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Kawasaki Ninja ZX-6R Service Manual

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Table of Contents
Ninja ZX-6R
Motorcycle
Service Manual
http://mototh.com

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  Summary of Contents for Kawasaki Ninja ZX-6R

  • Page 1 Ninja ZX-6R Motorcycle Service Manual http://mototh.com...
  • Page 2 http://mototh.com...
  • 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 4 http://mototh.com...
  • Page 5 All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2004 Kawasaki Heavy Industries, Ltd. First Edition (1): Sep. 30, 2004 (M) http://mototh.com...
  • Page 6 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 7: Emission Control Information

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

    Be alert for problems and non-scheduled correctly followed, could result in per- maintenance. sonal injury, or loss of life. • Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and CAUTION testers that are necessary when servicing This caution symbol identifies special...
  • Page 10 NOTE ○ This note symbol indicates points of par- ticular interest for more efficient and con- venient operation. • Indicates a procedural step or work to be done. ○ Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE.
  • Page 11 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-12 http://mototh.com...
  • Page 12: Before Servicing

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

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

    GENERAL INFORMATION 1-7 Model Identification ZX636-C1 (Europe) Left Side View ZX636-C1 (Europe) Right Side View http://mototh.com...
  • Page 18 1-8 GENERAL INFORMATION Model Identification ZX636-C1 (US and Canada) Left Side View ZX636-C1 (US and Canada) Right Side View http://mototh.com...
  • Page 19: General Specifications

    GENERAL INFORMATION 1-9 General Specifications Items ZX636-C1 (Ninja ZX-6R) Dimensions Overall Length 2 065 mm (81.3 in.) Overall Width 715 mm (28.1 in.) Overall Height 1 110 mm (43.7 in.) Wheelbase 1 390 mm (54.7 in.) Road Clearance 120 mm (4.7 in.) Seat Height 820 mm (32.3 in.)
  • Page 20 1-10 GENERAL INFORMATION General Specifications Items ZX636-C1 (Ninja ZX-6R) Duration 272° Lubrication System Forced lubrication (wet sump with cooler) Engine Oil: Type API SE, SF or SG API SH or SJ with JASO MA Viscosity SAE10W-40 Capacity 4.0 L (4.2 US qt)
  • Page 21 GENERAL INFORMATION 1-11 General Specifications Items ZX636-C1 (Ninja ZX-6R) Electrical Equipment Battery 12 V 8 Ah Headlight: Type Semi-sealed beam Bulb: High 12 V 55 W (quartz-halogen) × 2 12 V 55 W (quartz-halogen) Tail/Brake Light 12 V 0.5/4.1 W (LED)
  • Page 22: Unit Conversion Table

    1-12 GENERAL INFORMATION Unit Conversion Table Prefixes for Units Units of Length × 0.6214 mile Power Prefix Symbol × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque milli × 0.001 N·m ×...
  • Page 23: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart (United States, Canada Model)..........Periodic Maintenance Chart (Other than United States, Canada Model)....... Torque and Locking Agent...................... Specifications ......................... 2-15 Special Tools .......................... 2-17 Maintenance Procedure ......................2-18 Fuel System (DFI)........................ 2-18 Throttle Control System Inspection...................
  • Page 24 2-2 PERIODIC MAINTENANCE Rear Shock Absorber Oil Leak Inspection ................ 2-38 Rocker Arm Operation Inspection..................2-38 Tie-Rod Operation Inspection ................... 2-38 Steering System ........................2-39 Steering Play Inspection ....................2-39 Steering Play Adjustment....................2-39 Steering Stem Bearing Lubrication ................... 2-40 Electrical System .........................
  • Page 25: Periodic Maintenance Chart (United States, Canada Model)

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart (United States, Canada Model) 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 26 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart (United States, Canada Model) FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) Brake System Brake fluid leak (brake hose and •...
  • Page 27 PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart (United States, Canada Model) Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING come × 1 000 km first (× 1 000 mile) Page CHANGE/REPLACE ITEM Every (0.6) (7.5) (15) (24) (30) Air cleaner element # Every 18 000 km (12 000 mile) 2-50 •...
  • Page 28: Periodic Maintenance Chart (Other Than United States, Canada Model)

    2-6 PERIODIC MAINTENANCE Periodic Maintenance Chart (Other than United States, Canada Model) 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...
  • Page 29 PERIODIC MAINTENANCE 2-7 Periodic Maintenance Chart (Other than United States, Canada Model) FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) • • • • • • • Brake hose and pipe damage-inspect year 2-35...
  • Page 30 2-8 PERIODIC MAINTENANCE Periodic Maintenance Chart (Other than United States, Canada Model) Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING come × 1 000 km first (× 1 000 mile) Page CHANGE/REPLACE ITEM Every (0.6) (7.5) (15) (24) (30) Air cleaner element # Every 18 000 km (12 000 mile) 2-50 •...
  • Page 31: Torque And Locking Agent

    PERIODIC MAINTENANCE 2-9 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. G: Apply grease to the threads.
  • Page 32 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Water Hose Fitting Bolts 104 in·lb Water Pump Cover Bolts 104 in·lb Water Temperature Sensor Engine Top End Air Suction Valve Cover Bolts 104 in·lb Camshaft Cap Bolts 104 in·lb Camshaft Chain Tensioner Cap Bolt Camshaft Chain Tensioner Mounting Bolts...
  • Page 33 PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Lubrication System Coolant Drain Bolt (Water Pump) 0.90 78 in·lb Engine Oil Drain Bolt Impeller Bolt 87 in·lb Oil Cooler Mounting Bolts 104 in·lb Oil Filter EO, R Oil Filter Mounting Bolt Oil Jet Nozzle Bolts...
  • Page 34 2-12 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Pressure Switch Terminal Bolt 0.15 13 in·lb Plate Screws 0.60 52 in·lb 104 in·lb Shift Drum Bearing Holder Bolts Shift Drum Cam Holder Bolt 104 in·lb Shift Lever Bolt 0.70 61 in·lb...
  • Page 35 PERIODIC MAINTENANCE 2-13 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Nut (Lower) Rear Shock Absorber Nut (Upper) Swingarm Pivot Adjusting Collar Swingarm Pivot Adjusting Collar Locknut Swingarm Pivot Shaft Nut Tie-Rod Nuts Uni-Trak Rocker Arm Nut Steering Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper)
  • Page 36 2-14 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Rear Turn Signal Light Mounting Screws 0.12 10 in·lb Regulator/Rectifier Bolts 0.70 61 in·lb 0.90 78 in·lb Side Stand Switch Bolt Side Stand Switch Bracket Bolt 0.40 35 in·lb Spark Plugs 115 in·lb...
  • Page 37: Specifications

    PERIODIC MAINTENANCE 2-15 Specifications Item Standard Service Limit Fuel System 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 1 300 ±50 r/min (rpm) – – – Throttle Body Vacuum 27.3 ±1.3 kPa (205 ±10 mmHg) at idle speed –...
  • Page 38 2-16 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive 30 ∼ 35 mm (1.2 ∼ 1.4 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 39: Special Tools

    PERIODIC MAINTENANCE 2-17 Special Tools Inside Circlip Pliers: Pilot Screw Adjuster, C: 57001-143 57001-1292 Steering Stem Nut Wrench: Extension Tube: 57001-1100 57001-1578 Jack: Jack Attachment: 57001-1238 57001-1608 Oil Filter Wrench: 57001-1249 http://mototh.com...
  • Page 40: Maintenance Procedure

