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Ninja ZX-6R
Motorcycle
Service Manual
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Table of Contents

   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 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 5-21 Cylinder Head Cylinder Head 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) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Throttle Body Assembly (see Throttle Body Assembly Removal in the Fuel System (DFI) chapter)
  • Page 250: Cylinder Head Warp

    5-22 ENGINE TOP END Cylinder Head • Tighten the M9 cylinder head bolts following the tightening sequence [1 ∼ 10]. 148 mm (5.83 in.) 140 mm (5.51 in.) Torque - Cylinder Head Bolts (M9): First: 20 N·m (2.0 kgf·m, 15 ft·lb) Final: 39 N·m (4.0 kgf·m, 29 ft·lb) •...
  • Page 251: Valves

    ENGINE TOP END 5-23 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 the cylinder head (see Cylinder Head Removal in this chapter).
  • Page 252: Valve Guide Installation

    5-24 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). CAUTION Do not heat the cylinder head with a torch. This Will warp the cylinder head.
  • Page 253: Valve Seat Inspection

    ENGINE TOP END 5-25 Valves NOTE ○ The reading is not actual valve/valve guide clearance because the measuring point is above the guide. Valve/Valve Guide Clearance (Wobble Method) Standard: 0.09 ∼ 0.16 mm (0.0035 ∼ 0.0063 in.) Exhaust 0.03 ∼ 0.11 mm (0.0012 ∼ 0.0043 in.) Inlet Service Limit: Exhaust...
  • Page 254 5-26 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 255 ENGINE TOP END 5-27 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 256 5-28 ENGINE TOP END Valves If the seat width is too wide, make the 60° [A] grind de- scribed 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° angle until the seat width is within the specified range.
  • Page 257 ENGINE TOP END 5-29 Valves http://mototh.com...
  • Page 258: Cylinder, Pistons

    5-30 ENGINE TOP END Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal in this chap- ter) Water Hoses [A] • Remove the cylinder [A]. Cylinder Installation NOTE ○ If a new cylinder is used, use new piston ring. •...
  • Page 259: Piston Removal

    ENGINE TOP END 5-31 Cylinder, Pistons Piston Removal • Remove the cylinder (see Cylinder Removal in this chap- ter). • Place a clean cloth under the pistons and remove the pis- ton pin snap ring [A] from the outside of each piston. •...
  • Page 260: Cylinder Wear

    5-32 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 261: Piston Ring, Piston Ring Groove Wear

    ENGINE TOP END 5-33 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 262: Piston Ring End Gap

    5-34 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 263: Throttle Body Holder

    ENGINE TOP END 5-35 Throttle Body Holder Throttle Body Holder Installation • Be sure to install the O-rings [A]. • Install the clamps [B] as shown. • Apply a non-permanent locking agent to the throttle body holder bolts, and tighten them. Torque - Throttle Body Holder Bolts [C]: 12 N·m (1.2 kgf·m, 104 in·lb) Throttle Body Assy Holder Clamp Bolts [D]: 2.9...
  • Page 264: Muffler

    5-36 ENGINE TOP END Muffler WARNING To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. Muffler Body Removal • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) Clamp [A] Connectors [B]...
  • Page 265 ENGINE TOP END 5-37 Muffler • Slide the dust covers [A]. • Loosen the locknuts [B], and turn the adjuster [C] to give the cable plenty of play. • Loosen the locknuts [D]. • Remove the exhaust butterfly valve cable lower ends from the pulley [E].
  • Page 266: Muffler Body Installation

    5-38 ENGINE TOP END Muffler Muffler Body Installation • Replace the muffler body gasket [A] and center pipe gas- ket [B] with a new one. ○ Install the muffler body gasket and center pipe gasket until it is bottomed so that the chamfer side faces rear. •...
  • Page 267: Exhaust Pipe Removal

    ENGINE TOP END 5-39 Muffler • Install the exhaust butterfly valve cable, and adjust (see Exhaust Butterfly Valve Cable Installation in this chapter). • Thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts. • Install the removed parts (see appropriate chapters).
  • Page 268: Exhaust Pipe Installation

    5-40 ENGINE TOP END Muffler • Remove: Exhaust Pipe Clamp Bolt [A] • Remove the exhaust pipe forward. Exhaust Pipe Installation • Replace the exhaust pipe gaskets [A] and center pipe gasket [B] with new ones and install them. ○ Install the center pipe gasket until it is bottomed so that the chamfer side faces rear.
  • Page 269: Exhaust Butterfly Valve Cable Removal

    ENGINE TOP END 5-41 Muffler Exhaust Butterfly Valve Cable Removal • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) Guard Bracket [A] (see ECU Removal in the Fuel Sys- tem chapter) Cover (see Muffler Body Removal in this chapter) •...
  • Page 270 5-42 ENGINE TOP END Muffler • Install the exhaust butterfly valve cable upper ends to the pulley of actuator. Open Cable (Yellow) [A] Close Cable (Dark Green) [B] • Install the clamp. • Install the exhaust butterfly valve cable lower ends to the pulley of muffler body.
  • Page 271 ENGINE TOP END 5-43 Muffler http://mototh.com...
  • Page 272 http://mototh.com...
  • Page 273 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 .................. Cable Removal ......................... Cable Installation ......................Cable Lubrication ......................Clutch Lever Installation....................
  • Page 274: Exploded View

    6-2 CLUTCH Exploded View http://mototh.com...
  • Page 275 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Cover Bolt (M6, L = 50 mm) 104 in·lb Clutch Cover Bolts (M6, L = 40 mm) 104 in·lb L (1) Clutch Cover Bolts (M6, L = 30 mm) 104 in·lb L (1) Clutch Hub Nut...
  • Page 276: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch Spring Plate Free Play (Usable Range) 0.05 ∼ 0.55 mm (0.002 ∼ 0.022 in.) – – – Clutch Plate Assembly Length 39.1 mm (1.54 in.) –...
  • Page 277: Special Tool And Sealant

    CLUTCH 6-5 Special Tool and Sealant Clutch Holder: Kawasaki Bond (Silicone Sealant): 57001-1243 92104-0004 http://mototh.com...
  • Page 278: 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. Cable Removal •...
  • Page 279: Clutch Cover

    Clutch Cover Installation • Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Replace the clutch cover gasket with a new one. •...
  • Page 280: Release Shaft Installation

    6-8 CLUTCH Clutch Cover Release Shaft Installation • Apply high-temperature grease to the oil seal lips on the upper ridge of the clutch cover. • Apply engine oil to the needle bearings in the hole of the clutch cover. • Apply molybdenum disulfide grease to the pusher-holding portion [A] on the release shaft.
  • Page 281: Clutch Removal

    CLUTCH 6-9 Clutch Clutch Removal • Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Right Center Fairing (see Center Fairing Removal in the Frame chapter) Clutch Cover (see Clutch Cover Removal in this chapter) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with shim, bearing, pusher [C], spring and washer)
  • Page 282: Clutch Installation

    6-10 CLUTCH Clutch Clutch Installation • Install the following parts on the drive shaft. Spacer [A] Needle Bearing [B] Sleeve [C] Clutch Housing [D] Spacer [E] Clutch Hub [F] Sub Clutch Hub [G] Torque Limiter Springs [H] Nut [I] • Install the spacer [A] so that the stepped side [B] faces inward.
  • Page 283 CLUTCH 6-11 Clutch • Install the clutch housing. ○ If the clutch housing is replaced with a new one, select the proper clutch housing in accordance with the combination of the clutch housing gear and crankshaft markings. Clutch Housing Gear [A] Crankshaft [B] NOTE ○...
  • Page 284 6-12 CLUTCH Clutch • Install the spacer [A] so that the stepped side [B] faces outward. • Install the four torque limiter springs [A] as shown. ○ First Torque Limiter Spring Tang [B] ○ Second Torque Limiter Spring Tang [B] ○...
  • Page 285 CLUTCH 6-13 Clutch ○ Replace the clutch hub nut with a new one. • Holding the sub clutch hub, tighten the clutch hub nut. Special Tool - Clutch Holder: 57001-1243 Torque - Clutch Hub Nut: 135 N·m (14 kgf·m, 100 ft·lb) •...
  • Page 286: Spring Plate Free Play Measurement

    6-14 CLUTCH Clutch Spring Plate Free Play Measurement Insufficient clutch free play will cause the engine braking effect to be more sudden, resulting in rear wheel hop. On the other hand, if the free play is excessive, the clutch lever may feel “spongy”...
  • Page 287: Spring Plate Play Adjustment

    CLUTCH 6-15 Clutch Spring Plate Play Adjustment • Assemble the following parts so that the clutch plate as- sembly length [A] is specified length. Clutch Hub [B] Spring Seat [C] Spring [D] Sub Clutch Hub [E] Sub Clutch Hub Bolts [F] Friction Plates [G] Steel Plates [H] Spring Plate [I]...
  • Page 288: Clutch Spring Free Length Measurement

    6-16 CLUTCH Clutch Clutch Spring Free Length Measurement • Measure the free length of the clutch springs [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 41.6 mm (1.64 in.) Service Limit: 40.1 mm (1.58 in.) Damper Cam Inspection •...
  • Page 289 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Engine Oil Flow Chart......................Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ Oil Pan Removal .......................
  • Page 290: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View http://mototh.com...
  • Page 291: Engine Lubrication System

    ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb 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 0.70 61 in·lb...
  • Page 292: Specifications

    7-4 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SE, SF or SG API SH or SJ with JASO MA Viscosity SAE 10W-40 Capacity 3.4 L (3.6 US gt) (when filter is not removed) 3.6 L (3.8 US gt) (when filter is removed) 4.0 L (4.2 US gt) (when engine is completely dry) Level Between upper and lower level lines...
  • Page 293: Special Tools And Sealant

    ENGINE LUBRICATION SYSTEM 7-5 Special Tools and Sealant Outside Circlip Pliers: Oil Pressure Gauge Adapter, M18 × 1.5: 57001-144 57001-1278 Oil Pressure Gauge, 10 kgf/cm²: Kawasaki Bond (Silicone Sealant): 57001-164 56019-120 Oil Filter Wrench: 57001-1249 http://mototh.com...
  • Page 294: Engine Oil Flow Chart

    7-6 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart http://mototh.com...
  • Page 295 ENGINE LUBRICATION SYSTEM 7-7 Engine Oil Flow Chart http://mototh.com...
  • Page 296: 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 297: 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) • Remove the water hose from the oil pan clamp. •...
  • Page 298: Oil Pressure Relief Valve

