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Z800
Z800 ABS
Motorcycle
Service Manual

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Table of Contents

   Also See for Kawasaki Z800

   Summary of Contents for Kawasaki Z800

  • Page 1 Z800 Z800 ABS Motorcycle Service Manual...
  • Page 3: General Information

    Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 5 All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan.
  • Page 6 LIST OF ABBREVIATIONS ampere(s) inch(s) ABDC after bottom dead center km/h kilometers per hour antilock brake system liter(s) alternating current liquid crystal display ampere hour light emitting diode ATDC after top dead center pound(s) BBDC before bottom dead center meter(s) bottom dead center minute(s) BTDC...
  • Page 7: How To Use This Manual

    Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. • venient operation. Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and • Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 9 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................1-11 Unit Conversion Table ......................1-14...
  • Page 10: General Information

    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 11 Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.
  • Page 12 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 13 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 14 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 15: Model Identification

    GENERAL INFORMATION 1-7 Model Identification ZR800AD (Europe) Left Side View ZR800AD (Europe) Right Side View...
  • Page 16 1-8 GENERAL INFORMATION Model Identification ZR800BD (Europe) Left Side View ZR800BD (Europe) Right Side View...
  • Page 17 GENERAL INFORMATION 1-9 Model Identification ZR800CD Left Side View ZR800CD Right Side View...
  • Page 18 1-10 GENERAL INFORMATION Model Identification ZR800DD Left Side View ZR800DD Right Side View Frame Number Engine Number...
  • Page 19: General Specifications

    GENERAL INFORMATION 1-11 General Specifications Items ZR800AD/BD/CD/DD Dimensions Overall Length 2 100 mm (82.68 in.) Overall Width 800 mm (31.50 in.) Overall Height 1 050 mm (41.34 in.) Wheelbase 1 445 mm (56.89 in.) Road Clearance 150 mm (5.91 in.) Seat Height 834 mm (32.83 in.) Curb Mass:...
  • Page 20 1-12 GENERAL INFORMATION General Specifications Items ZR800AD/BD/CD/DD Spark Plug NGK CR9EK, ND U27ETR Cylinder Numbering Method Left to right, 1-2-3-4 Firing Order 1-2-4-3 Valve Timing: Intake: Open 38° BTDC Close 66° ABDC Duration 284° Exhaust: Open 51° BBDC Close 25° ATDC Duration 256°...
  • Page 21 GENERAL INFORMATION 1-13 General Specifications Items ZR800AD/BD/CD/DD Rear Tire: Type Tubeless Size 180/55ZR17 M/C (73W) Rim Size J17M/C × MT5.50 Front Suspension: Type Telescopic fork Wheel Travel 120 mm (4.72 in.) Rear Suspension: Type Swingarm (uni-trak) Wheel Travel 137 mm (5.39 in.) Brake Type: Front Dual discs...
  • Page 22: Unit Conversion Table

    1-14 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 N·m ×...
  • Page 23: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-11 Special Tools .......................... 2-13 Periodic Maintenance Procedures..................2-14 Fuel System (DFI)........................ 2-14 Air Cleaner Element Cleaning................... 2-14 Air Cleaner Element Replacement..................2-14 Idle Speed Inspection .......................
  • Page 24 2-2 PERIODIC MAINTENANCE Steering System ........................2-55 Steering Play Inspection ....................2-55 Steering Play Adjustment....................2-55 Steering Stem Bearing Lubrication ................... 2-56 Electrical System ......................... 2-57 Lights and Switches Operation Inspection................ 2-57 Headlight Aiming Inspection ..................... 2-59 Side Stand Switch Operation Inspection................2-60 Engine Stop Switch Operation Inspection.................
  • Page 25: Periodic Inspection

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection *A: Service at number of years shown or indicated odometer reading intervals, whichever comes first.
  • Page 26: Periodic Maintenance

    2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart Odometer Reading (*B) × 1 000 km (× 1 000 mile) year (*A) Page Items (0.6) (3.8) (7.6) (11.4) (15.2) Final Drive Drive chain lubrication condition (*C) 2-38 : every 600 km (400 mile) Drive chain slack (*C) 2-38 : every 1 000 km (600 mile)
  • Page 27: Torque And Locking Agent

