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NINJA 650R
ER-6f ABS
ER-6f
Motorcycle
Service Manual

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Table of Contents

   Summary of Contents for Kawasaki ER-6f ABS

  • Page 1 NINJA 650R ER-6f ABS ER-6f Motorcycle Service Manual...
  • Page 3 Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 5 All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
  • Page 6: Emission Control Information

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi-...
  • Page 7 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 8: How To Use This Manual

    Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. • venient operation. Use proper tools and genuine Kawasaki Mo- • torcycle parts. Special tools, gauges, and Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 9: Country And Area Codes

    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 °C degree(s) Celsius revolution direct current...
  • Page 11: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................1-10 Technical Information - Cassette Type Transmission ............. 1-13 Technical Information - Inlet Air Pressure Sensor ..............1-14 Technical Information – ABS (Anti – Lock Brake System)............1-15 Unit Conversion Table ......................
  • Page 12: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 13 Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
  • Page 14: Tightening Torque

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

    GENERAL INFORMATION 1-7 Model Identification EX650A6F (United States and Canada) Left Side View EX650A6F (United States and Canada) Right Side View...
  • Page 18 1-8 GENERAL INFORMATION Model Identification EX650A6F (Europe) Left Side View EX650A6F (Europe) Right Side View...
  • Page 19 GENERAL INFORMATION 1-9 Model Identification EX650B6F Left Side View EX650B6F Right Side View Frame Number Engine Number...
  • Page 20: General Specifications

    1-10 GENERAL INFORMATION General Specifications Items EX650A6F, EX650B6F Dimensions Overall Length 2 105 mm (82.9 in.) Overall Width 760 mm (29.9 in.) Overall Height 1 210 mm (47.6 in.) Wheelbase 1 410 mm (55.5 in.) Road Clearance 145 mm (5.7 in.) Seat Height 790 mm (31.1 in.) Dry Mass:...
  • Page 21 GENERAL INFORMATION 1-11 General Specifications Items EX650A6F, EX650B6F Exhaust: Open 50° BBDC Close 30° ATDC Duration 260° Lubrication System Forced lubrication (semi-dry sump) Engine Oil: Type API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE 10W-40 Capacity 2.4 L (2.5 US qt)
  • Page 22 1-12 GENERAL INFORMATION General Specifications Items EX650A6F, EX650B6F Type Swingarm Wheel Travel 125 mm (4.9 in.) Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 10 Ah Headlight: Type Semi-sealed beam Bulb 12 V 55 W × 2/55 W (Hi/Lo) Tail/Brake Light 12 V 5/21 W Alternator:...
  • Page 23: Technical Information - Cassette Type Transmission

    GENERAL INFORMATION 1-13 Technical Information - Cassette Type Transmission Cassette Type Transmission The transmission of the current model is unable to be removed without disassembling upper and lower crankcase halves. The EX650A/B enables transmission to be removed from the right side of engine as an assy, without disassembling crankcase halves (see Transmission Assy Removal in the Crankshaft/Transmission chapter).
  • Page 24: Technical Information - Inlet Air Pressure Sensor

    1-14 GENERAL INFORMATION Technical Information - Inlet Air Pressure Sensor Atmospheric pressure sensor and camshaft position sensor are not equipped with the EX650A/B. As a substitute of these sensors above, the EX650A/B recognizes atmospheric pressure and intake stroke of #1 by the signal of inlet air pressure sensor. The ECU detects atmospheric pressure when the ignition is switched ON.
  • Page 25: Technical Information - Abs (anti - Lock Brake System)

    17. Rear Wheel Rotation Sensor 6. Front Inlet Solenoid Valve 18. Rear Wheel Rotation Sensor Rotor 7. Front Outlet Solenoid Valve 19. ABS Kawasaki Self-diagnosis System Con- 8. Rear Inlet Solenoid Valve nector 9. Rear Outlet Solenoid Valve 20. ABS Solenoid Valve Relay 10.
  • Page 26 15. Hydraulic Unit 5. ABS Indicator Light (LED) 16. ABS Controller 6. ECU 17. ABS Hydraulic Unit 7. ABS Solenoid Valve Relay 18. ABS Kawasaki Self-diagnosis System Con- 8. Output nector 9. Monitor Input 19. Wheel Rotation Input 10. Valve Output 20.
  • Page 27 5. ABS Indicator Light (LED) 6. ABS Hydraulic Unit 7. ABS Fuse Box 8. ABS Kawasaki Self-diagnosis System Connector Wheel Rotation Sensor The wheel rotation sensors output the rotation speed of each wheel to the ECU in the ABS hydraulic unit.
  • Page 28 1-18 GENERAL INFORMATION Technical Information – ABS (Anti – Lock Brake System) ABS Hydraulic Unit The outlet and inlet solenoid valves, reservoir, pump motor, solenoid valve relay, motor relay, and ECU are built in the ABS hydraulic unit. 1. Brake Lever 2.
  • Page 29 GENERAL INFORMATION 1-19 Technical Information – ABS (Anti – Lock Brake System) Inlet Solenoid Valve Inlet solenoid valves control the brake pressure of each wheel by combining the operation of the outlet solenoid valve. The ECU changes the electric current in the solenoids of the inlet solenoid valve (2 way, 2 position electromagnetic valve) to move the tappet and change the fluid pressure to “Increase Mode”, “Hold Mode”, or “Decrease Mode”.
  • Page 30 1-20 GENERAL INFORMATION Technical Information – ABS (Anti – Lock Brake System) Reservoir When the passage opens between the caliper and the reservoir with the outlet solenoid valve in “Decrease Mode”, the brake fluid flows into the reservoir by pushing the piston, stays there temporar- ily, and then returns to the master cylinder.
  • Page 31 GENERAL INFORMATION 1-21 Technical Information – ABS (Anti – Lock Brake System) ABS Solenoid Valve Relay ABS solenoid valve relay supply or intercept the power to the inlet or outlet solenoid valves. ABS Motor Relay ABS motor relay supply or intercept the power to the pump motor. ECU inputs the sensor signal.
  • Page 32 1-22 GENERAL INFORMATION Technical Information – ABS (Anti – Lock Brake System) ABS Operation The ABS has two independent hydraulic lines, one for the front wheel and the other for the rear wheel. The front wheel system is explained here and is identical to the rear wheel system. ABS in Action (Increase Mode) When the caliper fluid pressure is to be increased, first the tappet of inlet solenoid valve opens...
  • Page 33 GENERAL INFORMATION 1-23 Technical Information – ABS (Anti – Lock Brake System) (Hold Mode) When the caliper fluid pressure is to be hold, the tappet of inlet solenoid valve closes, and the passage (master cylinder side) to the valve body is intercepted. No matter how hard the brake lever is pulled, the brake fluid pressure in the caliper is maintained at a given level.
  • Page 34 1-24 GENERAL INFORMATION Technical Information – ABS (Anti – Lock Brake System) (Decrease Mode) When the caliper fluid pressure is to be decreased, the tappet of inlet solenoid valve closes, and the passage to the valve body is intercepted. The valve of outlet solenoid valve is opened by the operation of the armature, and the brake fluid flows to the reservoir.
  • Page 35 GENERAL INFORMATION 1-25 Technical Information – ABS (Anti – Lock Brake System) ABS Disabled (Conventional Mode) During cruising (without braking) or in case of a malfunction with the ABS, the ECU stops operating. This is “Conventional Mode”. When the caliper fluid pressure is to be increased, first the tappet of inlet solenoid valve opens (normally open).
  • Page 36 1-26 GENERAL INFORMATION Technical Information – ABS (Anti – Lock Brake System) Riding Characteristics of ABS ABS is designed to help prevent the wheels from locking up when hard brakes are applied while running straight. The ABS automatically regulates brake force. Intermittently gaining gripping force and braking force helps prevent wheel lock-up and allows stable steering control while stopping.
  • Page 37: Unit Conversion Table

    GENERAL INFORMATION 1-27 Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 N·m ×...
  • Page 39: Periodic Maintenance

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-11 Special Tools .......................... 2-13 Periodic Maintenance Procedures..................2-14 Fuel System (DFI)........................ 2-14 Air Cleaner Element Cleaning................... 2-14 Throttle Control System Inspection................... 2-15 Engine Vacuum Synchronization Inspection..............
  • Page 40 2-2 PERIODIC MAINTENANCE Steering Stem Bearing Lubrication ................... 2-37 Electrical System ......................... 2-37 Spark Plug Condition Inspection..................2-37 Lights and Switches Operation Inspection................ 2-38 Headlight Aiming Inspection ..................... 2-40 Sidestand Switch Operation Inspection ................2-41 Engine Stop Switch Operation Inspection................. 2-42 Others ..........................
  • Page 41: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection FREQUENCY Whichever * ODOMETER READING comes ×...
  • Page 42 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) • • • Drive chain guide wear - inspect 2-31 Brake System Brake fluid leak (brake hose and pipe) -...
  • Page 43 PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page CHANGE/REPLACE ITEM Every (0.6) (7.5) (15) (24) (30) Air cleaner element # 2 years 2-45 •...
  • Page 44: Torque And Locking Agent

    2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. EO: Apply engine oil.
  • Page 45 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Muffler Body Mounting Bolt (Rear) Baffle Plate Bolts 0.60 52 in·lb Clutch Upper Cap on Clutch Cover 0.40 35 in·lb Lower Cap on Clutch Cover – – –...
  • Page 46 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Shift Drum Bearing Holder Screw 0.50 43 in·lb Connecting Rod Big End Nuts see Text ← ← Timing Rotor Bolt Oil Pressure Switch Oil Passage Plug Gear Positioning Lever Bolt 106 in·lb Shift Shaft Return Spring pin Shift Drum Cam Bolt...
  • Page 47 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Front Fork Top Plugs Rear Shock Absorber Bolt Rear Shock Absorber Nut Swingarm Pivot Shaft Nut 11.0 Steering Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper)
  • Page 48 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Starter Motor Cable Terminal Nut 0.60 53 in·lb Starter Motor Clutch Bolts Starter Motor Mounting Bolts 87 in·lb Starter Motor Terminal Locknut 97 in·lb Starter Motor Through Bolts 0.50 43 in·lb Stator Coil Bolts...
  • Page 49: Specifications

    PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – Throttle Grip Free Play Idle Speed 1 300 ±50 r/min (rpm) – – – Bypass Screws (Turn Out) 0 ∼ 2 1/2 (for reference) –...
  • Page 50 2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive 30 ∼ 40 mm (1.2 ∼ 1.6 in.) Drive Chain Slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Drive Chain Wear (20-link 323 mm (12.7 in.) Length) Standard Chain: Make...
  • Page 51: Special Tools

    PERIODIC MAINTENANCE 2-13 Special Tools Inside Circlip Pliers: Extension Tube: 57001-143 57001-1578 Steering Stem Nut Wrench: Pilot Screw Adjuster, E: 57001-1100 57001-1603 Oil Filter Wrench: 57001-1249...
  • Page 52: Periodic Maintenance Procedures

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Air Cleaner Element Cleaning NOTE ○ In dusty areas, the element should be cleaned more frequently than the recommended interval. ○ After riding through rain or on muddily roads, the ele- ment should be cleaned immediately.
  • Page 53: Throttle Control System Inspection

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures WARNING Clean the element in a well-ventilated area, and make sure that there are no sparks or flame any- where near the working area. Because of the danger of highly flammable liquids, do not use gasoline or a low-flash point solvent to clean the element.
  • Page 54: Engine Vacuum Synchronization Inspection

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures If necessary, adjust the throttle cable as follows. • Loosen the locknut [A] at the upper end of the accelerator cable. • Turn the adjuster [B] in completely so as to give the throttle grip plenty of play.
  • Page 55 PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Start the engine and warm it up thoroughly. • Check the idle speed. Tachometer [A] • Open and close the throttle. If the idle speed is out of the specified range, adjust it. CAUTION Do not measure the idle speed by the tachometer of the meter unit.
  • Page 56: Idle Speed Inspection

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Repeat the same procedure for other bypass screws. • Repeat the synchronization. If the vacuums are correct, check the output voltage of the main throttle sensor (see Main Throttle Sensor Output Voltage Inspection in the Fuel System (DFI) chapter). Main Throttle Sensor Output Voltage Connections to ECU Meter (+) →...
  • Page 57: Fuel Hose Inspection (fuel Leak, Damage, Installation Condition)

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Fuel Hose Inspection (fuel leak, damage, installation condition) ○ The fuel hose is designed to be used throughout the mo- torcycle’s life without any maintenance. However, if the motorcycle is not properly handled, the high pressure in- side the fuel line can cause fuel to leak [A] or the hose to burst.
  • Page 58: Cooling System

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check the liquid/vapor separator as follows. ○ Remove: Left Center Fairing (see Center Fairing Removal in the Frame chapter) ○ Disconnect the hoses from the separator, and remove the separator [A] from the motorcycle left side. ○...
  • Page 59: Radiator Hose Damage And Installation Condition Inspection

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Radiator Hose Damage and Installation Condition Inspection ○ The high pressure inside the radiator hose and pipe can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. •...
  • Page 60 2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check the valve clearance when the pistons are at TDC. ○ The pistons are numbered beginning with the engine left side. • Using a wrench [A] on the crankshaft rotation bolt, turn the crankshaft clockwise until the "1/T" mark on the timing rotor is aligned with the notch [B] in the edge of the upper hole in the clutch cover for #1 piston and "2/T"...
  • Page 61: Valve Clearance Adjustment

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Valve Clearance Measuring Position #2 Piston TDC at End of Compression Stroke → Inlet valve clearances of #2 piston, and Exhaust valve clearances of #2 piston If the valve clearance is not with in the specified range, first record the clearance, and adjust it.
  • Page 62 2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm.
  • Page 63 PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm.
  • Page 64: Clutch

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Clutch Operation Inspection • Pull the clutch lever just enough to take up the free play [A]. • Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully.
  • Page 65: Wheel/tire Damage Inspection

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Wheel/Tire Damage Inspection • Remove any imbedded stones [A] or other foreign parti- cles [B] from tread. • Visually inspect the tire for cracks and cuts, and replace the tire if necessary. Swelling or high spots indicate inter- nal damage, requiring tire replacement.
  • Page 66: Wheel Bearing Damage Inspection

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel Bearing Damage Inspection • Raise the front wheel off the ground with jack (see Front Wheel Removal in the Wheels/Tires chapter). • Turn the handlebar all the way to the right or left. •...
  • Page 67: Drive Chain Slack Inspection

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures • Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the O-rings so that the O-rings will be coated with oil. •...
  • Page 68: Wheel Alignment Inspection

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. ○...
  • Page 69: Drive Chain Wear Inspection

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Drive Chain Wear Inspection • Remove: Chain Cover (see Swingarm Removal in the Suspension chapter) • Rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain.
  • Page 70: Brake System

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake System Brake Fluid Leak (Brake Hose and Pipe) Inspection • Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A], fittings [B] and pipes [C]. If the brake fluid leaked from any position, inspect or re- place the problem part.
  • Page 71: Brake Operation Inspection

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Brake Operation Inspection • Inspect the operation of the front and rear brake by run- ning the vehicle on the dry road. If the brake operation is insufficiency, inspect the brake system. WARNING When inspecting by running the vehicle, note a surrounding traffic situation enough in the place of safety.
  • Page 72: Brake Pad Wear Inspection

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Follow the procedure below to install the rear brake fluid reservoir cap correctly. ○ First, tighten the rear brake fluid reservoir cap [B] clock- wise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].
  • Page 73: Suspensions

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Suspensions Front Forks/Rear Shock Absorber Operation Inspection • Pump the forks down and up [A] 4 or 5 times, and inspect the smooth stroke. If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see Front Fork Oil Change in the Suspension chapter).
  • Page 74: Steering System

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering System Steering Play Inspection • Raise the front wheel off the ground with jack (see Front Wheel Removal in the Wheels/Tires chapter). • With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.
  • Page 75: Steering Stem Bearing Lubrication

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures • Install the claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of stem locknut [C]. • Hand tighten the stem locknut until it touches the claw washer.
  • Page 76: Lights And Switches Operation Inspection

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Lights and Switches Operation Inspection First Step • Turn on the ignition switch. • The following lights should go on according to below table. City Light [A] goes on Taillight [B] goes on goes on License Plate Light [C] Meter Panel LCD [D] goes on...
  • Page 77 PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures • Turn off the ignition switch. • The all lights should go off. If the light does not go off, replace the ignition switch. Second Step • Turn the ignition switch to P (Park) position. •...
  • Page 78: Headlight Aiming Inspection

    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fourth Step • Set the dimmer switch [A] to low beam position. • Start the engine. • The low beam headlight should go on. If the low beam headlight does not go on, inspect or re- place the following item.
  • Page 79: Sidestand Switch Operation Inspection

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Headlight Beam Vertical Adjustment • Turn the vertical adjuster [A] on the headlight with the screwdriver in or out to adjust the headlight vertically. NOTE ○ ON high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated.
  • Page 80: Engine Stop Switch Operation Inspection

    2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the sidestand switch operation does not work, inspect or replace the following item. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Ignition Fuse 10 A (see Fuse Inspection in the Electrical System chapter)
  • Page 81: Others

    PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Others Chassis Parts Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○...
  • Page 82: Bolts, Nuts And Fasteners Tightness Inspection

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Bolts, Nuts and Fasteners Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).
  • Page 83: Replacement Parts

    PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures Replacement Parts Air Cleaner Element Replacement • Refer to the Air Cleaner Element Cleaning. Fuel Hose Replacement CAUTION When removing and installing the fuel hose joint, do not apply strong force to the outlet pipe on the fuel pump and delivery pipe on the throttle body assy.
  • Page 84: Coolant Change

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Coolant Change WARNING To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury.
  • Page 85 PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures • 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. ○ The coolant will drain from the radiator and engine. •...
  • Page 86: Radiator Hose And O-ring Replacement

    2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Temporarily install the reserve tank to the frame with two bolts. • Fill the reserve tank up to the “F” (full) level line [A] with coolant and install the cap [B]. • Start the engine, warm it up thoroughly until the radiator fan turns on and then stop the engine.
  • Page 87: Engine Oil Change

    PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Unscrew the oil filler plug [A]. • Place on oil pan beneath the engine. • Remove the engine oil drain bolt [A] to drain the oil. ○...
  • Page 88: Brake Hose And Pipe Replacement