    7-10 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • See Oil Pan Removal in this chapter. Oil Pressure Relief Valve Installation • See Oil Pan Installation in this chapter. 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 299: Oil Pump

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pump Oil Pump Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Water Hoses [A] Water Pump Cover Bolts [B] Water Pump Cover •...
  • Page 300: Oil Pump Drive Gear Removal

    7-12 ENGINE LUBRICATION SYSTEM Oil Pump • Fit the pin [A] of the oil pump cover [B] into the hole [C] in the crankcase. • Install: Pins [A] Water Pump Body [B] • Apply coolant to the surface of the rubber seal on the impeller.
  • Page 301: Oil Pump Drive Gear Installation

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump • Pull the oil pump drive gear [A]. Oil Pump Drive Gear Installation • Apply molybdenum disulfide oil solution to the journal por- tions [A] on the oil pump drive gear shaft [B]. • Install: Washer [C] •...
  • Page 302: Oil Cooler

    7-14 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Removal • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) •...
  • Page 303: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-15 Oil Pressure Measurement Oil Pressure Measurement • Remove the lower fairings (see Lower Fairing Removal 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, M18 ×...
  • Page 304: Oil Pressure Switch

    • 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) • Install the switch lead direction outward.
  • Page 305 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................http://mototh.com...
  • Page 306: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View http://mototh.com...
  • Page 307 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Adjusting Collar Locknut Lower Engine Mounting Bolt 87 in·lb Lower Engine Mounting Nut Middle Engine Mounting Bolt 87 in·lb Middle Engine Mounting Nut Upper Engine Mounting Bolts S: Follow the specific tightening sequence. http://mototh.com...
  • Page 308: Special Tool

    8-4 ENGINE REMOVAL/INSTALLATION Special Tool Engine Mount Nut Wrench: 57001-1450 http://mototh.com...
  • Page 309: Engine Removal/installation

    ENGINE REMOVAL/INSTALLATION 8-5 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 310 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Support the engine with a suitable stand [A]. ○ Put a plank [B] onto the suitable stand for engine balance. • Remove: Right and Left Upper Engine Mounting Bolts [A] • Using the nut wrench [A], loosen the locknut [B]. Special Tool - Engine Mount Nut Wrench: 57001-1450 •...
  • Page 311: Engine Installation

    ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation Engine Installation • Support the engine with a suitable stand. ○ Put a plank onto the suitable stand for engine balance. • Install the engine mounting bolts and nuts, following the specified installing sequence. ○ First, install the adjusting collars [A] to crankcase back- side upper, lower and frame.
  • Page 312 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation ○ Third, install the bolts [A] [B] [C] [D] temporally. ○ Fourth, install the lower [A] and middle [B] engine mount- ing bolts, and tighten the bolts counterclockwise. NOTE ○ Tighten the bolts until the clearance between the engine and collar come to 0 mm (0 in.).
  • Page 313 ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation • Run the leads, cable and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chap- ter). • Install the removed parts (see appropriate chapters). • Adjust: Throttle Cables (see Throttle Control System Inspection in the Periodic Maintenance chapter) Clutch Cable (see Clutch Operation Inspection in the Pe- riodic Maintenance chapter)
  • Page 314 http://mototh.com...
  • Page 315 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Crankcase Splitting......................... Crankcase Splitting ......................Crankcase Assembly ......................9-10 Crankshaft and Connecting Rods................... 9-13 Crankshaft Removal ......................9-13 Crankshaft Installation ...................... 9-13 Connecting Rod Removal ....................9-14 Connecting Rod Installation ....................
  • Page 316: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View http://mototh.com...
  • Page 317 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Breather Plate Bolts 0.60 52 in·lb ← ← ← Connecting Rod Big End Nuts see the text Crankcase Bolts (M8) MO, S Crankcase Bolts (M7, L = 38 mm) Crankcase Bolt (M7, L = 70 mm) Crankcase Bolts (M6, L = 65 mm) 104 in·lb Crankcase Bolts (M6, L = 50 mm)
  • Page 318 9-4 CRANKSHAFT/TRANSMISSION Exploded View http://mototh.com...
  • Page 319 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Gear Positioning Lever Bolt 104 in·lb Neutral Switch Shift Drum Cam Holder Bolt 104 in·lb Shift Lever Bolt 0.70 61 in·lb Shift Pedal Mounting Bolt Shift Shaft Return Spring Pin Tie-Rod Locknuts 0.70 61 in·lb...
  • Page 320: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankcase, Crankshaft, Connecting Rods Connecting Rod Bend – – – TIR 0.20/100 (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.20/100 (0.008/3.94 in.) 0.13 ∼ 0.33 mm Connecting Rod Big End Side Clearance 0.53 mm (0.0051 ∼...
  • Page 321 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit 34.000 ∼ 34.016 mm Crankcase Main Bearing Inside Diameter: – – – (1.3386 ∼ 1.3392 in.) Marking: ○ 34.000 ∼ 34.008 mm – – – (1.3386 ∼ 1.3389 in.) 34.009 ∼ 34.016 mm None –...
  • Page 322: Special Tools And Sealant

    9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealant Bearing Puller: Bearing Driver, 57001-135 57001-382 Outside Circlip Pliers: Kawasaki Bond (Silicone Sealant): 57001-144 56019-120 Bearing Puller Adapter: Kawasaki Bond: 57001-317 92104-1064 http://mototh.com...
  • Page 323: Crankcase Splitting

    CRANKSHAFT/TRANSMISSION 9-9 Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Crankshaft Sensor (see Crankshaft Sensor Removal in the Electrical System chapter) Clutch (see Clutch Removal in the Clutch chapter) Starter Motor (see Starter Motor Removal in the Electri-...
  • Page 324: Crankcase Assembly

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Assembly CAUTION The upper and lower crankcase halves are ma- chined at the factory in the assembled state, so the crankcase halves must be replaced as a set. • With a high-flash point solvent, clean off the mating sur- faces of the crankcase halves and wipe dry.
  • Page 325 CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting • Apply liquid gasket to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond: 92104-1064 NOTE ○ Especially, apply a sealant carefully so that it shall be filled up on the grooves. CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts, and oil passage holes.
  • Page 326 9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting • The M8 bolts has a copper plated washer, replace it with a new one. ○ Apply molybdenum disulfide oil to both side [C] of the cop- per plated washers and threads [B] of M8 bolts [A]. •...
  • Page 327: Crankshaft And Connecting Rods

    CRANKSHAFT/TRANSMISSION 9-13 Crankshaft and Connecting Rods Crankshaft Removal • See Connecting Rod Removal in this chapter. Crankshaft Installation • If the crankshaft is replaced with a new one, select the proper crankshaft in accordance with the combination of the crankshaft and clutch housing gear markings. Clutch Housing Gear [A] Crankshaft [B] NOTE...
  • Page 328: Connecting Rod Removal

    9-14 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods NOTE ○ If the crankshaft is replaced with a new one, refer to the Connecting Rod Big End Bearing/Crankshaft Main Bearing Insert Selection in the Specifications. 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...
  • Page 329 CRANKSHAFT/TRANSMISSION 9-15 Crankshaft and Connecting Rods • Apply molybdenum disulfide oil to the inner surface of the upper and lower bearing inserts [A]. • Apply molybdenum disulfide oil to the threads [B] and seating surface [C] of the connecting rod nuts. •...
  • Page 330 9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods (1) Bolt Length Measurement Method • Be sure to clean the bolts, nuts, and connecting rods thoroughly with a high-flash point solvent, because the new connecting rods, bolts, and nuts are treated with an anti-rust solution.
  • Page 331 CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods (2) Rotation Angle Method If you don’t have a point micrometer, you may tighten the nuts using the “Rotation Angle Method”. • Be sure to clean the bolts, nuts and connecting rods thor- oughly with a high-flash point solvent, because the new connecting rods, bolts and nuts are treated with an anti -rust solution.
  • Page 332: Crankshaft/connecting Rod Cleaning

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft/Connecting Rod Cleaning • After removing the connecting rods from the crankshaft, clean them with a high-flash point solvent. • Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages.
  • Page 333: Connecting Rod Big End Bearing Insert/crankpin Wear

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert/Crankpin Wear • Measure the bearing insert/crankpin [B] clearance with plastigage [A]. • Tighten the big end nuts to the specified torque (see Con- necting Rod Installation in this chapter). NOTE ○...
  • Page 334: Crankshaft Side Clearance

    9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Big End Inside Diameter Marks None: 33.000 ∼ 33.008 mm (1.2992 ∼ 1.2995 in.) ○ 33.009 ∼ 33.016 mm (1.2996 ∼ 1.2998 in.) Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] ○...
  • Page 335: Crankshaft Runout

    CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods Crankshaft Runout • Measure the crankshaft runout. If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: TIR 0.02 mm (0.0008 in.) or less Service Limit: TIR 0.05 mm (0.0020 in.) Crankshaft Main Bearing Insert/Journal Wear •...
  • Page 336 9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. ○ [A]: Crankcase Main Bearing Inside Diameter Marks, “ ” mark or no mark. •...
  • Page 337: Transmission

    CRANKSHAFT/TRANSMISSION 9-23 Transmission Shift Pedal Removal • Mark [A] the position of the shift lever [B] on the shift shaft so that it can be installed later in the same position. • Remove: Shift Lever Bolt [C] Shift Lever • Remove: Shift Pedal Mounting Bolt [A] Tie-Rod [B]...
  • Page 338: External Shift Mechanism Removal

    9-24 CRANKSHAFT/TRANSMISSION Transmission External Shift Mechanism Removal • Remove: Engine Oil (see Drain, Engine Oil Change in the Periodic Maintenance chapter) Clutch (see Clutch Removal in the Clutch chapter) Shift Pedal (see Shift Pedal Removal in this chapter) • Remove the shift shaft assembly [A] while pulling the shift mechanism arm.
  • Page 339: Transmission Shaft Removal

    CRANKSHAFT/TRANSMISSION 9-25 Transmission Transmission Shaft Removal • Split the crankcase (see Crankcase Splitting in this chap- ter). • Remove the drive shaft [A] and output shaft [B]. Transmission Shaft Installation • Check to see that the set ring [A] and set pin [B] are in place.
  • Page 340: Transmission Shaft Assembly