    PERIODIC MAINTENANCE 2-5 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: AD: Apply adhesive (see the text). AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
  • Page 28 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Water Pump Impeller Bolt 87 in·lb Water Pump Cover Bolts 97 in·lb Coolant Drain Bolt (Water Pump) 97 in·lb Engine Top End Air Suction Valve Cover Bolts 87 in·lb Cylinder Head Cover Bolts 87 in·lb...
  • Page 29 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Passage Plugs Oil Pipe Holder Bolts 115 in·lb Water Pump Cover Bolts 97 in·lb Coolant Drain Bolt (Water Pump) 97 in·lb Water Pump Impeller Bolt 87 in·lb Oil Pressure Relief Valve Oil Pan Bolts Engine Oil Drain Bolt...
  • Page 30 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Shift Pedal Mounting Bolt Wheels/Tires Front Axle Clamp Bolt Front Axle 11.0 79.7 Rear Axle Nut 11.0 79.7 Final Drive Engine Sprocket Cover Bolts 0.70 61 in·lb Engine Sprocket Nut 17.0 Chain Adjuster Locknuts...
  • Page 31 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Piston Rod Assy Stopper 17.5 1.78 12.9 Cylinder Unit Swingarm Pivot Shaft Nut 11.0 79.7 Swingarm Pivot Shaft 87 in·lb Swingarm Pivot Shaft Locknut Rear Shock Absorber Nut (Upper) Rear Shock Absorber Nut (Lower) Rocker Arm Nut Tie-Rod Nuts...
  • Page 32 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Timing Rotor Bolt Starter Motor Mounting Bolts 97 in·lb Crankshaft Sensor Cover Bolts 97 in·lb Crankshaft Sensor Bolts 0.60 52 in·lb Oil Pressure Switch Terminal Bolt 0.20 18 in·lb Oil Pressure Switch Alternator Lead Holding Plate Bolt...
  • Page 33: Specifications

    PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 1 100 ±50 r/min (rpm) – – – Bypass Screws (Turn Out) –...
  • Page 34 2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Air Pressure (when Cold): Front – – – Up to 180 kg (397 lb) load: 250 kPa (2.50 kgf/cm², 36 psi) Rear Up to 180 kg (397 lb) load: – – – 290 kPa (2.90 kgf/cm², 42 psi) Final Drive 20 ∼...
  • Page 35: Special Tools

    PERIODIC MAINTENANCE 2-13 Special Tools Inside Circlip Pliers: Vacuum Gauge: 57001-143 57001-1369 Steering Stem Nut Wrench: Throttle Sensor Setting Adapter: 57001-1100 57001-1538 Pilot Screw Adjuster, A: Extension Tube: 57001-1239 57001-1578 Oil Filter Wrench: 57001-1249...
  • Page 36: Periodic Maintenance Procedures

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Air Cleaner Element Cleaning NOTE ○ In dusty areas, the element should be cleaned more frequently than the recommended interval. WARNING If dirt or dust is allowed to pass through into the throttle assy, the throttle may become stuck, pos- sibly causing accident.
  • Page 37 PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Bolts [A] Fuel Tank Bracket [B] • Remove the air cleaner duct screws [A]. • Remove the air cleaner duct [B] backward. •...
  • Page 38: Idle Speed Inspection

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Fit the tongue [A] of the air cleaner duct into the slot [B] of the air cleaner housing. • Tighten: Torque - Air Cleaner Duct Screws: 3.8 N·m (0.39 kgf·m, 34 in·lb) Idle Speed Inspection •...
  • Page 39: Engine Vacuum Synchronization Inspection

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures If the free play is incorrect, adjust the throttle cable as follows. • Loosen the locknuts [A] [B]. • Screw both throttle cable adjusters [C] [D] to give the throttle grip plenty of play. •...
  • Page 40 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Connect a vacuum gauge (special tool) and hoses [A] to the fittings on the throttle body. Special Tool - Vacuum Gauge: 57001-1369 • Connect a highly accurate tachometer [B] to one of the stick coil primary leads.
  • Page 41 PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures If any vacuum is not within specifications, adjust the by- pass screws [A]. Upside View [B] Special Tool - Pilot Screw Adjuster, A: 57001-1239 • Adjust the each vacuum (#1 ∼ #4) to the standard value. •...
  • Page 42: Fuel System

