Rear Wheel Removal ............................... 10-5 Rear Wheel Installation............................10-6 Wheel Coupling Removal............................10-7 Wheel Coupling Installation............................10-8 Wheel Inspection..............................10-8 Axle Inspection.................................10-8 Wheel Balance................................. 10-9 Balance Inspection..............................10-9 Balance Adjustment ..............................
Page 286: Exploded View
10-2 WHEELS/TIRES Exploded View G: Apply grease. R: Replacement Parts S: Follow the speciﬁc tightening sequence. WL: Apply soap and water solution or rubber lubricant. EUR: European Model T1: 251 N m (2.5 kg m, 18 ft T2: 110 N m (11 kg m, 79.6 ft T3: 1.5 N...
Page 287: Speciﬁcations
WHEELS/TIRES 10-3 Speciﬁcations Item Standard Service Limit Wheels (Rims): Rim runout: Axial TIR 0.5 mm (0.02 in.) Radial TIR 0.8 mm (0.03 in.) Axle runout/100 mm TIR 0.05 mm (0.002 in.) or less TIR 0.2 mm (0.008 in.) Wheel balance 10 g (0.35 oz.) or less –...
Page 288: Wheels (Rims)
10-4 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Unscrew the front brake caliper mounting bolts [A] and remove the brake calipers [B] with the hose installed. • For the Europian Model, remove the cap. • Loosen: Front Axle Clamp Bolts [A] Front Axle [B] Using the jack [A] and the attachment jack [B] under the frame pipe ribs [C], and a commercially available jack [D] under the engine [E],...
Page 289: Front Wheel Installation
WHEELS/TIRES 10-5 Wheels (Rims) Front Wheel Installation • Apply grease to the seal lips. • Fit the collars [A] on the both side of the hub. The collars are identical. • Insert the axle from the right side of the wheel. •...
Page 290: Rear Wheel Installation
10-6 WHEELS/TIRES Wheels (Rims) • Squeeze the brake lever slowly and hold it with a band [A] CAUTION Be sure to hold the front brake when removing the rear wheel, or the motorcycle may fall over. The motorcycle could be damaged.
Page 291: Wheel Coupling Removal
WHEELS/TIRES 10-7 Wheels (Rims) • Insert the axle [A] from the left side of the rear wheel [B]. • Slide the rear wheel to the left side, and engage the ring gear hub splines with the wheel coupling hub splines. •...
Page 292: Wheel Coupling Installation
10-8 WHEELS/TIRES Wheels (Rims) Wheel Coupling Installation • Replace the O-ring [A] and the retaining ring [B]. • Grease the following: O-ring Bosses [C] of Rear Drum Hub • Install: Rubber Damper [D] Coupling [E] Retaining Ring Wheel Inspection • Raise the front or rear wheel off the ground.
Page 293: Wheel Balance
41075–1016 30 (1.1 oz.) NOTE Balance weights are available from Kawasaki Dealers in 10, 20, and 30 gram (0.35, 0.71 and 1.1 ounce) sizes. An imbalance of less than 10 grams (0.35 ounce) will not usually affect running stability. Do not use four or more balance weights (more than 90 gram, 3.2 ounce).
Page 294: Balance Weight Removal
10-10 WHEELS/TIRES Wheels (Rims) Balance Weight Removal (a) When the tire is not on the rim. • Push [A] the blade portion toward the outside with a regular tip screw driver, and slip the weight off the rim ﬂange. • Discard the used balance weight.
Page 295 WHEELS/TIRES 10-11 Wheels (Rims) • Check that the blade [A] and weight [B] seat fully on the rim ﬂange [C], and that the clip [D] is hooked over the rim ridge [E] and reaches rim ﬂat portion. • When required total weight exceeds 20 g, install balance weight at both sides of rim ﬂange as shown.
Page 296: Tires
10-12 WHEELS/TIRES Tires Air Pressure Inspection/Adjustment • Refer to the Tire Inspection in the Periodic Maintenance chapter. Tire Inspection • Refer to the Tire Inspection in the Periodic Maintenance chapter. Tire Removal • Remove the following. Wheel (see this chapter) Brake Disc (see Brakes chapter) Valve Core (let out the air) •...
Page 297 WHEELS/TIRES 10-13 Tires Insert the new air valve in the rear wheel rim. Valve Cap [A] Valve Body [B] Valve Nuts [C] Valve Washer [D] Rim [E] Valve Grommet [F] Coupling Dampar Side [G] Remove the valve cap, valve nuts, valve washer and insert the valve stem through the rim from the inside out.
Page 298: 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 (external) repair. Only appropriate permanent (internal) repairs are recommended. Repair methods may vary slightly from make to make.
Page 299: Hub Bearings (Wheel Bearings)
WHEELS/TIRES 10-15 Hub Bearings (Wheel Bearings) Hub Bearings Removal • Remove the wheel, and take out the following. Collars Grease Seals [A] Circlips [B] Coupling [C] (Out of Rear Hub) Front Hub [D] Rear Hub [E] Special Tool - Inside Circlip Pliers: 57001-143 •...
Page 300: Hub Bearings Inspection
10-16 WHEELS/TIRES Hub Bearings (Wheel Bearings) Replace the circlips with new ones. Special Tool - Inside Circlip Pliers: 57001-143 • Replace the grease seals with new ones. • Press in the grease seals [A] so that the seal surface is ﬂush [B] with the end of the hole.
Page 301 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View............11-2 Front Bevel Gears ..........11-21 Speciﬁcations ............11-5 Front Gear Case Removal ......11-21 Final Gear Case and Oil ..........11-6 Front Gear Case Installation ......11-21 Oil Level Inspection ...........11-6 Front Gear Case Disassembly ......
Page 302 11-2 FINAL DRIVE Exploded View...
Page 303 FINAL DRIVE 11-3 Exploded View Front Gear Case EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulﬁde oil. R: Replacement Parts St: Stake the fasteners. T1: 12 N m (1.2 kg m, 104 in T2: 18 N m (1.8 kg m, 13 ft...
Page 304 11-4 FINAL DRIVE Exploded View Final Gear Case G: Apply grease. T1: 8.8 N m (0.9 kg m, 78 in L: Apply a non-permanent locking agent. T2: 34 N m (3.5 kg m, 25 ft lb), MO: Apply molybdeum disulﬁde oil. T3: 23 N m (2.3 kg m, 17 ft...
Page 305 FINAL DRIVE 11-5 Speciﬁcations Item Standard Final Gear Case Oil: Grade API Service Classiﬁcation: GL-5 hypoid gear oil Viscosity When above 5 C (41 F) SAE90 When below 5 C (41 F) SAE80 Oil level Filler opening bottom Amount 200 mL (6.76 US oz.) Final Bevel Gear Backlash 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in.) (at gear hub splines) Preload for Pinion Gear Bearing:...
Page 306: Final Gear Case And Oil
11-6 FINAL DRIVE Final Gear Case and Oil Oil Level Inspection • Refer to Oil Level Inspection in Periodic Maintenance chapter. Oil Change • Refer to Oil Change in Periodic Maintenance chapter. Final Gear Case Removal If the ﬁnal gear case is to be disassembled, drain the ﬁnal gear case oil.
Page 307 FINAL DRIVE 11-7 Final Gear Case and Oil • Remove the ﬁnal gear case cover bolts [A]. • Use three tapped holes [B] to lift the ring gear assy from the gear case. The shim(s) comes off with the assy. NOTE Do not disassemble the ring gear assy (ring gear, ring gear hub, and ﬁnal gear case cover), but the oil seal can be removed.
Page 308 11-8 FINAL DRIVE Final Gear Case and Oil Final Gear Case 1. Pinion Gear Nut 13. Studs 2. Washer 14. Pinion Gear Shim(s) 3. Shim(s) for Preload 15. O-ring 4. Pinion Gear Joint 16. Oil Seal 5. O-ring 17. Tapered Roller Bearings 6.
Page 309 FINAL DRIVE 11-9 Final Gear Case and Oil • Replace the needle bearings [A] with new ones. • Apply a hypoid gear oil to the roller parts of the needle bearings. NOTE Install the bearing so that the marked side faces out. Press in the bearings until they are bottomed.
Page 310 11-10 FINAL DRIVE Final Gear Case and Oil • Unscrew the nut [A] while holding the pinion gear assembly [B] with the pinion gear holder [C]. Special Tool - Pinion Gear Holder: 57001-1165 • Remove: Washer [A] Shim(s) [B] Pinion gear joint [C] with the O-ring [D]. Pinion gear [E] with the Tapered Roller Bearing [F] •...
Page 311 FINAL DRIVE 11-11 Final Gear Case and Oil • Drive the tapered roller bearing [A] into the pinion gear housing [B] using the bearing driver set [C]. Special Tool - Bearing Driver Set: 57001–1129 • Drive the taperd roller bearing outer race [A] into the pinion gear housing [B] using the bearing Driver set [C].