    2-18 PERIODIC MAINTENANCE Maintenance Procedure Fuel System (DFI) Throttle Control System Inspection • Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) •...
  • Page 41 PERIODIC MAINTENANCE 2-19 Maintenance Procedure • Connect a commercially available vacuum gauge [A] to these right fittings of the throttle body as shown. Front [B] • Connect a highly accurate tachometer to one of the stick coil primary leads. • Plug: Vacuum Switch Valve Hose (Thick) and its Air Cleaner Housing Hole...
  • Page 42 2-20 PERIODIC MAINTENANCE Maintenance Procedure If any vacuum is not within the specifications, first syn- chronize the balance of the left (#1, #2) and right (#3, #4) assemblies. Example: #1: 165 mmHg #2: 190 mmHg #3: 170 mmHg #4: 200 mmHg •...
  • Page 43 PERIODIC MAINTENANCE 2-21 Maintenance Procedure • Remove the bypass screw [A], spring [B], washer [C] and O-ring [D]. ○ Check the bypass screw and its hole for carbon deposits. If any carbon accumulates, wipe the carbon off the bypass screw and the hole, using a cotton pad penetrated with a high-flash point solvent.
  • Page 44: Idle Speed Inspection

    2-22 PERIODIC MAINTENANCE Maintenance Procedure Idle Speed Inspection • Start the engine and warm it up thoroughly. • With the engine idling, turn the handlebar to both sides [A]. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed, or damaged.
  • Page 45: Evaporative Emission Control System (California Model)

    PERIODIC MAINTENANCE 2-23 Maintenance Procedure Evaporative Emission Control System (California Model) Evaporative Emission Control System Inspection • Inspect the canister as follows. ○ Remove: Left Upper Inner Fairing (see Upper Inner Fairing Re- moval in the Frame chapter) ○ Remove the canister [A], and disconnect the hoses from the canister.
  • Page 46: Cooling System

    2-24 PERIODIC MAINTENANCE Maintenance Procedure Cooling System Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature). • Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (Do not use the side stand).
  • Page 47: Engine Top End

    PERIODIC MAINTENANCE 2-25 Maintenance Procedure Engine Top End Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted when the engine is cold (at room temperature). • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Crankshaft Sensor Cover (see Crankshaft Sensor Re- moval in the Electrical System chapter) Cylinder Head Cover (see Cylinder Head Cover Re-...
  • Page 48: Valve Clearance Adjustment

    2-26 PERIODIC MAINTENANCE Maintenance Procedure ○ When positioning #1 piston TDC at the end of the compression stroke. Inlet Valve Clearance of #1 and #3 Cylinders Exhaust Valve Clearance of #1 and #2 Cylinders Measuring Valve [A] ○ When positioning #4 piston TDC at the end of the compression stroke.
  • Page 49 PERIODIC MAINTENANCE 2-27 Maintenance Procedure 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.
  • Page 50 2-28 PERIODIC MAINTENANCE Maintenance Procedure 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.
  • Page 51: Air Suction System

    PERIODIC MAINTENANCE 2-29 Maintenance Procedure Air Suction System Air Suction System Damage Inspection • Pull the vacuum switch valve hose [A] out of the air cleaner. • Start the engine and run it at idle speed. • Plug the vacuum switch valve hose end with your finger and feel vacuum pulsing in the hose.
  • Page 52: Wheels/Tires

    2-30 PERIODIC MAINTENANCE Maintenance Procedure • Push the release lever [A] toward the front of the motor- cycle until it becomes hard to turn. ○ At this time, the release lever should have the proper an- gle shown. 60° [B] If the angle is wrong, check the clutch and release parts for wear.
  • Page 53: Wheel Bearing Damage Inspection

    PERIODIC MAINTENANCE 2-31 Maintenance Procedure Tread Depth Standard: Front 3.6 mm (0.14 in.) Rear 5.8 mm (0.23 in.) Service Limit: Front 1 mm (0.04 in.) (AT, CH, DE) 1.6 mm (0.06 in.) Rear 2 mm (0.08 in.) (Up to 130 km/h) 3 mm (0.12 in.) (Over 130 km/h) WARNING To ensure safe handling and stability, use only the...
  • Page 54: Drive Train

    2-32 PERIODIC MAINTENANCE Maintenance Procedure Drive Train Drive Chain Lubrication Condition Inspection • If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. •...
  • Page 55: Drive Chain Slack Adjustment

    PERIODIC MAINTENANCE 2-33 Maintenance Procedure Drive Chain Slack Adjustment • Remove the cotter pin [A], and loosen the axle nut [B]. • Loosen the both chain adjuster locknuts [C]. If the chain is too loose, turn out the left and right chain adjuster [D] evenly.
  • Page 56: Wheel Alignment Inspection

    2-34 PERIODIC MAINTENANCE Maintenance Procedure Wheel Alignment Inspection • Check that the notch [A] on the left alignment indicator [B] aligns with the same swingarm mark or position [C] that the right alignment indicator notch aligns with. If they do not, adjust the chain slack and align the wheel alignment (see Drive Chain Slack Adjustment in this chap- ter).
  • Page 57: Chain Guide Wear Inspection

    PERIODIC MAINTENANCE 2-35 Maintenance Procedure Chain Guide Wear Inspection • Remove: Swingarm (see Swingarm Removal in the Suspension chapter) • Visually inspect the chain guide [A]. Replace the chain guide if it shows any signs of abnormal wear or damage. Brake System Brake Fluid Leak (Brake Hose and Pipe) Inspection •...
  • Page 58: Brake Fluid Level Inspection

    2-36 PERIODIC MAINTENANCE Maintenance Procedure Brake Fluid Level Inspection • Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE ○ Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C].
  • Page 59: Suspensions

    PERIODIC MAINTENANCE 2-37 Maintenance Procedure If it does not, adjust the brake light switch. • While holding the switch body, turn the adjusting nut to adjust the switch. Switch Body [A] Adjusting Nut [B] Light sooner as the body rises [C] Light later as the body lowers [D] CAUTION To avoid damaging the electrical connections in-...
  • Page 60: Front Fork Oil Leak Inspection

    2-38 PERIODIC MAINTENANCE Maintenance Procedure Front Fork Oil Leak Inspection • Visually inspect the front forks [A] for oil leakage. Replace or repair any defective parts, if necessary. Rear Shock Absorber Oil Leak Inspection • Visually inspect the shock absorber [A] for oil leakage. If the oil leakage is found on it, replace the shock absorber with a new one.
  • Page 61: Steering System

    PERIODIC MAINTENANCE 2-39 Maintenance Procedure Steering System Steering Play Inspection • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter). • Lift the front wheel off the ground using the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 •...
  • Page 62: Steering Stem Bearing Lubrication

    2-40 PERIODIC MAINTENANCE Maintenance Procedure • 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 63 PERIODIC MAINTENANCE 2-41 Maintenance Procedure • Measure the gap [A] with a wire-type thickness gauge. If the gap is incorrect, carefully bend the side electrode [B] with a suitable tool to obtain the correct gap. Spark Plug Gap : 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.) CAUTION Use only the recommended spark plugs (special marks...
  • Page 64: Lights And Switches Operation Inspection