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Back out the same number of turns counted when first turned in. This is to set the screw to its original position. NOTE ○ A throttle body has different “turns out” of the bypass screw for each individual unit.
  • Page 43 PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • Check that the hoses are routed according to Cable, Wire, and Hose Routing section in the Appendix chapter. Replace the hose if it has been sharply bent or kinked. Hose Joints [A] Fuel Outlet Hose [B] Fuel Intake Hose [C] Front [D] •...
  • Page 44: Fuel Hose Replacement

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel Hose Replacement WARNING Fuel is flammable and explosive under certain con- ditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is dis- connected, fuel spills out from the hose and the pipe because of residual pressure.
  • Page 45 PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures • Pull the joint lock [A] as shown. • Pull the fuel outlet hose joint [B] out of the delivery pipe. • Clean the delivery pipe [A]. • Cover the delivery pipe with the vinyl bag [B] to keep it clean.
  • Page 46 2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the fuel outlet hose with a new one. • Pull [A] the joint lock [B] fully as shown. • Insert the fuel outlet hose joint [A] straight onto the deliv- ery pipe until the hose joint clicks. •...
  • Page 47: Cooling System

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures 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 48 2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the left lower fairing (see Lower Fairing Removal (ZR800A/B Models) in the Frame chapter). • Place a container under the coolant drain bolt [A], then remove the drain bolt. • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter).
  • Page 49 PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures • Fill the radiator up to the filler neck [A] with coolant. NOTE ○ Pour in the coolant slowly so that it can expel the air from the engine and radiator. • Check the cooling system for leaks. •...
  • Page 50: Water Hose And O-ring Replacement

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Water Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Thermostat Housing [A] (see Thermostat Removal in the Cooling System chapter) Water Pump Cover [B] (see Oil Pump Removal in the Engine Lubrication System chapter) O-rings [C] Hoses [D]...
  • Page 51 PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures • Position the crankshaft at 1,4 piston TDC. TDC Mark [A] for #1, 4 Pistons Timing Mark [B] (Crankcase Halves Mating Surface) • Using the thickness gauge [A], measure the valve clear- ance between the cam and the valve lifter. Valve Clearance Standard: 0.22 ∼...
  • Page 52: Valve Clearance Adjustment

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Valve Clearance Adjustment • To change the valve clearance, remove the camshaft chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. NOTE ○ Mark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions.
  • Page 53 PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INTAKE VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm Measured clearance is 0.45 mm...
  • Page 54 2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm.
  • Page 55: Air Suction System Damage Inspection

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures NOTICE Be sure to remeasure the clearance after selecting a shim according to the table. If the clearance is out of the specified range, use the additional shim. ○ If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance.
  • Page 56: Engine Lubrication System

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch the engine or exhaust pipe during clutch adjustment. • Turn the adjuster [A] so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) [B] of threads are visible.
  • Page 57: Oil Filter Replacement

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Recommended Engine Oil Type: API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity: SAE 10W-40 Capacity: 3.1 L (3.3 US qt) (when filter is not removed) 3.4 L (3.6 US qt) (when filter is removed) 3.8 L (4.0 US qt) (when engine is completely dry) NOTE...
  • Page 58: Wheels/tires

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheels/Tires Air Pressure Inspection • Remove the air valve cap. • Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours).
  • Page 59: Wheel Bearing Damage Inspection

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Tread Depth Standard: Front 4.0 mm (0.16 in.) Rear 5.5 mm (0.22 in.) Service Limit: Front 1 mm (0.04 in.) (AT, CH, DE) 1.6 mm (0.06 in.) Rear Up to 130 km/h (80 mph): 2 mm (0.08 in.) Over 130 km/h (80 mph): 3 mm (0.12 in.) WARNING Some replacement tires may adversely affect han-...
  • Page 60: Final Drive

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Final Drive 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 61: Drive Chain Slack Adjustment

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures 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 in the left and right chain adjusters [D] evenly.
  • Page 62: Wheel Alignment Inspection

    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures 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).
  • Page 63: Chain Guide Wear Inspection

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Chain Guide Wear Inspection • Remove: Shift Pedal (see Shift Pedal Removal in the Crank- shaft/Transmission chapter) Footpeg Bracket Bolts [A] Left Footpeg Bracket [B] Chain Cover (see Drive Chain Removal/Installation in the Final Drive chapter) •...
  • Page 64: Brakes