    2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the filter with a new one. • Apply engine oil to the gasket [A] before installation. • Tighten the filter with the oil filter wrench. Torque - Oil Filter: 17.2 N·m (1.75 kgf·m, 13 ft·lb) NOTE ○...
  • Page 89: Brake Fluid Change

    PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures • Remove: Rear Fender Front (see Rear Fender Front Removal in the Frame chapter) (EX650B Models) Right Center Fairing (see Center Fairing Removal in the Frame chapter) (EX650B Models) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) (EX650B Models) •...
  • Page 90: Master Cylinder Rubber Parts Replacement

    2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Change the brake fluid. ○ Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. 1. Open the bleed valve [A]. 2. Apply the brake and hold it [B]. 3.
  • Page 91 PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures Rear Master Cylinder Disassembly NOTE ○ Do not remove the push rod clevis for master cylinder disassembly since removal reguires brake position ad- justment. • Remove the rear master cylinder (see Rear Master Cylin- der Removal in the Brakes chapter).
  • Page 92: Caliper Rubber Parts Replacement

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Caliper Rubber Parts Replacement Front Caliper Disassembly • Remove: Front Caliper (see Front Caliper Removal in the Brakes chapter) Brake Pads (see Front Brake Pad Removal in the Brakes chapter) • Using compressed air, remove the pistons. ○...
  • Page 93 PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures • Apply brake fluid to the outside of the pistons, and push them into each cylinder by hand. • Check the shaft rubber friction boot [A] and the dust cover [B] replace them with new ones if they are damaged. •...
  • Page 94: Spark Plug Replacement

    2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the fluid seal [A] with a new one. ○ Apply brake fluid to the fluid seal, and install it into the cylinder by hand. • Replace the dust seal [B] with a new one if it is damaged. ○...
  • Page 95 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................3-10 DFI System..........................3-12 DFI Parts Location........................3-15 Specifications ......................... 3-16 Special Tools and Sealant ...................... 3-18 DFI Servicing Precautions ...................... 3-20 DFI Servicing Precautions ....................3-20 Troubleshooting the DFI System ....................
  • Page 96 3-2 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25)..................3-57 Speed Sensor Removal/Installation.................. 3-57 Speed Sensor Inspection....................3-57 Speed Sensor Input Voltage Inspection................3-57 Speed Sensor Output Voltage Inspection ................. 3-57 Vehicle-down Sensor (Service Code 31)................3-59 Vehicle-down Sensor Removal ..................3-59 Vehicle-down Sensor Installation ..................
  • Page 97 FUEL SYSTEM (DFI) 3-3 Fuel Injector Power Source Voltage Inspection ..............3-91 Fuel Injector Output Voltage Inspection ................3-92 Injector Signal Test......................3-92 Injector Resistance Inspection ..................3-93 Injector Unit Test ....................... 3-94 Injector Fuel Line Inspection ..................... 3-94 Throttle Grip and Cables ......................3-96 Throttle Grip Free Play Inspection ..................
  • Page 98: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 99: Exploded View

    FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Pump Bolts 87 in·lb L, S 2. FI Indicator Light (LED) 3. Throttle Cable (Accelerator) 4. Throttle Cable (Decelerator) 5. Throttle Body Assy 6. Injectors 7. Meter Unit (EX650B Models) CL: Apply cable lubricant.
  • Page 100 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 101 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Water Temperature Sensor 106 in·lb Speed Sensor Bolt 0.80 69 in·lb Oxygen Sensor (Europe Models) 44.1 4.50 32.5 4. Inlet Air Pressure Sensor 5. Air Switching Valve 6. Inlet Air Temperature Sensor 7.
  • Page 102 3-8 FUEL SYSTEM (DFI) Exploded View California Model...
  • Page 103 FUEL SYSTEM (DFI) 3-9 Exploded View 1. Tube (Green) 2. Tube (Blue) 3. Tube (White) 4. Tube (Blue) 5. Tube (Red)
  • Page 104: Dfi System

    3-10 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 105 FUEL SYSTEM (DFI) 3-11 DFI System 1. Ignition Switch 2. Starter Lockout Switch 3. Starter Relay 4. Tachometer 5. FI Indicator Light (LED) 6. Inlet Air Pressure Sensor 7. Spark Plug 8. Crankshaft Sensor 9. Injector 10. Main Throttle Sensor 11.
  • Page 106 3-12 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 107 FUEL SYSTEM (DFI) 3-13 DFI System Part Name 1. Oxygen Sensor (Europe Models) 2. Crankshaft Sensor 3. Inlet Air Temperature Sensor 4. Water Temperature Sensor 5. Water-proof Joint E 6. Injectors 7. Vehicle-down Sensor 8. Water-proof Joint D 9. Inlet Air Pressure Sensor 10.
  • Page 108 3-14 FUEL SYSTEM (DFI) DFI System Terminal Names 1. Subthrottle Valve Actuator Drive Signal 2 27. Unused 2. Subthrottle Valve Actuator Drive Signal 1 28. Ground to Sensors 3. Water Temperature Warning Light Signal 29. Oxygen Sensor Heater Signal (Europe 4.
  • Page 109: Dfi Parts Location

    FUEL SYSTEM (DFI) 3-15 DFI Parts Location DFI: Digital Fuel Injection Parts 12. Speed Sensor 1. FI Indicator Light (LED) 13. Neutral Switch 2. Ignition Switch 14. Water Temperature Sensor 3. Throttle Body Assy 15. Subthrottle Sensor 4. Inlet Air Temperature Sensor 16.
  • Page 110: Specifications

    3-16 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 300 ±50 r/min (rpm) Throttle Assy: Type Two barrel type Bore 38 mm (1.50 in.) ECU (Electronic Control Unit): Make Denso Type Digital memory type, with built in IC igniter, sealed with resin 100 ∼...
  • Page 111 FUEL SYSTEM (DFI) 3-17 Specifications Item Standard with the sensor tilted 60 ∼ 70° or more: 0.65 ∼ 1.35 V Output Voltage with sensor arrow mark pointed up: 3.55 ∼ 4.45 V Subthrottle Sensor: Non-adjustable and non-removal 4.75 ∼ 5.25 V DC between BL and BR/BK leads Input Voltage 0.4 ∼...
  • Page 112: Special Tools And Sealant

    3-18 FUEL SYSTEM (DFI) Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Needle Adapter Set: 57001-125 57001-1457 Fork Oil Level Gauge: Throttle Sensor Setting Adapter: 57001-1290 57001-1538 Hand Tester: Sensor Harness Adapter: 57001-1394 57001-1561 Throttle Sensor Setting Adapter #1: Fuel Pressure Gauge Adapter: 57001-1400 57001-1593...
  • Page 113 FUEL SYSTEM (DFI) 3-19 Special Tools and Sealant Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 114: Dfi Servicing Precautions

    3-20 FUEL SYSTEM (DFI) DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 115 FUEL SYSTEM (DFI) 3-21 DFI Servicing Precautions ○ 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 plug [A] after filling the engine oil. Clutch Cover [B] Torque - Oil Filler Plug: Hand-tighten...
  • Page 116: Troubleshooting The Dfi System

    3-22 FUEL SYSTEM (DFI) Troubleshooting the DFI System Outline Outline When an abnormality in the system occurs, the FI indi- cator light (LED) 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 117 After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • 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 118 3-24 FUEL SYSTEM (DFI) Troubleshooting the DFI System • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. •...
  • Page 119 FUEL SYSTEM (DFI) 3-25 Troubleshooting the DFI System ○ There are two ways to inspect the DFI system. One is voltage Check Method and the other is Resistance Check Method. (Voltage Check Method) ○ This method is conducted by measuring the input voltage [B] to a sensor [A] first, and then the output voltage [C] from the sensor.
  • Page 120: Inquiries To Rider

    3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○...
  • Page 121 FUEL SYSTEM (DFI) 3-27 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. □ □ □ □ □ □...
  • Page 122 3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ other □ Poor running spark plug loose (tighten it) □ or no power at spark plug dirty, broken, or gap maladjusted (remedy it) high speed □ spark plug incorrect (replace it) □...
  • Page 123: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-29 DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. ○...
  • Page 124 3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) Clutch lever not pulled in and gear not in neutral Pull the lever in and shift the gear in neutral. whether sidestand up or not Though clutch lever pulled in, sidestand up and Sidestand down and clutch lever pulled in gear not in neutral whether gear in neutral or not...
  • Page 125: Poor Running At Low Speed

    FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) No valve clearance Adjust (see chapter 2). Valve guide worn Inspect and replace (see chapter 5). Valve spring broken or weak Inspect and replace (see chapter 5). Valve not seating properly (valve bent, worn or Inspect and repair or replace (see chapter 5).
  • Page 126 3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Engine stalls easily: Fuel pump trouble Inspect (see chapter 3). Fuel injector trouble Inspect (see chapter 3). Main throttle sensor trouble Inspect (see chapter 3). Fuel pressure too low or too high Inspect (see chapter 3).
  • Page 127 FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Loose terminal of battery (–) cable or engine Inspect and repair (see chapter 16). ground lead Delay of ignition timing Inspect crankshaft sensor and IC igniter in ECU (see chapter 16).
  • Page 128: Poor Running Or No Power At High Speed

    3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Inlet air temperature sensor trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3). Fuel injector trouble Inspect (see chapter 3).
  • Page 129 FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Throttle body assy O-ring damaged Replace (see chapter 3). Fuel tank air vent obstructed Inspect and repair (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Fuel pump operates intermittently and often DFI Pump bearings may wear.
  • Page 130 3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Drive train trouble Inspect drive chain (see chapter 2) and sprockets (see chapter 11). Camshaft cam worn Inspect and replace (see chapter 5). Air switching valve trouble Inspect and replace (see chapter 5).
  • Page 131: Self-diagnosis

    FUEL SYSTEM (DFI) 3-37 Self-Diagnosis Self-diagnosis Outline Self-diagnosis Outline The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User Mode The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator when DFI system and ignition system parts are faulty, and initiates fail-safe function.
  • Page 132: Service Code Clearing Procedures

    3-38 FUEL SYSTEM (DFI) Self-Diagnosis • To enter the self-diagnosis dealer mode 2, open [B] and ground [A] the lead more than five times [F] within 2 sec- onds [C] after the lead is first grounded, and then keep it grounded continuously [D] for more than 2 seconds.
  • Page 133 FUEL SYSTEM (DFI) 3-39 Self-Diagnosis...
  • Page 134: How To Read Service Codes

    3-40 FUEL SYSTEM (DFI) Self-Diagnosis How to Read Service Codes How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the FI indicator light (LED) as shown below. ○ Read 10th digit and unit digit as the FI indicator light (LED) blinks. ○...
  • Page 135: Service Code Table

    FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Service Code Table Service Code Table Service FI Indicator Light (LED) Problems Code Main throttle sensor malfunction, wiring open or short Inlet air pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Crankshaft sensor malfunction, wiring...
  • Page 136: Backups

    3-42 FUEL SYSTEM (DFI) Self-Diagnosis Backups Backups ○ The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the signal is out of the usable range, wiring short or open), the ECU locks ignition timing into the...
  • Page 137 FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria The stick coil primary If the ignition primary winding #1 has failures winding must send Stick Coil #1 (no signal, wiring short or open), the ECU signals (output voltage) (Ignition Coil)* shuts off the injector #1 to stop fuel to the...
  • Page 138: Main Throttle Sensor (service Code 11)

    3-44 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Removal/Adjustment CAUTION Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface.
  • Page 139: Main Throttle Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-45 Main Throttle Sensor (Service Code 11) Main Throttle Sensor Output Voltage Inspection • Measure the output voltage at the main throttle sensor in the same way as input voltage inspection, Note the following. • Disconnect the main throttle sensor connector and con- nect the harness adapter [A] between these connectors.
  • Page 140: Main Throttle Sensor Resistance Inspection

    3-46 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Resistance Inspection • Turn the ignition switch OFF. • Disconnect the main throttle sensor connector. • Connect a digital meter [A] to the main throttle sensor connector [B]. •...
  • Page 141: Inlet Air Pressure Sensor (service Code 12)

    FUEL SYSTEM (DFI) 3-47 Inlet Air Pressure Sensor (Service Code 12) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Inlet Air Pressure Sensor Removal • Remove: Left Upper Inner Fairing (see Upper Inner Fairing Re- moval in the Frame chapter) •...
  • Page 142: Inlet Air Pressure Sensor Output Voltage Inspection

    3-48 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Output Voltage Inspection NOTE ○ The output voltage changes according to the local at- mospheric pressure. • Measure the output voltage at the ECU in the same way as input voltage inspection.
  • Page 143 FUEL SYSTEM (DFI) 3-49 Inlet Air Pressure Sensor (Service Code 12) then Pv = Pl – Pg For example, suppose the following data is obtained: Pg = 8 cmHg (Vacuum gauge reading) Pl = 70 cmHg (Varometer reading) Vv = 3.2 V (Digital volt meter reading) then Pv = 70 –...
  • Page 144 3-50 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Pv = 55 ∼ 86 cmHg ID: Idling Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle Vacuum Pressure (Absolute) ST: Standard of Sensor Output Voltage (V) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (V) Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)
  • Page 145 FUEL SYSTEM (DFI) 3-51 Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Circuit 1. ECU 2. Water-proof Joint E 3. Water-proof Joint D 4. Inlet Air Pressure Sensor...
  • Page 146: Inlet Air Temperature Sensor (service Code 13)

    (see ECU Power Supply Inspection). If the wiring is good, check the sensor resistance. • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 147: Inlet Air Temperature Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-53 Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Resistance Inspection • Remove the inlet air temperature sensor (see Inlet Air Temperature Sensor Removal/Installation). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion is submerged.
  • Page 148: Water Temperature Sensor (service Code 14)

    And if the output voltage is 4.8 V, the ECU is nor- mal. If the wiring is good, check the water temperature sensor resistance. • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 149: Water Temperature Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-55 Water Temperature Sensor (Service Code 14) Water Temperature Sensor Circuit 1. ECU 2. Water Temperature Sensor 3. Water-proof Joint E 4. Meter Unit Water Temperature Sensor Resistance Inspection • Remove the water temperature sensor (see Water Tem- perature Sensor Removal/Installation).
  • Page 150: Crankshaft Sensor (service Code 21)

    3-56 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of the crankshaft sensor.
  • Page 151: Speed Sensor (service Code 24, 25)

    FUEL SYSTEM (DFI) 3-57 Speed Sensor (Service Code 24, 25) Speed Sensor Removal/Installation • Refer to the Speed Sensor Removal/Installation in the Electrical System chapter. Speed Sensor Inspection • Refer to the Speed Sensor Inspection in the Electrical System chapter. Speed Sensor Input Voltage Inspection NOTE ○...
  • Page 152 3-58 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) • Disconnect the speed sensor connector and connect the harness adapter [A] between the harness connector and speed sensor connector. • Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Setting Adapter #1: 57001 -1400 •...
  • Page 153: Vehicle-down Sensor (service Code 31)

    FUEL SYSTEM (DFI) 3-59 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Removal CAUTION Never drop the down-sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Bolts [A] Connector and Vehicle-down Sensor [B] Vehicle-down Sensor Installation •...
  • Page 154 • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 If the output voltage is normal, the wiring is suspect. Check the wiring. If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).
  • Page 155 FUEL SYSTEM (DFI) 3-61 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Circuit 1. ECU 2. Water-proof Joint E 3. Vehicle-down Sensor 4. Water-proof Joint D...
  • Page 156: Subthrottle Sensor (service Code 32)

    3-62 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Subthrottle Sensor Removal/Adjustment CAUTION Do not remove or adjust the subthrottle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface.
  • Page 157: Subthrottle Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-63 Subthrottle Sensor (Service Code 32) • Turn the ignition switch OFF. If the input voltage is normal, check the sensor output voltage. If the input voltage is less than the standard, remove the ECU and check the wiring between these connectors. ○...
  • Page 158: Subthrottle Sensor Resistance Inspection

    3-64 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) If the output voltage is out of the standard, inspect the subthrottle sensor resistance. If the output voltage is normal, check the wiring for conti- nuity. Wiring Connection ECU Connector [A] ←→ Subthrottle Sensor Connector [B] BL/W lead (terminal 24) BR/BK lead (terminal 28)
  • Page 159 FUEL SYSTEM (DFI) 3-65 Subthrottle Sensor (Service Code 32) Subthrottle Sensor Circuit 1. ECU 2. Water-proof Joint E 3. Water-proof Joint D 4. Subthrottle Sensor...
  • Page 160: Oxygen Sensor-not Activated (service Code 33) (europe Models)

    3-66 FUEL SYSTEM (DFI) Oxygen Sensor-not activated (Service Code 33) (Europe Models) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection • Warm up the engine thoroughly until the radiator fan starts.
  • Page 161 FUEL SYSTEM (DFI) 3-67 Oxygen Sensor-not activated (Service Code 33) (Europe Models) • Measure the output voltage of the sensor with the con- nector joined. Oxygen Sensor Output Voltage (without Plugs) Standard: 0.2 V or less If the reading is within range (with plugs: 0.7 V or more, without plugs: 0.2 V or less), the oxygen sensor is good.
  • Page 162: Stick Coils #1, #2: (service Code 51, 52)

    3-68 FUEL SYSTEM (DFI) Stick Coils #1, #2: (Service Code 51, 52) Stick Coil #1: Service Code 51 Stick Coil #2: Service Code 52 Stick Coil Removal/Installation CAUTION Never drop the stick coils, especially on a hard sur- face. Such a shock to the stick coil can damage it. •...
  • Page 163 FUEL SYSTEM (DFI) 3-69 Stick Coils #1, #2: (Service Code 51, 52) Stick Coil Circuit 1. ECU 2. Water-proof Joint C 3. Stick Coils 4. Engine Stop Switch 5. Ignition Switch 6. Ignition Fuse 10 A 7. Main Fuse 30 A 8.
  • Page 164: Radiator Fan Relay (service Code 56)

    3-70 FUEL SYSTEM (DFI) Radiator Fan Relay (Service Code 56) Radiator Fan Relay Removal/Installation • Radiator fan relay is built in the relay box. • Remove the relay box (see Relay Box Removal in the Electrical System chapter). Radiator Fan Relay Inspection •...
  • Page 165: Subthrottle Valve Actuator (service Code 62)

    FUEL SYSTEM (DFI) 3-71 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface.
  • Page 166: Subthrottle Valve Actuator Input Voltage Inspection

    3-72 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Connect the peak voltage adapter [A] and a digital meter [B] to the connector [C], using the needle adapter set [D].
  • Page 167: Air Switching Valve (service Code 64)