    2-42 PERIODIC MAINTENANCE Maintenance Procedure Lights and Switches Operation Inspection First Step • Turn on the ignition switch. • The following lights should go on according to below table. goes on City Light [A] goes on Taillight [B] License Plate Light [C] goes on Meter Panel LCD [D] goes on...
  • Page 65 PERIODIC MAINTENANCE 2-43 Maintenance Procedure Third Step • Turn on the turn signal switch [A] (left or right position). • The left or right turn signal lights [B] (front and rear) ac- cording to the switch position should flash. • The turn signal indicator LED [C] in the meter unit should flash.
  • Page 66: Headlight Aiming Inspection

    2-44 PERIODIC MAINTENANCE Maintenance Procedure • Set the dimmer switch to high beam position. • The low beam [A] and high beam [B] headlights should go on. • The high beam indicator LED [C] should go on. If the high beam headlight and/or high beam indicator LED does not go on, inspect or replace the following item.
  • Page 67: Side Stand Switch Operation Inspection

    PERIODIC MAINTENANCE 2-45 Maintenance Procedure NOTE ○ ON high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper an- gle according to local regulations. ○...
  • Page 68: Engine Stop Switch Operation Inspection

    2-46 PERIODIC MAINTENANCE Maintenance Procedure If the side stand 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 69: Others

    PERIODIC MAINTENANCE 2-47 Maintenance Procedure 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 70: Bolts, Nuts And Fasteners Tightness Inspection

    2-48 PERIODIC MAINTENANCE Maintenance Procedure • With the cable disconnected at both ends, the inner cable should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.
  • Page 71 PERIODIC MAINTENANCE 2-49 Maintenance Procedure Bolt, Nut and Fastener to be checked Engine: Clutch Lever Pivot Nut Engine Mounting Bolts Exhaust Pipe Clamp Bolts Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolts Wheels: Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut Rear Axle Nut Cotter Pin Brakes:...
  • Page 72: Replacement Parts

    Air Cleaner Element • Install a new element [A]. CAUTION Use only the recommended air cleaner element (Kawasaki part number 11013-0010). Using another air cleaner element will wear the engine prema- turely or lower the engine performance. NOTE ○ Be sure to install the fuel tank drain hose.
  • Page 73 PERIODIC MAINTENANCE 2-51 Maintenance Procedure • Pull the joint lock [A] as shown. • Pull the fuel hose joint [B] out of the delivery pipe. WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe.
  • Page 74: Coolant Change

    2-52 PERIODIC MAINTENANCE Maintenance Procedure 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 75 PERIODIC MAINTENANCE 2-53 Maintenance Procedure • Fill the radiator up to the radiator filler neck [A] with coolant, and install the radiator cap. NOTE ○ Pour in the coolant slowly so that it can expel the air from the engine and radiator. •...
  • Page 76: Radiator Hose And O-Ring Replacement

    2-54 PERIODIC MAINTENANCE Maintenance Procedure Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change in this chapter). • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Center Fairings (see Center Fairing Removal in the Frame chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter)
  • Page 77: Engine Oil Change

    PERIODIC MAINTENANCE 2-55 Maintenance Procedure Engine Oil Change • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter). • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the engine oil drain bolt [A] to drain the oil. ○...
  • Page 78: Brake Hose And Pipe Replacement

    2-56 PERIODIC MAINTENANCE Maintenance Procedure Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts. •...
  • Page 79 PERIODIC MAINTENANCE 2-57 Maintenance Procedure • Level the brake fluid reservoir. • Remove the reservoir cap. • Remove the rubber cap from the bleed valve [A] on the caliper. • Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container.
  • Page 80: Master Cylinder Rubber Parts Replacement

    2-58 PERIODIC MAINTENANCE Maintenance Procedure Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). • Remove the seal cover [A], circlip [B], connector [C] and O-ring [D].
  • Page 81: Caliper Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-59 Maintenance Procedure • Apply brake fluid to the new parts and to the inner wall of the cylinder. • Take care not to scratch the piston or the inner wall of the cylinder. • Tighten the brake lever pivot bolt and the locknut. Silicone Grease - Brake Lever Pivot Bolt Torque - Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 9...
  • Page 82 2-60 PERIODIC MAINTENANCE Maintenance Procedure NOTE ○ If compressed air is not available, do as follows for both calipers coincidentally, with the brake hose connected to the caliper. ○ Prepare a container for brake fluid, and perform the work above it. ○...
  • Page 83 PERIODIC MAINTENANCE 2-61 Maintenance Procedure Rear Caliper Disassembly • Remove the rear caliper (see Rear Caliper Removal in the Brakes chapter). • Remove the pads and pad spring (see Rear Brake Pad Removal in the Brakes chapter). • Using compressed air, remove the piston. ○...
  • Page 84: Spark Plug Replacement

    2-62 PERIODIC MAINTENANCE Maintenance Procedure • Apply brake fluid to the outside of the piston, and push it into the cylinder by hand. • Replace the shaft rubber friction boot [A] and dust boot [B]. • Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to the caliper holder shafts [C] and holder holes [D] (PBC is a special high temperature, water-resistance grease).
  • Page 85 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........Crankshaft Sensor (Service Code Specifications ........3-10 21)........... 3-63 Special Tools and Sealant ....3-12 Crankshaft Sensor DFI Parts Location......3-14 Removal/Installation....3-63 DFI System........3-16 Crankshaft Sensor Inspection..3-63 DFI Servicing Precautions ....
  • Page 86 3-2 FUEL SYSTEM (DFI) Subthrottle Valve Actuator Free Play Inspection ....3-103 Removal ........3-80 Free Play Adjustment....3-103 Subthrottle Valve Actuator Cable Installation ......3-103 Inspection........3-80 Cable Lubrication ......3-103 Resistance Inspection....3-80 Throttle Body Assy ......3-104 Input Voltage Inspection....
  • Page 87: Exploded View

    FUEL SYSTEM (DFI) 3-3 Exploded View Dummy Page http://mototh.com...
  • Page 88 3-4 FUEL SYSTEM (DFI) Exploded View http://mototh.com...
  • Page 89 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Cleaner Housing Clamp Bolts 0.20 17 in·lb Air Cleaner Housing Mounting Bolt 0.70 62 in·lb Air Inlet Duct Mounting Bolts 0.70 62 in·lb 4. Air Cleaner Element 5.
  • Page 90 3-6 FUEL SYSTEM (DFI) Exploded View http://mototh.com...
  • Page 91 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Delivery Pipe Mounting Screws (Nozzle Assy) 0.35 30 in·lb Delivery Pipe Mounting Screws (Throttle Body) 0.35 30 in·lb Fuel Hose Mounting Screw 0.50 43 in·lb Nozzle Assy Mounting Bolts 0.70 61 in·lb Throttle Body Assembly Holder Clamp Bolts...
  • Page 92 3-8 FUEL SYSTEM (DFI) Exploded View http://mototh.com...
  • Page 93 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Camshaft Position Sensor Bolt 104 in·lb Canister Bracket Mounting Bolt (M6) 0.70 61 in·lb Canister Bracket Mounting Bolt (M5) 0.04 4 in·lb Crankshaft Sensor Bolts 0.60 52 in·lb Exhaust Butterfly Valve Actuator Mounting Bolts 0.70 61 in·lb...
  • Page 94: Specifications