Page 312 11-12 FINAL DRIVE Final Gear Case and Oil • Replace the oil seal with a new one. • Drive the oil seal [A] using the bearing driver set [B]. Special Tool - Bearing Driver Set: 57001–1129 • Reinstall the above removed parts. Stake [A] the pinion gear nut with a punch.
Page 313 FINAL DRIVE 11-13 Final Gear Case and Oil Using Spring Scale: • Hook the spring scale [A] on the handle at the point 200 mm (7.87 in.) [B] from the center of the gear shaft. • Hold the bearing housing in a vise so that the gear shaft axis is vertical.
Page 314 11-14 FINAL DRIVE Final Gear Case and Oil Initial Clearance [C] 1. Washer 5. Tapered Roller Bearing Under No Preload [D] 2. Shim(s) 6. Tapered Roller Bearing Before Tightening [A] No Clearance [E] 3. Pinion Gear Joint After Tightening [B] Under Preload [F] 4.
Page 315 FINAL DRIVE 11-15 Final Gear Case and Oil Final Bevel Gear Adjustment The backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged. • After replacing any of the backlash-related parts, be sure to check and adjust the backlash and tooth contact of the bevel gears.
Page 316 11-16 FINAL DRIVE Final Gear Case and Oil Ring Gear Shims for Backlash Adjustment Pinion Gear Shims for Tooth Contact Adjustment Thickness (mm) Parts Number Thickness (mm) Parts Number 0.15 (0.0059 in.) 92025-1783 0.15 (0.0059 in.) 92180-1365 0.5 (0.02 in.) 92025-1784 0.5 (0.02 in.) 92180-1366...
Page 317 FINAL DRIVE 11-17 Final Gear Case and Oil Tooth Contact Adjustment • Clean any dirt and oil off the bevel gear teeth with a high-ﬂash point solvent. • Apply checking compound to 4 or 5 teeth of the pinion gear. NOTE Apply checking compound to the teeth in a thin, even coat with a fairly stiff paint brush.
Page 318 11-18 FINAL DRIVE Final Gear Case and Oil Correct Tooth Contact Pattern: No adjustment is required. Heel [A] Bottom [B] Top [C] Toe [D] Incorrect Tooth Contact Patterns (Example 1) Decrease the thickness of the pinion gear shim(s) by 0.05 mm (0.002 in.) to correct the pattern shown above. Heel [A] Bottom [B] Top [C]...
Page 319 FINAL DRIVE 11-19 Propeller Shaft Propeller Shaft Removal • Remove: Final Gear Case (see this chapter) Swingarm (see Suspension chapter) • Remove the propeller shaft from the front driven gear joint. Turn the propeller shaft so that the lockpin access hole [A] in the propeller shaft comes outside.
Page 320 11-20 FINAL DRIVE Propeller Shaft Propeller Shaft Joint Lubrication • Refer to the Propeller Shaft Joint Lubrication in the Periodic Mainte- nance chapter. Propeller Shaft Inspection • Check that the universal joint [A] works smoothly without rattling or sticking. If it does not work smoothly, the needle bearings of the universal joint are damaged.
Page 321 FINAL DRIVE 11-21 Front Bevel Gears Front Gear Case Removal • Remove: Engine (see Engine Removal/Installation chapter) Rear Shift Lever [A] The speed sensor connector [B] is disconnected during engine removal. • Unscrew the front gear case bolts [C] and remove the front gear case [D].
Page 322 11-22 FINAL DRIVE Front Bevel Gears • Remove the drive gear assy as follows. Pry off the gear case cap [A] with a tool. Pry open the drive gear nut [A] with a small chisel. Install: Damper Spring Cam Follower [B] Unscrew the drive gear nut while holding the drive gear shaft with the drive shaft holder [C] (special tool).
Page 323 FINAL DRIVE 11-23 Front Bevel Gears • Be sure to check and adjust the bearing preload, the bevel gear backlash, and tooth contact, when any of the backlash-related parts are replaced (see Front Bevel Gear Adjustment). • After completing all adjustment, reassemble the front gear case. Replace the drive gear nut with a new one.
Page 324 11-24 FINAL DRIVE Front Bevel Gears • Remove the driven gear joint [A] with the O-ring [B]. • Remove the driven gear from the bearing housing. • Remove the oil seal from the housing with a hook, and pull the tapered roller bearing out of the housing.
Page 325 FINAL DRIVE 11-25 Front Bevel Gears Damper Cam Installation • Replace the damper cam nut with a new one. • Remove the clutch push rod guide [A] and bolts, and crankcase bearing lower retainer and bolts. • Insert the bolt ( 12 mm, L100 mm 0.47 in., L3.94 in.) [B] into the engine mounting bolt hole.
Page 326 11-26 FINAL DRIVE Front Bevel Gears Front Bevel Gear Adjustment When any of the backlash-related parts are replaced, or the driven gear bolt is loosened; even if the purpose is not to replace the parts, be sure to check and adjust the bearing preload, the bevel gear backlash, and tooth contact by replacing shims.
Page 327 FINAL DRIVE 11-27 Front Bevel Gears Collars for Preload Adjustment Spacers for Preload Adjustment Length (mm) Part Number Thickness (mm) Part Number 22.8 (0.898 in.) 92027-1152 1.70 (0.0669 in.) 92025-1072 22.9 (0.902 in.) 92027-1153 1.72 (0.0677 in.) 92025-1073 23.0 (0.906 in.) 92027-1154 1.74 (0.0685 in.) 92025-1074...
Page 328 11-28 FINAL DRIVE Front Bevel Gears Backlash Adjustment • Clean any dirt and oil off bevel gear teeth with a high-ﬂash point solvent. • Install the drive gear with the primary shim (1.0 mm, 0.04 in., thickness), and tighten the nut to the speciﬁed torque. Torque - Drive Gear Nut: 265 N m (27 kg...
Page 329 FINAL DRIVE 11-29 Front Bevel Gears Tooth Contact Adjustment • Clean any dirt and oil off the bevel gear teeth with a high-ﬂash point solvent. • Apply checking compound to 4 or 5 teeth on the driven gear. NOTE Apply checking compound to the teeth in a thin, even coat with a fairly stiff paint brush.
Page 330 11-30 FINAL DRIVE Front Bevel Gears Incorrect Tooth Contact Patterns (Example 2): • Decrease the thickness of the drive gear shim(s) by 0.05 mm (0.002 in.), and/or decrease the thickness of the driven gear shim(s) by 0.05 mm (0.002 in.) to correct the pattern shown below. Repeat in 0.05 mm (0.002 in.) steps if necessary.
Page 331: Bearing And Oil Seal
FINAL DRIVE 11-31 Bearing and Oil Seal Ball or Needle Bearing Replacement • Using the bearing driver set or the oil seal & bearing remover, remove the bearings. Special Tools - Oil Seal & Bearing Remover: 57001-1058 Bearing Driver Set: 57001-1129 NOTE In the absence of the above mentioned tools, satisfactory results may be obtained by heating the case to approximately 93...
Page 332 11-32 FINAL DRIVE Bearing and Oil Seal Tapered Roller Bearing Inspection CAUTION Do not remove the tapered roller bearing for inspection. Removal may damage them. • Visually inspect the bearing in the front and ﬁnal gear cases for abrasion, color change, or other damage. If there is any doubt as to the condition of the bearing, replace it.
Page 333 BRAKES 12-1 Brakes Table of Contents Exploded View............12-2 Rear Brake Pad Installation......12-15 Speciﬁcations ............12-5 Brake Pad Wear Inspection......12-15 Brake Lever, Brake Pedal.........12-6 Master Cylinder............12-16 Brake Lever Position Adjustment ...... 12-6 Front Master Cylinder Removal.......12-16 Brake Pedal Position Adjustment ...... 12-6 Front Master Cylinder Installation....12-16 Brake Pedal Removal........12-7 Rear Master Cylinder Removal .......12-17...
Page 334 12-2 BRAKES Exploded View...
Page 335 BRAKES 12-3 Exploded View B: Apply brake ﬂuid. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the speciﬁc tightening sequence. Si: Apply silicone grease or PBC grease. T1: 7.8 N m (0.8 kg m, 69 in T2: 25 N m (2.5 kg m, 18 ft T3: 1.0 N...
Page 336 12-4 BRAKES Exploded View 1. Align the marks. T1: 34 N m (3.5 kg m, 25 ft B: Apply brake ﬂuid. T2: 64 N m (6.5 kg m, 47 ft G: Apply grease. T3: 27 N m (2.8 kg m, 20 ft L: Apply a non-permanent locking agent.
Page 337 BRAKES 12-5 Speciﬁcations Item Standard Service Limit Brake Lever, Brake Pedal: Brake lever position No.1 5-way adjustable Brake lever free play Non-adjustable – – – Pedal free play Non-adjustable – – – Pedal position About 110 mm (4.33 in.) – – – (height from pedal top to footpeg top) Brake Fluid: Grade...
Page 338 12-6 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A]. •...
Page 339 BRAKES 12-7 Brake Lever, Brake Pedal • Loosen the locknut [A] and turn the push rod with the hex head [B] to achieve the correct pedal position. If the length [C] is 80 ± 1 mm (3.1 ± 0.04 in.), the pedal position will be within the standard range.