    9-26 CRANKSHAFT/TRANSMISSION Transmission • Remove the ball bearing [A] from each shafts. Special Tools - Bearing Puller [B]: 57001-135 Bearing Puller Adapter [C]: 57001-317 • Discard the bearing. Transmission Shaft Assembly • Install the ball bearing on the drive shaft [A] with the groove [B] toward the clutch side using the bearing driver.
  • Page 341 CRANKSHAFT/TRANSMISSION 9-27 Transmission • Fit the steel balls into the 5th gear holes in the output shaft, aligning three oil holes. 5th Gear [A] Output Shaft [B] Steel Balls [C] Oil Holes [D] CAUTION Do not apply grease to the balls to hold them in place.
  • Page 342 9-28 CRANKSHAFT/TRANSMISSION Transmission 1. Output Shaft 14. Toothed Washer, 34 mm (1.34 in.) 2. Collar 15. Snap Ring 3. Ball Bearing 16. Bushing 4. 2nd Gear 17. Thrust Washer, 30 mm (1.18 in.) 5. 6th (Top) Gear 18. Snap Ring 6.
  • Page 343: Shift Drum And Fork Removal

    CRANKSHAFT/TRANSMISSION 9-29 Transmission Shift Drum and Fork Removal • Remove: Lower Crankcase Half (see Crankcase Splitting in this chapter) External Shift Mechanism (see External Shift Mecha- nism Removal in this chapter) Bolts [A] Shift Drum Bearing Holder [B] • Pull out the shift rods [C], and take off the shift forks. •...
  • Page 344: Shift Fork/gear Groove Wear

    9-30 CRANKSHAFT/TRANSMISSION Transmission Shift Fork/Gear Groove Wear • Measure the thickness of the shift fork ears [A], and mea- sure the width [B] of the gear grooves. If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced.
  • Page 345 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-7 Rear Wheel Installation..................... 10-8 Wheel Inspection ......................10-10 Axle Inspection........................
  • Page 346: Exploded View

    10-2 WHEELS/TIRES Exploded View http://mototh.com...
  • Page 347 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut AL: Tighten the two clamp bolts alternately two time to ensure even tightening. G: Apply grease. HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 348: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial – – – 0.5 mm (0.02 in.) Radial – – – 0.8 mm (0.03 in.) Axle Runout/100 mm 0.05 mm (0.002 in.) or less 0.2 mm (0.01 in.) Wheel Balance 10 g (0.35 oz.) or less –...
  • Page 349: 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, 25 × 28: 57001-1346 http://mototh.com...
  • Page 350: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Brake Caliper Mounting Bolts [A] Front Brake Calipers [B] • Loosen: Axle Clamp Bolts [A] (Left Side) Axle Nut [B] Axle Clamp Bolts (Right Side) • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter).
  • Page 351: Rear Wheel Removal

    WHEELS/TIRES 10-7 Wheels (Rims) • Apply high-temperature grease to the grease seal lip. • Fit the collars [A] on the both sides of the hub. ○ The collars are identical. • Insert the axle. • Tighten the axle nut [B]. Right Axle Clamp Bolts [C] Left Axle Clamp Bolts [D] Viewed from Rear [E]...
  • Page 352: Rear Wheel Installation

    10-8 WHEELS/TIRES Wheels (Rims) • Remove: Rear Caliper Mounting Bolts [A] Rear Caliper [B] • Remove: Cotter Pin [A] Axle Nut [B] Axle [C] (from Right Side) • Remove the drive chain [A] from the rear sprocket toward the left. •...
  • Page 353 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: 127 N·m (13 kgf·m, 94 ft·lb) •...
  • Page 354: Wheel Inspection

    10-10 WHEELS/TIRES Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground. 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 (see Hub Bearing Removal/Installation in this chapter).
  • Page 355: Balance Inspection

    WHEELS/TIRES 10-11 Wheels (Rims) Balance Inspection • Remove the front and rear wheels (see Front/Rear Wheel Removal in this chapter). • 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 356 30 g (1.06 oz) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20, and 30 gram (0.35 oz, 0.71 oz, and 1.06 oz) sizes. An imbalance of less than 10 grams (0.35 oz) will not usually affect running stability.
  • Page 357: 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 in this chapter) Valve Core (Let out the air) •...
  • Page 358 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 359: 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 360: Hub Bearing

    10-16 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheel (see Front/Rear Wheel Removal in this chapter), and take out the following. Collars Coupling (Out of rear hub) Grease Seals • Use the bearing remover to remove the hub bearing [A]. CAUTION Do not lay the wheel on the ground with the disc facing down.
  • Page 361: 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. http://mototh.com...
  • Page 362 http://mototh.com...
  • Page 363 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 364: Exploded View

    11-2 FINAL DRIVE Exploded View http://mototh.com...
  • Page 365: Final Drive

    FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Sprocket Cover Bolts 0.70 61 in·lb Engine Sprocket Nut Rear Axle Nut Rear Sprocket Nuts G: Apply grease. HG: Apply high-temperature grease. HO: Apply heavy oil. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil solution.
  • Page 366: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Standard Chain: Make ENUMA – – – Type EK520MVXL – – – Link 110 links – – – Sprockets Rear Sprocket Warp 0.4 mm (0.016 in.) or less 0.5 mm (0.02 in.) http://mototh.com...
  • Page 367: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129 http://mototh.com...
  • Page 368: 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 369: 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 370 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 371 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 372: Sprocket, Coupling

    11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer. NOTE ○ When loosening the engine sprocket nut, hold the rear brake on.
  • Page 373: Rear Sprocket Removal

    FINAL DRIVE 11-11 Sprocket, Coupling • Install the engine sprocket cover. • Install the stay [A] and clamp [B] as shown, and tighten the cover bolts. Torque - Engine Sprocket Cover Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb) • Bend the end of axle cotter pin surely after tightening the axle nut.
  • Page 374: Coupling Bearing Removal

    11-12 FINAL DRIVE Sprocket, Coupling • Apply grease to the O-ring [A]. • Install the collar [B] Coupling Bearing Removal • Remove: Coupling Grease Seal Circlip [A] Special Tool - Inside Circlip Pliers [B]: 57001-143 • Remove the bearing [A] by tapping from the wheel side. Special Tool - Bearing Driver Set [B]: 57001-1129 Coupling Bearing Installation •...
  • Page 375: Coupling Bearing Inspection

    FINAL DRIVE 11-13 Sprocket, Coupling Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances, the clearance can not normally be measured. NOTE ○ It is not necessary to remove the coupling bearing for inspection. If the bearing is removed, it will need to be replaced with a new one.
  • Page 376: Rear Sprocket Warp Inspection

    11-14 FINAL DRIVE Sprocket, Coupling Rear Sprocket Warp Inspection • Raise the rear wheel off the ground 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 377 BRAKES 12-1 Brakes Table of Contents Exploded View ........12-2 Rear Brake Pad Installation ..12-14 Specifications ........12-6 Brake Pad Wear Inspection ..12-14 Special Tools ........12-7 Master Cylinder ......... 12-15 Brake Lever, Brake Pedal....12-8 Front Master Cylinder Removal ... 12-15 Brake Lever Position Adjustment.
  • Page 378: Exploded View

    12-2 BRAKES Exploded View http://mototh.com...
  • Page 379 BRAKES 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Brake Disc Mounting Bolts Front Brake Light Switch Screw 0.12 10 in·lb Front Brake Pad Pins...
  • Page 380 12-4 BRAKES Exploded View http://mototh.com...
  • Page 381 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 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 382: Specifications

    12-6 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 6-way adjustable (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 60 mm (2.4 in.) below footpeg top –...
  • Page 383: Special Tools

    BRAKES 12-7 Special Tools Inside Circlip Pliers: Jack Attachment: 57001-143 57001-1608 Jack: 57001-1238 http://mototh.com...
  • Page 384: Brake Lever, Brake Pedal

    12-8 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 6 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 385: Brake Pedal Installation

    BRAKES 12-9 Brake Lever, Brake Pedal • Remove: Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] • Remove the mounting bolt [E] and take out the brake pedal. Brake Pedal Installation • Apply high-temperature grease to the pivot shaft [A] and install the washer [B].
  • Page 386: Calipers

    12-10 BRAKES 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. CAUTION Do not loosen the caliper assembly bolts [D]. Take out only the caliper mounting bolts for caliper re- moval.
  • Page 387: Front Caliper Disassembly

    BRAKES 12-11 Calipers WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc. The brakes will not function on the first appli- cation of the lever or pedal if this is not done.
  • Page 388: Rear Caliper Dust Boot And Friction Boot Damage

    12-12 BRAKES Calipers Rear Caliper Dust Boot and Friction Boot Damage • Check that the dust boot [A] and friction boot [B] are not cracked, worn, swollen, or otherwise damaged. If they show any damage, replace it. Caliper Piston and Cylinder Damage •...
  • Page 389: Brake Pads

    BRAKES 12-13 Brake Pads Front Brake Pad Removal • Loosen: Pad Pins [A] • Remove: Pad Pins [A] Pad Springs [B] Brake Pads [C] Front Brake Pad Installation • Push the caliper pistons in by hand as far as they will go. •...
  • Page 390: Rear Brake Pad Removal

    12-14 BRAKES Brake Pads Rear Brake Pad Removal • Remove the caliper with the hose installed. • Remove: Clip [A] Pad Pin [B] Brake Pads [C] Rear Brake Pad Installation • Push the caliper piston in by hand as far as it will go. •...
  • Page 391: Master Cylinder

    BRAKES 12-15 Master Cylinder Front Master Cylinder Removal • Remove the reservoir bracket nut [A]. • Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder (see Brake Hose Removal/In- stallation in this chapter). • Unscrew the clamp bolts [B], and take off the master cylin- der [C] as an assembly with the reservoir, brake lever, and brake switch installed.
  • Page 392: Rear Master Cylinder Removal

    12-16 BRAKES Master Cylinder Rear Master Cylinder Removal • Unscrew the brake hose banjo bolt [A] and brake hose [B]. • Remove: Cotter Pin [C] Joint Pin [D] Bolts [E] Foot Guard [F] Rear Master Cylinder • Slide out the clamp [G]. •...
  • Page 393 BRAKES 12-17 Master Cylinder • Check the dust covers [E] for damage. If they are damaged, replace them. • Check the piston return spring [F] for any damage. If the springs are damaged, replace them. • Check that relief port [G] and supply port [H] are not plugged.
  • Page 394: Brake Disc