    3-10 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 300 ±50 r/min (rpm) Throttle Assy: Type Oval type Bore 38 mm (1.5 in.) Throttle Body Vacuum 27.3 ±1.3 kPa (205 ±10 mmHg) Bypass Screws – – – ECU (Electronic Control Unit): Make Denso...
  • Page 95 FUEL SYSTEM (DFI) 3-11 Specifications Item Standard Vehicle-down Sensor: Detection Method Magnetic flux detection method More than 60 ∼ 70° for each bank Detection Angle Within 1.0 ∼ 1.5 second Detection Time with sensor arrow mark pointed up: 3.55 ∼ 4.45 V Output Voltage with sensor tilted 60 ∼...
  • Page 96: Special Tools And Sealant

    3-12 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 97 FUEL SYSTEM (DFI) 3-13 Special Tools and Sealant Speed Sensor Measuring Adapter: Kawasaki Bond (Silicone Sealant): 57001-1635 56019-120 http://mototh.com...
  • Page 98: Dfi Parts Location

    Subthrottle Sensor [F] Atmospheric Pressure Sensor [G] Battery [A] Relay Box [B] Exhaust Butterfly Valve Actuator [C] ECU (Electronic Control Unit) [D] Self-diagnosis Terminal [A] Kawasaki Diagnosis System (KDS) Connector [B] Vehicle-down Sensor [C] Inlet Air Temperature Sensor [A] http://mototh.com...
  • Page 99 FUEL SYSTEM (DFI) 3-15 DFI Parts Location Camshaft Position Sensor [A] Crankshaft Sensor [B] Speed Sensor [A] Neutral Switch [A] Ignition Key (Transponder) [A] Ignition Switch [B] Immobilizer Antenna [C] Immobilizer Amplifier [D] Immobilizer Amplifier [A] http://mototh.com...
  • Page 100: Dfi System

    3-16 FUEL SYSTEM (DFI) DFI System DFI System http://mototh.com...
  • Page 101 FUEL SYSTEM (DFI) 3-17 DFI System 1. ECU (Electrical Control Unit) 2. Crankshaft Sensor 3. Camshaft Position Sensor 4. Main Throttle Sensor 5. Subthrottle Sensor 6. Subthrottle Valve Actuator 7. Inlet Air Pressure Sensor 8. Atmospheric Pressure Sensor 9. Water Temperature Sensor 10.
  • Page 102 3-18 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram http://mototh.com...
  • Page 103 FUEL SYSTEM (DFI) 3-19 DFI System Part Name 1. Engine Stop Switch 2. Starter Button 3. Water Temperature Sensor 4. Vehicle-down Sensor 5. Subthrottle Valve Actuator 6. Primary Fuel Injector #1 7. Primary Fuel Injector #2 8. Primary Fuel Injector #3 9.
  • Page 104 3-20 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Subthrottle Valve Actuator Output Signal 2 31. Immobilizer Communication Line 2. Subthrottle Valve Actuator Output Signal 1 32. External Diagnosis System Signal 3. Exhaust Butterfly Valve Actuator (–) 33.
  • Page 105: Dfi Servicing Precautions

    FUEL SYSTEM (DFI) 3-21 DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 106 3-22 FUEL SYSTEM (DFI) DFI Servicing Precautions ○ The motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak or the hose to burst. Bend and twist the fuel hose while examining it. Replace the hose if any cracks or bulges are noticed.
  • Page 107: Troubleshooting The Dfi System

    FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System 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 108 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 109 FUEL SYSTEM (DFI) 3-25 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 110 3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System • Narrow down suspicious locations by repeating the con- tinuity tests from the ECU connectors. If no abnormality is found in the wiring or connectors, the DFI parts are the next likely suspects. Check the part, starting with input and output voltages.
  • Page 111: Inquiries To Rider

    FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.
  • Page 112 3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System 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 113 FUEL SYSTEM (DFI) 3-29 Troubleshooting the DFI System □ □ □ Poor running at low very low idle speed, very high idle speed, rough idle speed. □ speed battery voltage is low (charge the battery). □ spark plug loose (tighten it). □...
  • Page 114: Dfi System Troubleshooting Guide

    3-30 FUEL SYSTEM (DFI) 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 115 FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or possible Causes Actions 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 Side stand down and clutch lever pulled in gear not in neutral whether gear in neutral or not...
  • Page 116 3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or possible Causes Actions Cylinder head warped Inspect and replace (see chapter 5). 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).
  • Page 117 FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Incorrect idle speed: Water temperature sensor trouble Inspect (see chapter 3). Main throttle sensor trouble Inspect (see chapter 3). Engine stalls easily: Fuel pump trouble Inspect (see chapter 3). Fuel injector trouble Inspect (see chapter 3).
  • Page 118 3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Inlet air pressure sensor trouble Inspect (see chapter 3). Loose injector connectors Remedy (see chapter 3). Crankshaft sensor trouble Inspect and repair or replace (see chapter 16). Stick coil trouble Inspect and repair or replace (see chapter 16).
  • Page 119 FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Inlet air pressure sensor trouble Inspect (see chapter 3). Vacuum switch valve broken Inspect and replace (see chapter 5). Air suction valve trouble Inspect and replace (see chapter 5). After fire: Crankshaft sensor trouble Inspect (see chapter 16).
  • Page 120 3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Stick coil trouble Inspect (see chapter 16). Fuel/air mixture incorrect: Air cleaner clogged, poorly sealed, or missing Clean element or inspect sealing (see chapter 3). Air cleaner duct loose Reinstall (see chapter 3).
  • Page 121 FUEL SYSTEM (DFI) 3-37 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Speed sensor trouble Inspect (see chapter 3). Inspect throttle cable and lever linkage (see Throttle valves won’t fully open chapter 3). Inspect caliper fluid seal damage or clogging Brake dragging of master cylinder relief and supply ports (see chapter 12).
  • Page 122: Self-Diagnosis

    3-38 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal [A]. 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 123: Service Code Clearing Procedures

    FUEL SYSTEM (DFI) 3-39 Self-Diagnosis • To enter the self-diagnosis dealer mode 2 repeat opening [B] and grounding [A] the lead more than five times [F] within 2 seconds [C] after the lead is first grounded, and then keep it grounded continuously [D] for more than 2 seconds.
  • Page 124 3-40 FUEL SYSTEM (DFI) Self-Diagnosis http://mototh.com...
  • Page 125: Service Code Reading

    FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Service Code Reading ○ 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 126 3-42 FUEL SYSTEM (DFI) Self-Diagnosis Service FI Indicator Light (LED) Problems Codes Camshaft position sensor malfunction, wiring open or short Speed sensor malfunction Vehicle-down sensor malfunction, wiring open or short Subthrottle sensor malfunction, wiring open or short Exhaust butterfly valve sensor malfunction, wiring open or short Immobilizer amplifier malfunction Blank key detection...
  • Page 127: Backups

    FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the Main Throttle Sensor signal is out of the usable range, wiring short Main Throttle...
  • Page 128 3-44 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria Master or The user or master key If the blank key or broken key is used, the User Key must use register key. vehicle is no start and run.
  • Page 129: Main Throttle Sensor (Service Code 11)

    FUEL SYSTEM (DFI) 3-45 Main Throttle Sensor (Service Code 11) The main throttle sensor is a rotating variable resistor that changes output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 130: Output Voltage Inspection

    3-46 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) • Disconnect the main throttle sensor connector and con- nect the harness adapter [A] between the harness con- nector and main throttle sensor connector. • Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Setting Adapter: 57001 -1538...
  • Page 131 FUEL SYSTEM (DFI) 3-47 Main Throttle Sensor (Service Code 11) CAUTION Do not remove or adjust the main throttle sensor. It has been adjusted and set with precision at the factory. Never drop the throttle body assy can especially on a hard surface.
  • Page 132: Resistance Inspection