Page 340 12-8 BRAKES Brake Lever, Brake Pedal Brake Pedal Installation • Apply grease to the brake pedal shaft. • Install the pedal shaft [A] so that the punched mark on the shaft is aligned [B] with the punched mark on the brake lever [C]. •...
Page 341 BRAKES 12-9 Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B]. CAUTION Do not loosen the caliper assembly bolts [C]. Take out only the caliper mounting bolts for caliper removal.
Page 342 12-10 BRAKES Calipers • Move [A] the front caliper little. • Loosen the front caliper assembly bolts [B] and front caliper banjo bolt [C] and tighten them loosely. • Remove the front caliper [D] and banjo bolt. • Remove the front caliper assembly bolts and split the front caliper. •...
Page 343 BRAKES 12-11 Calipers • Replace the O-rings [A] if they are damaged. • Apply brake ﬂuid to the outside of the pistons, and push them into each cylinder by hand. • Be sure to install the O-rings. • Tighten the caliper assembly bolts. Torque - Front Caliper Assembly Bolts: 21 N m (2.1 kg...
Page 344 12-12 BRAKES Calipers • Remove the anti rattle spring [A]. • Remove the dust seals [B] and ﬂuid seals [C]. • Remove the rubber friction boots [D]. • Remove the bleed valve [E] and rubber cap [F]. Rear Caliper Assembly •...
Page 345 BRAKES 12-13 Calipers Caliper Fluid Seal Damage The ﬂuid seals [A] around the piston maintain the proper pad/disc clearance. If the seals are not satisfactory, pad wear will increase, and constant pad drag on the disc will raise brake and brake ﬂuid temperature.
Page 346 12-14 BRAKES Brake Pads Front Brake Pad Removal • Unscrew the pad spring bolts [A], and remove the pad spring [B]. • Draw out the snap pin [A], and take off the pad pin [B]. • Remove the brake pads [C]. Front Brake Pad Installation •...
Page 347 BRAKES 12-15 Brake Pads Rear Brake Pad Installation • Before installation, clean the pads with a high-ﬂash point solvent. • Push [A] the caliper pistons in by hand as far as they will go. • Be sure to install the snap pin for the caliper. Do not attempt to ride the motorcycle until a full pedal is obtained by pumping the brake lever or pedal until the pads are against the disc.
Page 348: Master Cylinder
12-16 BRAKES Master Cylinder Front Master Cylinder Removal • Disconnect the front brake light switch connectors [A]. • Draw out the brake ﬂuid from the reservoir with a means like the fork oil level gage. • Pull the bolt caps [B] out. •...
Page 349 BRAKES 12-17 Master Cylinder Rear Master Cylinder Removal • Remove the brake ﬂuid reservoir cover (see Brake Pedal Position Adjustment). • Draw out the brake ﬂuid from the reservoir with a means like the fork oil level gage. • Remove the brake ﬂuid reservoir (see Brake Pedal Position Adjust- ment).
Page 350 12-18 BRAKES Master Cylinder Front Master Cylinder Disassembly • Remove the front master cylinder. • Remove the reservoir cap, plate and diaphragm. • Unscrew the locknut and pivot bolt, and remove the brake lever. • Pull the dust cover [A] out of place, and remove the circlip [B]. Special Tool - Inside Circlip Pliers: 57001-143 •...
Page 351 BRAKES 12-19 Master Cylinder Master Cylinder Inspection • Disassemble the front and rear master cylinders. • Check that there are no scratches, rust or pitting on the inner wall [A] of each master cylinder and on the outside of each piston [B]. If a master cylinder or piston shows any damage, replace them.
Page 352: Brake Discs
12-20 BRAKES Brake Discs Brake Disc Removal • Remove the wheel (see Wheels/Tires chapter). • Unscrew the mounting bolts [A], and take off the disc. Brake Disc Installation • Install the brake disc [A] on the wheel so that the marked side [B] faces out.
Page 353: Brake Fluid
BRAKES 12-21 Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in Periodic Maintenance chapter. Brake Line Bleeding The brake ﬂuid has a very low compression coefﬁcient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action.
Page 354 12-22 BRAKES Brake Fluid • Remove the clear plastic hose. • Tighten: Torque - Caliper Bleed Valve: 7.8 N m (0.8 kg m, 69 in Front Brake Reservoir Cap Screws: 1.5 N m (0.15 kg m, 13 • Repeat the above steps for other caliper. NOTE For the rear brake caliper [A], bleed the brake line for two bleed valves [B].
Page 355 BRAKES 12-23 Brake Hoses Brake Hose Removal/Installation CAUTION Brake ﬂuid quickly ruins painted surfaces; any spilled ﬂuid should be completely washed away immediately. • When removing the brake hose, take care not to spill the brake ﬂuid on the painted or plastic parts. •...
Page 357 SUSPENSION 13-1 Suspension Table of Contents Exploded View.................................13-2 Speciﬁcations .................................. 13-4 Front Fork..................................13-5 Fork Oil Change ...............................13-5 Front Fork Removal (each fork leg) ......................... 13-5 Front Fork Installation (each fork leg) ........................13-6 Front Fork Disassembly............................13-6 Front Fork Assembly ..............................13-8 Inner Tube, Outer Tube Inspection.........................13-10 Dust Seal Inspection ..............................
Page 358: Exploded View
13-2 SUSPENSION Exploded View 1. Left Fork Leg T1: 20 N m (2.0 kg m, 14 ft 2. Right Fork Leg T2: 25 N m (2.5 kg m, 18 ft L: Apply a non-permanent locking agent. T3: 5.9 N m (0.6 kg m, 52 ft R: Replacement Parts T4: 34 N...
Page 359 SUSPENSION 13-3 Exploded View 1. Air Valves G: Apply grease. WL: Apply a soap and water solution or rubber lubricant. T1: 5.4 N m (0.55 kg m, 47 in T2: 110 N m (11 kg m, 79.6 ft T3: 34 N m (3.5 kg m, 25 ft...
Page 360: Speciﬁcations
13-4 SUSPENSION Speciﬁcations Standard Item Front Fork (per one unit): Fork inner tube diameter 43 mm ( 1.7 in.) Fork spring setting Non-adjustable Air pressure Atmospheric pressure (Non-adjustable) Rebound damper setting Non-adjustable Fork oil viscosity SAE 10W-20 Fork oil capacity: Right Fork Leg 507 ±...
Page 361: Front Fork
SUSPENSION 13-5 Front Fork Fork Oil Change The oil should be changed in accordance with the Periodic Mainte- nance Chart. • Refer to the Fork Oil Change in Periodic Maintenance chapter. Front Fork Removal (each fork leg) • Loosen the front axle nut (see wheels/Tires chapter). •...
Page 362: Front Fork Installation (Each Fork Leg)
13-6 SUSPENSION Front Fork Front Fork Installation (each fork leg) • Install the fork so that the top end [A] of the outer tube is ﬂush with the upper surface [B] of the steering stem head bracket. • Tighten the lower fork clamp bolts and fork top bolt. Torque - Front Fork Clamp Bolt (Lower): 20 N m (2.0 kg...
Page 363 SUSPENSION 13-7 Front Fork • Remove: Piston Rod Nut [A] Stopper [B] Coller [C] Spring Joint [D] Fork Spring [E] • Drain the fork oil into a suitable container. Using the piston rod puller [A], pump the piston rod up and down at least ten times to expel the oil from the fork.
Page 364: Front Fork Assembly
13-8 SUSPENSION Front Fork • Drain the fork oil into a suitable contain [A]. • Remove: Coller [B] Washer [C] Fork Spring [D] Both Fork Legs: • Separate the inner tube from the outer tube as follows: Pull out the dust seal [A] from the outer tube. Remove the retaining ring [B] from the outer tube.
Page 365 SUSPENSION 13-9 Front Fork Right Fork Leg: • Install the centering plate [A] onto the bottom end of the cylinder unit [B]. • Put the cylinder unit with the centering plate into the inner tube [C]. • Apply a non-permanent locking agent to the bottom Allen bolt. •...
Page 366: Inner Tube, Outer Tube Inspection
13-10 SUSPENSION Front Fork Inner Tube, Outer Tube Inspection • Visually inspect the inner tube [A] and repair any damage. • Nick or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage. If the damage is not repairable, replace the inner tube.
Page 367: Rear Shock Absorber (Air Type)
SUSPENSION 13-11 Rear Shock Absorber (Air Type) Rebound Damping Adjustment The rebound damping force adjuster on each rear shock absorber has 4 positions so that the rebound damping force can be adjusted for different road and loading conditions. The numbers on the adjuster show the setting position.