    2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brakes Brake System Brake Fluid Leak (Brake Hose and Pipe) Inspection • For ABS equipped models; note the following. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Right Side Fairing (see Side Fairing Removal in the Frame chapter) •...
  • Page 65: Brake Fluid Level Inspection

    PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Brake Hose and Pipe Damage and Installation Condi- tion Inspection • For ABS equipped models; note the following. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Right Side Fairing (see Side Fairing Removal in the Frame chapter) •...
  • Page 66: Brake Fluid Change

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [A]. • Check that the brake fluid level in the rear brake reservoir [A] is above the lower level line [B]. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C].
  • Page 67 PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures • Level the brake fluid reservoir. • Remove the reservoir cap, diaphragm plate and di- aphragm. • 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 68: Brake Hose And Pipe Replacement

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Replacement NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Brake Hose Banjo Bolts [A] •...
  • Page 69: Master Cylinder Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). • Remove: Front Master Cylinder Reservoir Cap Screws [A] Reservoir Cap [B] Diaphragm Plate [C] Diaphragm [D]...
  • Page 70: Caliper Rubber Parts Replacement

    2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Apply brake fluid to the new parts and to the inner wall of the cylinder. • Take care not to scratch the piston or the inner wall of the cylinder. • Apply silicone grease to the followings. Front: Brake Lever Pivot Bolt Rear:...
  • Page 71 PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures Front Caliper Assembly (ZR800A/B/D Models) • Clean the caliper parts except for the pads. NOTICE For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • Install the bleed valve and rubber cap. Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb) •...
  • Page 72 2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING The piston in the brake caliper can crush hands and fingers. Never place your hand or fingers in front of the piston. ○ Pull out the pistons by hand. • Remove the dust seals [A] and fluid seals [B]. •...
  • Page 73 PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures • Using compressed air, remove the piston. ○ Cover the piston area with a wooden board [A]. ○ Blow compressed air [B] into the hole for the banjo bolt to remove the piston. WARNING The piston in the brake caliper can crush hands and fingers.
  • Page 74: Brake Pad Wear Inspection

    2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Pad Wear Inspection • Remove the brake pads (see Front/Rear Brake Pad Re- moval in the Brakes chapter). • Check the lining thickness [A] of the pads in each caliper. If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set.
  • Page 75: Suspension

    PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures • 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] NOTICE To avoid damaging the electrical connections in- side the switch, be sure that the switch body does...
  • Page 76 2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures 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 77: Steering System

    PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures Steering System Steering Play Inspection • Raise the front wheel off the ground with the jack (see Front Wheel Removal in the Wheels/Tires chapter). • With the front wheel pointing straight ahead, alternately tap each end of the handlebars. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.
  • Page 78: Steering Stem Bearing Lubrication

    2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Adjust the steering. Special Tool - Steering Stem Nut Wrench [A]: 57001-1100 If the steering is too tight, loosen the stem nut a fraction of a turn. If the steering is too loose, tighten the stem nut a fraction of a turn.
  • Page 79: Electrical System

    PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step • Turn the ignition switch on. • The following lights should go on according to below table. City Lights [A] go on Taillight (LED) [B] goes on License Plate Light [C] goes on...
  • Page 80 2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Turn the turn signal switch [A] (left or right position) on. • The left or right turn signal lights [B] (front and rear) ac- cording to the switch position should blink. • The green turn signal indicator light (LED) [C] in the meter unit should blink.
  • Page 81: Headlight Aiming Inspection

    PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures • Set the dimmer switch to high beam position. • The low beam [A] and high beam [B] headlights should go on. • The blue high beam indicator light (LED) [C] should go on. If the high beam headlight and/or blue high beam indicator light (LED) does not go on, inspect or replace the following item.
  • Page 82: Side Stand Switch Operation Inspection

    2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures Side Stand Switch Operation Inspection • Inspect the side stand switch [A] operation accordance to the following table. Side Stand Switch Operation Gear Clutch Engine Engine Side Stand Position Lever Start Continue Neutral Released Starts running Continue...
  • Page 83: Engine Stop Switch Operation Inspection

    PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures Engine Stop Switch Operation Inspection First Step • Turn the ignition switch on. • Set the neutral position. • Turn the engine stop switch to stop position [A]. • Push the starter button. • The engine does not start.
  • Page 84: Others