    3-48 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) 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]. • Measure the main throttle sensor resistance. Main Throttle Sensor Resistance Connections: BL lead [C] ←→...
  • Page 133: Inlet Air Pressure Sensor (Service Code 12)

    FUEL SYSTEM (DFI) 3-49 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. Removal • Turn the ignition switch OFF. • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in this chapter) Inlet Air Pressure Sensor Connector [A] Inlet Air Pressure Sensor [B]...
  • Page 134: Output Voltage Inspection

    3-50 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) If the reading is within the standard range, and check the input voltage again at the sensor connector. • Remove the air cleaner housing (see Air Cleaner Housing Removal in this chapter). •...
  • Page 135 FUEL SYSTEM (DFI) 3-51 Inlet Air Pressure Sensor (Service Code 12) If the output voltage is far out of the usable range, check the output voltage again at the sensor connector [A] (when the lead is open, the output voltage is about 1.8 V.).
  • Page 136 3-52 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) • Remove the inlet air pressure sensor [A] and disconnect the vacuum hose from the sensor. ○ Do not disconnect the sensor connector. • Connect an auxiliary hose [B] to the inlet air pressure sen- sor.
  • Page 137 FUEL SYSTEM (DFI) 3-53 Inlet Air Pressure Sensor (Service Code 12) 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) http://mototh.com...
  • Page 138: Inlet Air Temperature Sensor (Service Code 13)

    3-54 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal in this chapter).
  • Page 139: Sensor Resistance Inspection

    (see wiring diagram in this section). • 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 wiring is good, check the sensor resistance. Sensor Resistance Inspection •...
  • Page 140 3-56 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) 1. ECU 2. Inlet Air Temperature Sensor http://mototh.com...
  • Page 141: Water Temperature Sensor (Service Code 14)

    Water Temperature Sensor [A] • Apply silicone sealant to the threads of the water temper- ature sensor and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Water Temperature Sensor: 25 N·m (2.5 kgf·m, 18 ft·lb) • Fill the engine with coolant and bleed the air from the cooling system (see Coolant Filling in the Cooling System chapter).
  • Page 142: Sensor Resistance Inspection

    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 1. ECU 2. Meter Unit 3. Water Temperature Sensor Sensor Resistance Inspection •...
  • Page 143: Atmospheric Pressure Sensor (Service Code 15)

    FUEL SYSTEM (DFI) 3-59 Atmospheric Pressure Sensor (Service Code 15) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Removal • Turn the ignition switch OFF. • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in this chapter) Atmospheric Pressure Sensor Connector [A] Damper [B]...
  • Page 144: Output Voltage Inspection

    3-60 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) If the reading is within the standard range, check the input voltage again at the sensor connector. • Remove the air cleaner housing (see Air Cleaner Housing Removal in this chapter). •...
  • Page 145 FUEL SYSTEM (DFI) 3-61 Atmospheric Pressure Sensor (Service Code 15) If the output voltage is far out of the usable range, check the output voltage at the sensor connector [A] (when the wiring is open, the output voltage is about 1.8 V.). •...
  • Page 146 3-62 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) If you know the local atmospheric pressure using a barometer, substitute the atmospheric pressure for throt- tle vacuum pressure in the inlet air pressure sensor chart (see Inlet Air Pressure Sensor section in this chapter). And get the usable range of the atmospheric pressure sensor output voltage and check if output voltage is within the standard or not in the same way as Output...
  • Page 147: Crankshaft Sensor (Service Code 21)

    FUEL SYSTEM (DFI) 3-63 Crankshaft Sensor (Service Code 21) Crankshaft Sensor Removal/Installation • See the Crankshaft Sensor Removal/Installation in the Electrical System chapter. Crankshaft Sensor Inspection ○ The crankshaft have no power source, and when the en- gine stops, the crankshaft generates no signals. •...
  • Page 148: Camshaft Position Sensor (Service Code 23)

    3-64 FUEL SYSTEM (DFI) Camshaft Position Sensor (Service Code 23) Camshaft Position Sensor Removal/Installation The camshaft position sensor detects the position of the camshaft, and distinguishes the cylinder. • See the Camshaft Position Sensor Removal/Installation in the Electric System chapter. Camshaft Position Sensor Inspection ○...
  • Page 149: Speed Sensor (Service Code 24)

    FUEL SYSTEM (DFI) 3-65 Speed Sensor (Service Code 24) Speed Sensor Removal/Installation • See the Speed Sensor Removal/Installation in the Elec- trical System chapter. Speed Sensor Inspection • See the Speed Sensor Inspection in the Electrical System chapter. Input Voltage Inspection NOTE ○...
  • Page 150 3-66 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) • Disconnect the speed sensor connector [A], and connect the harness adapter [B] between the harness connector and speed sensor connector. • Connect a digital meter to the harness adapter leads. Special Tool - Speed Sensor Measuring Adapter: 57001 -1635 Speed Sensor Output Voltage...
  • Page 151: Vehicle-Down Sensor (Service Code 31)

    FUEL SYSTEM (DFI) 3-67 Vehicle-down Sensor (Service Code 31) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks 60 ∼ 70° or more to either side (in fact falls down), the weight turns and shuts off the signal.
  • Page 152 3-68 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) • Connect a digital volt meter [A] to the connector of the vehicle-down sensor [B], with the needle adapter set [C]. Vehicle-down Sensor Power Source Voltage Connections to Sensor Meter (+) → BL lead [D] Meter (–) →...
  • Page 153 • 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 out of the specified, replace the vehicle-down sensor. 1. ECU 2.
  • Page 154: Subthrottle Sensor (Service Code 32)

    3-70 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 155: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-71 Subthrottle Sensor (Service Code 32) • Disconnect the subthrottle sensor connector [A] and con- nect the harness adapter [B] between the harness con- nector and sub throttle sensor connector. • Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Setting Adapter: 57001 -1538...
  • Page 156 3-72 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) If the output voltage is within the standard range, check the ECU for a good ground, and power supply (see ECU Power Supply Inspection in this chapter). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation in this chapter).
  • Page 157: Resistance Inspection

    FUEL SYSTEM (DFI) 3-73 Subthrottle Sensor (Service Code 32) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the subthrottle sensor connector. • Connect a digital meter [A] to the subthrottle sensor con- nector [B]. • Measure the subthrottle sensor resistance. Subthrottle Sensor Resistance Connections: BL lead [C] ←→...
  • Page 158: Exhaust Butterfly Valve Actuator Sensor (Service Code 34)

    3-74 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Inspection • Turn the ignition switch OFF. • Disconnect the exhaust butterfly valve actuator sensor connector. • Connect a digital meter [A] to the exhaust butterfly valve actuator sensor connector [B].
  • Page 159: Immobilizer Amplifier (Service Code 35)

    FUEL SYSTEM (DFI) 3-75 Immobilizer Amplifier (Service Code 35) Antenna Resistance Inspection • Remove: Fuel Tank (see Fuel Tank Removal in this chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in this chapter) • Disconnect: Antenna Lead Connector [A] •...
  • Page 160: Blank Key Detection (Service Code 36)