Page 368: Rear Shock Absorber Removal
13-12 SUSPENSION Rear Shock Absorber (Air Type) Take off each air valve cap [A] on the right and left shock absorbers. Front [B] Check the air pressure with the air pressure gauge. NOTE Do not use tire gauges for checking air pressure. They may not indicate the correct air pressure because of air leakage that occur when the gauge is applied to the valve.
Page 369: Rear Shock Absorber Installation
SUSPENSION 13-13 Rear Shock Absorber (Air Type) Rear Shock Absorber Installation • Install the sleeve [A] so the ﬂange side faces inside. • Install the rear shock absorber so that the air valve [B] faces forward [C]. • Tighten the rear shock absorber nuts (cap nuts) [D] to the speciﬁed torque.
Page 370: Swingarm
13-14 SUSPENSION Swingarm Swingarm Removal • Remove: Bolts [A] Swingarm Cover [B] • Remove the rear exhaust pipe (see Engine Top End chapter). • Loosen: Right Mufﬂer Chamber Bolt [A] Front Exhaust Pipe Clamp Bolt [B] • Remove: Swingarm Pivot Cap [C] •...
Page 371: Swingarm Installation
SUSPENSION 13-15 Swingarm Swingarm Installation • Apply grease to the needle bearings and grease seals. • Apply grease to the threads [A] of the swingarm pivot shaft. Torque - Swingarm Pivot Shaft: 110 N m (11 kg m, 79.6 ft •...
Page 372: Swingarm Bearing Installation
13-16 SUSPENSION Swingarm Swingarm Bearing Installation • Apply plenty of grease to the needle bearings, and sleeve. • Be sure to install the needle bearings so that the manufacturer’s marks are faced out. This prevents bearing damage. • Position the bearings [A] as shown, using a suitable bearing driver in the bearing driver set.
Page 373 STEERING 14-1 Steering Table of Contents Exploded View.................................14-2 Speciﬁcations .................................. 14-3 Handlebar..................................14-4 Handlebar Removal..............................14-4 Handlebar Installation...............................14-4 Steering...................................14-6 Steering Check.................................14-6 Steering Adjustment..............................14-6 Steering Stem ................................. 14-7 Steering Stem Removal ............................14-7 Steering Stem Installation ............................14-8 Steering Stem Warp...............................14-10 Steering Stem Bearing..............................14-11 Stem Bearing Removal ............................
Page 374: Exploded View
14-2 STEERING Exploded View 1. O–rings T1: 54 N m (5.5 kg m, 40 ft AD: Apply adhesive. T2: 20 N m (2.0 kg m, 14 ft G: Apply grease. T3: 34 N m (3.5 kg m, 25 ft L: Apply a non-permanent locking agent. T4: 3.4 N m (0.35 kg m, 30 in...
Page 375: Speciﬁcations
STEERING 14-3 Speciﬁcations Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398 Steering Stem Nut Wrench: 57001-1100 Head Pipe Outer Race Remover: 57001-1107 Head Pipe Outer Race Press Shaft: 57001-1075 Head Pipe Outer Race Driver: 57001-1077 Steering Stem Bearing Driver: 57001-1344 Steering Stem Bearing Driver Adapter: 57001-1345...
Page 376: Handlebar
14-4 STEERING Handlebar Handlebar Removal • Cut the straps. • Remove: Clutch Master Cylinder [A] Left Handlebar Switch Housing [B] Grip End Cap [C] (Left-hand threads) Front Brake Master Cylinder [A] Right Handlebar Switch Housing [B] Throttle Grip [C] with Grip End Cap [D] (Left-hand threads) •...
Page 377 STEERING 14-5 Handlebar • Apply adhesive [A] the inside the left grip [B] as shown. • Insert the left grip until it end ﬂush with the handlebar end [C]. • Apply a non-permanent locking agent to the thread of the grip end cap [D].
Page 378: Steering Check
14-6 STEERING Steering Steering Check • Refer to the Steering Check in the Periodic Maintenance chapter. Steering Adjustment • Refer to the Steering Adjustment in the Periodic Maintenance chapter.
Page 379: Steering Stem
STEERING 14-7 Steering Stem Steering Stem Removal • Using the jack [A] and attachment jack [B] under the frame pipe ribs [C], and a commercially available jack [D] under the engine [E], lift the front wheel [F] OFF the ground until the rear wheel [G] touches the ground.
Page 380: Steering Stem Installation
14-8 STEERING Steering Stem • Remove: O-ring [A] • Take off the steering stem head [A] with the handlebar [B]. CAUTION Cover the fuel tank with a thick towel [C] or cloth to protect the painted surface of the fuel tank. •...
Page 381 STEERING 14-9 Steering Stem • Install the fork leg [A] and push [B] it up tightly against the stem bottom. • Temporarily tighten the lower fork clamp bolts [C]. • Install: Steering Stem Head [A] with Handlebar O-ring [B] Washer [C] Stem Head Nut [D] •...
Page 382: Steering Stem Warp
14-10 STEERING Steering Stem Steering Stem Warp • Whenever the steering stem is removed, or if the steering cannot be adjusted for smooth action, check the steering stem for straightness. If the steering stem [A] is bent, replace the steering stem.
Page 383: Steering Stem Bearing
STEERING 14-11 Steering Stem Bearing Stem Bearing Removal • Remove the steering stem (see this chapter). • Drive out the bearing outer races from the head pipe. Special Tool - Head Pipe Outer Race Remover: 57001-1107 [A] NOTE If either steering stem bearing is damaged, it is recommended that both the upper and lower bearings (including outer races) be replaced with new ones.
Page 384: Stem Bearing Lubrication
14-12 STEERING Steering Stem Bearing Check that there is no play and the steering stem turns smoothly without rattles. If not, the steering stem bearings may be damaged. • Remove the stem nut. • Install the O-rings and adjust the steering (see Periodic Maintenance chapter).
Page 385 FRAME 15-1 Frame Table of Contents Exploded View.................................15-2 Speciﬁcations .................................. 15-4 Seat....................................15-5 Seat Removal................................15-5 Seat Installation................................15-5 Side Covers..................................15-6 Left Side Cover Removal ............................15-6 Left Side Cover Installation ............................15-6 Right Side Cover Removal............................15-6 Right Side Cover Installation............................15-6 Fenders ................................... 15-7 Front Fender Removal..............................15-7 Rear Fender Removal..............................15-7 Rear Fender Installation............................15-7...
Page 386: Exploded View
15-2 FRAME Exploded View...
Page 387 FRAME 15-3 Exploded View G: Apply grease. T1: 25 N m (2.5 kg m, 18 ft L: Apply a non-permanent locking agent. T2: 44 N m (4.5 kg m, 33 ft CA: Canadian Model US: United States of American Model...
Page 388: Speciﬁcations
15-4 FRAME Speciﬁcations Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398...
Page 389: Seat
FRAME 15-5 Seat Seat Removal • Remove the seat bolts [A]. • Pull the seat backward [B], then remove it. Seat Installation • Slip the seat hook [A] under the brace [B] on the frame. • Tighten the seat bolts.
Page 390: Side Covers
15-6 FRAME Side Covers Left Side Cover Removal • Insert the ignition switch key [A] into the left side cover, and turn the key clockwise until the key slot is vertical. • Pull [B] the rear part of the left side cover towards you, push [C] the left side cover slightly forward, and remove it.
Page 391: Fenders
FRAME 15-7 Fenders Front Fender Removal CAUTION Be careful not to scratch the painted surface during removal or installation. • Remove the mounting bolts [A] on both sides to separate the front fender [B] from the front fork [C]. • Remove the brake hose clamps [D].
Page 392: Battery Case
15-8 FRAME Battery Case Battery Case Removal • Remove: Seat (see this chapter) Bolts [A] and Battery Holder [B] Battery [C] (see Electrical System chapter) ECU [D] (see Fuel System chapter) Vehicle-down Sensor [F] (see Fuel System chapter) Rear Fender (see this chapter) •...
Page 393: Tool Box