    2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the spark plug with a new one. Standard Spark Plug Type: NGK CR9EK or ND U27ETR • Insert the new spark plug in the plug hole, and finger -tighten it first. • Using the plug wrench [A] vertically, tighten the plug.
  • Page 85 PERIODIC MAINTENANCE 2-63 Periodic Maintenance Procedures Cables: Lubricate with Rust Inhibitor. Clutch Cable Throttle Cables • Lubricate the cables by seeping the oil between the cable and housing. ○ The cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant.
  • Page 86: Condition Of Bolts, Nuts And Fasteners Tightness Inspection

    2-64 PERIODIC MAINTENANCE Periodic Maintenance Procedures Condition of Bolts, Nuts and Fasteners Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○...
  • Page 87 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................3-10 DFI Parts Location........................3-20 Specifications ......................... 3-22 Special Tools and Sealant ...................... 3-24 DFI Servicing Precautions ...................... 3-26 DFI Servicing Precautions ....................3-26 Troubleshooting the DFI System .................... 3-28 Outline ..........................
  • Page 88 3-2 FUEL SYSTEM (DFI) Vehicle-down Sensor Installation ..................3-72 Vehicle-down Sensor Input Voltage Inspection..............3-73 Vehicle-down Sensor Output Voltage Inspection .............. 3-74 Subthrottle Sensor (Service Code 32)..................3-76 Subthrottle Sensor Removal/Adjustment ................3-76 Subthrottle Sensor Input Voltage Inspection..............3-76 Subthrottle Sensor Output Voltage Inspection ..............3-77 Subthrottle Sensor Resistance Inspection ................
  • Page 89 FUEL SYSTEM (DFI) 3-3 DFI Power Source ........................3-111 ECU Fuse Removal ......................3-111 ECU Fuse Installation ....................... 3-111 ECU Fuse Inspection ......................3-111 ECU Main Relay Removal/Installation ................3-111 ECU Main Relay Inspection ....................3-111 Fuel Line..........................3-112 Fuel Pressure Inspection ....................3-112 Fuel Flow Rate Inspection ....................
  • Page 90: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 91: Exploded View

    FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Throttle Cable Plate Bolt 0.60 52 in·lb Throttle Body Cover Mounting Bolts 0.41 35 in·lb Delivery Pipe Assy Mounting Screws 0.36 31 in·lb Throttle Body Assy Holder Clamp Bolts 0.11 10 in·lb Air Cleaner Duct Screws...
  • Page 92 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 93 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Vehicle-down Sensor Bolts 0.60 52 in·lb Throttle Cable Plate Bolt 0.60 52 in·lb Water Temperature Sensor 106 in·lb Oxygen Sensor Speed Sensor Bolt 106 in·lb Crankshaft Sensor Bolts 0.60 52 in·lb 7.
  • Page 94 3-8 FUEL SYSTEM (DFI) Exploded View...
  • Page 95 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Pump Bolts 87 in·lb L, S Fuel Level Sensor Bolts 0.70 61 in·lb Exhaust Butterfly Valve Actuator Mounting Bolts 0.70 61 in·lb Exhaust Butterfly Valve Actuator Pulley Bolt 0.50 43 in·lb 5.
  • Page 96: Dfi System