    FUEL SYSTEM (DFI) 3-73 Air Switching Valve (Service Code 64) Air Switching Valve Removal/Installation • Refer to the Air Switching Valve Removal/Installation in the Engine Top End chapter. Air Switching Valve Inspection • Refer to the Air Switching Valve Operation Test/Unit Test in the Electrical System chapter.
  • Page 168: Oxygen Sensor Heater (service Code 67) (europe Models)

    3-74 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67) (Europe Models) Oxygen Sensor Heater Removal/Installation The oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see Oxygen Sensor Removal in the Electrical System chapter).
  • Page 169 FUEL SYSTEM (DFI) 3-75 Oxygen Sensor Heater (Service Code 67) (Europe Models) Oxygen Sensor Circuit 1. ECU 2. Oxygen Sensor 3. Water-proof Joint E 4. Water-proof Joint D 5. Oxygen Sensor Heater Fuse 10 A 6. Main Fuse 30 A 7.
  • Page 170: Oxygen Sensor-incorrect Output Voltage (service Code 94) (europe Models)

    3-76 FUEL SYSTEM (DFI) Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Europe Models) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection • Warm up the engine thoroughly until the radiator fan starts.
  • Page 171 FUEL SYSTEM (DFI) 3-77 Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Europe Models) • Measure the output voltage of the sensor with the con- nector joined. Oxygen Sensor Output Voltage (without Plugs) Standard: 0.2 V or less If the reading is within range (with plugs: 0.7 V or more, without plugs: 0.2 V or less), the oxygen sensor is good.
  • Page 172: Fi Indicator Light (led)

    3-78 FUEL SYSTEM (DFI) FI Indicator Light (LED) Inspection Flow Chart...
  • Page 173: Fi Indicator Light (led) Inspection

    FUEL SYSTEM (DFI) 3-79 FI Indicator Light (LED) FI Indicator Light (LED) Inspection • Remove the meter unit (see Meter Unit Removal in the Electrical System chapter). • Using two auxiliary leads, supply battery power to the FI indicator light (LED) [A]. 12 V Battery [B] FI Indicator Light (LED) Check Connector:...
  • Page 174: Ecu

    3-80 FUEL SYSTEM (DFI) CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Removal • Remove: Seat (see Seat Removal in the Frame chapter) Grab Rails [A] (see Seat Cover Removal in the Frame chapter) Center Seat Cover [B] (see Seat Cover Removal in the Frame chapter)
  • Page 175: Ecu Power Supply Inspection

    FUEL SYSTEM (DFI) 3-81 ECU Power Supply Inspection • Visually inspect the terminals [A] of the ECU connectors. If the connector is clogged with mud or dust, blow it off with compressed air. Replace the main harness if the terminals of the main harness connectors are cracked, bent, or otherwise dam- aged.
  • Page 176 3-82 FUEL SYSTEM (DFI) ECU Power Source Circuit 1. ECU 2. Water-proof Joint C 3. Ignition Switch 4. Water-proof Joint A 5. ECU Main Fuse 15 A 6. ECU Main Relay 7. Relay Box 8. Main Fuse 30 A 9. Battery 10.
  • Page 177: Fuel Line

    FUEL SYSTEM (DFI) 3-83 Fuel Line Fuel Pressure Inspection NOTE ○ This inspection can determine which trouble the DFI system has, mechanical or electrical trouble. ○ It is preferable to measure the fuel pressure while run- ning the motorcycle just when trouble occurred in order to know symptom well.
  • Page 178 3-84 FUEL SYSTEM (DFI) Fuel Line • Turn the ignition switch ON. The fuel pump will turn for 3 seconds, and then stop. CAUTION Do not drive the fuel pump without the fuel in the fuel tank. • Measure the fuel pressure with the engine stopped. Fuel Pressure Right after Ignition Switch ON, with pump running: Standard:...
  • Page 179: Fuel Flow Rate Inspection

    FUEL SYSTEM (DFI) 3-85 Fuel Line Fuel Flow Rate Inspection NOTE ○ Be sure the battery is fully charged. WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 180 3-86 FUEL SYSTEM (DFI) Fuel Line CAUTION Do not drive the fuel pump without the fuel in the fuel tank. • Measure the discharge for 3 seconds with the plastic hose filled with fuel. ○ Repeat this operation several times. Amount of Fuel Flow Standard: 60 mL or more for 3 seconds...
  • Page 181: Fuel Pump

    FUEL SYSTEM (DFI) 3-87 Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 182: Fuel Pump Operation Inspection

    3-88 FUEL SYSTEM (DFI) Fuel Pump • Replace the fuel pump gasket [A] with a new one. • Apply a non-permanent locking agent to the threads of the fuel pump bolts. • Tighten the fuel pump bolts to a snug fit, tighten them alternating diagonally.
  • Page 183: Pressure Regulator Removal

    FUEL SYSTEM (DFI) 3-89 Fuel Pump • Connect the hand tester (25 V DC) to the fuel pump con- nector [A] with needle adapter set. Special Tools - Hand Tester: 57001-1394 Needle Adapter Set: 57001-1457 ○ Measure the operating voltage with the engine stopped, and with the connector joined.
  • Page 184 3-90 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Circuit 1. ECU 2. Water-proof Joint C 3. Engine Stop Switch 4. Ignition Switch 5. Ignition Fuse 10 A 6. Fuel Pump Relay 7. Relay Box 8. Main Fuse 30 A 9. Battery 10.
  • Page 185: Fuel Injectors

    FUEL SYSTEM (DFI) 3-91 Fuel Injectors Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Audible Inspection • Start the engine. • Apply the tip of a screwdriver [A] to the injector [B]. Put the grip end onto your ear, and listen whether the injector is clicking or not.
  • Page 186: Fuel Injector Output Voltage Inspection

    Remove the needle adapter. • Apply silicone sealant to the seals of the ECU connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Injector Signal Test • Prepare two test light sets with male terminals as shown. Rating of Bulb [A]: 12 V × 3 ∼ 3.4 W Terminal Width [B]: 1.8 mm (0.071 in.)
  • Page 187: Injector Resistance Inspection

    FUEL SYSTEM (DFI) 3-93 Fuel Injectors • Remove the fuel tank (see Fuel Tank Removal). • Remove the air cleaner housing (see Air Cleaner Housing Removal) • Remove connectors for injector [A]. • Connect each test light set [B] to the injector sub harness connector [C].
  • Page 188: Injector Unit Test

    3-94 FUEL SYSTEM (DFI) Fuel Injectors Injector Unit Test • Use two leads [A] and the same test light set [B] as in “Injector Signal Test”. Rating of Bulb [C]: 12 V × (3 ∼ 3.4) W 12 V Battery [D] CAUTION Be sure to connect the bulb in series.
  • Page 189 FUEL SYSTEM (DFI) 3-95 Fuel Injectors • Watch the gauge for at least 6 seconds. If the pressure holds steady, the system is good. If the pressure drops at once or if bubbles are found in the area, the line is leaking. Replace the delivery pipe, injectors and related parts.
  • Page 190: Throttle Grip And Cables

    3-96 FUEL SYSTEM (DFI) Throttle Grip and Cables Throttle Grip Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Throttle Grip Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter.
  • Page 191: Throttle Body Assy

    FUEL SYSTEM (DFI) 3-97 Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter. Engine Vacuum Synchronization Inspection/Ad- justment • Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter. High Altitude Performance Adjustment •...
  • Page 192: Throttle Body Assy Installation

    3-98 FUEL SYSTEM (DFI) Throttle Body Assy • Loosen the locknut and screw in the throttle cable adjuster fully to give the cables plenty of play. • Remove the right switch housing and take out the acceler- ator cable upper end [A] and the decelerator cable upper end [B].
  • Page 193: Throttle Body Assy Disassembly

    FUEL SYSTEM (DFI) 3-99 Throttle Body Assy • Fit the accelerator cable end [A] and the decelerator cable end [B] into the throttle pulley. • Check fuel leakage from the throttle body assy. WARNING Fuel spilled from the carburetors is hazardous. •...
  • Page 194: Throttle Body Assy Assembly

    3-100 FUEL SYSTEM (DFI) Throttle Body Assy • Remove: Screws [A] Delivery Pipe [B] Fuel Injectors [C] Throttle Body Assy Assembly ○ Replace the O-rings [A] and seals [B] with the new ones. • Before assembling, blow away dirt or dust from the throttle body and delivery pipe by applying compressed air.
  • Page 195: Air Cleaner

    FUEL SYSTEM (DFI) 3-101 Air Cleaner Air Cleaner Element Removal/Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Element Inspection • Remove the air cleaner element (see Air Cleaner Element Replacement in the Periodic Maintenance chapter). •...
  • Page 196: Air Cleaner Housing Installation

    3-102 FUEL SYSTEM (DFI) Air Cleaner • Unscrew the bolts [A] and remove the air cleaner housing [B]. Air Cleaner Housing Installation • Install the clamp on the hose [A] so that its pinch heads [B] face the right. • Install the clamp on the breather hose [C] so that its pinch heads [D] face the front.
  • Page 197: Fuel Tank

    FUEL SYSTEM (DFI) 3-103 Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explo- sive 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 198 3-104 FUEL SYSTEM (DFI) Fuel Tank • Disconnect the fuel pump lead connector [A] and the tube [B]. • Remove: Fuel Return Hose [C] (Red, California Model) Fuel Tank Breather Hose [D] (Blue, California Model) • Be sure to place a piece of cloth [A] around the fuel hose joint.
  • Page 199: Fuel Tank Installation

    FUEL SYSTEM (DFI) 3-105 Fuel Tank • Close the fuel tank cap. • Remove the fuel tank, and place it on a flat surface. ○ Do not apply the load to the fuel pump outlet portion [A] especially the outlet pipe made from resin. •...
  • Page 200: Fuel Tank And Cap Inspection

    3-106 FUEL SYSTEM (DFI) Fuel Tank • Be sure that the trim seal [A] is on the fuel tank. Reverse Side of Fuel Tank [B] Side Cover [C] Approx. 17 mm (0.67 in.) [D] Front [E] • For California model, note the following. ○...
  • Page 201: Fuel Tank Cleaning

    FUEL SYSTEM (DFI) 3-107 Fuel Tank Fuel Tank Cleaning WARNING 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 or highly flammable liquids, do not use gasoline or low-flash point solvents to clean the tank.
  • Page 202: Evaporative Emission Control System (california Model)

    3-108 FUEL SYSTEM (DFI) Evaporative Emission Control System (California Model) The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.
  • Page 203: Separator Operation Test

    FUEL SYSTEM (DFI) 3-109 Evaporative Emission Control System (California Model) Separator Operation Test WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 205 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Special Tools .......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal/Installation ..............Water Pump..........................
  • Page 206: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 207 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Radiator Hose Clamp Screws 0.20 17 in·lb Water Pump Impeller Bolt 87 in·lb Water Pump Cover Bolts 87 in·lb Water Pump Drain Bolt 0.70 62 in·lb Thermostat Housing Bolts 87 in·lb Water Temperature Sensor 106 in·lb...
  • Page 208: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart...
  • Page 209 COOLING SYSTEM 4-5 Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 210: Specifications

    4-6 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type (Recommended) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point −35°C (−31°F) Total Amount...
  • Page 211: Special Tools

    COOLING SYSTEM 4-7 Special Tools Bearing Driver Set: Oil Seal Driver: 57001-1129 57001-1660...
  • Page 212: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the right center fairing (see Center Fairing Re- moval in the Frame chapter). • Visually inspect the coolant [A] in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded.
  • Page 213: Cooling System Flushing

    COOLING SYSTEM 4-9 Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the effi- ciency of the cooling system.
  • Page 214: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Loosen the clamp and remove the radiator hose [A] from the water pump cover [B]. • Remove the water pump cover bolts [C]. •...
  • Page 215: Mechanical Seal Inspection

    COOLING SYSTEM 4-11 Water Pump • Install the water pump cover, being careful of the two dowel pins [A]. Torque - Water Pump Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Mechanical Seal Inspection • Visually inspect the mechanical seal. If any one of the parts is damaged, replace the mechani- cal seal as a unit.
  • Page 216: Impeller Assembly

    4-12 COOLING SYSTEM Water Pump Impeller Assembly • Clean the sliding surface of the mechanical seal with a high-flash point solvent, and apply a little coolant to the sliding surface to give the mechanical seal initial lubrica- tion. • Apply coolant to the surfaces of the rubber seal [A] and sealing seat [B], and install the rubber seal and sealing seat into the impeller by pressing them by hand until the seat stops at the bottom of the hole.
  • Page 217: Radiator

    COOLING SYSTEM 4-13 Radiator Radiator and Radiator Fan Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Center Fairings (see Center Fairing in the Frame chap- ter) Reserve Tank (see Coolant Change in the Periodic Main- tenance chapter) Radiator Fan Motor Connector [A] (Disconnect) Radiator Hose Clamp Screw [B] (Loosen)
  • Page 218: Radiator And Radiator Fan Installation

    4-14 COOLING SYSTEM Radiator Radiator and Radiator Fan Installation • Install the radiator [A] to the frame. ○ Align [B] the projection on the frame with the hole on the radiator. ○ Tighten the radiator bolt [C]. ○ Note the baffle plate on the cylinder head cover when installing the radiator.
  • Page 219: Radiator Filler Neck Inspection

    COOLING SYSTEM 4-15 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 leaks. • Watching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gauge needle flicks downward.
  • Page 220: Thermostat

    4-16 COOLING SYSTEM Thermostat Thermostat Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Left Center Fairing (see Center Fairing Removal in the Frame chapter) Thermostat Hosing Bolts [A] Thermostat Hosing [B] • Pull the thermostat [A] out of the cylinder head. Thermostat Installation •...
  • Page 221 COOLING SYSTEM 4-17 Thermostat • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water. ○ The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [B] in the water so that the heat sen- sitive portions [C] are located in almost the same depth.
  • Page 222: Hose And Pipes

    4-18 COOLING SYSTEM Hose and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). •...
  • Page 223: Water Temperature Sensor

    COOLING SYSTEM 4-19 Water Temperature Sensor CAUTION The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it. Water Temperature Sensor Removal/Installation • Refer to the Water Temperature Sensor Removal/Instal- lation in the Fuel System (DFI) chapter.
  • Page 225 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........................Exhaust System........................Specifications ......................... 5-10 Special Tools and Sealant ...................... 5-12 Clean Air System........................5-14 Air Suction Valve Removal....................5-14 Air Suction Valve Installation..................... 5-14 Air Suction Valve Inspection ..................... 5-14 Air Switching Valve Removal ....................
  • Page 226 5-2 ENGINE TOP END Piston Ring Groove Width....................5-39 Piston Ring Thickness ...................... 5-39 Piston Ring End Gap ......................5-40 Throttle Body Holder....................... 5-41 Throttle Body Holder Installation..................5-41 Muffler............................. 5-42 Muffler Body Removal....................... 5-42 Exhaust Pipe Removal...................... 5-42 Muffler Body and Exhaust Pipe Installation ..............5-43...
  • Page 227: Exploded View

    ENGINE TOP END 5-3 Exploded View Dummy Page...
  • Page 228 5-4 ENGINE TOP END Exploded View...
  • Page 229 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Suction Valve Cover Bolts 87 in·lb Cylinder Head Cover Bolts 87 in·lb Camshaft Cap Bolts 106 in·lb Cylinder Head Bolts (M10 New Bolts) MO, S Cylinder Head Bolts (M10 Used Bolts) MO, S Cylinder Head Bolts (M6) 106 in·lb...
  • Page 230 5-6 ENGINE TOP END Exploded View...
  • Page 231 ENGINE TOP END 5-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Bolt (M8) 27.5 MO,S Cylinder Nut (M10) MO,S Cylinder Bolts (M6) 106 in·lb Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolt (Front) Muffler Body Mounting Bolt (Rear) 7.
  • Page 232: Exhaust System

    5-8 ENGINE TOP END Exhaust System Exhaust System EX650A6F/EX650B6F Full: Full Power H: Honeycomb Type Catalyst Silencer [A] with Hole [B] for Oxygen Sensor [C]...
  • Page 233 ENGINE TOP END 5-9 Exhaust System Manifold Mark Position [A] Silencer Mark Position [A]...
  • Page 234: Specifications

    5-10 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: 35.843 ∼ 35.957 mm (1.4111 ∼ 1.4156 in.) 35.74 mm (1.4071 in.) Exhaust 36.543 ∼ 36.657 mm (1.4387 ∼ 1.4432 in.) 36.44 mm (1.4346 in.) Inlet 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.) Camshaft Journal, Camshaft 0.16 mm (0.0063 in.) Cap Clearance...
  • Page 235 ENGINE TOP END 5-11 Specifications Item Standard Service Limit Valve Spring Free Length: Exhaust 41.91 mm (1.650 in.) 40.3 mm (1.587 in.) Inlet 41.91 mm (1.650 in.) 40.3 mm (1.587 in.) Cylinder, Pistons 82.994 ∼ 83.006 mm Cylinder Inside Diameter 83.10 mm (3.2716 in.) (3.2675 ∼...
  • Page 236: Special Tools And Sealant

    5-12 ENGINE TOP END Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 60° - 30: 57001-221 57001-1123 Valve Spring Compressor Assembly: Valve Seat Cutter Holder Bar: 57001-241 57001-1128 Valve Seat Cutter, 45° - 35: Valve Seat Cutter, 45° - 30: 57001-1116 57001-1187 Valve Seat Cutter, 32°...
  • Page 237 Special Tools and Sealant Compression Gauge Adapter, M10 × 1.0: Piston Pin Puller: 57001-1317 57001-1568 Valve Seat Cutter Holder, 4.5: Piston Pin Puller Adapter C: 57001-1330 57001-1657 Valve Guide Arbor, 4.5: Kawasaki Bond (Silicone Sealant): 57001-1331 92104-0004 Valve Guide Reamer, 4.5: 57001-1333...
  • Page 238: Clean Air System

    5-14 ENGINE TOP END Clean Air System Air Suction Valve Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Air Switching Valve with Hoses (see Air Switching Valve Removal) Air Suction Valve Cover Bolts [A] and Clamp Air Suction Valve Cover [B]...
  • Page 239: Air Switching Valve Operation Test

    ENGINE TOP END 5-15 Clean Air System Air Switching Valve Operation Test • Refer to the Air Switching Valve Operation Test in the Electrical System chapter. Air Switching Valve Unit Test • Refer to the Air Switching Valve Unit Test in the Electrical System chapter.
  • Page 240: Cylinder Head Cover