FRAME 15-9 Tool Box Tool Box Removal • Remove the left side cover (see this chpater). • For california model ; remove the band [A] and canister [B]. • Unscrew the bolts [C]. • Pull the tool box [D] out.
Page 394: Downtube
15-10 FRAME Downtube Removal • Using the jack and the attachment jack, raise the rear wheel off the ground (see Wheels/Tires chapter). Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398 • Remove: Brake Reservoir Cover [A] Brake Reservoir (see Brakes chapter) •...
Page 395: Sidestand
FRAME 15-11 Sidestand Sidestand Installation • Tighten: Torque - Sidestand Nut: 44 N m (4.5 kg m, 32 ft • Install the sidestand spring [A], noting the direction of the hooks [B].
Page 396: Frame Inspection
15-12 FRAME Frame Frame Inspection • Visually inspect the frame [A] for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
Page 397 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Electrical Parts Location...........16-3 Interlock Operation Inspection......16-41 Exploded View............16-4 IC Igniter Inspection ........16-42 VN1500-P1 Wiring Diagram (Canada, and United States Starter Motor ............16-44 of America).............16-10 Starter Motor Removal ........16-44 VN1500-P1 Wiring Diagram (Other Than AU, CA and Starter Motor Installation.........16-44 US) .................
Page 398 16-2 ELECTRICAL SYSTEM Rear Brake Light Switch Check/Adjustment (Peri- Junction Box Fuse Circuit Inspection....16-77 odic)..............16-74 Starter Circuit/Headlight Relay Inspection ..16-77 Radiator Fan Switch Removal......16-74 Diode Circuit Inspection ........16-78 Radiator Fan Switch Installation......16-74 Fuse................16-80 Radiator Fan Switch Inspection.......16-75 Main Fuse Removal.........16-80 Water Temperature Switch Removal....16-75 Junction Box Fuse Removal......16-80 Water Temperature Switch Installation....16-75...
Page 399 ELECTRICAL SYSTEM 16-3 Electrical Parts Location DFI: DFI Parts (see Fuel System chapter) 1. Speedometer 2. Tachometer 3. Ignition Switch 4. Front Brake Light Switch 5. Starter Lockout Switch 6. Intank Fuel Pump (DFI) with Fuel Reserve Switch 7. Indicator Light Cover 8.
Page 400 16-4 ELECTRICAL SYSTEM Exploded View...
Page 401 ELECTRICAL SYSTEM 16-5 Exploded View 1. Starter Lockout Switch 2. Front Brake Light Switch 3. Ignition Switch 4. Fuel Reserve Switch L: Apply a non-permanent locking agent. AU: Australian Model CA: Canadian Model US: United States of American Model T1: 2.9 N m (0.30 kg m, 26 in T2: 3.4 N...
Page 402 16-6 ELECTRICAL SYSTEM Exploded View...
Page 403 12. Diode (Rectiﬁer) for Fuel Indicator Light 13. ECU (Electronic Control Unit) L: Apply a non-permanent locking agent. Si: Apply silicone grease. SS: Apply silicone sealant (Kawasaki Bond: 56019-120). T1: 18 N m (1.8 kg m, 13.0 ft T2: 6.9 N m (0.7 kg...
Page 404 16-8 ELECTRICAL SYSTEM Exploded View...
Page 405 : The molybdenum disulﬁde oil is a mixture of engine oil and molybdenum disulﬁde grease with a weight ratio (10:1). WL: Apply a soap and water solution or rubber lubricant. SS: Apply silicone sealant (Kawasaki Bond: 59019-120). Si: Apply silicone grease.
Page 406 16-10 ELECTRICAL SYSTEM VN1500-P1 Wiring Diagram (Canada, and United States of America)
Page 407 ELECTRICAL SYSTEM 16-11 VN1500-P1 Wiring Diagram (Canada, and United States of America)
Page 408 16-12 ELECTRICAL SYSTEM VN1500-P1 Wiring Diagram (Other Than AU, CA and US)
Page 409 ELECTRICAL SYSTEM 16-13 VN1500-P1 Wiring Diagram (Other Than AU, CA and US)
Page 410 16-14 ELECTRICAL SYSTEM VN1500-P1 Wiring Diagram (Australia)
Page 411 ELECTRICAL SYSTEM 16-15 VN1500-P1 Wiring Diagram (Australia)
Page 412 16-16 ELECTRICAL SYSTEM Speciﬁcations Item Standard Battery: Type MF Battery Model name FTZ16-BS Capacity 12 V 18 Ah Voltage 12.6 V or more Charging System: Alternator type Three-phase AC with delta connection, and rare-earth single magnet rotor DC battery charging voltage 15 V @3 000 r/min (rpm) Alternator output voltage (no load) 96 V @3 000 r/min (rpm)
Page 413 ELECTRICAL SYSTEM 16-17 Speciﬁcations Special Tools - Hand Tester: 57001-1394 Spark Plug Wrench, Hex 18: 57001-1024 Timing Light: 57001-1241 Driver-Filler Cap: 57001–1454 Flywheel Holder: 57001-1410 Jack: 57001-1238 Attachment Jack: 57001-1398 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
Page 414 16-18 ELECTRICAL SYSTEM Servicing Precautions There are a number of important precautions that should be followed servicing electrical systems. Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. Always check battery condition before condemning other parts of an electrical system.
Page 415 ELECTRICAL SYSTEM 16-19 Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage.
Page 416 16-20 ELECTRICAL SYSTEM Battery Battery Removal CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch in ON, as this could damage the ECU (Electronic Control Unit). Never reverse the connections of the battery, this could damage the ECU.
Page 417 ELECTRICAL SYSTEM 16-21 Battery • Put the battery holder [A] on the battery. • Tighten the bolts securely. • Connect the sub harness [B], fuel pump [C] and battery (–) lead [D] connectors. • Install the seat (see Frame chapter). Electrolyte Filling •...
Page 418 16-22 ELECTRICAL SYSTEM Battery • Place the electrolyte container upside down aligning the six seals with the six battery ﬁller ports. • Push the container down strongly enough to break the seals. Now the electrolyte should start to ﬂow into the battery. NOTE Do not tilt the container as the electrolyte ﬂow may be interrupted.
Page 419 ELECTRICAL SYSTEM 16-23 Battery Precautions No need of topping-up No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that. Refreshing charge If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been discharged.
Page 420 16-24 ELECTRICAL SYSTEM Battery If the reading is 12.6 V or more, no refresh charge is required, however, if the read is below the speciﬁed, refresh charge is required. Battery Terminal Voltage Standard: 12.6 V or more Terminal Voltage (V) [A] Battery Charge Rate (%) [B] Refresh charge is required [C] Good [D]...
Page 421 ELECTRICAL SYSTEM 16-25 Charging System Alternator Outer Cover Removal • Remove (left side view): Left Front Footpeg [A] (see Crankshaft/Transmission chapter) Shift Pedal [B] (see Crankshaft/Transmission chapter) • Unscrew the bolts [A] and take off the alternator outer cover [B]. Alternator Outer Cover Installation •...
Page 422: Charging System
• Apply silicone sealant to the area [A] to the pickup coil wire grommet [B]. Stator Lead Grommet [C] Sealant - Kawasaki Bond (Silicone Sealant): 56019–120 • Tighten the cover bolts. Torque - Alternator Cover Bolts: 11 N m (1.1 kg...
Page 423: Engine Mounting Bolts And Nuts
ELECTRICAL SYSTEM 16-27 Charging System • Lift up [A] the front part of the engine, using the jack until the lower part of the alternator inner cover clears the lower frame [B]. NOTE Turn the propeller shaft so that the engine can be raised as high as possible.
Page 424 16-28 ELECTRICAL SYSTEM Charging System Be sure to align the balancer gear mark (shorter) with the alternator mark (line marks) [A] while keeping the front position on its top dead center. Top Mark for Rear Piston [B] (longer mark) Top Mark for Front Piston [C] (longer mark) •...
Page 425 ELECTRICAL SYSTEM 16-29 Charging System • Install the pickup coils as shown. Pickup Coil [A] with shorter leads (BK and BK/Y) for #1 (front) Pickup Coil [B] with longer leads (BK/W and BK/R) for #2 (rear) Torque - Pickup Coil Screws: 2.9 N m (0.30 kg m, 26 in Run the longer pickup coil leads over the shorter pickup coil leads...
Page 426 16-30 ELECTRICAL SYSTEM Charging System Alternator Inspection There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism. A short or open in one of the stator coil leads will result in either a low output, or no output at all. A loss in rotor magnetism, which may be caused by dropping or hitting the alternator, by leaving it near an electromagnetic ﬁeld, or just by aging, will result in low output.
Page 427 If the tester readings are not as speciﬁed, replace the regulator/ rectiﬁer. CAUTION Use only Kawasaki Hand Tester 57001-1394 for this test. A tester other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large-capacity battery is used,...