    12-18 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. Brake Disc Installation • Install the brake disc on the wheel so that the marked side [B] faces out.
  • Page 395: Brake Fluid

    BRAKES 12-19 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 396 12-20 BRAKES Brake Fluid • Bleed the brake line and the master cylinder. ○ 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 397 BRAKES 12-21 Brake Fluid • Install: Diaphragm [A] Diaphragm Plate [B] Front Brake Reservoir Cap [C] Clamp [D] Screw [E] • Follow the procedure below to install the front/rear brake fluid reservoir cap correctly. ○ First, tighten the brake fluid reservoir cap [B] clockwise [C] by hand until the resistance is felt fully;...
  • Page 398 12-22 BRAKES 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 399: Brake Hose

    BRAKES 12-23 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 Con- nection Inspection in the Periodic Maintenance chapter. http://mototh.com...
  • Page 400 http://mototh.com...
  • Page 401 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-9 Rebound Damping Force Adjustment................13-9 Compression Damping Force Adjustment ................ 13-9 Spring Preload Adjustment ....................13-10 Front Fork Removal (Each Fork Leg) ................13-10 Front Fork Installation .......................
  • Page 402: Exploded View

    13-2 SUSPENSION Exploded View http://mototh.com...
  • Page 403 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolts Front Fork Bottom Allen Bolts Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Front Fork Top Plugs Piston Rod Nuts AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.
  • Page 404 13-4 SUSPENSION Exploded View http://mototh.com...
  • Page 405 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Bracket Nut 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 G: Apply grease.
  • Page 406: Specifications

    13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Diameter 41 mm (1.6 in.) Air Pressure Atmospheric pressure (non-adjustable) Rebound Damper Setting 1 3/4 turns out from the fully clockwise position (Usable range: 0 ←→ 2 turns out) Compression Damper Setting 3/4 turn out from the fully clockwise position (Usable range: 0 ←→...
  • Page 407: Special Tools

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Fork Piston Rod Puller, M12 × 1.25: 57001-143 57001-1289 Oil Seal & Bearing Remover: Fork Oil Level Gauge: 57001-1058 57001-1290 Bearing Driver Set: Bearing Remover Head, 20 × 22: 57001-1129 57001-1293 Jack: Bearing Remover Shaft, 13: 57001-1238 57001-1377 Fork Oil Seal Driver, 41:...
  • Page 408 13-8 SUSPENSION Special Tools Hook Wrench T=3.2 R37: Stem Bearing Driver, 28: 57001-1539 57001-1610 Fork Spring Compressor: Clamp: 57001-1587 57001-1626 Swingarm Pivot Nut Wrench: Spacer, 57001-1597 57001-1636 Jack Attachment: Spacer, 57001-1608 57001-1637 Needle Bearing Driver, 17/ 18: Hook Wrench R37: 57001-1609 57001-1641 http://mototh.com...
  • Page 409: Front Fork

    SUSPENSION 13-9 Front Fork Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebound damping adjuster [A] until you feel a click. ○ The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 1 3/4 turns out from the fully clockwise position.
  • Page 410: Spring Preload Adjustment

    13-10 SUSPENSION Front Fork Spring Preload Adjustment • Turn the spring preload adjuster [A] to change spring preload setting. ○ The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 17 mm (0.67 in.) [B] from top as shown. Adjuster Protrusion (from top) Standard: 17 mm (0.67 in.)
  • Page 411: Front Fork Installation

    SUSPENSION 13-11 Front Fork Front Fork Installation • Install the fork so that the top end [A] of the outer tube as shown. 6.5 mm (0.26 in.) [B] • Tighten the lower fork clamp bolts and fork top plug. Torque - Front Fork Clamp Bolts (Lower): 25 N·m (2.5 kgf·m, 18 ft·lb) Front Fork Top Plug: 35 N·m (3.5 kgf·m, 26 ft·lb) •...
  • Page 412 13-12 SUSPENSION Front Fork • Insert the holder bar [A] into the axle hole of the front fork [B]. • Insert the compression shaft and install the nut. • Insert the lower end of the compression shaft [A] into the hole [B] of the holder bar.
  • Page 413 SUSPENSION 13-13 Front Fork • Holding the piston rod nut with a wrench [A], remove the top plug assy [B] from the piston rod. • Remove: Washer [A] Collar [B] Collar [C] Fork Spring [D] • Drain the fork oil into a suitable container. ○...
  • Page 414 13-14 SUSPENSION Front Fork Oil Level (fully compressed, without spring) Standard: 109 ±2 mm (4.29 ±0.08 in.) (from the top of the outer tube) NOTE ○ Fork oil lever may also be measured using the fork oil level gauge. Special Tool - Fork Oil Level Gauge [A]: 57001-1290 ○...
  • Page 415: Front Fork Disassembly

    SUSPENSION 13-15 Front Fork • Screw in the top plug assy [A] stopped onto the piston rod. • Check the O-ring [B] on the top plug and replace it with a new one if damaged. • Holding the top plug with a wrench, tighten the piston rod nut [C] against the top plug.
  • Page 416: Front Fork Assembly

    13-16 SUSPENSION Front Fork • Separate the outer tube from the inner tube. • Pull out the dust seal. • Remove the retaining ring [A] from the outer tube. • Remove the oil seal [B] and washer [C]. Front Fork Assembly •...
  • Page 417: Dust Seal Inspection

    SUSPENSION 13-17 Front Fork CAUTION If the inner tube is badly bent or creased, replace Excessive bending, followed by subsequent straightening, can weaken the inner tube. • Temporarily assemble the inner and outer tubes, and pump them back and forth manually to check for smooth operation.
  • Page 418: Rear Shock Absorber

    13-18 SUSPENSION Rear Shock Absorber Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the lower damping adjuster [A] to the desired position, until you feel a click. ○ The standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 9th click from the 1st click of the fully clockwise position.
  • Page 419: Rear Shock Absorber Removal

    SUSPENSION 13-19 Rear Shock Absorber • To adjust the spring preload, turn in the adjusting nut [A] to the desired position and tighten the locknut [B]. Spring Length [C] Spring Preload Setting Standard: Spring length 182.7 mm (7.19 in.) Spring length 177.7 ∼ 187.7 mm (6.996 Usable Range: ∼...
  • Page 420: Rear Shock Absorber Installation

    13-20 SUSPENSION Rear Shock Absorber • Remove: Lower Shock Absorber Nut and Bolt [A] Upper Tie-Rod Nut and Bolt [B] Upper Shock Absorber Nut and Bolt [C] • Remove the shock absorber downward. Rear Shock Absorber Installation • Tighten: Torque - Rear Shock Absorber Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) Tie-Rod Nuts: 59 N·m (6.0 kgf·m, 43 ft·lb) Rear Shock Absorber Inspection...
  • Page 421: Swingarm

    SUSPENSION 13-21 Swingarm Swingarm Removal • Remove: Bolts [A] Chain Cover [B] Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter) • Remove: Bolt [A] Brake Hose Clamp [B] •...
  • Page 422: Swingarm Installation

    13-22 SUSPENSION Swingarm • Unscrew the swingarm pivot collar locknut [A] using the nut wrench [B]. Special Tool - Swingarm Pivot Nut Wrench: 57001-1597 • Unscrew the swingarm pivot shaft [A] few times. ○ Turn out the swingarm pivot adjusting collar [B]. •...
  • Page 423: Swingarm Bearing Removal

    SUSPENSION 13-23 Swingarm • Be sure to install the washer [A]. • Tighten the adjusting collar locknut [A] with the swingarm pivot nut wrench [B]. Special Tool - Swingarm Pivot Nut Wrench: 57001-1597 Torque - Swingarm Pivot Adjusting Collar Locknut: 98 N·m (10 kgf·m, 72 ft·lb) •...
  • Page 424: Swingarm Bearing Installation

    13-24 SUSPENSION Swingarm Swingarm Bearing Installation • Replace the ball and needle bearings [A] with new ones. • Install the ball and needle bearings so that the manufac- turer’s marks face out. Special Tools - Bearing Driver Set: 57001-1129 Needle Bearing Driver, 28 [B]: 57001-1610 Spacer, 28: 57001-1637 •...
  • Page 425: Chain Guide Inspection

    SUSPENSION 13-25 Swingarm • Turn the bearing in the coupling back and forth [A] while checking for plays, roughness, or binding. If 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 426: Tie-rod, Rocker Arm

    13-26 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter). • Squeeze the brake lever slowly and hold it with a band [A]. • Using the jack, raise the rear wheel off the ground. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 •...
  • Page 427: Rocker Arm Installation

    SUSPENSION 13-27 Tie-Rod, Rocker Arm Rocker Arm Installation • Apply grease to the inside of the grease seals. • Tighten: Torque - Uni-Trak Rocker Arm Nut: 34 N·m (3.5 kgf·m, 25 ft·lb) Tie-Rod Nuts: 59 N·m (6.0 kgf·m, 43 ft·lb) Rear Shock Absorber Nut (Lower): 34 N·m (3.5 kgf·m, 25 ft·lb) Tie-Rod and Rocker Arm Bearing Removal...
  • Page 428 13-28 SUSPENSION Tie-Rod, Rocker Arm ○ Screw the needle bearing driver [A] into the driver holder [B]. ○ Insert the needle bearing driver into the needle bearing [C] and press the needle bearing into the housing until the driver contacts the end surface of the housing. Bearing Pressing Depth: 5.5 mm (0.22 in.)[D] 5.0 mm (0.20 in.)[E] NOTE...
  • Page 429: Rocker Arm/tie-rod Bearing, Sleeve Inspection

    SUSPENSION 13-29 Tie-Rod, Rocker Arm Rocker Arm/Tie-Rod Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection. Re- moval may damage them. • Visually inspect the locker arm, or tie-rod sleeves [A] and needle bearings [B]. • The rollers in a needle bearing normally wear very little, and wear is difficult to measure.
  • Page 430 http://mototh.com...
  • Page 431 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 Steering Stem Bearing Lubrication ................... 14-9 Steering Stem Warp......................
  • Page 432: Exploded View