    Cylinder Head Cover Installation • Replace the head cover gasket [A] with a new one. • Apply silicone sealant [B] to the cylinder head as shown. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install: Dowel Pins [C] Plug Hole Gaskets [D] •...
  • Page 241 ENGINE TOP END 5-17 Cylinder Head Cover • Install the baffle plate [A]. • Tighten: Torque - Baffle Plate Bolts [B]: 5.9 N·m (0.60 kgf·m, 52 in·lb)
  • Page 242: Camshaft Chain Tensioner

    5-18 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 243: Camshaft, Camshaft Chain

    ENGINE TOP END 5-19 Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) • Position the crankshaft as follows. ○ Remove the upper [A] and lower [B] caps on the clutch cover.
  • Page 244 5-20 ENGINE TOP END Camshaft, Camshaft Chain • Apply molybdenum disulfide oil solution to all cams [A] journals [B] and thrust blocks [C] with × marks. • If a new camshaft is to be used, apply a thin coat of molyb- denum disulfide grease to the cam surfaces.
  • Page 245 ENGINE TOP END 5-21 Camshaft, Camshaft Chain ○ The timing marks must be aligned with the cylinder head upper surface [C]. EX Mark [D] (Between #1 Pin and #2 Pin) IN Mark [E] (Between #31 Pin and #32 Pin) #1 Pin [F] #2 Pin [G] #31 Pin [H] #32 Pin [J]...
  • Page 246: Camshaft And Sprocket Assembly

    5-22 ENGINE TOP END Camshaft, Camshaft Chain Camshaft and Sprocket Assembly ○ The inlet and exhaust sprockets are identical. • Install the sprockets so that the marked (“IN” and “EX”) side faces to the right side. CAUTION Inlet sprocket must use “IN” marked bolts holes [A]. Exhaust sprocket must use “EX”...
  • Page 247: Camshaft Runout

    ENGINE TOP END 5-23 Camshaft, Camshaft Chain Camshaft Runout • Remove the camshaft (see Camshaft Removal). • Set the camshaft in a camshaft alignment jig or on V blocks. • Measure runout with a dial gauge at the specified place as shown.
  • Page 248: Cylinder Head

    5-24 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter)
  • Page 249: Cylinder Head Removal

    ENGINE TOP END 5-25 Cylinder Head ○ The following table should be consulted if the obtainable compression reading is not within the us- able range. Problem Diagnosis Remedy (Action) Cylinder compression Carbon accumulation on piston and in is higher than usable combustion chamber possibly due to Remove the carbon deposits range...
  • Page 250: Cylinder Head Installation

    5-26 ENGINE TOP END Cylinder Head • Firstly remove the M6 cylinder head bolts and M6 cylinder bolts [A]. • Secondly, remove the M8 bolts [B]. • Thirdly, remove the M10 nut [C]. • Fourthly, remove the M10 bolts [D]. Cylinder Head Installation NOTE ○...
  • Page 251 ENGINE TOP END 5-27 Cylinder Head • Apply molybdenum disulfide oil solution [A] to both sides of washers and the threads of bolts and nut. M10 Cylinder Head Bolts [B] M10 Cylinder Nut [C] M8 Cylinder Bolt [D] • Tighten the all the bolts and nut following the tightening sequence [1 ∼...
  • Page 252: Cylinder Head Warp

    5-28 ENGINE TOP END Cylinder Head • Tighten the M6 cylinder head bolts and M6 cylinder bolts [A]. Torque - Cylinder Head Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb) Cylinder Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb) • Install the front camshaft chain guide [A].
  • Page 253: Valves

    ENGINE TOP END 5-29 Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove cylinder head (see Cylinder Head Removal). •...
  • Page 254: Valve Guide Installation

    5-30 ENGINE TOP END Valves Valve Guide Installation • Apply engine oil to the valve guide outer surface before installation. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). • Drive the valve guide in from the top of the head using the valve guide arbor.
  • Page 255: Valve Seat Inspection

    ENGINE TOP END 5-31 Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
  • Page 256 5-32 ENGINE TOP END Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
  • Page 257 ENGINE TOP END 5-33 Valves • Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range.
  • Page 258 5-34 ENGINE TOP END Valves If the seat width is too wide, make the 60° or 55° [A] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 60°...
  • Page 259 ENGINE TOP END 5-35 Valves...
  • Page 260: Cylinder, Pistons

    5-36 ENGINE TOP END Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Front Engine Mounting Bolts (Both Side) [A] (see Engine Removal in the Engine Removal/Installation chapter) Front Engine Brackets (Both Side) [B] (see Engine Re- moval in the Engine Removal/Installation chapter) Cylinder [C] Cylinder Installation...
  • Page 261: Piston Installation

    ENGINE TOP END 5-37 Cylinder, Pistons • Remove the piston pins. Special Tools - Piston Pin Puller [A]: 57001-1568 Piston Pin Puller Adapter C [D]: 57001-1657 Center Bolt [B] Shall of Piston [C] • Remove the pistons. • Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove •...
  • Page 262: Cylinder Wear

    5-38 ENGINE TOP END Cylinder, Pistons NOTE ○ If a new piston is used, use new piston ring. • Install the piston with its marking hollow facing forward. • Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the slit [B] of the piston pin hole.
  • Page 263: Piston Ring, Piston Ring Groove Wear

    ENGINE TOP END 5-39 Cylinder, Pistons Piston Ring, Piston Ring Groove Wear • Check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. •...
  • Page 264: Piston Ring End Gap

    5-40 ENGINE TOP END Cylinder, Pistons Piston Ring End Gap • Place the piston ring [A] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. •...
  • Page 265: Throttle Body Holder

    ENGINE TOP END 5-41 Throttle Body Holder Throttle Body Holder Installation • Be sure to install the O-rings [A]. • Install the clamps [B] as shown and so that their projec- tions fit [C] on the holes of the holders. ○...
  • Page 266: Muffler

    5-42 ENGINE TOP END Muffler Muffler Body Removal WARNING To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. • Remove: Right Frame Cover (see Frame Cover Removal in the Frame chapter) •...
  • Page 267: Muffler Body And Exhaust Pipe Installation

    ENGINE TOP END 5-43 Muffler Muffler Body and Exhaust Pipe Installation • Replace the exhaust pipe gaskets [A] and muffler body connection gasket [B] with new ones and install them. ○ Install the muffler body connection gasket until it is bot- tomed so that the chamfer side [C] feces muffler body [D].
  • Page 269 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool and Sealant ......................Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Clutch Cable Removal ...................... Clutch Cable Installation ....................Clutch Cable Lubrication....................
  • Page 270: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 271 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Cap on Clutch Cover 0.40 35 in·lb Lower Cap on Clutch Cover – – – Hand-tighten Oil Filler Plug – – – Hand-tighten Clutch Cover Mounting Bolts 87 in·lb Clutch Spring Bolts 87 in·lb Clutch Hub Nut...
  • Page 272: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) Friction Plate Thickness 2.8 mm (0.110 in.) Friction Plate Warp 0.15 mm (0.16 in.) or less 0.3 mm (0.012 in.) Steel Plate Warp...
  • Page 273: Special Tool And Sealant

    CLUTCH 6-5 Special Tool and Sealant Clutch Holder: Kawasaki Bond (Silicone Sealant): 57001-1243 92104-0004...
  • Page 274: Clutch Lever And Cable

    6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Cable Removal •...
  • Page 275: Clutch Lever Installation

    CLUTCH 6-7 Clutch Lever and Cable Clutch Lever Installation • Install the clutch lever so that the mating surface [B] of the clutch lever clamp is aligned with the punch mark [A]. • Tighten the upper clamp bolt first, and then the lower clamp bolt.
  • Page 276: Clutch Cover

    Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket and to the crankshaft sensor lead grommet [B]. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Be sure that the dowel pins [C] are in position.
  • Page 277: Release Shaft Removal

    CLUTCH 6-9 Clutch Cover Release Shaft Removal CAUTION Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary. If re- moved, the oil seal replacement may be required. • Remove the clutch cover (see Clutch Cover Removal). •...
  • Page 278: Clutch Cover Assembly

    6-10 CLUTCH Clutch Cover • Remove the oil level gauge [A]. Clutch Cover Assembly • Replace the needle bearings and oil seal with new ones. NOTE ○ Install the needle bearings so that the manufacture’s mark face out. • Install the needle bearings [A] and oil seal [B] position as shown.
  • Page 279: Clutch Removal

    CLUTCH 6-11 Clutch Clutch Removal • Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with thrust bearing and pusher [C]) •...
  • Page 280 6-12 CLUTCH Clutch • Be sure that the spacer [A] is in position. • Insert the following on the drive shaft. Clutch Housing [A] with Chain [B] and Sprocket [C] Sleeve [D] • Align [E] the hole on the oil pump sprocket with the oil pump shaft.
  • Page 281: Clutch Plate, Wear, Damage Inspection

    CLUTCH 6-13 Clutch ○ Replace the clutch hub nut with a new one. ○ Holding the clutch hub, tighten the clutch hub nut. Special Tool - Clutch Holder: 57001-1243 Torque - Clutch Hub Nut: 132 N·m (13.5 kgf·m, 98 ft·lb) •...
  • Page 282: Clutch Plate Warp Inspection

    6-14 CLUTCH Clutch Clutch Plate Warp Inspection • Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C].
  • Page 283 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealant ...................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ Oil Pan Removal .......................
  • Page 284: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 285 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Oil Drain Bolt Filter Plate Bolts 87 in·lb Oil Filter 17.2 1.75 EO, R Holder Mounting Bolt Oil Pan Bolts 106 in·lb Oil Pipe Plate Bolt 87 in·lb Oil Pressure Relief Valve Oil Pressure Switch Oil Pump Cover Bolts...
  • Page 286: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 287 ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart...
  • Page 288: Specifications

    7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE 10W-40 Capacity: 1.7 L (1.8 US gt) (when filter is not removed) 1.9 L (2.0 US gt) (when filter is removed) 2.4 L (2.5 US gt) (when engine is completely dry) Level Between upper and lower level lines...
  • Page 289: Special Tools And Sealant

    ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: Oil Filter Wrench: 57001-164 57001-1249 Oil Pressure Gauge Adapter, PT3/8: Kawasaki Bond (Silicone Sealant): 57001-1233 56019-120...
  • Page 290: Engine Oil And Oil Filter

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil Level Inspection • Check that the engine oil level is between the upper [A] and lower [B] levels in the gauge.
  • Page 291: Oil Pan

    ENGINE LUBRICATION SYSTEM 7-9 Oil Pan Oil Pan Removal • Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Muffler Body (see Muffler Body Removal in the Engine Top End chapter) Oil Pan Bolts [A] Oil Pan [B]...
  • Page 292: Oil Pan Installation

    7-10 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Installation • Apply grease to the O-rings on the oil pipes [A]. • Install the oil pipe plate [B] so that its guide portion [C] fits the breather pipe [D] as shown. •...
  • Page 293: Oil Pressure Relief Valve

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Refer to the Oil Pan Removal. Oil Pressure Relief Valve Installation • Refer to the Oil Pan Installation. Oil Pressure Relief Valve Inspection • Check to see if the valve [A] slides smoothly when push- ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure.
  • Page 294: Oil Pump

    7-12 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Clutch (see Clutch Removal in the Clutch chapter) Oil Pump Cover Bolts [A] Oil Pump Cover [B] •...
  • Page 295: Oil Pump Installation

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump Oil Pump Installation • Apply molybdenum disulfide grease to the portion [A] of the oil pump shaft as shown. • Install: Outer Rotor [B] for Feed Pump Inner Rotor [C] for Feed Pump Oil Pump Shaft [D] and Pin [E] Dowel Pin [F] Oil Pump Body [G] Pin [H] and Inner Rotor [I] for Scavenge Pump...
  • Page 296: Oil Pressure Measurement

    7-14 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement • Remove the right lower fairing (see Lower Fairing Re- moval in the Frame chapter). • Remove the oil passage plug, and attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT3/8: 57001 -1233...
  • Page 297: Oil Pressure Switch

    Oil Pressure Switch Installation • Apply silicone sealant to the threads of the oil pressure switch and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb) • Tighten the terminal bolt securely.
  • Page 299 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 300: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 301 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Engine Mounting Nuts Front Engine Mounting Bolts Engine Mounting Bracket Bolts 4. Engine Mounting Brackets 5. Collar S: Follow the specified tightening sequence.
  • Page 302: Engine Removal/installation

    8-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Support the rear part of the swingarm with a stand. • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over.
  • Page 303 ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation • Disconnect the crankshaft sensor lead connector [A]. • Remove: Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Muffler Body (see Muffler Body Removal in the Engine Top End chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Switching Valve and Hose (see Air Switching Valve Removal in the Engine Top End chapter)
  • Page 304 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove the engine sprocket cover (see Engine Sprocket Removal in the Final Drive chapter). • Remove the shift pedal [A] (see Shift Pedal Removal in the Crankshaft/Transmission chapter). • Disconnect: Oxygen Sensor Lead Connector [B] (Europe Models) Neutral Switch Lead Terminal [C] •...
  • Page 305: Engine Installation

    ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation Engine Installation • Firstly, insert the rear engine mounting bolts [A] from the left side of the engine. • Secondly, temporally tighten the right engine mounting bracket bolts [B] and then the right front engine mounting bolt [C].
  • Page 307 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Crankcase Splitting......................... 9-10 Crankcase Splitting ......................9-10 Crankcase Assembly ......................9-11 Crankshaft and Connecting Rods................... 9-17 Crankshaft Removal ......................9-17 Crankshaft Installation ...................... 9-17 Connecting Rod Removal ....................9-17 Connecting Rod Installation ....................
  • Page 308: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 309 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Connecting Rod Big End Nuts see Text ← ← Timing Rotor Bolt Oil Plate Bolts 87 in·lb Breather Plate Bolts 87 in·lb Shift Shaft Return Spring Pin Oil Pipe Bolts 87 in·lb Crankcase Bolts (M9, L = 113 mm) MO, S...
  • Page 310 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 311 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Gear Positioning Lever Bolt 106 in·lb Transmission Case Bolts Shift Drum Cam Bolt 106 in·lb Shift Drum Bearing Holder Screw 0.50 43 in·lb Shift Rod Plate Bolt 87 in·lb Neutral Switch Holder Screw 0.50 43 in·lb Neutral Switch...
  • Page 312: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Bend – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.2/100 mm (0.008/3.94 in.) 0.13 ∼ 0.38 mm Connecting Rod Big End Side Clearance 0.58 mm (0.0051 ∼...
  • Page 313 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankshaft Runout TIR 0.02 mm (0.0008 in.) TIR 0.05 mm or less (0.0020 in.) 0.012 ∼ 0.036 mm Crankshaft Main Bearing Insert/Journal Clearance 0.07 mm (0.0005 ∼ 0.0014 in.) (0.0028 in.) 37.984 ∼ 38.000 mm Crankshaft Main Journal Diameter: 37.96 mm (1.4954 ∼...
  • Page 314 9-8 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit 31.000 ∼ 31.016 mm Crankcase Bearing Bore Diameter: – – – (1.2205 ∼ 1.2228 in.) Marking: ○ 31.000 ∼ 31.008 mm – – – (1.2205 ∼ 1.2208 in.) 31.009 ∼ 31.016 mm None –...
  • Page 315: Special Tools And Sealant

    CRANKSHAFT/TRANSMISSION 9-9 Special Tools and Sealant Outside Circlip Pliers: Kawasaki Bond: 57001-144 92104-1064 Bearing Driver Set: 57001-1129...
  • Page 316: Crankcase Splitting

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Splitting • Remove: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) Cylinder (see Cylinder Removal in the Engine Top End chapter) Pistons (see Piston Removal in the Engine Top End chapter) Stater Motor (see Starter Motor Removal in the Electrical System chapter) Clutch (see Clutch Removal in the Clutch chapter) Transmission Assy (see Transmission Assy Removal)
  • Page 317: Crankcase Assembly

    CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting If the oil pipe is to be removed, follow the next procedure. ○ Unscrew the bolts [A] and remove the oil pipe [B]. ○ Prepare a 5 mm rod [A], and insert it to the hole of the upper crankcase half.
  • Page 318 9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Press and insert [A] the new needle bearing [B] for the shift drum until it is bottomed. Special Tool - Bearing Driver Set: 57001-1129 • Press and insert [C] the new needle bearing [D] for the shift shaft so that the bearing surface is flush with the end of the hole.
  • Page 319 CRANKSHAFT/TRANSMISSION 9-13 Crankcase Splitting • Install the crankshaft assembly and the balancer shaft as- sembly on the upper crankcase half. ○ Align [A] the timing mark on the balancer gear [B] with the timing mark on the balancer drive gear [C] of the crank- shaft.
  • Page 320 9-14 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond: 92104-1064 NOTE ○ Especially, apply a liquid gasket carefully so that it shall be filled up on the grooves.
  • Page 321 CRANKSHAFT/TRANSMISSION 9-15 Crankcase Splitting • Fit the lower crankcase half to the upper crankcase half. ○ Insert [A] the breather pipe [B] on the upper crankcase half through the hole [C] on the lower crankcase half. NOTE ○ Make the application finish within 20 minutes when the liquid gasket to the mating surface of the lower crankcase half is applied.
  • Page 322 9-16 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Tighten the lower crankcase bolts using the following steps. ○ Following the sequence numbers on the lower crankcase half, tighten the M9 bolts [1, 2] L= 113 mm (4.45 in.) with washers. Torque - Crankcase Bolts (M9): 44 N·m (4.5 kgf·m, 32 ft·lb) ○...
  • Page 323: Crankshaft And Connecting Rods

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft [A]. Crankshaft Installation CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.
  • Page 324: Connecting Rod Installation

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Installation CAUTION To minimize vibration, the connecting rods should have the same weight mark. Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] ○ Diameter Mark [D]: “ ” or no mark CAUTION If the connecting rods, big end bearing inserts, or crankshaft are replaced with new ones, select the...
  • Page 325 CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods • Install the crankshaft (see Crankshaft Installation). • Install each connecting rod on its original crankpin. NOTE ○ Install each connecting rod so that its oil jet [A] faces the exhaust side (the front [B]) (see Engine Oil Flow Chart in the Engine Lubrication System chapter).
  • Page 326 9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Dent both bolt head and bolt tip with a punch as shown. • Before tightening, use a point micrometer [A] to measure the length of new connecting rod bolts and record the val- ues to find the bolt stretch.
  • Page 327: Crankshaft/connecting Rod Cleaning

    CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Apply a small amount of molybdenum disulfide oil solution to the following. Threads [A] of Nuts and Bolts Seating Surfaces [B] of Nuts and Con-rods •...
  • Page 328: Connecting Rod Twist

    9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Twist • With the big-end arbor [A] still on V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being paralleled with the surface plate over a 100 mm (3.94 in.) length of the arbor to de- termine the amount of connecting rod twist.
  • Page 329 CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rods If any crankpin has worn past the service limit, replace the crankshaft with a new one. If the measured crankpin diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it.
  • Page 330: Crankshaft Side Clearance

    9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Side Clearance • Insert a thickness gauge [A] between the crankcase main bearing and the crank web at the No. 2 journal [B] to determine clearance. If the clearance exceeds the service limit, replace the crankcase halves as a set.
  • Page 331 CRANKSHAFT/TRANSMISSION 9-25 Crankshaft and Connecting Rods Crankshaft Main Journal Diameter 37.984 ∼ 38.000 mm (1.4954 ∼ 1.4961 in.) Standard: Service Limit: 37.96 mm (1.4945 in.) If any journal has worn past the service limit, replace the crankshaft with a new one. If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it.
  • Page 332 9-26 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install the new inserts in the crankcase halves and check insert/journal clearance with the plastigage.
  • Page 333: Balancer

    CRANKSHAFT/TRANSMISSION 9-27 Balancer Balancer Removal • Split the crankcase (see Crankcase Splitting). • Pull the balancer shaft with the balancer gear out of the crankcase. Balancer Installation • Apply molybdenum disulfide oil solution to the inside of the balancer shaft bearing insert. •...
  • Page 334 9-28 CRANKSHAFT/TRANSMISSION Balancer If either journal has worn past the service limit, replace the balancer shaft with a new one. If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings on the balancer shaft, write new marks on it.
  • Page 335: Transmission

    CRANKSHAFT/TRANSMISSION 9-29 Transmission Shift Pedal Removal • Remove: Shift Lever Bolt [A] Shift Lever [B] Shift Pedal Installation • Align the mark [A] on the shift shaft with the slit [B] on the shift lever. • Tighten the shift lever bolt securely. •...
  • Page 336: External Shift Mechanism Installation

    9-30 CRANKSHAFT/TRANSMISSION Transmission • Remove: Clutch (see Clutch Removal in the Clutch chapter) Gear Positioning Lever Bolt [A] Gear Positioning Lever [B], Spacer, Washer and Spring External Shift Mechanism Installation • Install the gear positioning lever [A] as shown. Spring [B] Washer [C] Spacer [D] Bolt [E]...
  • Page 337: External Shift Mechanism Inspection

    CRANKSHAFT/TRANSMISSION 9-31 Transmission • When the new needle bearing [A] is installed in the shift shaft cover [B], press and insert the new needle bearing until it is bottomed. Special Tool - Bearing Driver Set: 57001-1129 • When the new oil seal [C] is installed in the shift cover, press and insert the new oil seal so that its surface is flush with the end of the hole.
  • Page 338: Transmission Assy Removal

    9-32 CRANKSHAFT/TRANSMISSION Transmission • Check the gear positioning lever [A] and its spring for breaks or distortion. If the lever or spring are damaged in any way, replace them. • Visually inspect the shift drum cam [B]. If they are badly worn or if they show any damage, replace Transmission Assy Removal •...
  • Page 339: Transmission Assy Disassembly

    CRANKSHAFT/TRANSMISSION 9-33 Transmission Transmission Assy Disassembly • Remove the transmission assy (see Transmission Assy Removal). • Remove the following from the transmission case [A]. Shift Rods [B] Shift Forks [C] Drive Shaft [D] Output Shaft [E] • Remove: Shift Drum Cam Bolt [A] Shift Drum [B] and Pin Shift Drum [C] Transmission Assy Assembly...
  • Page 340: Transmission Assy Installation

    9-34 CRANKSHAFT/TRANSMISSION Transmission • Install the following on the transmission case [A]. Shift Drum [B] Pin [C] Shift Drum Cam [D] ○ Align the pin with the hole on the shift drum cam. • Apply a non-permanent locking agent to the shift drum cam bolt [E] and tighten it.
  • Page 341: Transmission Shaft Removal

    CRANKSHAFT/TRANSMISSION 9-35 Transmission • Install the gear positioning lever (see External Shift Mech- anism Installation). • Install the shift rod plate. Torque - Shift Rod Plate Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Set the gear positioning lever to the neutral position [A]. •...
  • Page 342: Transmission Shaft Disassembly

    9-36 CRANKSHAFT/TRANSMISSION Transmission • Install the transmission assy on the crankcase (see Trans- mission Assy Installation). • Press in the oil seal [A] onto collar [B] so that the surface of the oil seal is flush with the surface [C] of the crankcase. ○...
  • Page 343 CRANKSHAFT/TRANSMISSION 9-37 Transmission • The drive shaft gears can be recognized by size: the gear with the smallest diameter is 1st gear, and the largest one is 6th gear. Be sure that all parts are put back in the cor- rect sequence and all circlips and washers are properly in place.
  • Page 344 9-38 CRANKSHAFT/TRANSMISSION Transmission 1. 1st Gear 16. Collar 2. 2nd Gear 17. Washer 3. 3rd Gear 18. Nut 4. 4th Gear 19. O-ring 5. 5th Gear 20. Bearing 6. 6th (Top) Gear 21. Spacer, 39 mm (1.54 in.) 7. Ball Bearing 22.
  • Page 345: Shift Drum And Fork Removal

    CRANKSHAFT/TRANSMISSION 9-39 Transmission Shift Drum and Fork Removal • Remove the transmission assy (see Transmission Assy Removal). • Remove the shift forks [A] and shift drum [B] (see Trans- mission Assy Disassembly). Shift Drum and Fork Installation • Refer to the Transmission Assy Assembly and Installa- tion.
  • Page 346: Shift Fork Guide Pin/drum Groove Wear

    9-40 CRANKSHAFT/TRANSMISSION Transmission Shift Fork Guide Pin/Drum Groove Wear • Measure the diameter of each shift fork guide pin [A], and measure the width [B] 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 347: Ball Bearing, Needle Bearing, And Oil Seal

    CRANKSHAFT/TRANSMISSION 9-41 Ball Bearing, Needle Bearing, and Oil Seal Ball and Needle Bearing Replacement CAUTION Do not remove the ball or needle bearings unless it is necessary. Removal may damage them. • Using a press or puller, remove the ball bearing and/or needle bearings.
  • Page 349 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-8 Rear Wheel Installation..................... 10-8 Wheel Inspection ......................10-10 Axle Inspection........................
  • Page 350: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 351 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle 11.0 Front Axle Clamp Bolt Rear Axle Nut 11.0 4. Caliper Bracket (EX650B Models) G: Apply grease. HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 352: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 1.0 mm (0.04 in.) Axle Runout/100 mm (3.94 in.) TIR 0.03 mm (0.0012 in.) or less TIR 0.2 mm (0.008 in.) Wheel Balance 10 g (0.35 oz.) or less...
  • Page 353: Special Tools

    WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: Bearing Remover Shaft, 13: 57001-1129 57001-1377 Jack: Jack Attachment: 57001-1238 57001-1608 Bearing Remover Head, 20 × 22: 57001-1293...
  • Page 354: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Brake Caliper Mounting Bolts [A] Front Brake Calipers [B] • Loosen: Axle Clamp Bolt [A] • Remove the front axle [B]. • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter).
  • Page 355 WHEELS/TIRES 10-7 Wheels (Rims) • Apply high-temperature grease to the grease seal lips. • Fit the collars [A] on the both sides of the hub. • Insert the front axle, and tighten the axle. Torque - Front Axle: 108 N·m (11.0 kgf·m, 80 ft·lb) •...
  • Page 356: Rear Wheel Removal

    10-8 WHEELS/TIRES Wheels (Rims) Rear Wheel Removal • Raise the rear wheel off the ground with stand [A]. • Remove: Brake Caliper Mounting Bolts [A] Rear Brake Caliper [B] • Remove the rear wheel rotation sensor from the caliper bracket (see Rear Wheel Rotation Sensor Removal in the Brakes chapter) (EX650B Models).
  • Page 357 WHEELS/TIRES 10-9 Wheels (Rims) • Engage the drive chain with the rear sprocket. • Install the caliper bracket [A] onto the swingarm stop [B]. • Insert the axle from the right side of the wheel, and tighten the axle nut. Torque - Rear Axle Nut: 108 N·m (11.0 kgf·m, 80 ft·lb) •...
  • Page 358: Wheel Inspection

    10-10 WHEELS/TIRES Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground with jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 • Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings. •...
  • Page 359: Balance Inspection

    WHEELS/TIRES 10-11 Wheels (Rims) Balance Inspection • Remove the front and rear wheels (see Front/Rear Wheel Removal). • Support the wheel so that it can be spun freely. • Spin the wheel lightly, and mark [A] the wheel at the top when the wheel stops.
  • Page 360 30 g (1.06 oz.) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20, and 30 grams (0.35, 0.71, and 1.06 oz.) sizes. An imbalance of less than 10 grams (0.35 oz.) will not usually affect running stability.
  • Page 361: Tires

    WHEELS/TIRES 10-13 Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove: Wheel (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...
  • Page 362 10-14 WHEELS/TIRES Tires • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull [B] the valve stem through the rim from the inside out until it snaps into place.
  • Page 363: Tire Repair

    Also, permanent (internal) repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire. For these reasons, Kawasaki does not recommend temporary (exter- nal) repair. Only appropriate permanent (internal) repairs are recommended. Repair methods may vary slightly from make to make.
  • Page 364: Hub Bearing

    10-16 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheel (see Front/Rear Wheel Removal), and take out the following. Collars Coupling (Out of rear hub) Grease Seals • Use the bearing remover to remove the hub bearings [A]. CAUTION Do not lay the wheel on the ground with the disc facing down.
  • Page 365: Hub Bearing Lubrication

    WHEELS/TIRES 10-17 Hub Bearing Hub Bearing Lubrication NOTE ○ Since the hub bearings are packed with grease and sealed, lubrication is not required.
  • Page 367 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................11-2 Specifications ......................... 11-4 Special Tools .......................... 11-5 Drive Chain..........................11-6 Drive Chain Slack Inspection .................... 11-6 Drive Chain Slack Adjustment ..................11-6 Wheel Alignment Inspection/Adjustment ................11-6 Drive Chain Wear Inspection .................... 11-6 Drive Chain Lubrication.....................
  • Page 368: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 369 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Sprocket Nut 12.7 Rear Axle Nut 11.0 Rear Sprocket Nuts Speed Sensor Bolt 0.80 69 in·lb Speed Sensor Bracket Bolts 87 in·lb G: Apply grease. HG: Apply high-temperature grease. HO: Apply heavy oil.
  • Page 370: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain 30 ∼ 40 mm (1.2 ∼ 1.6 in.) Drive Chain Slack – – – Drive Chain Wear (20-link Length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) Standard Chain: Make ENUMA...
  • Page 371: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...
  • Page 372: Drive Chain

    11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection/Adjustment •...
  • Page 373: Drive Chain Installation

    FINAL DRIVE 11-7 Drive Chain • Screw the pin holder until it touches chain pin. • Be sure that the cutting pin hits center of chain pin. • Screw the handlebar [A] into body. • Turn the pin holder with wrench [B] clockwise to extract chain pin.
  • Page 374 11-8 FINAL DRIVE Drive Chain • Fit the plate holder (a) to link plate. • Turn the pin holder by hand until plate holder (b) touches the other link plate. • Turn the pin holder by wrench clockwise until two pins of link come into groove of plate holder (a).
  • Page 375 FINAL DRIVE 11-9 Drive Chain • After staking, check the staked area of the link pin for cracks. • Measure the outside diameter [A] of the link pin and link plates width [B]. Link Pin Outside Diameter 5.7 ∼ 6.0 mm (0.22 ∼ 0.24 in.) Standard: Link Plates Outside Width 17.25 ∼...
  • Page 376: Sprocket, Coupling

    11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] • Remove: Speed Sensor Bracket Bolts [A] Speed Sensor Bracket [B] • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer. NOTE ○...
  • Page 377: Engine Sprocket Installation

    FINAL DRIVE 11-11 Sprocket, Coupling Engine Sprocket Installation • Replace the sprocket washer and axle cotter pin. • Install the engine sprocket [A] so that “OUTSIDE” letters face outward. • Apply molybdenum disulfide oil solution to the threads of the output shaft and seating surface of the engine sprocket nut.
  • Page 378: Coupling Installation

    11-12 FINAL DRIVE Sprocket, Coupling Coupling Installation • Apply high-temperature grease to the coupling grease seal lips [A]. • Apply grease to the coupling internal surface [B]. • Grease the following. Wheel Flange Portion [A] O-ring [B] • Install the collar [C]. Coupling Bearing Removal •...
  • Page 379: Coupling Bearing Inspection

    FINAL DRIVE 11-13 Sprocket, Coupling • Replace the grease seal with a new one. • Press in the grease seal so that the seal surface is flush with the end of the hole. ○ Apply high-temperature grease to the grease seal lips. Special Tool - Bearing Driver Set: 57001-1129 Coupling Bearing Inspection Since the coupling bearing is made to extremely close...
  • Page 380: Rear Sprocket Warp Inspection

    11-14 FINAL DRIVE Sprocket, Coupling Rear Sprocket Warp Inspection • Raise the rear wheel off the ground with stand so that it will turn freely. • Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown, and rotate [C] the rear wheel to measure the sprocket runout (warp).
  • Page 381 BRAKES 12-1 Brakes Table of Contents Exploded View........12-3 Brake Hose Removal/Installation. 12-28 Specifications ........12-12 Brake Hose Inspection....12-28 Special Tools ........12-13 Anti-Lock Brake System ....12-29 Brake Lever, Brake Pedal....12-14 ABS Servicing Precautions ..12-32 Brake Lever Position Adjustment. 12-14 ABS Troubleshooting Outline..
  • Page 382 12-2 BRAKES Front Wheel Rotation Sensor Wheel Rotation Sensor Rotor Removal ........12-55 Inspection........12-57 Front Wheel Rotation Sensor Brake Hose and Pipe Installation ......... 12-56 Removal/Installation....12-57 Rear Wheel Rotation Sensor Brake Hose and Pipe Inspection.. 12-58 Removal ........12-56 ABS Solenoid Valve Relay Fuse Rear Wheel Rotation Sensor...
  • Page 383: Exploded View

    BRAKES 12-3 Exploded View Dummy Page...
  • Page 384 12-4 BRAKES Exploded View...
  • Page 385 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valve 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Brake Disc Mounting Bolts Front Brake Light Switch Screw 0.10 9 in·lb Front Brake Reservoir Cap Screws...
  • Page 386 12-6 BRAKES Exploded View...
  • Page 387 BRAKES 12-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valve 0.80 69 in·lb Brake Hose Banjo Bolts Brake Pedal Bolt 0.90 78 in·lb Rear Brake Disc Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut B: Apply brake fluid.
  • Page 388 12-8 BRAKES Exploded View EX650B Models...
  • Page 389 BRAKES 12-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valve 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Brake Pipe Joint Nuts Front Brake Disc Mounting Bolts Front Brake Light Switch Screw 0.10 9 in·lb...
  • Page 390 12-10 BRAKES Exploded View...
  • Page 391 BRAKES 12-11 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valve 0.80 69 in·lb Brake Hose Banjo Bolts Brake Pedal Bolt 0.90 78 in·lb Brake Pipe Joint Nuts Rear Brake Disc Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut B: Apply brake fluid.
  • Page 392: Specifications

    12-12 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 5-way adjustable (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 40 mm (1.6 in.) below top of footpeg –...
  • Page 393: Special Tools

    BRAKES 12-13 Special Tools Inside Circlip Pliers: Hand Tester: 57001-143 57001-1394 Jack: Jack Attachment: 57001-1238 57001-1608...
  • Page 394: Brake Lever, Brake Pedal

    12-14 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] to align the number with the arrow mark [B] on the lever holder.
  • Page 395: Brake Pedal Removal

    BRAKES 12-15 Brake Lever, Brake Pedal Brake Pedal Removal • Remove: Frame Cover (see Frame Cover Removal in the Frame chapter) Bolts [A] Right Footpeg Stay [B] • Remove: Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] •...
  • Page 396 12-16 BRAKES Brake Lever, Brake Pedal • Install the right footpeg stay, and tighten the bolts. Torque - Footpeg Stay Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) ○ Depress the brake pedal [A] and then align the bolts holes of the master cylinder [B]. Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) •...
  • Page 397: Calipers

    BRAKES 12-17 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], and detach the caliper [C] from the disc. • Unscrew the banjo bolt and remove the brake hoses [D] from the caliper (see Brake Hose Removal/Installation).
  • Page 398: Front Caliper Disassembly

    12-18 BRAKES Calipers Front Caliper Disassembly • Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter. Front Caliper Assembly • Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter. Rear Caliper Disassembly •...
  • Page 399: Caliper Piston And Cylinder Damage

    BRAKES 12-19 Calipers Caliper Piston and Cylinder Damage • Visually inspect the pistons [A] and cylinder surfaces [B]. Replace the caliper if the cylinder and piston are badly scores or rusty. Rear Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts [A].
  • Page 400: Brake Pads

    12-20 BRAKES Brake Pads Front Brake Pad Removal • Remove the front caliper with the hose installed (see Front Caliper Removal). • Draw out the holder shaft pin [A], and take off the holder shaft [B]. • Remove the pad [C] on the piston side. •...
  • Page 401: Master Cylinder

    BRAKES 12-21 Master Cylinder Front Master Cylinder Removal • Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder [B] (see Brake Hose Removal/In- stallation). • Disconnect the front brake light switch connectors [A]. • Unscrew the clamp bolts [B], and take off the master cylin- der as an assembly with the reservoir, brake lever and brake switch installed.
  • Page 402: Rear Master Cylinder Removal

    12-22 BRAKES Master Cylinder Rear Master Cylinder Removal • Unscrew the brake hose banjo bolt [A] on the master cylin- der (see Brake Hose Removal/Installation). • Unscrew the master cylinder mounting bolts [A]. • Remove the cotter pin [B]. NOTE ○...
  • Page 403: Master Cylinder Inspection