Page 428 16-32 ELECTRICAL SYSTEM Charging System Regulator/Rectiﬁer Internal Resistance Unit: k Tester (+) Lead Connection Terminal W/R1 W/R2 ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ — ∞ ∞ ∞ ∞ ∞ ∞ ∞ W/R1 — ∞ ∞ ∞ ∞ ∞ ∞...
Page 429 ELECTRICAL SYSTEM 16-33 Charging System Charging System 1. Alternator 5. Main Fuse 30 A 2. Regulator/Rectiﬁer 6. Starter Relay 3. Ignition Switch 7. MF Battery 12 V 18 Ah 4. Load 8. Headlight Relay in Junction Box (AU, CA and US)
Page 430: Neutral Switch
16-34 ELECTRICAL SYSTEM Ignition System Ignition System Circuit #1: For Front Cylinder #2: For Rear Cylinder 1. Ignition Switch 8. Junction Box 15. Pickup Coil #1 2. Engine Stop Switch 9. Ignition Fuse 10 A 16. Neutral Switch 3. Starter Button 10.
Page 431 ELECTRICAL SYSTEM 16-35 Ignition System...
Page 432 16-36 ELECTRICAL SYSTEM Ignition System The ignition system produces extremely high voltage. not touch the spark plugs, ignition coils, or spark plug high- tension cables while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running.
Page 433: Ignition System
ELECTRICAL SYSTEM 16-37 Ignition System • Disconnect the right handlebar switch, fan motor and rear brake switch connectors [A]. • Remove the mounting nuts [B] and connector bracket [C]. • Take on the #2 ignition coil. • Disconnect the primary wires. Ignition Coil Installation •...
Page 434 16-38 ELECTRICAL SYSTEM Ignition System • Measure the primary winding resistance as follows. Connect the hand tester between the coil terminals. Set the tester to the range, and read the tester. • Measure the secondary winding resistance as follows. Remove the plug caps by turning them counterclockwise. Connect the tester between the spark plug High-Tension cables.
Page 435 ELECTRICAL SYSTEM 16-39 Ignition System • Install a commercially available peak voltage adapter [A] into the hand tester [B]. • Connect the adapter between the ignition coil primary wire terminal and the engine ground with the primary wire left connected. Recommended Tool: Peak Voltage Adapter Type: KEK-54-9-B...
Page 436 16-40 ELECTRICAL SYSTEM Ignition System Pickup Coil Installation Refer to Alternator Stator Installation in this chapter. Pickup Coil Inspection • Remove the alternator outer cover (see this chapter). • Remove all the spark plug caps but do not remove the spark plugs. •...
Page 437 ELECTRICAL SYSTEM 16-41 Ignition System • Set the hand tester [A] to the range and wire it to the pickup coil lead connector [B]. Connections: Tester Connections Front Pickup Coil: BK/Y Rear Pickup Coil: BK/R BK/W If there is more resistance than the speciﬁed value, the coil has an open wire and must be replaced.
Page 438 16-42 ELECTRICAL SYSTEM Ignition System 2nd Check Using a stand, raise the rear wheel off the ground. • Inspect the engine for its secure stop after the following operations are completed. • Run the engine to the following conditions. Condition: Transmission Gear 1st Position Clutch Lever...
Page 439 ELECTRICAL SYSTEM 16-43 Ignition System...
Page 440 16-44 ELECTRICAL SYSTEM Starter Motor Starter Motor Removal • Slide out the cap [A] • Remove: Starter Motor Terminal Nut [B] Cable [C] Starter Motor Bolts [D] • Pull the starter motor [A] toward the left and remove it. CAUTION Never drop the starter motor, especial on a hard surface.
Page 441 ELECTRICAL SYSTEM 16-45 Starter Motor Disassembly • Remove the starter motor (see this section). • Take off the starter motor assy bolts [A] and remove both end covers [B] and pull the armature out of the yoke. • Take the positive carbon brushes [B] out of the brush holders [A]. •...
Page 442 16-46 ELECTRICAL SYSTEM Starter Motor • Put the armature [A] among the brushes, and remove the plastic washers [B]. • Fit the tang [A] of the brush plate into the left end cover groove [B]. • Apply a thin coat of grease to the oil seal [B] in the right end cover [A].
Page 443: Starter Motor
ELECTRICAL SYSTEM 16-47 Starter Motor Brush Inspection • Measure the length [A] of each brush. If any is worn down to the service limit, replace the carbon brush holder assy [B] and the terminal bolt assy [C]. Starter Motor Brush Length Standard: 12 mm (0.47 in.) Service Limit:...
Page 444 16-48 ELECTRICAL SYSTEM Starter Motor Brush Assy Inspection • Using the hand tester range, measure the resistance as follows. Terminal Bolt and Positive Brushes [A] Brush Plate and Negative Brushes [B] Plastic [C] The reading should be zero. If there is not close to zero ohms, the brush lead has an open. Replace the terminal bolt assembly and the brush holder assembly.
Page 445 ELECTRICAL SYSTEM 16-49 Starter Motor Electric Starter Circuit 1. Ignition Switch 5. Starter Circuit Relay 9. Starter Motor 2. Engine Stop Switch 6. Ignition Fuse 10 A 10. Starter Relay 3. Starter Button 7. Starter Lockout Switch 11. Main Fuse 30 A 4.
Page 446: Lighting System
16-50 ELECTRICAL SYSTEM Lighting System US, Canadian, and Australian models have a full-time headlight system with a headlight relay in the junction box. In these models, the headlight does not go on when the ignition switch and the engine stop switch are ﬁrst turned on.
Page 447 ELECTRICAL SYSTEM 16-51 Lighting System • Pull the headlight unit and drop it out. • Pull the headlight connector [A]. • Remove the headlight dust cover [B]. • Push the hook [A] to unlock. • Take out the bulb [A]. CAUTION When handling the quartz-halogen bulb, never touch the glass portion with bare hands.
Page 448 16-52 ELECTRICAL SYSTEM Lighting System • Disconnect the wiring connectors [A]. • Remove the headlight body nuts [B], then take off the body [C]. City Light Bulb Replacement (other than US, CA and AU) • Remove the headlight unit (see this chapter). •...
Page 449 ELECTRICAL SYSTEM 16-53 Lighting System • Put the hooks [A] to the edge [B] of the tail/brake light cover. • Tighten the lens screws. Be careful not to overtighten them.
Page 450 16-54 ELECTRICAL SYSTEM Lighting System Headlight Circuit (Other Than Australia, Canada, and United States of America) Headlight Circuit (Australia, Canada, and United States of America) 1. Ignition Switch 6. High Beam Indicator Light 11. Main Fuse 30 A 2. Headlight Switch 7.
Page 451 ELECTRICAL SYSTEM 16-55 Automatic Turn Signal Canceling System Automobiles use a turn signal canceling system actuated by steering wheel turn. But, motorcycles turn with a bank additionally, and so have a smaller steer angle. This makes difﬁcult to adopt an automobile type turn signal canceling system because of inaccurate operation in motorcycles.
Page 452 16-56 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System Wiring Inspection • Connect all the connectors. • Remove the right side cover (see Frame chapter). • Remove the turn signal control relay [A]. • Pull off the 6-pin connector of the unit, the 9-pin and 4-pin meter connectors in the headlight housing, and the 9-pin left handlebar switch connector under the fuel tank.
Page 453 ELECTRICAL SYSTEM 16-57 Automatic Turn Signal Canceling System Turn Signal Switch Inspection • Remove the fuel tank (see Fuel System chapter). • Unplug the 9-pin connectors that leads to the left handlebar switch. • Check the turn signal switch connections according to the table. If the switch has an open circuit or a short, it can be disassembled for repair.
Page 454 16-58 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System Turn Signal Light Bulb Replacement • Remove the turn signal light lens screws [A] and take off the lens [B]. • Push the bulb [A] in the socket and turn the bulb counterclockwise [B].
Page 455 ELECTRICAL SYSTEM 16-59 Radiator Fan System The radiator fan is connected directly to the battery. The fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DISCONNECTED. TOUCHING THE FAN BEFORE THE CON- NECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES.
Page 456 16-60 ELECTRICAL SYSTEM Oil Pressure Warning System Motorcycle operation with low engine oil level, even if it is higher than the lower level line, will cause oil level change when sudden acceleration, or deceleration, and may lead ﬂicker of the oil pressure warning light because of too rapid response of the oil pressure switch.