    3-76 FUEL SYSTEM (DFI) Blank Key Detection (Service Code 36) This code appears in the following conditions. ○ The transponder [A] in the master and/or user key is mal- function. ○ When the spare key of unregistration is used. ○ When the master key is registered in the registered ECU.
  • Page 161 6. Fuse Box 7. Ignition Fuse 10 A 8. ECU Fuse 15 A 9. Relay Box 10. ECU Main Relay 11. Starter Relay 12. Main Fuse 30 A 13. Battery 12 V 8 Ah 14. Immobilizer/Kawasaki Diagnostic System Connector http://mototh.com...
  • Page 162: Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54)

    3-78 FUEL SYSTEM (DFI) Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) Stick Coil #1: Service Code 51 Stick Coil #2: Service Code 52 Stick Coil #3: Service Code 53 Stick Coil #4: Service Code 54 Removal/Installation CAUTION Never drop the stick coils, especially on a hard sur-...
  • Page 163 FUEL SYSTEM (DFI) 3-79 Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) 1. Ignition Switch 2. Engine Stop Switch 3. Stick Coil #1 4. Stick Coil #2 5. Stick Coil #3 6. Stick Coil #4 7. ECU 8.
  • Page 164: Subthrottle Valve Actuator (Service Code 62)

    3-80 FUEL SYSTEM (DFI) 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 165: Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-81 Subthrottle Valve Actuator (Service Code 62) 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]. Special Tools - Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B Needle Adapter Set: 57001-1457...
  • Page 166: Exhaust Butterfly Valve Actuator (Service Code 63)

    3-82 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator (Service Code 63) Exhaust Butterfly Valve Actuator Removal • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) • Put off the rubber boots of exhaust butterfly valve cables. • Loosen the locknuts [A] and adjuster nut [B].
  • Page 167: Exhaust Butterfly Valve Actuator Inspection

    FUEL SYSTEM (DFI) 3-83 Exhaust Butterfly Valve Actuator (Service Code 63) • Install the actuator [A] on the frame. Collars [B] Washers [C] Exhaust Butterfly Valve Actuator Mounting Bolts [D] • Tighten: Torque - Exhaust Butterfly Valve Actuator Mounting Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb) •...
  • Page 168: Output Voltage Inspection

    3-84 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator (Service Code 63) Output Voltage Inspection • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) • Measure the output voltage at the 3 pins connector of the exhaust butterfly valve actuator [A] when the pulley is original position as follows.
  • Page 169: Ecu

    FUEL SYSTEM (DFI) 3-85 CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Identification ○ Most countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU with each other and use only the ECU for your model.
  • Page 170: Ecu Installation

    3-86 FUEL SYSTEM (DFI) • Remove: ECU Lead Connectors [A] ECU [B] • Refer to the Immobilizer System Parts Replacement in the Electrical System chapter for Europe model. ECU Installation • Install: ECU [A] (In rubber protector [B]) ECU Lead Connectors ECU Power Supply Inspection •...
  • Page 171 FUEL SYSTEM (DFI) 3-87 • Check the ECU power source voltage with a tester [A]. ○ Position the terminal in accordance with terminal numbers of ECU connectors in this chapter figure. Battery [B] ECU Power Source Inspection Tester Connections: between 16 (W/Y) Terminal and Battery (–) Terminal between 17 (W/BK) Terminal and Battery (–) Terminal Ignition Switch OFF: 16 (W/Y) Terminal 0 V,...
  • Page 172: Dfi Power Source

    3-88 FUEL SYSTEM (DFI) DFI Power Source ECU Fuse Removal • Refer to the Electrical System chapter for the ECU Fuse Removal. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 173: Fi Indicator Light (Led)

    FUEL SYSTEM (DFI) 3-89 FI Indicator Light (LED) 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: Fuel Line

    3-90 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Fuel Tank Bolts (see Fuel Tank Removal in this chapter) •...
  • Page 175: Fuel Flow Rate Inspection

    FUEL SYSTEM (DFI) 3-91 Fuel Line Fuel Pressure (Idling) Standard: 304 kPa (3.1 kgf/cm², 44 psi) NOTE ○ The gauge hand will fluctuate. Read the pressure at the average of the maximum and minimum indications. If the fuel pressure is much higher than the specified, re- place the fuel pump (see Fuel Pump Removal/Installation in this chapter).
  • Page 176 3-92 FUEL SYSTEM (DFI) Fuel Line • Open the fuel tank cap [A] to lower the pressure in the tank. • Be sure to place a piece of cloth around the fuel supply pipe of the fuel pump. • Remove the fuel hose from the fuel supply pipe of the fuel pump (see Fuel Tank Removal in this chapter).
  • Page 177: Fuel Pump

    FUEL SYSTEM (DFI) 3-93 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 178: Operation Inspection

    3-94 FUEL SYSTEM (DFI) Fuel Pump • Check that the fuel pump terminals [A], fuel reserve switch terminal [B] and band [C] are in place. Front [D] • Apply a non-permanent locking agent to the threads of the fuel pump bolts. •...
  • Page 179 FUEL SYSTEM (DFI) 3-95 Fuel Pump 1. ECU 2. Ignition Switch 3. Engine Stop Switch 4. ECU Main Relay 5. Fuel Pump Relay 6. ECU Fuse 15 A 7. Ignition Fuse 10 A 8. Battery 12 V 8 Ah 9. Fuel Pump 10.
  • Page 180: Fuel Injectors

    3-96 FUEL SYSTEM (DFI) Fuel Injectors CAUTION Never drop the injector, especially on a hard sur- face. Such a shock to the injector can damage it. Audible Inspection Primary Fuel Injector • 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 181: Injector Resistance Inspection

    FUEL SYSTEM (DFI) 3-97 Fuel Injectors • Remove connectors for injector [A]. • Connect each test light set [B] to the injector sub harness connector [C]. • Turn the ignition switch ON. • While cranking the engine with the starter motor, watch the test lights.
  • Page 182: Injector Unit Test

    3-98 FUEL SYSTEM (DFI) Fuel Injectors Secondary Fuel Injector • Remove the fuel tank (see Fuel Tank Removal in this chapter). • Disconnect the connector from the injector [A] (see Noz- zle Assy Removal in this chapter). • Measure the injector resistance with the hand tester. Special Tool - Hand Tester: 57001-1394 Secondary Fuel Injector Resistance Connections to Injectors...
  • Page 183: Injector Voltage Inspection

    FUEL SYSTEM (DFI) 3-99 Fuel Injectors Injector Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove: Fuel Tank (see Fuel Tank Removal in this chapter) • Connect a digital voltmeter [A] to the connector [B], with the needle adapter set.
  • Page 184 3-100 FUEL SYSTEM (DFI) Fuel Injectors Secondary Fuel Injector Output Voltage Connections to Injector #1 Meter (+) → O/R lead Meter (–) → Battery (–) Terminal Connections to Injector #2 Meter (+) → O/G lead Meter (–) → Battery (–) Terminal Connections to Injector #3 Meter (+) →...
  • Page 185: Injector Fuel Line Inspection

    FUEL SYSTEM (DFI) 3-101 Fuel Injectors Injector Fuel Line Inspection • Remove the throttle body assy (see Throttle Body Assy Removal in this chapter). • Remove the nozzle assy (see Nozzle Assy Removal in this chapter). • Check the injector fuel line for leakage as follows: ○...
  • Page 186 3-102 FUEL SYSTEM (DFI) Fuel Injectors 1. ECU 2. Secondary Fuel Injector #4 3. Secondary Fuel Injector #3 4. Secondary Fuel Injector #2 5. Secondary Fuel Injector #1 6. Primary Fuel Injector #4 7. Primary Fuel Injector #3 8. Primary Fuel Injector #2 9.
  • Page 187: Throttle Grip And Cables