    14-2 STEERING Exploded View http://mototh.com...
  • Page 433 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 Bolts Handlebar Position Bolts 87 in·lb Steering Stem Head Nut Steering Stem Nut Switch Housing Screws 0.36 31 in·lb AD: Apply adhesive.
  • Page 434: Special Tools

    14-4 STEERING Special Tools Bearing Puller Adapter: Bearing Driver Set: 57001-136 57001-1129 Bearing Puller: Steering Stem Bearing Driver, 42.5: 57001-158 57001-1344 Head Pipe Outer Race Press Shaft: Steering Stem Bearing Driver Adapter, 41.5: 57001-1075 57001-1345 Steering Stem Nut Wrench: Head Pipe Outer Race Driver, 55: 57001-1100 57001-1446 http://mototh.com...
  • Page 435: Steering Inspection

    STEERING 14-5 Steering Steering Inspection • Refer to the Steering Inspection in the Periodic Mainte- nance chapter. Steering Adjustment • Refer to the Steering Adjustment in the Periodic Mainte- nance chapter. http://mototh.com...
  • Page 436: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fork (see Front Fork Removal in the Suspension chapter) Brake Hose Clamp Bolt [A] •...
  • Page 437: Stem, Stem Bearing Installation

    STEERING 14-7 Steering Stem • Remove the lower bearing inner race (with its oil seal) [A] which is pressed onto the steering stem [B] with the bearing puller [C] and adapter [D]. Special Tools - Bearing Puller Adapter: 57001-136 Bearing Puller: 57001-158 Stem, Stem Bearing Installation •...
  • Page 438 14-8 STEERING Steering Stem • Settle the bearings in place as follows. ○ Tighten the steering stem nut with 55 N·m (5.6 kgf·m, 41 ft·lb) of torque first, and loosen it a fraction of a turn until it turns lightly (To tighten the stem nut to the specified torque, hook the wrench on the stem nut, and pull the wrench at the hole by 305 N (31.0 kgf, 69 lb) [B] force in the direction shown.).
  • Page 439: Steering Stem Bearing Lubrication

    STEERING 14-9 Steering Stem NOTE ○ Tighten the upper fork clamp bolts [A] first, next the stem head nut [B], last the lower fork clamp bolts [C] and the handlebar bolts [D]. ○ Tighten the two lower fork clamp bolts alternately two times to ensure even tightening torque.
  • Page 440: Handlebar

    14-10 STEERING Handlebar Handlebar Removal • Remove: Clutch Lever Clamp Bolts [A] Clutch Lever Assembly [B] Left Switch Housing [C] Handlebar Weight [D] • Remove: Front Brake Master Cylinder [A] (see Front Master Cylin- der Removal in the Brakes chapter) Right Switch Housing [B] Throttle Case [C] Handlebar Weight [D]...
  • Page 441 STEERING 14-11 Handlebar • Install the left and right switch housings. ○ Fit the projection [A] into a small hole [B] in the handlebar. Torque - Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb) • Install: Clutch Lever (see Clutch Lever Installation in the Clutch chapter) •...
  • Page 442 http://mototh.com...
  • Page 443 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Seats ............................15-8 Rear Seat Removal......................15-8 Rear Seat Installation......................15-8 Front Seat Removal ......................15-8 Front Seat Installation ....................... 15-8 Fairings........................... 15-9 Lower Fairing Removal ..................... 15-9 Lower Fairing Installation ....................15-9 Center Fairing Removal ....................
  • Page 444: Exploded View

    15-2 FRAME Exploded View http://mototh.com...
  • Page 445 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Footpeg Bracket Bolts Rear Footpeg Bracket Bolts Rear Frame Bolts L (2) Side Stand Bolt Side Stand Bracket Bolts Side Stand Switch Bolt 0.90 78 in·lb Side Stand Switch Bracket Bolt 0.40 G: Apply grease.
  • Page 446 15-4 FRAME Exploded View http://mototh.com...
  • Page 447 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fender Mounting Bolts 0.40 35 in·lb 2. United States and Canada Models R: Replacement Parts http://mototh.com...
  • Page 448 15-6 FRAME Exploded View http://mototh.com...
  • Page 449 FRAME 15-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Inlet Duct Mounting Bolts 0.70 Windshield Mounting Bolts 0.04 4 in·lb L: Apply a non-permanent locking agent. R: Replacement Parts http://mototh.com...
  • Page 450: Seats

    15-8 FRAME Seats Rear Seat Removal • Insert the ignition switch key [A] into the seat lock, turning the key counterclockwise, pulling the front part of the seat [B] up, and pull the seat forward. Rear Seat Installation • Put the rear seat hook [A] on the rib [B]. •...
  • Page 451: Fairings

    FRAME 15-9 Fairings Lower Fairing Removal • Remove: Bolts [A] with Washers • Clear the hook portion from the slot. • Pull up the core [A] by the thin blade driver. • Remove: Quick Rivets [B] • Separate the right lower fairing from the left lower fairing. Lower Fairing Installation •...
  • Page 452: Center Fairing Installation

    15-10 FRAME Fairings • Remove: Right Turn Signal Lead Connector [A] Immobilizer Amplifier Connector [B] (Immobilizer Mod- els) Center Fairing Installation • Install the separator bracket bolt (California Model). • Connect the immobilizer amplifier connector (Immobilizer Models). • Connect the turn signal lead connectors. •...
  • Page 453: Upper Fairing Disassembly

    FRAME 15-11 Fairings • Open the clamps [A] (Both Side). • Disconnect the meter lead connector [A]. • Remove: Bolts [A] (Both Side) Upper Fairing ○ Pull out the upper fairing forward. Upper Fairing Disassembly • Remove: Center Inner Fairing (see Center Inner Fairing Removal in this chapter) Nuts [A] and Rear View Mirrors (Both Side) Meter Unit (see Meter Unit Removal in the Electrical Sys-...
  • Page 454: Upper Fairing Installation

    15-12 FRAME Fairings Upper Fairing Installation • Fit the opening [A] of the upper fairing into the ram air duct [B]. • Apply a non-permanent locking agent to the threads and, tighten the bolts. Torque - Air Inlet Duct Mounting Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb) Upper Inner Fairing Removal •...
  • Page 455: Right And Left Inner Fairing Removal

    FRAME 15-13 Fairings Right and Left Inner Fairing Removal • Remove: Right and Left Center Fairings (see Center Fairing Re- moval in this chapter) Bolts [A] Inner Fairing [B] Right and Left Inner Fairing Installation • Tighten the bolts [A]. http://mototh.com...
  • Page 456: Side Covers

    15-14 FRAME Side Covers Left Side Cover Removal • Remove: Bolts [A] • Pull out the side cover [B]. Left Side Cover Installation • Insert the projections [A] into the holes [B]. Right Side Cover Removal • Remove: Bolt [A] •...
  • Page 457: Seat Cover

    FRAME 15-15 Seat Cover Seat Cover Removal • Remove: Seats (see Rear/Front Seat Removal in this chapter) Bolts [A] • Remove: Rivet Screws [A] • Pull the seat cover backward, and clear the stoppers. • Disconnect: Tail/Brake Light Connector [A] •...
  • Page 458: Fenders

    15-16 FRAME Fenders Front Fender Removal • Remove: Brake Hose Clamps [A] (Both Side) Bolts [B] with Washer (Both Side) • Remove the front fender assy [C]. • Remove: Bolts [A] • Separate the front fender cover [B] and front fender [C]. Front Fender Installation •...
  • Page 459: Flap And Rear Fender Rear Installation

    FRAME 15-17 Fenders • Remove: Nuts [A] Bolts [B] Flap [C] (with License Light) Turn Signal Lights • Remove: Muffler Body and Center Pipe (see Muffler Body Re- moval in the Engine Top End chapter) Battery (see Battery Removal in the Electrical System chapter) Exhaust Butterfly Valve Actuator (see Exhaust Butterfly Valve Actuator Removal in the Fuel System (DFI) chap-...
  • Page 460: Rear Fender Front Removal

    15-18 FRAME Fenders • Install the removed parts (see appropriate chapters). • Install the harness clamp in accordance with Cable, Wire, and Hose Routing section in the Appendix chapter. • Install the flap. If there is a gap between the tire and flap, adjust it using the washer [A].
  • Page 461: Rear Frame Removal

    FRAME 15-19 Frame Rear Frame Removal • Remove: Rear Fender Front (see Rear Fender Front Removal in this chapter) Frame Bolts [A] and Nuts Rear Footpeg Bracket Bolts [B] and Bracket (Both Side) Rear Frame Installation • Apply a non-permanent locking agent to the threads of rear frame bolt.
  • Page 462: Side Stand

    15-20 FRAME Side Stand Side Stand Removal • Raise the rear wheel off the ground with the stand. • Remove: Lower Fairings (see Lower Fairing Removal in this chap- ter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) •...
  • Page 463 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Parts Location........16-3 Stick Coil (Ignition Coil together Exploded View........16-4 with Spark Plug Cap) Removal . 16-41 Wiring Diagram (United States, Stick Coil (Ignition Coil together Canada and New Zealand)..... 16-10 with Spark Plug Cap) Wiring Diagram (Other than United Installation .........
  • Page 464 16-2 ELECTRICAL SYSTEM License Plate Light Bulb Brake Light Timing Inspection..16-93 Replacement ......16-56 Brake Light Timing Adjustment ..16-93 Turn Signal Light Bulb Neutral Switch Replacement..16-93 Replacement ......16-58 Switch Inspection ......16-94 Turn Signal Relay Inspection ..16-59 Water Temperature Sensor Radiator Fan System......
  • Page 465: Parts Location

    ELECTRICAL SYSTEM 16-3 Parts Location 1. Starter Lockout Switch 12. Starter Motor 2. Ignition Switch with Immobilizer Antenna 13. Speed Sensor 3. Stick Coils 14. Side Stand Switch 4. Water Temperature Sensor 15. Neutral Switch 5. Alternator 16. Turn Signal Relay 6.
  • Page 466: Exploded View