    BRAKES 12-23 Master Cylinder Master Cylinder Inspection • Remove the master cylinders (see Front/Rear Master Cylinder Removal). • 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].
  • Page 404: Brake Disc

    12-24 BRAKES Brake Disc Brake Disc Removal • Remove the wheel (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Unscrew the mounting bolts, and take off the disc. • Remove the gaskets. Brake Disc Installation • Replace the gaskets with new ones. •...
  • Page 405: Brake Fluid

    BRAKES 12-25 Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance 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 406 12-26 BRAKES Brake Fluid • Bleed the brake line and the caliper. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].
  • Page 407 BRAKES 12-27 Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.
  • Page 408: Brake Hose

    12-28 BRAKES Brake Hose Brake Hose Removal/Installation • Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter. Brake Hose Inspection • Refer to the Brake Hose Damage and Installation Condi- tion Inspection in the Periodic Maintenance chapter.
  • Page 409: Anti-lock Brake System

    1. Front Wheel Rotation Sensor 2. Front Wheel Rotation Sensor Rotor 3. Rear Wheel Rotation Sensor 4. Rear Wheel Rotation Sensor Rotor 5. ABS Indicator Light (LED) 6. ABS Hydraulic Unit 7. ABS Fuse Box 8. ABS Kawasaki Self-diagnosis System Connector...
  • Page 410 ABS System Wiring Diagram 1. Ignition Switch 2. ABS Hydraulic Unit 3. ABS Self-diagnosis Terminal 4. ABS Kawasaki Self-diagnosis System Connector 5. Front Wheel Rotation Sensor 6. Rear Wheel Rotation Sensor 7. ABS Solenoid Valve Relay 8. ABS Motor Relay 9.
  • Page 411 6. Unused 7. Power Supply to Rear Wheel Rotation Sensor 8. Unused 9. Unused 10. Unused 11. ABS Kawasaki Self-diagnosis System Terminal 12. ABS Indicator Light (LED) 13. Unused 14. Unused 15. Unused 16. Power Supply to Front Wheel Rotation Sensor 17.
  • Page 412: Abs Servicing Precautions

    12-32 BRAKES Anti-Lock Brake System ABS Servicing Precautions There are a number of important precautions that should be followed servicing the ABS system. ○ This ABS system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 413 BRAKES 12-33 Anti-Lock Brake System ○ The ABS indicator light (LED) [A] may light if the tire pres- sure is incorrect, a non-recommended tire is installed, or the wheel is deformed. If the indicator light lights, remedy the problem and clear the service code. WARNING Use of non-recommended tires may cause malfunc- tioning of ABS and can lead to extended braking...
  • Page 414: Abs Troubleshooting Outline

    12-34 BRAKES Anti-Lock Brake System ABS Troubleshooting Outline When an abnormality in the system occurs, the ABS in- dicator light (LED) lights up to alert the rider. In addition, the nature of the fault is stored in the memory of the ABS hydraulic unit and when in the self-diagnosis mode, the ser- vice code [A] is indicated by the number of times the ABS indicator light (LED) blinks.
  • Page 415 BRAKES 12-35 Anti-Lock Brake System • Visually inspect the wiring for signs of burning or fraying. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it.
  • Page 416 12-36 BRAKES Anti-Lock Brake System ABS Diagnosis Flow Chart...
  • Page 417: Inquiries To Rider

    BRAKES 12-37 Anti-Lock Brake System Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of condition the rider is dissatisfied with. ○ Try to find out exactly what problem occurs under exactly what conditions by asking the rider; know- ing this information may help you reproduce the problem in the shop.
  • Page 418 12-38 BRAKES Anti-Lock Brake System Pre-Diagnosis Inspection 1...
  • Page 419: Self-diagnosis Outline

    BRAKES 12-39 Anti-Lock Brake System Pre-Diagnosis Inspection 2 Self-diagnosis Outline When the indicator light has blinked or come on, the ABS hydraulic unit memorizes and stores the service code (15 codes including “Normal Code”) for the service person to troubleshoot easily. The service code memory is powered directly by the battery and cannot be canceled by the ignition switch.
  • Page 420: Service Code Clearing Procedures

    12-40 BRAKES Anti-Lock Brake System • Remove the seat (see Seat Removal in the Frame chap- ter). • Ground the self-diagnosis terminal [A] (Gray) to the bat- tery (–) terminal or battery (–) lead connector, using a lead. • Turn on the ignition switch. ○...
  • Page 421 BRAKES 12-41 Anti-Lock Brake System Self-diagnosis Flow Chart...
  • Page 422: How To Read Service Codes

    12-42 BRAKES Anti-Lock Brake System How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the ABS indicator light (LED) as shown below. ○ Read 10th digit and unit digit as the ABS indicator light (LED) blinks. ○...
  • Page 423 BRAKES 12-43 Anti-Lock Brake System Service Code Table Service ABS Indicator Light (LED) Problems Light State Code After starts, Start code (not fault) turn off Rear inlet solenoid valve trouble (open, temperature abnormal) Rear outlet solenoid valve trouble (open, temperature abnormal) Front inlet solenoid valve trouble (open, temperature abnormal) Front outlet solenoid valve trouble (open,...
  • Page 424: Abs Indicator Light (led) Inspection

    12-44 BRAKES Anti-Lock Brake System ABS Indicator Light (LED) Inspection • Turn the ignition switch ON. If the ABS indicator light (LED) [A] lights, it is normal. If the ABS indicator light (LED) does not light, go to step “ABS Indicator Light (LED) is Unlit (When the Ignition Switch turned to ON)”.
  • Page 425: Solenoid Valve Inspection (service Code 13,14,17,18)

    BRAKES 12-45 Anti-Lock Brake System ABS Indicator Light (LED) Lights (When the Motorcycle is Running, - No Service Code) • Do the 1st step test. ○ Check the terminal voltage between the orange/black and black/yellow lead terminals of the meter connector [A]. Special Tool - Hand Tester: 57001-1394 Terminal Voltage Standard:...
  • Page 426 12-46 BRAKES Anti-Lock Brake System • Do the 2nd step test. ○ Disconnect the ABS hydraulic unit connector [A]. ○ Check for continuity between the white/red and black/yel- low lead terminals of the ABS hydraulic unit connector. If there is the continuity in the lead, replace the ABS hy- draulic unit.
  • Page 427: Front, Rear Wheel Rotation Difference Abnormal (service Code 25)

    BRAKES 12-47 Anti-Lock Brake System Front, Rear Wheel Rotation Difference Abnormal (Service Code 25) • Do the 1st step test. ○ Check the following and correct the faulty part. Incorrect the tire pressure. Tires not recommended for the motorcycle were installed (incorrect tire size).
  • Page 428: Front Wheel Rotation Sensor Signal Abnormal (service Code 42)

    12-48 BRAKES Anti-Lock Brake System • Do the 4th step test. ○ Check the battery terminal voltage between the red/white lead terminal of the fuse box [A] and ground. Special Tool - Hand Tester: 57001-1394 Battery Terminal Voltage Standard: Battery Voltage If the battery terminal voltage is not within the specifica- tion, 5th step.
  • Page 429: Front Wheel Rotation Sensor Wiring Inspection (service Code 43)

    BRAKES 12-49 Anti-Lock Brake System • Do the 2nd step test. ○ Check that there is iron or other magnetic deposits be- tween the sensor [A] and sensor rotor [B], and the sensor rotor slots for obstructions. ○ Check the installation condition of the sensor for loose- ness.
  • Page 430: Rear Wheel Rotation Sensor Signal Abnormal (service Code 44)

    12-50 BRAKES Anti-Lock Brake System • Do the 3rd step test. ○ Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit.
  • Page 431: Rear Wheel Rotation Sensor Wiring Inspection (service Code 45)

    (Service Code 52) • Do the 1st step test. ○ Disconnect the ABS Kawasaki self-diagnosis system con- nector and ABS hydraulic unit connector. ○ Check for continuity between the brown lead terminal of the main harness side connector [A] and brown lead ter- minal of the main harness side connector [B].
  • Page 432: Power Supply Voltage Abnormal (over-voltage) (service Code 53)

    Connect the ABS Kawasaki self-diagnosis system con- nector and ABS hydraulic unit connector. ○ Check the battery terminal voltage, connect the hand tester to the brown terminal of ABS Kawasaki self-diagnosis system connector [A] and ground. Special Tool - Hand Tester: 57001-1394 Battery Terminal Voltage Standard:...
  • Page 433: Ecu Inspection (service Code 55)

    BRAKES 12-53 Anti-Lock Brake System • Do the 3rd step test. ○ Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit.
  • Page 434: Abs Hydraulic Unit Installation

    12-54 BRAKES Anti-Lock Brake System • Remove: Bolts [A] • Remove: Brake Pipe Joint Nuts [A] [B] [C] [D] • Tape the brake line opening to prevent brake fluid leakage or contamination by foreign matter. CAUTION Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately.
  • Page 435: Abs Hydraulic Unit Inspection

    BRAKES 12-55 Anti-Lock Brake System ABS Hydraulic Unit Inspection • Remove the ABS hydraulic unit (see ABS Hydraulic Unit Removal). • Visually inspect the ABS hydraulic unit. Replace the ABS hydraulic unit if any of them are cracked, or otherwise damaged. •...
  • Page 436: Front Wheel Rotation Sensor Installation

    12-56 BRAKES Anti-Lock Brake System • Remove: Clamp [A] Bolt [B] Front Wheel Rotation Sensor [C] Front Wheel Rotation Sensor Installation • Installation is the reverse of removal. ○ Route the lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). Rear Wheel Rotation Sensor Removal CAUTION The wheel rotation sensor should be handled care-...
  • Page 437: Wheel Rotation Sensor Inspection

    BRAKES 12-57 Anti-Lock Brake System Wheel Rotation Sensor Inspection • Remove the front wheel rotation sensor [A] from the front fork. • Remove the rear wheel rotation sensor [B] from the caliper bracket. • Visually inspect the wheel rotation sensors. Replace the wheel rotation sensor if it is cracked, bent, or otherwise damaged.
  • Page 438: Brake Hose And Pipe Inspection

    12-58 BRAKES Anti-Lock Brake System Brake Hose and Pipe Inspection • Refer to the Brake Hose and Pipe Damage and Instal- lation Condition Inspection in the Periodic Maintenance chapter. ABS Solenoid Valve Relay Fuse Removal • Remove the seat (see Seat Removal in the Frame chap- ter).
  • Page 439: Fuse Inspection

    BRAKES 12-59 Anti-Lock Brake System Fuse Inspection • Remove the fuse (see ABS Solenoid Valve Relay/ABS Motor Relay Fuse Removal). • Inspect the fuse element. If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit.
  • Page 441 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-9 Front Fork Removal ......................13-9 Front Fork Installation ....................... 13-9 Front Fork Oil Change ...................... 13-9 Front Fork Disassembly ....................13-11 Front Fork Assembly......................
  • Page 442: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 443 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolt Front Fork Bottom Allen Bolts Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Front Fork Top Plugs 6. Outer Tube (EX650B Models) AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.
  • Page 444 13-4 SUSPENSION Exploded View...
  • Page 445 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Bolt Rear Shock Absorber Nut Swingarm Pivot Shaft Nut 11.0 G: Apply grease. R: Replacement Parts...
  • Page 446: Specifications

    13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Outside Diameter 41 mm (1.6 in.) Air Pressure Atmospheric pressure (Non-adjustable) Fork Spring Setting Non-adjustable Damper Setting Non-adjustable Fork Oil: Viscosity KAYABA KHL34-G10 or equivalent Amount: EX650A Models approx.
  • Page 447: Special Tools

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Jack: 57001-143 57001-1238 Fork Cylinder Holder Handle: Fork Oil Seal Driver, 41: 57001-183 57001-1288 Fork Cylinder Holder Adapter: Fork Oil Level Gauge: 57001-1057 57001-1290 Oil Seal & Bearing Remover: Jack Attachment: 57001-1058 57001-1608 Bearing Driver Set: Stem Bearing Driver, 28: 57001-1129...
  • Page 448 13-8 SUSPENSION Special Tools Spacer, 57001-1663...
  • Page 449: Front Fork

    SUSPENSION 13-9 Front Fork Front Fork Removal • Remove: Upper Inner Fairing (see Upper Inner Fairing Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender (see Front Fender Removal in the Frame chapter) Front Wheel Rotation Sensor (see Front Wheel Rotation Sensor Removal in the Brakes chapter) (EX650B Mod-...
  • Page 450 13-10 SUSPENSION Front Fork • Compress [A] the fork [B] upside down to draw out the oil into the suitable container [C]. • Pour in the specified amount of oil. Fork Oil Viscosity: KAYABA KHL34-G10 or equivalent Amount (Per Side): When changing oil: EX650A Models approx.
  • Page 451: Front Fork Disassembly

    SUSPENSION 13-11 Front Fork Front Fork Disassembly • Remove the front fork (see Front Fork Removal). • Remove the top plug [A] with O-ring, take out the collar [B], fork spring seat [C], and fork spring [D]. • Drain the fork oil (see Front Fork Oil Change). •...
  • Page 452: Front Fork Assembly

    13-12 SUSPENSION Front Fork • Remove the following from the inner tube. Inner Guide Bushing [A] Outer Guide Bushing [B] Washer [C] Oil Seal [D] • Remove the cylinder base [A] from the bottom of the outer tube. Front Fork Assembly •...
  • Page 453: Inner Tube Inspection

    SUSPENSION 13-13 Front Fork • Apply non-permanent locking agent to the threads of the bottom Allen bolt [A]. • Hold the front fork horizontally in a vise [B]. • Hold the cylinder unit [C] with the special tools and tighten the bottom Allen bolt to secure the cylinder in place.
  • Page 454: Fork Spring Inspection

    13-14 SUSPENSION Front Fork Fork Spring Inspection • Measure the free length [A] of the fork spring [B]. If the measured length is shorter than the service limit, the spring must be replaced. If the free length of the replace- ment spring and that of the remaining spring vary greatly, the remaining spring should also be replaced in order to keep the fork legs balanced to ensure stability.
  • Page 455: Rear Shock Absorber

    SUSPENSION 13-15 Rear Shock Absorber Spring Preload Adjustment • Using the hook wrench [A], turn the adjusting nut [B] to adjust the spring preload. ○ The standard adjuster setting for average-build rider of 68 kg (150 Ib) with no passenger and no accessories is 2nd position.
  • Page 456: Rear Shock Absorber Installation

    13-16 SUSPENSION Rear Shock Absorber • Remove: Upper Shock Absorber Bolt [A] Lower Shock Absorber Nut and Washer Lower Shock Absorber Bolt [B] • Remove the shock absorber [C] from backward. Rear Shock Absorber Installation • Installation is the reverse of removal. •...
  • Page 457: Swingarm

    SUSPENSION 13-17 Swingarm Swingarm Removal • Remove: Chain Cover Bolts [A] and Cover [B] • Remove: Right Side Cover (see Side Cover Removal in the Frame chapter) Frame Covers (see Frame Cover Removal in the Frame chapter) • Remove the brake hose banjo bolt from the rear caliper, free the brake hose [A] from the clamps [B], and remove the footpeg stay with the rear master cylinder (see Rear Caliper Removal in the Brakes chapter).
  • Page 458: Swingarm Bearing Removal

    13-18 SUSPENSION Swingarm Swingarm Bearing Removal • Remove: Swingarm (see Swingarm Removal) Collar [A] Oil Seals [B] Sleeve [C] Circlip [D] Special Tool - Inside Circlip Pliers: 57001-143 • Remove the ball bearing and needle bearings. Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058 Swingarm Bearing Installation •...
  • Page 459: Swingarm Bearing, Sleeve Inspection

    SUSPENSION 13-19 Swingarm • Install the needle bearings [A], ball bearing [B] and oil seals [C] position as shown. Circlip [D] 25 mm (0.98 in.) [E] 17 mm (0.67 in.) [F] 1 mm (0.04 in.) [G] 0.5 mm (0.02 in.) [H] 1 mm (0.04 in.) [I] 23.5 mm (0.93 in.) [J] 6 mm (0.24 in.) [K]...
  • Page 460: Swingarm Bearing Lubrication

    13-20 SUSPENSION Swingarm • Turn the bearing in the swingarm back and forth [A] while checking for plays, roughness, or binding. If the bearing play, roughness, or binding is found, replace the bearing. • Examine the bearing seal [B] for tears or leakage. If the seal is torn or is leaking, replace the bearing.
  • Page 461 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Steering ..........................14-5 Steering Inspection ......................14-5 Steering Adjustment......................14-5 Steering Stem......................... 14-6 Stem, Stem Bearing Removal................... 14-6 Stem, Stem Bearing Installation..................14-7 Stem Bearing Lubrication....................14-9 Steering Stem Warp......................
  • Page 462: Exploded View

    14-2 STEERING Exploded View...
  • Page 463 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Handlebar Holder Bolts Left Switch Housing Screws 0.36 31 in·lb Right Switch Housing Screws 0.36 31 in·lb Steering Stem Head Bolt 11.0 Steering Stem Nut AD: Apply adhesive.
  • Page 464: Special Tools

    14-4 STEERING Special Tools Steering Stem Nut Wrench: Steering Stem Bearing Driver, 42.5: 57001-1100 57001-1344 Bearing Driver Set: Steering Stem Bearing Driver Adapter, 41.5: 57001-1129 57001-1345...
  • Page 465: Steering Inspection

    STEERING 14-5 Steering Steering Inspection • Refer to the Steering Play Inspection in the Periodic Main- tenance chapter. Steering Adjustment • Refer to the Steering Play Adjustment in the Periodic Maintenance chapter.
  • Page 466: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Under Bracket [A] (see Upper Fairing Bracket Removal in the Frame chapter) • Remove: Upper Fairing Bracket [A] (see Upper Fairing Bracket Removal in the Frame chapter) •...
  • Page 467: Stem, Stem Bearing Installation

    STEERING 14-7 Steering Stem • To remove the bearing outer races [A] pressed into the head pipe [B], insert a bar [C] into the recesses of head pipe, and applying it to both recess alternately hammer it to drive the race out. NOTE ○...
  • Page 468 14-8 STEERING Steering Stem • Install the stem [A] through the head pipe and install the ball bearing [B] and inner race [C] on it. • Install the stem cap [D] and steering stem nut [E]. • Settle the inner races in place as follows. ○...
  • Page 469: Stem Bearing Lubrication

    STEERING 14-9 Steering Stem Stem Bearing Lubrication • Refer to the Steering Stem Bearing Lubrication in the Pe- riodic Maintenance chapter. 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.
  • Page 470: Handlebar