    FUEL SYSTEM (DFI) 3-103 Throttle Grip and Cables Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Cable Installation •...
  • Page 188: Throttle Body Assy

    3-104 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter . Throttle Bore Cleaning • Check the throttle bore for cleanliness as follows: ○ Remove: Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) ○...
  • Page 189 FUEL SYSTEM (DFI) 3-105 Throttle Body Assy • Remove: Vacuum Switch Valve Vacuum Hose [A] Vacuum Hose (California Model) • Loosen: Clamp Bolts [B] • Remove the throttle body assy from the holder. CAUTION When removing the throttle body assy, put the main throttle valves in the throttle bore, be careful to damage to valves.
  • Page 190: Throttle Body Assy Installation

    3-106 FUEL SYSTEM (DFI) Throttle Body Assy Throttle Body Assy Installation • Install the holder clamp bolts [A] in the direction as shown. Bolt Heads [B] • Install the lower ends of the throttle cables in the throttle body assy, and install the throttle body assy. CAUTION When installing the throttle body assy, put the main throttle valves in the throttle bore, be careful to...
  • Page 191: Throttle Body Assy Assembly

    FUEL SYSTEM (DFI) 3-107 Throttle Body Assy CAUTION Do not remove, disassemble or adjust the main throttle sensor, subthrottle sensor, subthrottle valve actuator, throttle link mechanism and throttle body assy, because they are adjust or set surely at the manufacturer. Adjustment of these parts could result in poor performance, requiring replacement of the throttle body assy.
  • Page 192: Nozzle Assy

    3-108 FUEL SYSTEM (DFI) Nozzle Assy Nozzle Assy Removal • Remove: Fuel Tank (see Fuel Tank Removal in this chapter) Nozzle Assy Lead Connectors [A] Fuel Hose [B] Nozzle Assy Mounting Bolts [C] Nozzle Assy [D] WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
  • Page 193: Nozzle Assy Assembly

    FUEL SYSTEM (DFI) 3-109 Nozzle Assy Nozzle Assy Assembly • Before assembling, blow away dirt or dust from the nozzle and delivery pipe assy [A] by applying compressed air [B]. • Apply engine oil to the new O-rings [A] and the dust seals [B] of each injector.
  • Page 194 3-110 FUEL SYSTEM (DFI) Nozzle Assy • Tighten the screws [A]. Torque - Delivery Pipe Mounting Screws: 3.4 N·m (0.35 kgf·m, 30 in·lb) Stay Plate [B] • Apply engine oil to the O-ring [A]. • Tighten: Torque - Fuel Hose Mounting Screw [B]: 4.9 N·m (0.50 kgf·m, 43 in·lb) •...
  • Page 195: Air Cleaner

    FUEL SYSTEM (DFI) 3-111 Air Cleaner Element Removal • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Element Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Element Inspection •...
  • Page 196: Air Cleaner Housing Installation

    3-112 FUEL SYSTEM (DFI) Air Cleaner • Remove the fuel hose [A]. • Remove the engine breather hose [B]. • Remove the drain hose. • Remove the vacuum switch valve hose [A]. Air Cleaner Housing Installation • Install the vacuum switch valve hose to the air cleaner housing.
  • Page 197: Air Cleaner Housing Disassembly

    FUEL SYSTEM (DFI) 3-113 Air Cleaner Air Cleaner Housing Disassembly • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in this chapter) Ducts [A] Air Cleaner Housing Assembly • Apply adhesive to the hatched area [A] on the duct. Adhesive- Cemedine #540 or equivalent •...
  • Page 198: Fuel Tank

    3-114 FUEL SYSTEM (DFI) 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 199 FUEL SYSTEM (DFI) 3-115 Fuel Tank • Be sure to place a piece of cloth around the fuel hose joint [A]. • Push the joint lock claws [B]. • Pull the joint lock [A] as shown. • Pull the fuel hose joint [B] out of the delivery pipe. WARNING Be prepared for fuel spillage;...
  • Page 200: Fuel Tank Installation

    3-116 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Installation • Note the above WARNING (see Fuel Tank Removal in this chapter). • Route the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • For California Model, note the following. ○...
  • Page 201: Fuel Tank And Cap Inspection

    FUEL SYSTEM (DFI) 3-117 Fuel Tank Fuel Tank and Cap Inspection • Visually inspect the gasket [A] on the tank cap for any damage. Replace the gasket if it is damaged. • Check to see if the water drain pipe [B] and fuel breather pipe [C] (California Model) in the tank are not clogged.
  • Page 202: Evaporative Emission Control System (California Model)

    3-118 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) 3-119 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 204 http://mototh.com...
  • Page 205 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Coolant Flow Chart......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal ..................
  • Page 206: Exploded View

    4-2 COOLING SYSTEM Exploded View http://mototh.com...
  • Page 207 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Coolant By-pass Fitting Bolt 0.90 78 in·lb Coolant Drain Bolt (Cylinder) 87 in·lb Coolant Drain Bolt (Water Pump) 0.90 78 in·lb Coolant Reserve Tank Mounting Bolts 0.70 61 in·lb Impeller Bolt 87 in·lb Oil Cooler Mounting Bolts...
  • Page 208: Specifications

    4-4 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 209: Special Tools And Sealant

    COOLING SYSTEM 4-5 Special Tools and Sealant Bearing Driver, 32: Kawasaki Bond (Silicone Sealant): 57001-382 56019-120 Bearing Driver Set: 57001-1129 http://mototh.com...
  • Page 210: Coolant Flow Chart

    4-6 COOLING SYSTEM Coolant Flow Chart http://mototh.com...
  • Page 211 COOLING SYSTEM 4-7 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 212: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Visually inspect the coolant in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.
  • 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 • Refer to the Oil Pump Removal in the Engine Lubrication System chapter. Water Pump Installation • Refer to the Oil Pump Installation in the Engine Lubrica- tion System chapter. Water Pump Impeller Disassembly/Assembly •...
  • Page 215: Water Pump Housing Assembly

    COOLING SYSTEM 4-11 Water Pump • Take the oil seal [A] out of the housing [B] with a hook [C]. Water Pump Housing Assembly CAUTION Do not reuse the mechanical seal and oil seal. • Apply high-temperature grease to the oil seal lips [A]. •...
  • Page 216: Radiator

    4-12 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Radiator Fan Lead Connector [A] •...
  • Page 217: Radiator And Radiator Fan Installation

    COOLING SYSTEM 4-13 Radiator • Remove: Radiator Fan Mounting Bolts [A] Radiator Fan [B] Radiator and Radiator Fan Installation • Insert the plugs [A] in the holes of heat insulation rubber plate [B]. • Install the heat insulation rubber plate [C] on the engine. •...
  • Page 218 4-14 COOLING SYSTEM Radiator • Cover [A] the heat insulation rubber plate on the radiator. • Install the radiator to the projection [B] as shown. http://mototh.com...
  • Page 219 COOLING SYSTEM 4-15 Radiator • Enchase the heat insulation rubber plate [A] to the radia- tor stay. • Through the radiator fan lead [B] in the heat insulation rubber plate hole, and clamp the radiator fan lead and horn lead [C] with the radiator clamp [D]. •...
  • Page 220 4-16 COOLING SYSTEM Radiator • Install the radiator bracket collar [A] as shown. Rubber Damper [B] Radiator [C] Horn [D] Harness Stay [E] Bolt [F] • Tighten: Torque - Radiator Upper Bolt [G]: 12 N·m (1.2 kgf·m, 104 in·lb) Radiator Lower Bolt [H]: 6.9 N·m (0.70 kgf·m, 61 in·lb) •...
  • Page 221: Radiator Inspection