    16-4 ELECTRICAL SYSTEM Exploded View http://mototh.com...
  • Page 467 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Turn Signal Light Lens Screws 0.10 9 in·lb Front Turn Signal Light Mounting Screws 0.12 10 in·lb Headlight Mounting Screws 0.12 10 in·lb Licence Light Assembly Screws 0.09 8 in·lb Licence Light Mounting Screws 0.12...
  • Page 468 16-6 ELECTRICAL SYSTEM Exploded View http://mototh.com...
  • Page 469 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Light Switch Screw 0.12 10 in·lb Starter Motor Clutch Bolts Starter Motor Mounting Bolts 97 in·lb Starter Motor Cable Terminal Bolt 0.28 24 in·lb Starter Relay Cable Terminal Bolts 0.40 35 in·lb Switch Housing Screws...
  • Page 470 16-8 ELECTRICAL SYSTEM Exploded View http://mototh.com...
  • Page 471 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Alternator Cover Bolts 104 in·lb Alternator Lead Holding Plate Bolts 0.70 61 in·lb Alternator Rotor Bolt Camshaft Position Sensor Bolt 104 in·lb Crankshaft Sensor Bolts 0.60 52 in·lb Crankshaft Sensor Cover Bolts 87 in·lb L (1) Engine Ground Lead Terminal Bolt...
  • Page 472: Wiring Diagram (united States, Canada And New Zealand)

    16-10 ELECTRICAL SYSTEM Wiring Diagram (United States, Canada and New Zealand) http://mototh.com...
  • Page 473 ELECTRICAL SYSTEM 16-11 Wiring Diagram (United States, Canada and New Zealand) http://mototh.com...
  • Page 474: Wiring Diagram (other Than United States, Canada, New Zealand, Australia And Malaysia)

    16-12 ELECTRICAL SYSTEM Wiring Diagram (Other than United States, Canada, New Zealand, Australia and Malaysia) http://mototh.com...
  • Page 475 ELECTRICAL SYSTEM 16-13 Wiring Diagram (Other than United States, Canada, New Zealand, Australia and Malaysia) http://mototh.com...
  • Page 476 16-14 ELECTRICAL SYSTEM Wiring Diagram (Australia) http://mototh.com...
  • Page 477 ELECTRICAL SYSTEM 16-15 Wiring Diagram (Australia) http://mototh.com...
  • Page 478: Wiring Diagram (malaysia)

    16-16 ELECTRICAL SYSTEM Wiring Diagram (Malaysia) http://mototh.com...
  • Page 479 ELECTRICAL SYSTEM 16-17 Wiring Diagram (Malaysia) http://mototh.com...
  • Page 480: Specifications

    16-18 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed battery Capacity 12 V 8 Ah Voltage 12.8 V or more Charging System Type Three-phase AC Alternator Output Voltage 42 V or more @4 000 r/min (rpm) 0.3 ∼ 0.4 Ω Stator Coil Resistance 14.2 ∼...
  • Page 481: Special Tools And Sealant

    Key Registration Unit: 57001-1394 57001-1582 Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: Flywheel & Pulley Holder: 57001-1405 57001-1605 Peak Voltage Adapter: Kawasaki Bond (Silicone Sealant): 57001-1415 56019-120 Lead Wire - Peak Voltage Adapter: Kawasaki Bond (Silicone Sealant): 57001-1449 92104-0004 http://mototh.com...
  • Page 482: Precautions

    16-20 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 lead connections. This will burn out the diodes on the electrical parts. ○...
  • Page 483 ELECTRICAL SYSTEM 16-21 Precautions Male Connectors [B] http://mototh.com...
  • Page 484: Electrical Wiring

    16-22 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 485: Battery

    ELECTRICAL SYSTEM 16-23 Battery Battery Removal • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Bolts [A] Connector [B] Fuel Tank Bracket [C] • Slide the caps [A].
  • Page 486 16-24 ELECTRICAL SYSTEM Battery CAUTION Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. • Place the battery on a level surface. •...
  • Page 487 Newly activated sealed batteries require an initial charge. Standard Charge: 0.9 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 488: Precautions

    16-26 ELECTRICAL SYSTEM Battery NOTE ○ To ensure maximum battery life and customer satisfac- tion, it is recommended the battery be load tested at three times its amp-hour rating for 15 seconds. Re-check voltage and if less than 12.8 V repeat the charging cycle and load test.
  • Page 489: Charging Condition Inspection

    ELECTRICAL SYSTEM 16-27 Battery Charging Condition Inspection ○ Battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter [A]. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery Cable Caps (see Battery Removal in this chap- ter) •...
  • Page 490 16-28 ELECTRICAL SYSTEM Battery Terminal Voltage: 11.5 ∼ less than 12.8 V Standard Charge 0.9 A × 5 ∼ 10 h (see following chart) Quick Charge 4 A × 1 h CAUTION If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on.
  • Page 491: 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 492: 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 • Secure the alternator lead with a holding plate, and apply a non-permanent locking agent to the threads of the plate bolts and tighten them.
  • Page 493 ELECTRICAL SYSTEM 16-31 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 494: Alternator Inspection

    16-32 ELECTRICAL SYSTEM Charging System Alternator Inspection There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all.
  • Page 495: Regulator/rectifier Removal

    ELECTRICAL SYSTEM 16-33 Charging System Regulator/Rectifier Removal • Remove: Bolts [A] Regulator/Rectifier [B] • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Connector [A] Regulator/Rectifier Inspection Rectifier Circuit Check • Check the rectifier resistance as follows. •...
  • Page 496 16-34 ELECTRICAL SYSTEM Charging System Regulator Circuit Check To test the regulator out of circuit, use three 12 V batteries and a test light (12 V 3 ∼ 6 W bulb in a socket with leads). CAUTION The test light works as an indicator and also a cur- rent limiter to protect the regulator/rectifier from ex- cessive current.
  • Page 497: Charging Voltage Inspection

    ELECTRICAL SYSTEM 16-35 Charging System Charging Voltage Inspection • Check the battery condition (see Charging Condition In- spection in this chapter). • Warm up the engine to obtain actual alternator operating conditions. • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Caps •...
  • Page 498 16-36 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 2. Alternator 3. Regulator/rectifier 4. Main Fuse 30 A 5. Battery 12 V 8 Ah 6. Load http://mototh.com...
  • Page 499: Starter Motor Clutch

    ELECTRICAL SYSTEM 16-37 Starter Motor Clutch Starter Motor Clutch Removal/Inspection • Refer to the Alternator Rotor Removal and Installation in this chapter. Starter Motor Clutch Inspection • Remove: Alternator Cover (see Alternator Cover Removal in this chapter) Starter Idle Gear •...
  • Page 500: Ignition System

    16-38 ELECTRICAL SYSTEM Ignition System http://mototh.com...
  • Page 501: Crankshaft Sensor Removal

    ELECTRICAL SYSTEM 16-39 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 leads or any other electrical connections when the ignition switch is on, or while the engine is running.
  • Page 502: Crankshaft Sensor Installation

    Torque - Crankshaft Sensor Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) • Apply silicone sealant. Crankshaft Sensor Lead Grommet (Around) [A] Crankcase Halves Mating Surfaces [B] Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install the gasket. • Apply a non-permanent locking agent. Crankshaft Sensor Cover Bolt [A] •...
  • Page 503: Timing Rotor Removal

    ELECTRICAL SYSTEM 16-41 Ignition System • Set the hand tester [A] to the × 10 V DC range, and con- nect it peak voltage adapter [B]. • Connect the black lead (–) [D] of the adapter to black/yel- low lead and red lead (+) [C] to black lead in the crankshaft sensor connector [E].
  • Page 504: Stick Coil (ignition Coil Together With Spark Plug Cap) Installation

    16-42 ELECTRICAL SYSTEM Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Installation • Connect the connectors [A]. CAUTION Do not tap the coil head while installing the coil. • Run the hoses and harness correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
  • Page 505: Stick Coil

    ELECTRICAL SYSTEM 16-43 Ignition System Stick Coil Primary Peak Voltage NOTE ○ Be sure the battery is fully charged. • Remove the stick coils (see Stick Coil (Ignition Coil to- gether with Spark Plug Cap) Removal in this chapter), but do not remove the spark plugs.
  • Page 506: Spark Plug Installation

    16-44 ELECTRICAL SYSTEM Ignition System Spark Plug Installation • Refer to the Spark Plug Replacement in the Periodic Maintenance chapter. Spark Plug Clean and Inspection • Refer to the Spark Plug Clean and Gap Inspection in the Periodic Maintenance chapter. Spark Plug Gap Inspection •...
  • Page 507: Camshaft Position Sensor Peak Voltage Inspection

    ELECTRICAL SYSTEM 16-45 Ignition System • Set the hand tester to the × 10 Ω range and connect it to the terminals. Special Tool - Hand Tester: 57001-1394 If there is more resistance than the specified value, the sensor coil has an open lead and must be replaced. Much less than this resistance means the sensor coil is shorted, and must be replaced.
  • Page 508: Interlock Operation Inspection

    16-46 ELECTRICAL SYSTEM Ignition System Interlock Operation Inspection • Using the stand [A], raise the rear wheel off the ground. 1st Check • Start the engine to the following conditions. Condition Transmission Gear → 1st Position Clutch Lever → Release Side Stand →...
  • Page 509: Ic Igniter Inspection

    ELECTRICAL SYSTEM 16-47 Ignition System IC Igniter Inspection ○ The IC igniter is built in the ECU [A]. • Refer to the Interlock Operation Inspection, Ignition Sys- tem Troubleshooting chart and Fuel System (DFI) chapter for ECU Power Supply Inspection. http://mototh.com...
  • Page 510 16-48 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. ECU 13. Ignition Switch 2. Side Stand Switch 14. Starter Lockout Switch 3. Crankshaft Sensor 15. ECU Fuse 15 A 4. Main Throttle Sensor 16. Ignition Fuse 10 A 5. Subthrottle Sensor 17.
  • Page 511: Electric Starter System

    ELECTRICAL SYSTEM 16-49 Electric Starter System Starter Motor Removal • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Slide back the rubber cap. • Remove the starter motor terminal bolt [A] and the mount- ing bolts [B].
  • Page 512: Brush Inspection

    16-50 ELECTRICAL SYSTEM Electric Starter System • Press the springs holding the brush leads with suitable clips [A] as shown. • Put the armature [B] among the brushes. • Install the O-rings [A] as shown. • Align the groove [A] in the right-hand end cover and the hollow mark [B] on the yoke.
  • Page 513: Commutator Cleaning And Inspection

    ELECTRICAL SYSTEM 16-51 Electric Starter System Commutator Cleaning and Inspection • Smooth the commutator surface [A] if necessary with fine emery cloth [B], and clean out the grooves. • Measure the diameter [A] of the commutator [B]. If the commutator diameter is less than the service limit, replace the starter motor with a new one .
  • Page 514: Right-hand End Cover Assembly Inspection