    14-10 STEERING Handlebar Handlebar Removal • Remove: Clutch Lever Assembly [A] Left Switch Housing [B] Left Handlebar Weight [C] • Remove: Front Brake Master Cylinder [A] (see Front Master Cylin- der Removal in the Brakes chapter) Right Switch Housing [B] Right Handlebar Weight [C] Throttle Grip [D] •...
  • Page 471 STEERING 14-11 Handlebar • Install the clutch lever (see Clutch Lever Installation in the Clutch chapter). • Apply adhesive cement to the inside of the left handlebar grip. • Apply a non-permanent locking agent to the left handlebar weight bolt. •...
  • Page 473 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Seat ............................15-8 Seat Removal ........................15-8 Seat Installation ........................ 15-8 Fairings........................... 15-9 Lower Fairing Removal ..................... 15-9 Lower Fairing Installation ....................15-9 Center Fairing Removal ....................15-9 Center Fairing Installation ....................15-9 Windshield Removal ......................
  • Page 474: Exploded View

    15-2 FRAME Exploded View...
  • Page 475 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Footpeg Stay Bolts Sidestand Bolt Sidestand Switch Bolt 0.90 78 in·lb 4. EX650B Models 5. EX650A Models G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts...
  • Page 476 15-4 FRAME Exploded View...
  • Page 477 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fender Bolts 0.40 35 in·lb Front Fender Bracket Bolts 0.90 78 in·lb Front Turn Signal Light Mounting Screws 0.12 11 in·lb L: Apply a non-permanent locking agent.
  • Page 478 15-6 FRAME Exploded View...
  • Page 479 FRAME 15-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Grab Rail Mounting Bolts Seat Lock Mounting Screws 0.12 11 in·lb 3. Seat (United States and Canada Models) 4. Seat Lock Bracket (EX650B Models) 5. EX650B Models 6. Grab Rails (Other than United States and Canada Models) 7.
  • Page 480: Seat

    15-8 FRAME Seat Seat Removal • Insert the ignition switch key [A] into the seat lock, turning the key clockwise, pulling up on the rear of the seat [B], and pulling the seat backward. Seat Installation • Slip the seat hook [A] under the brace [B] on the fuel tank bracket.
  • Page 481: Fairings

    FRAME 15-9 Fairings Lower Fairing Removal • Pull up the core by the thin blade driver. • Remove the quick rivets [A]. • Remove the bolts [B] with collar and washers. • Clear the hook portions from the slots. • Separate the left lower fairing from the right lower fairing.
  • Page 482: Windshield Removal

    15-10 FRAME Fairings • Insert the hook [A] into the slot [B]. • Insert the projection [A] into the hole [B]. • Connect the turn signal lead connector. • Install the bolt and screws. Windshield Removal • Remove: Bolts [A] with Washers Windshield [B] Dampers Windshield Installation...
  • Page 483: Upper Fairing Disassembly

    FRAME 15-11 Fairings Upper Fairing Disassembly • Remove: Headlight [A] (see Headlight Removal/Installation in the Electrical System chapter) Upper Fairing Assembly • Install the headlight (see Headlight Removal/Installation in the Electrical System chapter). Upper Fairing Installation • Installation is the reverse of removal. Upper Inner Fairing Removal •...
  • Page 484: Inner Fairing Removal

    15-12 FRAME Fairings • Remove: Bolts [A] Clamps [B] Upper Fairing Bracket [C] Inner Fairing Removal • Remove: Center Fairings (see Center Fairing Removal) Mounting Screws [A] Inner Fairing [B] Inner Fairing Installation • Tighten the mounting screws. Torque - Front Turn Signal Light Mounting Screws: 1.2 N·m (0.12 kgf·m, 11 in·lb) •...
  • Page 485: Side Covers

    FRAME 15-13 Side Covers Side Cover Removal • Remove the seat (see Seat Removal). • Remove the bolt [A]. • Pull the side cover [B] evenly outward to clear the stop- pers. Side Cover Installation • Insert the tabs [A] into the holes [B]. •...
  • Page 486: Seat Covers

    15-14 FRAME Seat Covers Seat Cover Removal • Remove: Seat (see Seat Removal) Bolts [A] Grab Rails [B] (Other than United States and Canada Models) Screw Rivets [C] • Push the central pin, and then remove the quick rivets [A]. •...
  • Page 487: Fenders

    FRAME 15-15 Fenders Front Fender Removal • Remove: Brake Hose Clamps [A] Bolts [B] with Collar (Both Side) • Remove the front fender [C]. Front Fender Installation • Tighten: Torque - Front Fender Bolts: 3.9 N·m (0.40 kgf·m, 35 in·lb) •...
  • Page 488: Rear Fender Front Removal

    15-16 FRAME Fenders Rear Fender Front Removal • Remove: Rear Fender Rear (see Flap and Rear Fender Rear Re- moval) Battery (see Battery Removal in the Electrical System chapter) Relay Box (see Relay Box Removal in the Electrical Sys- tem chapter) Starter Relay (see Starter Relay Inspection in the Elec- trical System chapter) •...
  • Page 489: Frame

    FRAME 15-17 Frame Frame Inspection • Visually inspect the frame for cracks, dents, bending or warp. ○ If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
  • Page 490: Sidestand

    15-18 FRAME Sidestand Sidestand Removal • Raise the rear wheel off the ground with stand. • Remove: Frame Cover (see Frame Cover Removal) Bolts [A] Footpeg Stay [B] • Remove: Sidestand Switch Bolt [A] with Clamp Sidestand Switch [B] • Remove: Spring [A] Sidestand Nut [B]...
  • Page 491: Frame Cover

    FRAME 15-19 Frame Cover Frame Cover Removal • Remove the bolt [A]. • Pull the frame cover [B] outward to clear the stoppers. Frame Cover Installation • Insert the projections [A] into the holes [B]. • Tighten the bolt.
  • Page 493 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-3 Specifications ......................... 16-10 Special Tools and Sealants ....................16-11 Parts Location......................... 16-12 Wiring Diagram (Europe, Korea, Hong Kong and Kuwait) ............. 16-14 Wiring Diagram (United States, Canada, New Zealand and Malaysia)........16-16 Wiring Diagram (Australia and South Africa)................
  • Page 494 16-2 ELECTRICAL SYSTEM Electric Starter System ......................16-49 Starter Motor Removal...................... 16-49 Starter Motor Installation....................16-49 Starter Motor Disassembly....................16-50 Starter Motor Assembly ....................16-50 Brush Inspection ....................... 16-51 Commutator Cleaning and Inspection................16-51 Armature Inspection......................16-52 Brush Lead Inspection ...................... 16-52 Brush Plate and Terminal Bolt Inspection .................
  • Page 495: Exploded View

    ELECTRICAL SYSTEM 16-3 Exploded View Dummy Page...
  • Page 496 16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 497 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Turn Signal Light Mounting Screws 0.12 11 in·lb License Plate Light Cover Screws 0.90 0.090 8 in·lb License Plate Light Mounting Screws 0.12 11 in·lb Meter Screws 0.12 11 in·lb 5.
  • Page 498 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 499 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Light Switch Screw 0.12 11 in·lb Left Switch Housing Screws 0.36 31 in·lb Right Switch Housing Screws 0.36 31 in·lb Starter Motor Cable Terminal Nut 0.60 53 in·lb Starter Motor Mounting Bolts 87 in·lb Starter Motor Terminal Locknut...
  • Page 500 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 501 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Alternator Cover Bolts 87 in·lb Alternator Lead Holding Plate Bolt 87 in·lb Alternator Rotor Bolt 15.8 Crankshaft Sensor Bolts 0.60 53 in·lb Neutral Switch Oil Pressure Switch Oxygen Sensor 44.1 4.50 32.5...
  • Page 502: Specifications

    16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name YTX12-BS Capacity 12 V 10 Ah Voltage 12.8 V or more Charging System Type Three-phase AC Alternator Output Voltage 42 V or more at 4 000 r/min (rpm) 0.18 ∼...
  • Page 503: Special Tools And Sealants

    Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: Flywheel & Pulley Holder: 57001-1405 57001-1605 Peak Voltage Adapter: Rotor Holder: 57001-1415 57001-1658 Lead Wire - Peak Voltage Adapter: Kawasaki Bond (Silicone Sealant): 57001-1449 56019-120 Needle Adapter Set: Kawasaki Bond (Silicone Sealant): 57001-1457 92104-0004...
  • Page 504: Parts Location

    16-12 ELECTRICAL SYSTEM Parts Location 1. Air Switching Valve 13. Rear Brake Light Switch 2. Alternator 14. Regulator/Rectifier 3. Battery 12 V 10 Ah 15. Relay Box 4. Crankshaft Sensor 16. Sidestand Switch 5. ECU 17. Speed Sensor 6. Fan Motor 18.
  • Page 505 ELECTRICAL SYSTEM 16-13 Parts Location Dummy Page...
  • Page 506: Wiring Diagram (europe, Korea, Hong Kong And Kuwait)

    16-14 ELECTRICAL SYSTEM Wiring Diagram (Europe, Korea, Hong Kong and Kuwait)
  • Page 507 ELECTRICAL SYSTEM 16-15 Wiring Diagram (Europe, Korea, Hong Kong and Kuwait)
  • Page 508: Wiring Diagram (united States, Canada, New Zealand And Malaysia)

    16-16 ELECTRICAL SYSTEM Wiring Diagram (United States, Canada, New Zealand and Malaysia)
  • Page 509 ELECTRICAL SYSTEM 16-17 Wiring Diagram (United States, Canada, New Zealand and Malaysia)
  • Page 510: Wiring Diagram (australia And South Africa)

    16-18 ELECTRICAL SYSTEM Wiring Diagram (Australia and South Africa)
  • Page 511 ELECTRICAL SYSTEM 16-19 Wiring Diagram (Australia and South Africa)
  • Page 512: Wiring Diagram (ex650b Models)

    16-20 ELECTRICAL SYSTEM Wiring Diagram (EX650B Models)
  • Page 513 ELECTRICAL SYSTEM 16-21 Wiring Diagram (EX650B Models)
  • Page 514: Precautions

    16-22 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○...
  • Page 515 ELECTRICAL SYSTEM 16-23 Precautions Male Connectors [B]...
  • Page 516: Electrical Wiring

    16-24 ELECTRICAL SYSTEM 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. If the connector is corroded or dirty, clean it carefully.
  • Page 517: Battery

    ELECTRICAL SYSTEM 16-25 Battery Battery Removal • Remove: Seat (see Seat Removal in the Frame chapter) • Disconnect the negative (–) cable [A]. • Slide out the positive (+) terminal cap [B] and then discon- nect the positive (+) cable. CAUTION Be sure to disconnect the negative (–) cable first.
  • Page 518 16-26 ELECTRICAL SYSTEM Battery • Remove the electrolyte container from the vinyl bag. • Detach the strip of caps [A] from the container and set aside, these will be used later to seal the battery. NOTE ○ Do not pierce or otherwise open the sealed cells [B] of the electrolyte container.
  • Page 519 Newly activated sealed batteries require an initial charge. Standard Charge: 1.2 A × 5 ∼ 10 hours If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers Optimate III Yuasa 1.5 Amp Automatic Charger Battery Mate 150-9 If the above chargers are not available, use equivalent one.
  • Page 520: Precautions

    16-28 ELECTRICAL SYSTEM Battery Precautions 1) 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. 2) Refreshing charge.
  • Page 521: Charging Condition Inspection

    ELECTRICAL SYSTEM 16-29 Battery Charging Condition Inspection ○ Battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter [A]. • Remove: Seat (see Seat Removal in the Frame chapter) Battery Cable Cap (see Battery Removal) •...
  • Page 522 16-30 ELECTRICAL SYSTEM Battery Terminal Voltage: 11.5 ∼ less than 12.8 V Standard Charge 1.2 A × 5 ∼ 10 h (see following chart) Quick Charge 5 A × 1 h CAUTION If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on.
  • Page 523: Charging System

    Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface [A] on the front and rear sides of the cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Check that dowel pins [B] are in place on the crankcase.
  • Page 524: Stator Coil Installation

    Apply silicone sealant to the circumference of the alter- nator lead grommet, and fit the grommet into the notch of the cover securely. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install the alternator cover (see Alternator Cover Installa- tion).
  • Page 525 ELECTRICAL SYSTEM 16-33 Charging System • Install the starter gear [A] and washer [B]. • Again, clean the crankshaft tapered portion [C] and dry there. • Install the alternator rotor [A] while turning [B] it counter- clockwise. • Install the washer [A]. NOTE ○...
  • Page 526: Alternator Inspection

    16-34 ELECTRICAL SYSTEM Charging System • Apply a thin coat of molybdenum disulfide grease to the shafts [A], and install them. • Install the torque limiter [B] and starter idle gear [C]. • Install the alternator cover (see Alternator Cover Installa- tion).
  • Page 527: Regulator/rectifier Inspection

    ELECTRICAL SYSTEM 16-35 Charging System If there is more resistance than shown in the table, or no hand tester reading (infinity) for any two leads, the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced.
  • Page 528 16-36 ELECTRICAL SYSTEM Charging System Rectifier Circuit Check • Check conductivity of the following pair of terminals. Rectifier Circuit Inspection W/BL-BK1, W/BL-BK2, W/BL-BK3 Tester connection BK/Y-BK1, BK/Y-BK2, BK/Y-BK3 The resistance should be low in one direction and more than ten times as much in the other direction. If any two leads are low or high in both directions, the rectifier is defective and the regulator/rectifier must be replaced.
  • Page 529 ELECTRICAL SYSTEM 16-37 Charging System • Do the 3rd step regulator circuit test. ○ Connect the test light and the 12 V battery in the same manner as specified in the “Regulator Circuit Test-1st Step”. ○ Momentarily apply 24 V to the voltage BR terminal by adding a 12 V battery.
  • Page 530: Charging Voltage Inspection

    16-38 ELECTRICAL SYSTEM Charging System Charging Voltage Inspection • Check the battery condition (see Charging Condition In- spection). • Warm up the engine to obtain actual alternator operating conditions. • Remove the seat (see Seat Removal in the Frame chap- ter).
  • Page 531 ELECTRICAL SYSTEM 16-39 Charging System Charging System Circuit 1. Ignition Switch 2. Alternator 3. Regulator/Rectifier 4. Water-proof Joint C 5. Main Fuse 30 A 6. Battery 12 V 10 Ah 7. Load...
  • Page 532: Starter Motor Clutch

    16-40 ELECTRICAL SYSTEM Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal/Installation. Starter Motor Clutch Inspection • Remove: Alternator Cover (see Alternator Cover Removal) Starter Idle Gear and Torque Limiter Shafts • Turn the starter motor clutch gear [A] by hand. The starter motor clutch gear should turn clockwise [B] freely, but should not turn counterclockwise [C].
  • Page 533: Ignition System

    ELECTRICAL SYSTEM 16-41 Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs or stick coils 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 534: Crankshaft Sensor Installation

    Torque - Crankshaft Sensor Bolts: 6.0 N·m (0.60 kgf·m, 53 in·lb) • Apply silicone sealant [A] to the crankshaft sensor lead grommet. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install the removed parts (see appropriate chapters). Crankshaft Sensor Inspection •...
  • Page 535: Timing Rotor Removal

    ELECTRICAL SYSTEM 16-43 Ignition System • Pushing the starter button, turn the engine 4 ∼ 5 sec- onds with the transmission gear in neutral to measure the crankshaft sensor peak voltage. • Repeat the measurement 5 or more times. Crankshaft Sensor Peak Voltage Standard: 1.9 V or more Special Tools - Hand Tester: 57001-1394...
  • Page 536: Stick Coil (ignition Coil Together With Spark Plug Cap) Inspection

    16-44 ELECTRICAL SYSTEM Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection • Remove the stick coils (see Stick Coil (Ignition Coil to- gether with Spark Plug Cap) Removal). • Measure the primary winding resistance [A] as follows. ○...
  • Page 537: Spark Plug Removal

    ELECTRICAL SYSTEM 16-45 Ignition System WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • Turn the ignition switch and the engine stop switch ON. • Pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measure the primary peak voltage.
  • Page 538: Ic Igniter Inspection

    16-46 ELECTRICAL SYSTEM Ignition System 2nd Check • Start the engine to the following conditions. Condition Transmission Gear → 1st Position Clutch Lever → Pulled in Sidestand → Up ○ Turn the ignition switch ON and push the starter button. ○...
  • Page 539 ELECTRICAL SYSTEM 16-47 Ignition System...
  • Page 540 16-48 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Ignition Switch 12. Water Temperature Sensor 22. Ignition Fuse 10 A 2. Engine Stop Switch 13. Neutral Switch 23. Fuse Box 3. Spark Plugs 14. Crankshaft Sensor 24. ECU Main Relay 4.
  • Page 541: Electric Starter System

    ELECTRICAL SYSTEM 16-49 Electric Starter System Starter Motor Removal CAUTION Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Right Center Fairing (see Center Fairing Removal in the Frame chapter)
  • Page 542: Starter Motor Disassembly

    16-50 ELECTRICAL SYSTEM Electric Starter System Starter Motor Disassembly • Remove the starter motor (see Starter Motor Removal). • Take off the starter motor through bolts [A] and remove the both end covers [B] and pull the armature out of the yoke [C].
  • Page 543: Brush Inspection

    ELECTRICAL SYSTEM 16-51 Electric Starter System • Install the new O-ring [A] as shown. • Install: Washers [B] and Terminal Locknut [C] • Tighten: Torque - Starter Motor Terminal Locknut: 11 N·m (1.1 kgf·m, 97 in·lb) • Align the lines [A] on the yoke with the end cover lines [B]. •...
  • Page 544: Armature Inspection

    16-52 ELECTRICAL SYSTEM Electric Starter System Armature Inspection • Using the × 1 Ω hand tester range, measure the resis- tance between any two commutator segments [A]. Special Tool - Hand Tester: 57001-1394 If there is a high resistance or no reading (∞) between any two segments, a winding is open and the starter motor must be replaced.
  • Page 545: Starter Relay Inspection