    COOLING SYSTEM 4-17 Radiator Radiator Inspection • Remove the radiator (see Radiator and Radiator Fan Re- moval in this chapter). • Check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them.
  • Page 222: Radiator Filler Neck Inspection

    4-18 COOLING SYSTEM Radiator Radiator Filler Neck Inspection • Remove the right upper inner fairing (see Upper Inner Fairing Removal in the Frame chapter). • Remove the radiator cap. • Check the radiator filler neck for signs of damage. • Check the condition of the top and bottom sealing seats [A] in the filler neck.
  • Page 223: Thermostat

    COOLING SYSTEM 4-19 Thermostat Thermostat Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Thermostat Housing Cover Bolts [A] Bracket [B]...
  • Page 224: Thermostat Inspection

    4-20 COOLING SYSTEM Thermostat • Align the line [A] of thermostat housing cover and white mark [B] of water hose. • Install the bracket [C] as shown. • Tighten the thermostat housing cover bolts. Torque - Thermostat Housing Cover Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) •...
  • Page 225 COOLING SYSTEM 4-21 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 226: Hoses And Pipes

    4-22 COOLING SYSTEM Hoses 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 in accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter. •...
  • Page 227: Water Temperature Sensor

    COOLING SYSTEM 4-23 Water Temperature Sensor CAUTION The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to their parts can damage them. Water Temperature Sensor Removal • Refer to the Water Temperature Sensor Removal in the Fuel System (DFI) chapter.
  • Page 228 http://mototh.com...
  • Page 229 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Valve Clearance Inspection ..5-23 Specifications ........Valve Clearance Adjustment..5-23 Special Tools and Sealant ....Valve Removal ......5-23 Clean Air System....... 5-11 Valve Installation ......5-23 Air Suction Valve Removal...
  • Page 230: Exploded View

    5-2 ENGINE TOP END Exploded View http://mototh.com...
  • Page 231 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Suction Valve Cover Bolts 104 in·lb Camshaft Cap Bolts 104 in·lb Camshaft Chain Tensioner Cap Bolt Camshaft Chain Tensioner Mounting Bolts 97 in·lb Cam Sprocket Mounting Bolts Coolant Drain Bolt (Cylinder) 87 in·lb Crankshaft Sensor Cover Bolts...
  • Page 232 5-4 ENGINE TOP END Exploded View http://mototh.com...
  • Page 233 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Exhaust Butterfly Valve Actuator Mounting Bolts 0.70 61 in·lb Exhaust Butterfly Valve Actuator Pulley Bolt 0.50 43 in·lb Exhaust Butterfly Valve Cable Adjuster Locknuts 0.70 61 in·lb Exhaust Butterfly Valve Cable Locknuts 0.70 61 in·lb Exhaust Butterfly Valve Cover Bolt...
  • Page 234 5-6 ENGINE TOP END Exploded View Manifold Mark Position [A] Silencer Mark Position [A] http://mototh.com...
  • Page 235: Specifications

    ENGINE TOP END 5-7 Specifications Item Standard Service Limit Clean Air System Open → Close Vacuum Switch Valve – – – 41 ∼ 49 kPa (310 ∼ 370 mmHg) Closing Pressure Camshafts Cam Height: 33.146 ∼ 33.254 mm (1.3050 ∼ 1.3092 in.) Exhaust 33.05 mm (1.301 in.) 34.146 ∼...
  • Page 236 5-8 ENGINE TOP END Specifications Item Standard Service Limit Valve Spring Free Length: Exhaust 39.39 mm (1.551 in.) 38.0 mm (1.496 in.) Inlet 35.27 mm (1.389 in.) 33.9 mm (1.335 in.) Cylinder, Piston 68.000 ∼ 68.012 mm (2.677 ∼ 2.678 in.) Cylinder Inside Diameter 68.10 mm (2.68 in.) 67.975 ∼...
  • Page 237: Special Tools And Sealant

    ENGINE TOP END 5-9 Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 32° - 25: 57001-221 57001-1118 Valve Spring Compressor Assembly: Valve Seat Cutter, 32° - 28: 57001-241 57001-1119 Piston Pin Puller Assembly: Valve Seat Cutter Holder Bar: 57001-910 57001-1128 Valve Seat Cutter, 45°...
  • Page 238 Valve Seat Cutter Holder, 4: Compression Gauge Adapter, M10 × 1.0: 57001-1275 57001-1601 Fork Oil Level Gauge: L-Shape Hose: 57001-1290 57001-1606 Valve Seat Cutter, 60° - 25: Attachment C: 57001-1328 57001-1624 Valve Seat Cutter, 60° - 27: Kawasaki Bond (Silicone Sealant): 57001-1409 92104-0004 http://mototh.com...
  • Page 239: Clean Air System

    ENGINE TOP END 5-11 Clean Air System Air Suction Valve Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) • Separate the hoses [A] from the air suction valve cover.
  • Page 240: Vacuum Switch Valve Installation

    5-12 ENGINE TOP END Clean Air System Vacuum Switch Valve Installation • Install the vacuum switch valve so that the air duct [A] faces right side. • Route the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). Vacuum Switch Valve Test •...
  • Page 241: Cylinder Head Cover

    Remove the cylinder head cover [A] to backward floating it a little up. Cylinder Head Cover Installation • Replace the head cover gasket with a new one. • Apply silicone sealant [A] to the cylinder head as shown. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 http://mototh.com...
  • Page 242 5-14 ENGINE TOP END Cylinder Head Cover • Install: Dowel Pins [A] Plug Hole Gaskets [B] • Install the washer [A] with the metal side faces upward. • Install the cylinder head cover. • Tighten the cover bolts [A]. Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 243: Camshaft Chain Tensioner

    ENGINE TOP END 5-15 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 244: Camshaft, Camshaft Chain

    5-16 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval in this chapter) Crankshaft Sensor Cover (see Crankshaft Sensor Re- moval in the Electrical System chapter) • Position the crankshaft at #1, 4 piston TDC. TDC mark [A] for #1, 4 Pistons Timing Mark (Crankcase Halves Mating Surface) [B] •...
  • Page 245 ENGINE TOP END 5-17 Camshaft, Camshaft Chain • Install the cam sprockets as shown in figure. #4 Cam Positions [A] Inlet Cam Sprocket [B] Exhaust Cam Sprocket [C] • Apply a non-permanent locking agent to the threads and tighten the bolts. Torque - Cam Sprocket Mounting Bolts: 15 N·m (1.5 kgf·m, 11 ft·lb) •...
  • Page 246: Camshaft, Camshaft Cap Wear

    5-18 ENGINE TOP END Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear • Remove: Camshaft Cap (see Camshaft Removal in this chapter) • Cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position.
  • Page 247: Cam Wear

    ENGINE TOP END 5-19 Camshaft, Camshaft Chain Cam Wear • Remove the camshaft (see Camshaft Removal in this chapter). • Measure the height [A] of each cam with a micrometer. If the cams are worn down past the service limit, replace the camshaft.
  • Page 248: Cylinder Head

    5-20 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