Page 457: Oil Pressure Warning System
ELECTRICAL SYSTEM 16-61 Oil Pressure Warning System • Disconnect the wire [A] of the oil pressure switch [B] and ground [C] it to the engine, using an auxiliary wire. • Turn the ignition switch [D] ON. If the oil pressure warning LED light [E] is lit, replace the oil pressure switch.
Page 458 16-62 ELECTRICAL SYSTEM Meter, Gauge Meter Unit Removal • Remove the headlight unit (see this chapter). • Open the clamp [A] and disconnect the meter connectors [B]. • Unscrew the bolts [A] and take the meter unit [B]. • Unscrew the screws [A] and remove the meter cover [B] from the meter unit.
Page 459 ELECTRICAL SYSTEM 16-63 Meter, Gauge Meter Unit Disassemble • Remove the meter unit (see this chapter). • Remove: Screws [A] • Separate the upper meter cover [B]. • Remove the screw [A], meter light sockets [B] and rubber lid [C]. •...
Page 460 16-64 ELECTRICAL SYSTEM Meter, Gauge Meter Unit Assembly • Connect the connectors of the meter harness. • Put on the rubber lid [A] on the lower cover [B]. Tighten the screw together with the harness clamp [C] as shown. Meter Unit Inspection Mode Select and Reset Button Checks: •...
Page 461 ELECTRICAL SYSTEM 16-65 Meter, Gauge Clock Setting: • In the HOUR/MINUTE setting mode, push the reset button [A] again to effect the HOUR setting mode. The hour display ﬂashes [B] on the display. • Push the mode select button to set the hour. •...
Page 462 16-66 ELECTRICAL SYSTEM Meter, Gauge • Using the auxiliary wires, connect a 12 V battery to the meter unit connector terminals. First Connections: Battery Positive Terminal (+) Terminal [7] Battery Negative Terminal (–) Terminal [3] Next Connections: Battery Positive Terminal (+) Terminal [1] •...
Page 463 ELECTRICAL SYSTEM 16-67 Meter, Gauge Tachometer Inspection: • If an oscillator is available, check the tachometer as follows. Connect the terminals in the same way as in the LCD segment inspection. Connect the oscillator [A] to the terminal [4]. The rpm that corre- sponds to the input frequency will be displayed when a short wave from such as the one show in the diagram is input.
Page 464 16-68 ELECTRICAL SYSTEM Meter, Gauge Distance Sensor Inspection: • Install the meter unit (see Meter Unit Installation). • Disconnect the connector of the speed sensor (see Speed Sensor Removal). • Connect the oscillator [C] to the LG/R terminal [B] of the connector [A] on the main harness.
Page 465 ELECTRICAL SYSTEM 16-69 Meter, Gauge LED and Indicator Lights Inspection: • Connect the 12 V battery to the meter terminals in the same way as in the LCD segment inspection. FI Indicator LED Light Connections: Battery Negative Wire (–) to Terminal [9] •...
Page 466 16-70 ELECTRICAL SYSTEM Meter, Gauge Indicator Panel Bulb Replacement • Remove the indicator panel bolt [A] • Raise [B] the rear of the panel and pull the panel backward [C]. • Disconnect the indicator light connector [A]. • Pull out the indicator light socket [B] backward and then pull out the lens [A] from the socket .
Page 467 ELECTRICAL SYSTEM 16-71 Meter, Gauge 1. Oil Pressure Warning Light Delay Unit 12. Ignition Switch 2. Speed Sensor 13. Water Temperature Switch 3. Speedometer 14. E.C.U. (Electronic Control Unit) 4. Tachometer 15. Junction Box 5. Odo/Trip/Clock Indicator 16. Ignition Fuse 10 A 6.
Page 468 16-72 ELECTRICAL SYSTEM Meter, Gauge • Inspect the water temperature warning LED light and the system wiring. Turn on the ignition switch. Disconnect the water temperature switch wire [A], then ground it to the frame or engine using an auxiliary wire. If the water temperature warning LED light is lit, inspect the water temperature switch [B] (see Switches and Sensors section).
Page 469: Switch And Sensors
ELECTRICAL SYSTEM 16-73 Switch and Sensors Fuel Reserve Switch Inspection • Fill the fuel tank with fuel. • Close the fuel tank cap surely. • Remove: Seat (see Frame chapter) Fuel Pump Connector (see Fuel System chapter) • Connect the test light (12 V 3.4 W bulb a socket with wires) [B] and 12 V battery and the 12 V battery [A] to the fuel pump connector [C].
Page 470 16-74 ELECTRICAL SYSTEM Switch and Sensors Speed Sensor Inspection • Remove: Speed Sensor (see Speed Sensor Removal) • Connect the speed sensor connector [A] with a battery [B], 10 k resistor [C] and hand tester [D] as shown. • Set the tester to the DC 25 V range. Special Tool - Hand Tester : 57001–1394 •...
Page 471 Remove the water temperature switch [A] from the radiator. Water Temperature Switch Installation • Apply silicone sealant to the threads of the water temperature switch. Sealant - Kawasaki Bond: 59019–120 Torque - Water Temperature Switch: 7.8 N m (0.8 kg m, 69 in •...
Page 472 16-76 ELECTRICAL SYSTEM Switch and Sensors Water Temperature Switch Inspection • Remove the water temperature switch. • Suspend the switch [A] in a container of machine oil so that the heat- sensitive portion and threaded portion are submerged. • Suspend an accurate thermometer [B] with heat-sensitive portions [C] located in almost the same depth.
Page 473 ELECTRICAL SYSTEM 16-77 Junction Box The junction box [A] has fuses [B], relays, and diodes. The relays and diodes can not be removed. Junction Box Fuse Circuit Inspection • Remove the right side cover (see Frame chapter). • Remove the junction box. •...
Page 474 16-78 ELECTRICAL SYSTEM Junction Box Relay Circuit Inspection (with the battery connected) Tester Battery Tester Connection Reading Reading Connection (–) Headlight Relay – – Starter Circuit (–) Not ∞** – – Relay (*): USA, Canadian, and Australian Models only (**): The actual reading varies with the hand tester used. (+): Apply tester positive wire.
Page 475 ELECTRICAL SYSTEM 16-79 Junction Box Junction Box Internal Circuit (Australia, Canada, and United States of America) Junction Box Internal Circuit (Other Than Australia, Canada, and United States of America) Accessory Fuse 10 A 32 V [A] Ignition Fuse 10 A 32 V [E] Starter Diode [I] Fan Fuse 10 A...
Page 476 16-80 ELECTRICAL SYSTEM Fuse Main Fuse Removal • Remove the right side cover (see Frame chapter). • Remove the junction box and the reserve tank. • Remove the starter relay [A]. • Pull out the main fuse [B] from the starter relay with needle nose pliers.
Page 477 TROUBLESHOOTING 17-1 Troubleshooting Table of Contents Troubleshooting Guide (except DFI) ..........................17-2...
Page 478 17-2 TROUBLESHOOTING Troubleshooting Guide (except DFI) NOTE Compression Low: Refer to Fuel System chapter for most of DFI Spark plug loose troubleshooting guide. Cylinder head not sufﬁciently tightened down This is not an exhaustive list, giving every possi- Cylinder, piston worn ble cause for each problem listed.
Page 479: Poor Running Or No Power At High Speed
TROUBLESHOOTING 17-3 Troubleshooting Guide (except DFI) Poor Running or No Power at High Speed: nearest service facility to correct it) Firing incorrect: For KLEEN, do not push-start with a dead battery Spark plug dirty, broken, or maladjusted (Connect another full-charged battery with jumper Spark plug cap or high tension wiring trouble cables, and start the engine using the electric Spark plug cap shorted or not in good contact...
Page 480: Clutch Operation Faulty
17-4 TROUBLESHOOTING Troubleshooting Guide (except DFI) Clutch Operation Faulty: Valve noise: Clutch slipping: Engine not sufﬁciently warmed up after HLA installa- Friction plate worn or warped tion Steel plate worn or warped HLA damaged (worn, seizure, or spring broken) Spring plate free play maladjustment HLA aeration due to low oil level Clutch spring broken or weak Air in HLA...
Page 481: Exhaust Smokes Excessively
TROUBLESHOOTING 17-5 Troubleshooting Guide (except DFI) Disc brake noise: Wheel bearing worn Pad installed incorrectly Handlebar nuts loose Pad surface glazed Steering stem head nut loose Disc warped Front, rear axle runout excessive Caliper trouble Handlebar pulls to one side: Master cylinder damaged Frame bent Other noise:...