    16-52 ELECTRICAL SYSTEM Electric Starter System Right-hand End Cover Assembly Inspection • Using the highest hand tester range, measure the resis- tance as shown. Terminal and Right-hand End Cover [A] Special Tool - Hand Tester: 57001-1394 If there is any reading, the right-hand end cover assembly have a short.
  • Page 515 ELECTRICAL SYSTEM 16-53 Electric Starter System Electric Starter Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Neutral Switch 5. Side Stand Switch 6. Battery 12 V 8 Ah 7. Starter Relay 8. Main Fuse 30 A 9.
  • Page 516: Lighting System

    16-54 ELECTRICAL SYSTEM 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 517: City Light Bulb Replacement

    ELECTRICAL SYSTEM 16-55 Lighting System • Turn the dust cover clockwise, align the mark [A] on the headlight and mark [B] the dust cover. • After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter). City Light Bulb Replacement •...
  • Page 518: Tail/brake Light (led) Removal

    16-56 ELECTRICAL SYSTEM Lighting System Tail/Brake Light (LED) Removal • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) • Unscrew the mounting bolt [A]. • Remove the tail/brake light (LED) [B]. Tail/Brake Light (LED) Installation • Refer to the Seat Cover Installation in the Frame chapter. License Plate Light Bulb Replacement •...
  • Page 519 ELECTRICAL SYSTEM 16-57 Lighting System Headlight/Tail Light Circuit 1. Ignition Switch 2. Headlight (High Beam) 3. Headlight (Low Beam) 4. Regulator/Rectifier 5. License Plate Light 6. Tail/Brake Light (LED) 7. Battery 12 V 8 Ah 8. Main Fuse 30 A 9.
  • Page 520: Turn Signal Light Bulb Replacement

    16-58 ELECTRICAL SYSTEM Lighting System Turn Signal Light Bulb Replacement For the European, Malaysian and Australian Models • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Center Fairings (see Center Fairing Removal in the Frame chapter) • Turn the socket [A] counterclockwise and pull out the socket together with the bulb.
  • Page 521: 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, ant turn the bulb clockwise.
  • Page 522 16-60 ELECTRICAL SYSTEM Lighting System Other than United States, Canada and New Zealand Models • Connect one 12 V battery and turn signal lights as indi- cated in the figure, and count how may times the lights flash for one minute. Turn Signal Relay [A] Turn Signal Lights [B] 12 V Battery [C]...
  • Page 523 ELECTRICAL SYSTEM 16-61 Lighting System Turn Signal Light Circuit 1. Meter Unit 2. Ignition Switch 3. Front Right Turn Signal Light 4. Front Left Turn Signal Light 5. Turn Signal Switch 6. Turn Signal Relay Fuse 10 A 7. Turn Signal Relay 8.
  • Page 524: Radiator Fan System

    16-62 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Inspection • Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). • Disconnect the connector [A]. • Using an auxiliary leads, supply battery power to the fan motor.
  • Page 525 ELECTRICAL SYSTEM 16-63 Radiator Fan System Radiator Fan Circuit 1. ECU 2. Water Temperature Sensor 3. Radiator Fan 4. Starter Button 5. Engine Stop Switch 6. Ignition Switch 7. Ignition Fuse 10 A 8. ECU Fuse 15 A 9. Fan Fuse 15 A 10.
  • Page 526: Meter, Gauge, Indicator Unit

    16-64 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Unit Removal • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Nuts [A] Screws [B] • Remove the bolts [A]. • Remove the screws [A]. CAUTION Place the meter unit so that the face is up. If a meter unit is left upside down or sideways for any length of time, it will malfunction.
  • Page 527: Electronic Combination Meter Assembly Inspection

    ELECTRICAL SYSTEM 16-65 Meter, Gauge, Indicator Unit Electronic Combination Meter Assembly Inspection • Remove the meter assembly [A]. [1] Ignition [2] Fuel Reserve Switch [3] Stop Watch (+) [4] Lap Time (+) [5] Neutral Indicator Light (LED) Ground (–) [6] FI Indicator Light (LED) Ground (–) [7] Tachometer Pulse [8] Water Temperature Sensor [9] Ground (–)
  • Page 528 16-66 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit ○ The tachometer LCD segments momentarily to it last readings two times and segment movement is reversal. ○ When the terminals are connected, all the LCD segments [A] and LED light [B] appear for three seconds. If the LCD segments and LED warning light will not ap- pear, replace the meter assembly.
  • Page 529 ELECTRICAL SYSTEM 16-67 Meter, Gauge, Indicator Unit • In the HOUR setting mode, press the reset button [C] to effect the MINUTE setting mode. ○ The minute display flashes on the display. • Press the mode selector button [A] to set the minute. •...
  • Page 530 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 531 ELECTRICAL SYSTEM 16-69 Meter, Gauge, Indicator Unit Tachometer Check • Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • The revolutions per minute (rpm) equivalent to the input frequency is indicated in the oscillator [A] if the square wave (illustrated as shown) would be input into the termi- nal [7].
  • Page 532 16-70 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Stop Watch Check • Connect the 12 V battery and terminal in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • Press the mode selector button each time to set the stop watch mode.
  • Page 533 ELECTRICAL SYSTEM 16-71 Meter, Gauge, Indicator Unit FI Indicator Light (LED) Battery Negative (–) Terminal To Terminal [6] Oil Pressure Warning Indicator Light (LED) Battery Negative (–) Terminal To Terminal [11] Right and Left Turn Signal Indicator Light (LED) Battery Positive (+) Terminal to Terminal [13] Battery Positive (+) Terminal to Terminal [14] High Beam Indicator Light (LED) Battery Positive (+) Terminal to Terminal [15]...
  • Page 534 16-72 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Shift Up Indicator Light (LED) • Connect the 12 V battery and terminal in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • The revolutions per minute (rpm) equivalent to the input frequency is indicated in the oscillator [A] if the square wave (illustrated as shown) would be input into the termi- nal [7].
  • Page 535 ELECTRICAL SYSTEM 16-73 Meter, Gauge, Indicator Unit Meter Circuit 1. ECU 2. Neutral Switch 3. Oil Pressure Switch 4. Speed Sensor 5. Water Temperature Sensor 6. Stop Watch Switch 7. Ignition Switch 8. Meter Unit 9. Lap Switch 10. Fuse Box 11.
  • Page 536: Immobilizer System (equipped Models)

    Prepare a new spare user key. • Cut the key in accordance with the shape of the current user key. • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) • Disconnect the immobilizer/Kawasaki self-diagnosis sys- tem connector [A]. http://mototh.com...
  • Page 537 ELECTRICAL SYSTEM 16-75 Immobilizer System (Equipped Models) • Connect the key registration unit [A]. Special Tool - Key Registration Unit: 57001-1582 • Insert the master key to the ignition switch and turn it ON. Verified ○ The FI indicator light [A] blinks to display the registration mode (go to the next step).
  • Page 538 16-76 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) • Insert the user key 1 to the ignition switch and turn it ON. NOTE ○ Keep the other user key away from the immobilizer an- tenna. ○ If there is any problem in the registration, the FI indicator light [A] blinks to display the collation error.
  • Page 539 ELECTRICAL SYSTEM 16-77 Immobilizer System (Equipped Models) • Turn the user key 1 OFF and remove off the user key 1. ○ The FI indicator light [A] blinks to display the registration mode. NOTE ○ Turn off the ignition switch and wait for the period of 15 seconds or more.
  • Page 540 The registration mode automatically ends. • FI indicator light goes off [A]. • Remove the key registration unit and connect the immo- bilizer Kawasaki self-diagnostic system connector. NOTE ○ Turn the ignition switch ON with the registered user key. ○...
  • Page 541 ELECTRICAL SYSTEM 16-79 Immobilizer System (Equipped Models) Spare User Key Registration Flow Chart http://mototh.com...
  • Page 542 System Parts Replacement in this chapter) Front Seat (see Front Seat Removal in the Frame chap- ter) • Disconnect the immobilizer/Kawasaki self-diagnostic sys- tem connector. • Connect the key registration unit [A]. Special Tool - Key Registration Unit: 57001-1582 •...
  • Page 543 ELECTRICAL SYSTEM 16-81 Immobilizer System (Equipped Models) Not Verified ○ The FI indicator light [A] blinks to display the collation er- ror. Immobilizer Amplifier Failure Master Key Collation Error • Turn off and remove the new user key 1. • Temporarily place the antenna [A] on the new ignition switch [B].
  • Page 544 16-82 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) When Registered User Key is Inserted. User Key Collation Error • The user key 1 is successfully registered in the ECU. ○ The FI indicator light [A] blinks 2 times and stops for 1 second and then repeats this cycle to indicate successful registering of user key 1.
  • Page 545 ELECTRICAL SYSTEM 16-83 Immobilizer System (Equipped Models) ○ If there is any problem in the registration, the FI indicator light [A] blinks to display the collation error. Immobilizer Amplifier Failure When Registered User Key is Inserted. User Key Collation Error •...
  • Page 546 16-84 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) • Remove the key registration unit and connect the immo- bilizer/Kawasaki self-diagnostic system connector. NOTE ○ Turn the ignition switch ON with the registered user key. ○ Check that the engine can be started using all regis- tered user keys.
  • Page 547 ELECTRICAL SYSTEM 16-85 Immobilizer System (Equipped Models) • The master key is registered in the ECU. ○ The FI indicator light [A] blinks 1 time and stops for 1 second and the repeats this cycle to indicate successful registration of the master key. •...
  • Page 548 16-86 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) User Key Collation Error • The user key 1 is registered in the ECU. ○ The FI indicator light [A] blinks 2 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key.
  • Page 549 ELECTRICAL SYSTEM 16-87 Immobilizer System (Equipped Models) When Registered User Key is Inserted. User Key Collation Error • The user key 2 is registered in the ECU. ○ The FI indicator light [A] blinks 3 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key 2.
  • Page 550 16-88 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) • Prepare a new ECU [A], new master key [B] and current user keys [C]. NOTE ○ The key registration unit is not required. ○ The key registration process is same as the electric con- trol unit replacement.
  • Page 551 ELECTRICAL SYSTEM 16-89 Immobilizer System (Equipped Models) All Keys Initial Registration Flow Chart http://mototh.com...
  • Page 552: Immobilizer System Parts Replacement