    3-10 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 97 FUEL SYSTEM (DFI) 3-11 DFI System 1. ECU 2. Battery 12 V 8 Ah 3. Pressure Regulator 4. Fuel Filter 5. Water Temperature Sensor 6. Intake Air Pressure Sensor #2 7. Intake Air Pressure Sensor #1 8. Fuel Flow 9. Fuel Pump 10.
  • Page 98 3-12 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram (ZR800A/B Models)
  • Page 99 1. Oxygen Sensor 2. Joint Connector E 3. ECU 4. Joint Connector D 5. Exhaust Butterfly Valve Actuator 6. Immobilizer/Kawasaki Diagnostic System Connector 7. Frame Ground 4 8. Frame Ground 3 9. Frame Ground 2 10. Frame Ground 1 11. Engine Ground 12.
  • Page 100 3-14 FUEL SYSTEM (DFI) DFI System ○ Color Codes: BK: Black GY: Gray PU: Purple BL: Blue LB: Light Blue R: Red BR: Brown V: Violet LG: Light Green CH: Chocolate O: Orange W: White DG: Dark Green P: Pink Y: Yellow G: Green Terminal Numbers of ECU Connectors (ZR800A/B Models)
  • Page 101 47. Stick Coil #2: BK/R 48. Ground: P 49. Unused 50. External Communication Line (Immobilizer System/*KDS): GY/BL 51. Meter Unit (Tachometer): LB 52. Immobilizer Amplifier: P/BK 53. Ground for Fuel System: BK/Y 54. Ground for Ignition System: BK/Y *: KDS (Kawasaki Diagnostic System)
  • Page 102 3-16 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram (ZR800C/D Models)
  • Page 103 DFI System Part Names 1. Oxygen Sensor 2. Joint Connector E 3. ECU 4. Joint Connector D 5. Immobilizer/Kawasaki Diagnostic System Connector 6. Frame Ground 4 7. Frame Ground 3 8. Frame Ground 2 9. Frame Ground 1 10. Engine Ground 11.
  • Page 104 3-18 FUEL SYSTEM (DFI) DFI System ○ Color Codes: BK: Black GY: Gray PU: Purple BL: Blue LB: Light Blue R: Red BR: Brown V: Violet LG: Light Green CH: Chocolate O: Orange W: White DG: Dark Green P: Pink Y: Yellow G: Green Terminal Numbers of ECU Connectors (ZR800C/D Models)
  • Page 105 47. Stick Coil #2: BK/R 48. Ground: P 49. Ground: BK/Y 50. External Communication Line (Immobilizer System/*KDS): GY/BL 51. Meter Unit (Tachometer): LB 52. Immobilizer Amplifier: P/BK 53. Ground for Fuel System: BK/Y 54. Ground for Ignition System: BK/Y *: KDS (Kawasaki Diagnostic System)
  • Page 106: Dfi Parts Location

    3-20 FUEL SYSTEM (DFI) DFI Parts Location Main Throttle Sensor [A] Subthrottle Sensor [B] Fuel Injectors #1, #2, #3, #4 [C] Crankshaft Sensor [A] Oxygen Sensor [B] Ignition Key (Transponder) [A] Ignition Switch [B] Immobilizer Antenna [C] Yellow Warning Indicator Light (LED) [D] Stick Coils #1, #2, #3, #4 [A] Air Switching Valve [B] Subthrottle Valve Actuator [A]...
  • Page 107 Fuse Box 2 [B] (Radiator Fan Fuse 15 A) Fuse Box 1 [C] (Ignition Fuse 15 A) Battery 12 V 8 Ah [D] Relay Box [A] (ECU Main Relay, Radiator Fan Relay, Fuel Pump Relay) ECU [B] Immobilizer/Kawasaki Diagnostic System Connector [C] Fuel Pump [A]...
  • Page 108: Specifications

    3-22 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 100 ±50 r/min (rpm) Throttle Body Assy: Throttle Valve Dual throttle valve Bore 34 mm (1.34 in.) Throttle Body Vacuum 35.3 ±1.3 kPa (265 ±10 mmHg) at idle speed Bypass Screws (Turn Out) –...
  • Page 109 FUEL SYSTEM (DFI) 3-23 Specifications Item Standard With sensor tilted 60 ∼ 70° or more right or left: DC Output Voltage 0.65 ∼ 1.35 V With sensor arrow mark pointed up: DC 3.55 ∼ 4.45 V Subthrottle Sensor: DC 4.75 ∼ 5.25 V Input Voltage DC 0.48 ∼...
  • Page 110: Special Tools And Sealant

    3-24 FUEL SYSTEM (DFI) Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Peak Voltage Adapter: 57001-125 57001-1415 Fork Oil Level Gauge: Needle Adapter Set: 57001-1290 57001-1457 Vacuum Gauge: Throttle Sensor Setting Adapter: 57001-1369 57001-1538 Hand Tester: Extension Tube: 57001-1394 57001-1578 Throttle Sensor Setting Adapter #1: Fuel Pressure Gauge Adapter:...
  • Page 111 FUEL SYSTEM (DFI) 3-25 Special Tools and Sealant Fuel Hose: Measuring Adapter: 57001-1607 57001-1700 Speed Sensor Measuring Adapter: Liquid Gasket, TB1211: 57001-1667 56019-120 Oxygen Sensor Measuring Adapter: 57001-1682...
  • Page 112: Dfi Servicing Precautions