This manual is also suitable for:

Vulcan 1500 mean streak

Kawasaki VN1500 MEAN STREAK Service Manual

Quick Links

7 General Information 1-1 1 General Information

55 Periodic Maintenance 2-1 Periodic Maintenance

57 Periodic Maintenance Chart

58 Speciﬁcations

60 Periodic Maintenance Procedures

82 Electrical System

82 General Lubrication

84 Nut, Bolt, and Fastener Tightness

85 Fuel System (Dfi) 3-1 Fuel System (Dfi)

171 Cooling System 4-1 Cooling System

223 Clutch 6-1 Clutch

237 Engine Lubrication System 7-1 Engine Lubrication System

247 Engine Removal/Installation

255 Crankshaft/Transmission 9-1 Crankshaft/Transmission

285 Wheels/Tires 10-1 Wheels/Tires

Chapters

7 General Information 1-1 1 General Information

55 Periodic Maintenance 2-1 Periodic Maintenance

57 Periodic Maintenance Chart

58 Speciﬁcations

60 Periodic Maintenance Procedures

82 Electrical System

82 General Lubrication

84 Nut, Bolt, and Fastener Tightness

85 Fuel System (Dfi) 3-1 Fuel System (Dfi)

171 Cooling System 4-1 Cooling System

223 Clutch 6-1 Clutch

237 Engine Lubrication System 7-1 Engine Lubrication System

247 Engine Removal/Installation

255 Crankshaft/Transmission 9-1 Crankshaft/Transmission

285 Wheels/Tires 10-1 Wheels/Tires

Also See for Kawasaki VN1500 MEAN STREAK

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Summary of Contents for Kawasaki VN1500 MEAN STREAK

7
General Information 1-1 1 General Information

55
Periodic Maintenance 2-1 Periodic Maintenance

57
Periodic Maintenance Chart

58
Speciﬁcations

60
Periodic Maintenance Procedures

82
Electrical System

82
General Lubrication

84
Nut, Bolt, and Fastener Tightness

85
Fuel System (Dfi) 3-1 Fuel System (Dfi)

171
Cooling System 4-1 Cooling System

223
Clutch 6-1 Clutch

237
Engine Lubrication System 7-1 Engine Lubrication System

247
Engine Removal/Installation

255
Crankshaft/Transmission 9-1 Crankshaft/Transmission

285
Wheels/Tires 10-1 Wheels/Tires

7
General Information 1-1 1 General Information

55
Periodic Maintenance 2-1 Periodic Maintenance

57
Periodic Maintenance Chart

58
Speciﬁcations

60
Periodic Maintenance Procedures

82
Electrical System

82
General Lubrication

84
Nut, Bolt, and Fastener Tightness

85
Fuel System (Dfi) 3-1 Fuel System (Dfi)

171
Cooling System 4-1 Cooling System

223
Clutch 6-1 Clutch

237
Engine Lubrication System 7-1 Engine Lubrication System

247
Engine Removal/Installation

255
Crankshaft/Transmission 9-1 Crankshaft/Transmission

285
Wheels/Tires 10-1 Wheels/Tires