    16-90 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) Immobilizer System Parts Replacement Immobilizer Antenna • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) • Disconnect the lead connectors [A]. • Remove: Steering Stem Head and Handlebar (see Handlebar Re- moval in the Steering chapter) •...
  • Page 553 • Install: Guard Bracket [A] CAUTION Do not pinch the leads. • Tighten new screws [B] use Kawasaki genuine screws of which threads are coated with locking agent. Immobilizer Relational Parts Replacement Chart Failed or Lost Part Master User Ignition...
  • Page 554: Immobilizer System Inspection

    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 Self-diagnostic System Connector http://mototh.com...
  • Page 555: Switches And Sensors

    ELECTRICAL SYSTEM 16-93 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. Neutral Switch Replacement CAUTION Never drop the neutral switch, especially on a hard...
  • Page 556: Switch Inspection

    16-94 ELECTRICAL SYSTEM Switches and Sensors Switch Inspection • Using a hand tester, check to see that only the con- nections shown in the table have continuity (about zero ohms). ○ For the handlebar switches and the ignition switch, refer to the tables in the Wiring Diagram.
  • Page 557: Water Temperature Sensor Inspection

    ELECTRICAL SYSTEM 16-95 Switches and Sensors Water Temperature Sensor Inspection • Remove the water temperature sensor (see Water Tem- perature Sensor Removal in the Fuel System (DFI) chap- ter). • Suspend the sensor [A] in a container of coolant so that the temperature-sensing projection [E] and threaded por- tion [E] are submerged.
  • Page 558: Speed Sensor Inspection

    16-96 ELECTRICAL SYSTEM Switches and Sensors Speed Sensor Inspection • Remove: Speed Sensor (see Speed Sensor Removal in this chap- ter) • Connect the speed sensor connector [A] with the battery [B], 10 kΩ resistor [C] and hand tester [D] as shown. •...
  • Page 559: Relay Box

    ELECTRICAL SYSTEM 16-97 Relay Box The relay box [A] has relays and diodes. The relays and diodes can not be removed. Relay Box Removal • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) • Take out the relay box [A] and disconnect the connectors [B].
  • Page 560: Diode Circuit Inspection

    16-98 ELECTRICAL SYSTEM Relay Box Relay Circuit Inspection (with the battery connected) Battery Tester Tester Connection Connection Reading (Ω) (–) 15-9 11-16 ECU Main Relay 5-10 12-13 Fuel Pump Relay 12-14 Fan Relay 18-20 17-19 Battery Tester Connection Tester Connection DC 25 V Range Reading (V) (–)
  • Page 561 ELECTRICAL SYSTEM 16-99 Relay Box Relay Box Internal Circuit A: Headlight Relay B: ECU Main Relay C: Fuel Pump Relay D: Starter Circuit Relay E: Fan Relay http://mototh.com...
  • Page 562: Fuse

    16-100 ELECTRICAL SYSTEM Fuse 30 A Main Fuse Removal • Remove: Left Side Cover (see Left Side Cover Removal in the Frame chapter) 30 A Main Fuse Connector [A] • Pull out the main fuse [A] from the starter relay with needle nose pliers.
  • Page 563: Fuse Installation

    ELECTRICAL SYSTEM 16-101 Fuse • Pull the ECU fuse [A] straight out of the fuse box with needle nose pliers. 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.
  • Page 564 http://mototh.com...
  • Page 565 APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-28 http://mototh.com...
  • Page 566 17-2 APPENDIX Cable, Wire, and Hose Routing http://mototh.com...
  • Page 567 APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Meter Connector 2. Left Switch Housing Lead Connector 3. Front Right Turn Signal Light Connector 4. Headlight Harness Connector 5. Immobilizer Amplifier (Equipped Models) 6. Right Switch Housing Lead Connector 7. Horn Lead Connectors 8.
  • Page 568 17-4 APPENDIX Cable, Wire, and Hose Routing http://mototh.com...
  • Page 569 Cable, Wire, and Hose Routing 1. Fuel Pump Lead 2. Fuel Tank 3. Frame 4. Clamp 5. Immobilizer/Kawasaki Diagnosis System Connector 6. Fuel Pump Lead Connector 7. Vehicle-down Sensor Lead Connector 8. Clamp 9. Self-diagnosis Indicator Terminal 10. Exhaust Butterfly Valve Actuator Lead Connector 11.
  • Page 570 17-6 APPENDIX Cable, Wire, and Hose Routing http://mototh.com...
  • Page 571 APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Battery Positive Terminal 2. Starter Relay 3. Battery Negative Terminal 4. Clamp 5. Relay Box 6. Run the seat lock cable into the relay box bracket. 7. Fuse Box 8. Turn Signal Relay 9.
  • Page 572 17-8 APPENDIX Cable, Wire, and Hose Routing http://mototh.com...
  • Page 573 APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Meter Connector 2. Clamp the meter connector and front turn signal light connector. 3. Front Left Turn Signal Light Connector 4. Left Switch Housing Lead 5. United States, Canada and California Model only 6.
  • Page 574 17-10 APPENDIX Cable, Wire, and Hose Routing http://mototh.com...
  • Page 575 APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Reserve Return Hose 2. Clamp 3. Starter Motor Cable 4. Main Harness 5. Run the harnesses under the breather hose. 6. Clamp 7. Clamp 8. Speed Sensor 9. Force the harness into between the bosses of the upper crankcase. 10.
  • Page 576 17-12 APPENDIX Cable, Wire, and Hose Routing http://mototh.com...
  • Page 577 APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Insert the holes of heat insulation rubber plate in to the radiator stay. 2. Run the fan lead from the holes of heat insulation rubber plate. 3. After install the holes of heat insulation rubber plate, clamp the lead as shown. 4.
  • Page 578 17-14 APPENDIX Cable, Wire, and Hose Routing http://mototh.com...
  • Page 579 APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Front 2. Horn Lead 3. Clamps 4. Fit the clamp to the air suction valve cover. 5. Vacuum Switch Valve 6. Radiator Fan Lead 7. Clamp the together with radiator fan lead and horn lead. 8.
  • Page 580 17-16 APPENDIX Cable, Wire, and Hose Routing http://mototh.com...
  • Page 581 APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Radiator 2. Clamp 3. Radiator Over Flow Hose 4. Clamp 5. Radiator Coolant Return Hose 6. To the Cylinder Head 7. Install the bolt head of the hose clamp as shown. 8. Insert radiator hose to the corner position of the radiator pipe. 9.
  • Page 582 17-18 APPENDIX Cable, Wire, and Hose Routing http://mototh.com...
  • Page 583 APPENDIX 17-19 Cable, Wire, and Hose Routing 1. Hose Clamp 2. Hose Clamp 3. Hose 4. Oil Cooler 5. Oil Filter 6. White Mark 7. Clamp 8. Hose 9. Clamp 10. Radiator Hose 11. Front View 12. Align the paint mark and embossed line. 13.
  • Page 584 17-20 APPENDIX Cable, Wire, and Hose Routing http://mototh.com...
  • Page 585 APPENDIX 17-21 Cable, Wire, and Hose Routing 1. Main Harness 2. Run the clutch cable over the throttle cable. 3. Run the throttle cable over the front master cylinder. 4. Throttle Cables 5. Run the clutch and throttle cable into the clamp. 6.
  • Page 586 17-22 APPENDIX Cable, Wire, and Hose Routing http://mototh.com...
  • Page 587 APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Brake Hose 2. Clamp 3. Install the brake hose so that align the mark with the center of opening of the clamp. 4. Mark 5. Clamps 6. Brake Hose 7. Face the paint mark outside. 8.
  • Page 588 17-24 APPENDIX Cable, Wire, and Hose Routing http://mototh.com...
  • Page 589 APPENDIX 17-25 Cable, Wire, and Hose Routing 1. Rear Frame 2. Exhaust Butterfly Valve Cable (Accelerator) 3. Exhaust Butterfly Valve Cable (Decelerator) 4. Holder 5. Position the exhaust butterfly valve cable (accelerator) over the exhaust butterfly valve cable (decelerator). 6. Dust Cover 7.
  • Page 590 17-26 APPENDIX Cable, Wire, and Hose Routing California Model http://mototh.com...
  • Page 591 APPENDIX 17-27 Cable, Wire, and Hose Routing 1. White Marks 2. Hose (Green) 3. View A 4. White Marks 5. Clamp 6. Position the red hose under the blue hose, and clamp the them. 7. Run the green hose over the harness. 8.
  • Page 592 17-28 APPENDIX Troubleshooting Guide NOTE Camshaft position sensor trouble ○ Refer to the Fuel System chapter for most Neutral, starter lockout, or side stand switch of DFI trouble shooting guide. trouble ○ This is not an exhaustive list, giving every Crankshaft sensor trouble possible cause for each problem listed.
  • Page 593 APPENDIX 17-29 Troubleshooting Guide No valve clearance Valve not seating properly (valve bent, Cylinder, piston worn worn, or carbon accumulation on the Piston ring bad (worn, weak, broken, or seating surface.) sticking) Knocking: Piston ring/groove clearance excessive Carbon built up in combustion chamber Cylinder head warped Fuel poor quality or incorrect Cylinder head gasket damaged...
  • Page 594 17-30 APPENDIX Troubleshooting Guide Gear Shifting Faulty: Brake dragging Lubrication inadequate: Doesn’t go into gear; shift pedal doesn’t Engine oil level too low return: Engine oil poor quality or incorrect Clutch not disengaging Oil cooler incorrect: Shift fork bent or seized Oil cooler clogged Gear stuck on the shaft Gauge incorrect:...
  • Page 595 APPENDIX 17-31 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 Vacuum switch valve damaged Cylinder worn...
  • Page 596 17-32 APPENDIX Troubleshooting Guide Rear shock adjustment too soft Front fork, rear shock absorber spring weak Rear shock absorber oil leaking Brake Doesn’t Hold: Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in master cylinder...
  • Page 597 MODEL APPLICATION Year Model Beginning Frame No. □ JKBZXJC1 5A000001 2005 ZX636-C1 JKBZX636CCA000001 ZX636C-000001 □ :This digit in the frame number changes from one machine to another. Part No.99924-1345-02 Printed in Japan http://mototh.com...

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Zx6rNinja zx-6r 2005

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