    3-26 FUEL SYSTEM (DFI) DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 113 FUEL SYSTEM (DFI) 3-27 DFI Servicing Precautions ○ If the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see Fuel Tank Removal) and check the fuel hose.
  • Page 114: Troubleshooting The Dfi System

    3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System Outline When a problem occurs with DFI system, the yellow en- gine warning indicator light (LED) [A] goes on to alert the rider. When a problem occurs with immobilizer system, the red warning indicator light (LED) [A] blinks and immobi- lizer warning symbol [B] is displayed on the LCD, when a problem occurs in the system.
  • Page 115 (LED) goes off. But the service codes stored in memory of the ECU are not erased to preserve the prob- lem history. The problem history can be referred using the KDS (Kawasaki Diagnostic System) when solving unstable problems When the motorcycle is down, the vehicle-down sensor operates and the ECU shuts off the fuel pump relay, fuel in- jectors and ignition system.
  • Page 116 3-30 FUEL SYSTEM (DFI) Troubleshooting the DFI System • When checking the DFI parts, use a digital meter which can be read two decimal place voltage or resistance. ○ The DFI part connectors [A] have seals [B], including the ECU. When measuring the input or output voltage with the connector joined, use the needle adapter set [C].
  • Page 117 FUEL SYSTEM (DFI) 3-31 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 118: Inquiries To Rider

    3-32 FUEL SYSTEM (DFI) 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 119 FUEL SYSTEM (DFI) 3-33 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 120 3-34 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ □ □ Poor running very low idle speed, very high idle speed, rough idle speed. at low speed □ battery voltage is low (charge the battery). □ spark plug loose (tighten it). □...
  • Page 121: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system.
  • Page 122 3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Intake air pressure sensor #1 trouble Inspect (see chapter 3).
  • Page 123 FUEL SYSTEM (DFI) 3-37 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Intake air pressure sensor #1 trouble Inspect (see chapter 3). Intake air pressure sensor #2 trouble Inspect (see chapter 3).
  • Page 124: Poor Running Or No Power At High Speed

    3-38 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Other: Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight, and examine leads for signs of burning or fraying (see chapter 3). Poor Running or No Power at High Speed Symptoms or Possible Causes Actions (chapter)
  • Page 125 FUEL SYSTEM (DFI) 3-39 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Intake air temperature sensor trouble Inspect (see chapter 3). Miscellaneous: Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Speed sensor trouble Inspect (see chapter 3).
  • Page 126: Self-diagnosis

    3-40 FUEL SYSTEM (DFI) Self-Diagnosis Self-Diagnosis Outline The self-diagnosis system is monitoring the following mechanisms. DFI System and Ignition System Immobilizer System The following warning indicator lights (LED) are used for symbols of below table. LED Color Warning Indicator Symbols Oil Pressure Battery Red [A]...
  • Page 127: Self-diagnosis Procedures

    FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Dealer Mode The LCD (Liquid Crystal Display) displays the service code(s) [A] to show the problem(s) which the above system has at the moment of diagnosis. Self-Diagnosis Procedures NOTE ○ Use a fully charged battery when conducting self-diagnosis.
  • Page 128 3-42 FUEL SYSTEM (DFI) Self-Diagnosis • Push the left button [A] to display the odometer. • Push the left button for more than two seconds. • The service code [B] is displayed on the LCD by the num- ber of two digits. •...
  • Page 129 FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Self-Diagnosis Flow Chart...
  • Page 130: Service Code Reading

    3-44 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Reading ○ The service code(s) is displayed on the LCD by the number of two digits. ○ When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order.
  • Page 131 FUEL SYSTEM (DFI) 3-45 Self-Diagnosis Service Code Table Service Code System Problems Main throttle sensor malfunction, wiring open or short Intake air pressure sensor #1 malfunction, wiring open or short Intake air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Intake air pressure sensor #2 malfunction, wiring open or short Crankshaft sensor malfunction, wiring open or short...
  • Page 132: Backups

    3-46 FUEL SYSTEM (DFI) Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI, ignition or immo- bilizer system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the output voltage is out of the usable range, Main Throttle...
  • Page 133 FUEL SYSTEM (DFI) 3-47 Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria Exhaust If the exhaust butterfly valve sensor system Butterfly fails (the output voltage is out of the usable Valve Output Voltage range, wiring short or open), the ECU locks Actuator 0.1 ∼...
  • Page 134 3-48 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria The oxygen sensor heater If the oxygen sensor heater fails (wiring short Oxygen raises temperature of or open), the ECU stops the current to the Sensor the sensor for its earlier heater, and it stops the feedback mode of the...
  • Page 135: Main Throttle Sensor (service Code 11)