    ELECTRICAL SYSTEM 16-53 Electric Starter System Starter Relay Inspection • Remove: Bolt [A] and Cover [B] • Disconnect the connector [A]. • Disconnect the starter motor cable [B] and battery positive (+) cable [C] from the starter relay [D]. CAUTION The battery positive (+) cable with the rubber cap is connected directly to the battery positive (+) termi- nal even when the ignition switch off, so take care...
  • Page 546 16-54 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit 1. Ignition Switch 2. Water-proof Joint B 3. Starter Lockout Switch 4. Ignition Fuse 10 A 5. Fuse Box 6. Starter Circuit Relay 7. Relay Box 8. Starter Motor 9. Starter Relay 10.
  • Page 547: Lighting System

    ELECTRICAL SYSTEM 16-55 Lighting System This motorcycle adopt the daylight system and have a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off.
  • Page 548: City Light Bulb Replacement (europe Models)

    16-56 ELECTRICAL SYSTEM Lighting System • Fit the dust cover [A] onto the bulb [B] firmly as shown. Good [C] Bad [D] • After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter). City Light Bulb Replacement (Europe Models) •...
  • Page 549: License Plate Light Bulb Replacement

    ELECTRICAL SYSTEM 16-57 Lighting System License Plate Light Bulb Replacement • Remove: Screws [A] License Plate Light Cover [B] • Push and turn the bulb counterclockwise and remove it. • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise.
  • Page 550: Turn Signal Light Bulb Replacement

    16-58 ELECTRICAL SYSTEM Lighting System Headlight/Tail Light Circuit 12. Main Fuse 30 A 1. Ignition Switch 2. Water-proof Joint A 13. Battery 12 V 10 Ah 3. Water-proof Joint B 14. Frame Ground 4. Position Light 15. Tail/Brake Light 5. Headlight (High Beam) 16.
  • Page 551: Turn Signal Relay Inspection

    ELECTRICAL SYSTEM 16-59 Lighting System • Push and turn the bulb [A] counterclockwise and remove • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise.
  • Page 552 16-60 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit 1. Meter Unit 2. Water-proof Joint A 3. Water-proof Joint B 4. Front Right Turn Signal Light 5. Front Left Turn Signal Light 6. Turn Signal Relay 7. Hazard Button 8. Turn Signal Switch 9.
  • Page 553: Air Switching Valve

    ELECTRICAL SYSTEM 16-61 Air Switching Valve Air Switching Valve Operation Test • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Pull the air switching valve hose [A] out of the air cleaner base. •...
  • Page 554 16-62 ELECTRICAL SYSTEM Air Switching Valve • Blow the air to the inlet air duct [A], and make sure does not flow the blown air from the outlet air duct [B]. • Disconnect the 12 V battery. • Blow the air to the inlet air duct [A], and make sure does not flow the blown air from the outlet air duct [B].
  • Page 555: Radiator Fan System

    ELECTRICAL SYSTEM 16-63 Radiator Fan System Fan Motor Inspection • Disconnect the connector [A]. • Using an auxiliary leads, supply battery power to the fan motor. If the fan does not rotate, the fan motor is defective and must be replaced. Radiator Fan Circuit 1.
  • Page 556: Meter, Gauge, Indicator Unit

    16-64 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Unit Removal/Installation • Remove: Windshield (see Windshield Removal in the Frame chapter) Upper Inner Fairings (see Upper Inner Fairing Removal in the Frame chapter) Screws [A] (Both Side) and Meter Cover [B] •...
  • Page 557: Electronic Combination Meter Unit Inspection

    ELECTRICAL SYSTEM 16-65 Meter, Gauge, Indicator Unit Electronic Combination Meter Unit Inspection • Remove the meter unit [A] (see Meter Unit Removal/In- stallation). [1] Ignition [2] Fuel Level Warning Indicator Light (LED) (–) [3] Unused (EX650A Models) ABS Indicator Light (LED)(–)(EX650B Models) [4] Unused [5] Neutral Indicator Light (LED) (–) [6] FI Indicator Light (LED) (–)
  • Page 558 16-66 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit ○ When the terminals are connected, the LCD segment [A] and LED warning lights [B] appear. If the LCD segment and LED warning lights will not ap- pear, replace the meter assembly. • Disconnect the terminal [1].
  • Page 559 ELECTRICAL SYSTEM 16-67 Meter, Gauge, Indicator Unit • In the HOUR/MINUTE setting mode, press the RESET button again to effect the HOUR setting mode. ○ The hour display flashes on the display. • Press the MODE button to set the hour. •...
  • Page 560 16-68 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Speed Sensor Electric Source Check • Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • Set the hand tester to the DC 25 V range and connect it to the terminals [12] and [9].
  • Page 561 ELECTRICAL SYSTEM 16-69 Meter, Gauge, Indicator Unit Indicator Lights Inspection • Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments check”. Neutral Indicator Light (LED) [A] FI Indicator Light (LED) [B] Oil Pressure Warning Indicator Light (LED) [C] Right Turn Signal Indicator Light (LED) [D] Left Turn Signal Indicator Light (LED) [E]...
  • Page 562 16-70 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit High Beam Indicator Light (LED) Battery Positive (+) Terminal to Terminal [15] Neutral Indicator Light (LED) Battery Negative (–) Terminal to Terminal [5] Right and Left Turn Signal Indicator Light (LED) For Right Turn Signal Indicator Light (LED) Battery Positive (+) Terminal to Terminal [13] For Left Turn Signal Indicator Light (LED) Battery Positive (+) Terminal to Terminal [14]...
  • Page 563 ELECTRICAL SYSTEM 16-71 Meter, Gauge, Indicator Unit EX650B Models ABS Indicator Light (LED) Battery Negative (–) Terminal to Terminal [3] • If the light (LED) keeps going on, replace the meter as- sembly.
  • Page 564 16-72 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Circuit 1. Ignition Switch 11. Fuel Reserve Switch 2. Frame Ground 12. Joint Connector 3. Meter Unit 13. ECU 4. Water-proof Joint B 14. Oil Pressure Switch 5. ECU Fuse 15 A 15.
  • Page 565: Switches And Sensors

    ELECTRICAL SYSTEM 16-73 Switches and Sensors Brake Light Timing Inspection • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Brake Light Timing Adjustment • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Switch Inspection •...
  • Page 566: Water Temperature Sensor Inspection

    16-74 ELECTRICAL SYSTEM Switches and Sensors Water Temperature Sensor Inspection • Remove the water temperature sensor (see Removal/In- stallation in the Fuel System (DFI) chapter). • Suspend the sensor [A] in a container of coolant so that the temperature-sensing projection [C] and threaded por- tion [C] are submerged.
  • Page 567: Speed Sensor Inspection

    ELECTRICAL SYSTEM 16-75 Switches and Sensors Speed Sensor Inspection • Remove the speed sensor (see Speed Sensor Removal). • Connect the speed sensor connector [A] with the battery [B], 10 kΩ resistor [C] and hand tester [D] as shown. • Set the tester to the DC 25 V range.
  • Page 568: Oxygen Sensor Inspection (europe Models)

    16-76 ELECTRICAL SYSTEM Switches and Sensors Oxygen Sensor Inspection (Europe Models) • Refer to the Oxygen Sensor Inspection in the Fuel System (DFI) chapter. Fuel Reserve Switch Inspection • Fill the fuel tank with fuel. • Close the fuel tank cap surely. •...
  • Page 569: Relay Box

    ELECTRICAL SYSTEM 16-77 Relay Box The relay box [A] has relays and diodes. The relays and diodes can not be removed. Relay Box Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) • Take out the relay box [A] and disconnect the connectors [B].
  • Page 570: Diode Circuit Inspection

    16-78 ELECTRICAL SYSTEM Relay Box Relay Circuit Inspection (with the battery connected) Battery Tester Tester Connection Connection Reading (Ω) (–) 2-11 ECU Main Relay Fuel Pump Relay 9-10 Fan Relay 18-19 17-20 Battery Tester Tester Connection Connection DC 25 V Range Reading (V) (–) Starter...
  • Page 571 ELECTRICAL SYSTEM 16-79 Relay Box Relay Box Internal Circuit A: Headlight Relay B: ECU Main Relay C: Fuel Pump Relay D: Starter Circuit Relay E: Fan Relay...
  • Page 572: Fuse

    16-80 ELECTRICAL SYSTEM Fuse 30 A Main Fuse Removal • Remove: Left Side Cover (see Side Cover Removal in the Frame chapter) Cover (see Starter Relay Inspection) Connector [A] • Pull out the main fuse [B] from the starter relay with needle nose pliers.
  • Page 573: Fuse Installation

    ELECTRICAL SYSTEM 16-81 Fuse Fuse Installation • If a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage. • Install the fuse box fuses on the original position as spec- ified on the lid.
  • Page 575 APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-46...
  • Page 576 17-2 APPENDIX Cable, Wire, and Hose Routing...
  • Page 577 APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Clamp (From the on sequentially, through the ignition switch lead, left switch housing lead and main harness.) 2. Left Switch Housing Lead Connector 3. Clamp (Insert the clamp from air cleaner side.) 4.
  • Page 578 17-4 APPENDIX Cable, Wire, and Hose Routing...
  • Page 579 APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Relay Box 2. Main Harness 3. Clamp (Insert the clamp in the bracket.) 4. Battery Negative Cable 5. Battery Positive Cable 6. ECU Connectors 7. Clamp 8. Clamp 9. Tail Light Connector 10.
  • Page 580 17-6 APPENDIX Cable, Wire, and Hose Routing EX650B Models...
  • Page 581 APPENDIX 17-7 Cable, Wire, and Hose Routing 1. To Main Harness 2. Battery Positive Cable 3. ABS Kawasaki Self-diagnosis System Connector (Insert the connector to the bracket.) 4. ABS Motor Relay Fuse 5. ABS Solenoid Valve Relay Fuse...
  • Page 582 17-8 APPENDIX Cable, Wire, and Hose Routing...
  • Page 583 APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Inlet Pressure Sensor 2. Turn Signal Relay 3. Air Cleaner Drain Tube 4. From this side, through the fuel tank drain tube, corrugated tube and air cleaner drain tube between chain guide and engine. 5.
  • Page 584 17-10 APPENDIX Cable, Wire, and Hose Routing...
  • Page 585 APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Clamp (Through the right switch housing lead, and insert the clamp in the frame.) 2. Clutch Cable 3. Throttle Cables 4. Clamp 5. Right Switch Housing Lead 6. Clamp (Through the clutch cable in the clamp.) 7.
  • Page 586 17-12 APPENDIX Cable, Wire, and Hose Routing EX650B Models...
  • Page 587 APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Brake Hose 2. Clutch Cable 3. Throttle Cables 4. Clamp 5. Right Switch Housing Lead 6. Clamp (Through the clutch cable in the clamp.) 7. Frame (Through the coolant hose in the frame.) 8.
  • Page 588 17-14 APPENDIX Cable, Wire, and Hose Routing EX650B Models...
  • Page 589 APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Right Switch Housing Lead 2. Throttle Cable (Decelerator) 3. Throttle Cable (Accelerator) 4. Through the brake hose at the right side of the throttle cables.
  • Page 590 17-16 APPENDIX Cable, Wire, and Hose Routing...
  • Page 591 APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Crankshaft Sensor Lead Connector 2. Clamp (Insert the clamp in the bracket.)
  • Page 592 17-18 APPENDIX Cable, Wire, and Hose Routing...
  • Page 593 6. Clamp (Insert the clamp in the rear fender rear.) 7. Diagnosis Connector 8. Clamp (Insert the clamp in the rear fender front.) 9. Rear Brake Light Switch Lead 10. Band (Clamp the main harness with the frame.) 11. Band 12. ABS Kawasaki Self-diagnosis System Connector (EX650B Models)
  • Page 594 17-20 APPENDIX Cable, Wire, and Hose Routing...
  • Page 595 APPENDIX 17-21 Cable, Wire, and Hose Routing 1. Right Switch Housing Lead 2. Throttle Cables 3. Headlight (LO) Connector (Green Tape) 4. Headlight (HI) Connector 5. Brake Hose 6. Clamp 7. Ignition Switch Lead 8. Main Harness 9. Left Switch Housing Lead 10.
  • Page 596 17-22 APPENDIX Cable, Wire, and Hose Routing EX650B Models...
  • Page 597 APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Right Switch Housing Lead 2. Throttle Cables 3. Headlight (LO) Connector (Green Tape) 4. Headlight (HI) Connector 5. Brake Hose (Through the brake hose at the right side of the throttle cables.) 6.
  • Page 598 17-24 APPENDIX Cable, Wire, and Hose Routing...
  • Page 599 APPENDIX 17-25 Cable, Wire, and Hose Routing 1. Clamp 2. Clamp 3. Clamp 4. Clamp (Clamp the subthrottle sensor lead and subthrottle valve actuator lead to the delivery pipe.) 5. Ground Lead 6. Clamp 7. Subthrottle Sensor Lead Connector 8. Subthrottle Valve Actuator Lead Connector 9.
  • Page 600 17-26 APPENDIX Cable, Wire, and Hose Routing...
  • Page 601 APPENDIX 17-27 Cable, Wire, and Hose Routing 1. Regulator/Rectifier Lead 2. Clamp (Insert the clamp in the frame.) 3. Rear Brake Light Switch Lead Connector 4. Through the rear brake light switch lead and vehicle-down sensor lead from the front side of the rear shockabsorber installation part.
  • Page 602 17-28 APPENDIX Cable, Wire, and Hose Routing EX650B Models...
  • Page 603 APPENDIX 17-29 Cable, Wire, and Hose Routing 1. ABS Hydraulic Unit Lead (ECU) (Through the lead to the forward of frame cross pipe.) 2. ABS Hydraulic Unit 3. Through the rear wheel rotation sensor lead upper the starter motor cable and engine ground cable.
  • Page 604 17-30 APPENDIX Cable, Wire, and Hose Routing EX650B Models...
  • Page 605 APPENDIX 17-31 Cable, Wire, and Hose Routing 1. Front Wheel Rotation Sensor Lead 2. Ignition Switch Lead 3. Left Switch Housing Lead 4. Clamp (Clamp the front wheel rotation sensor lead.) 5. Main Harness 6. Clamp (Clamp the front wheel rotation sensor lead.)
  • Page 606 17-32 APPENDIX Cable, Wire, and Hose Routing...
  • Page 607 APPENDIX 17-33 Cable, Wire, and Hose Routing 1. To Meter Unit 2. Clamp 3. To Front Right Turn Signal Light Lead 4. Left Switch Housing Lead 5. Ignition Switch Lead 6. Main Harness 7. To Front Left Turn Signal Light Lead...
  • Page 608 17-34 APPENDIX Cable, Wire, and Hose Routing...
  • Page 609 APPENDIX 17-35 Cable, Wire, and Hose Routing 1. Clamp 2. Clamp (Insert the clamp to the inner fairing.) 3. Clamp (Insert the clamp to the upper fairing bracket.)
  • Page 610 17-36 APPENDIX Cable, Wire, and Hose Routing California Model...
  • Page 611 APPENDIX 17-37 Cable, Wire, and Hose Routing 1. Through the hose between main harness and air cleaner housing. 2. To Fuel Tank (Red) 3. To Fuel Tank (Blue) 4. Left Side View 5. Through the hose between main harness and air cleaner housing. 6.
  • Page 612 17-38 APPENDIX Cable, Wire, and Hose Routing...
  • Page 613 APPENDIX 17-39 Cable, Wire, and Hose Routing 1. Clamp (Insert the clamp in the front fender.) 2. Brake Hose 3. Clamp 4. Clamp...
  • Page 614 17-40 APPENDIX Cable, Wire, and Hose Routing EX650B Models...
  • Page 615 APPENDIX 17-41 Cable, Wire, and Hose Routing 1. Clamp (Insert the clamp in the front fender.) 2. Brake Hose...
  • Page 616 17-42 APPENDIX Cable, Wire, and Hose Routing...
  • Page 617 APPENDIX 17-43 Cable, Wire, and Hose Routing 1. Brake Hose 2. Clamp 3. Clamp...
  • Page 618 17-44 APPENDIX Cable, Wire, and Hose Routing EX650B Models...
  • Page 619 APPENDIX 17-45 Cable, Wire, and Hose Routing 1. Brake Hose 2. Clamp 3. Clamp 4. Clamp...
  • Page 620: Troubleshooting Guide

    17-46 APPENDIX Troubleshooting Guide NOTE Spark plug dirty, broken, or gap malad- ○ Refer to the Fuel System chapter for most justed of DFI trouble shooting guide. Stick coil shorted or not in good contact ○ This is not an exhaustive list, giving every Stick coil trouble possible cause for each problem listed.
  • Page 621 APPENDIX 17-47 Troubleshooting Guide Compression low: Cylinder head gasket damaged Spark plug loose Cylinder head warped Cylinder head not sufficiently tightened Valve spring broken or weak down Valve not seating properly (valve bent, No valve clearance worn, or carbon accumulation on the Cylinder, piston worn seating surface) Piston ring bad (worn, weak, broken, or...
  • Page 622: Gear Shifting Faulty

    17-48 APPENDIX Troubleshooting Guide Gear Shifting Faulty: Engine oil viscosity too high Drive train trouble Doesn’t go into gear; shift pedal doesn’t Brake dragging return: Lubrication inadequate: Clutch not disengaging Engine oil level too low Shift fork bent or seized Engine oil poor quality or incorrect Gear stuck on the shaft Gauge incorrect:...
  • Page 623: Exhaust Smokes Excessively

    APPENDIX 17-49 Troubleshooting Guide Engine mount loose O-ring at the oil passage in the crankcase Crankshaft bearing worn damaged Primary gear worn or chipped Exhaust Smokes Excessively: Camshaft chain tensioner trouble Camshaft chain, sprocket, guide worn White smoke: Air suction valve damaged Piston oil ring worn Air switching valve damaged Cylinder worn...
  • Page 624: Battery Trouble

    17-50 APPENDIX Troubleshooting Guide Battery Trouble: Rear shock adjustment too soft Front fork, rear shock absorber spring weak Battery discharged: Rear shock absorber oil leaking Charge insufficient Battery faulty (too low terminal voltage) Brake Doesn’t Hold: Battery lead making poor contact Load excessive (e.g., bulb of excessive Air in the brake line wattage)
  • Page 625 MODEL APPLICATION Year Model Beginning Frame No. □ JKAEXEA1 6A000001 2006 EX650A6F JKAEX650AAA000001 2006 EX650B6F JKAEX650ABA000001 □ :This digit in the frame number changes from one machine to another. Part No.99924-1361-01 Printed in Japan...

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  • bodzio Mar 12, 2017 09:40:
    ok moze pomoc bo instrukcja orginalna jest bardzo uboga