    FUEL SYSTEM (DFI) 3-49 Main Throttle Sensor (Service Code 11) The main throttle sensor is a rotating variable resistor that change 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 136: Main Throttle Sensor Output Voltage Inspection

    3-50 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→...
  • Page 137: Main Throttle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-51 Main Throttle Sensor (Service Code 11) • Turn the ignition switch off. • Measure the output voltage with the engine stopped and with the connector joined. • Turn the ignition switch on. Output Voltage DC 0.995 ∼ 1.025 V at idle throttle opening Standard: DC 4.05 ∼...
  • Page 138 3-52 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Circuit 1. Main Throttle Sensor 2. Water Proof Joint 1 3. Water Proof Joint 2 4. ECU...
  • Page 139: Intake Air Pressure Sensor #1 (service Code 12)

    FUEL SYSTEM (DFI) 3-53 Intake Air Pressure Sensor #1 (Service Code 12) Intake Air Pressure Sensor #1 Removal NOTICE Never drop the intake air pressure sensor espe- cially on a hard surface. Such a shock to the sensor can damage it. •...
  • Page 140: Intake Air Pressure Sensor #1 Input Voltage Inspection

    3-54 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) Intake Air Pressure Sensor #1 Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Remove the fuel tank (see Fuel Tank Removal). •...
  • Page 141: Intake Air Pressure Sensor #1 Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-55 Intake Air Pressure Sensor #1 (Service Code 12) Intake Air Pressure Sensor #1 Output Voltage Inspection • Measure the output voltage at the intake air pressure sen- sor #1 in the same way as input voltage inspection, note the following.
  • Page 142 3-56 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) If the wiring is good, check the sensor for various vacuum. • Remove the intake air pressure sensor #1 [A] and discon- nect the vacuum hose from the sensor. •...
  • Page 143 FUEL SYSTEM (DFI) 3-57 Intake Air Pressure Sensor #1 (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: Intake Air Pressure Sensor #1 Output Voltage (V) (Digital Meter Reading)
  • Page 144 3-58 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) Intake Air Pressure Sensor Circuit 1. Water Proof Joint 1 2. Water Proof Joint 2 3. Intake Air Pressure Sensor 4. ECU...
  • Page 145: Intake Air Temperature Sensor (service Code 13)

    FUEL SYSTEM (DFI) 3-59 Intake Air Temperature Sensor (Service Code 13) Intake Air Temperature Sensor Removal/Instal- lation NOTICE Never drop the intake air temperature sensor espe- cially on a hard surface. Such a shock to the sensor can damage it. •...
  • Page 146: Intake Air Temperature Sensor Resistance Inspection

    3-60 FUEL SYSTEM (DFI) Intake Air Temperature Sensor (Service Code 13) • Turn the ignition switch off. If the reading is within the standard, check the ECU for its ground and power supply (see ECU Power Supply In- spection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
  • Page 147 FUEL SYSTEM (DFI) 3-61 Intake Air Temperature Sensor (Service Code 13) Intake Air Temperature Sensor Circuit 1. Intake Air Temperature Sensor 2. Water Proof Joint 2 3. ECU...
  • Page 148: Water Temperature Sensor (service Code 14)

    3-62 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Water Temperature Sensor Removal/Installation NOTICE Never drop the water temperature sensor especially on a hard surface. Such a shock to the sensor can damage it. • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).
  • Page 149: Water Temperature Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-63 Water Temperature Sensor (Service Code 14) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→...
  • Page 150: Intake Air Pressure Sensor #2 (service Code 16)

    3-64 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #2 (Service Code 16) Intake Air Pressure Sensor #2 Removal NOTICE Never drop the intake air pressure sensor #2 espe- cially on a hard surface. Such a shock to the sensor can damage it. •...
  • Page 151: Intake Air Pressure Sensor #2 Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-65 Intake Air Pressure Sensor #2 (Service Code 16) Intake Air Pressure Sensor #2 Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Disconnect the intake air pressure sensor #2 connector and connect the measuring adapter [A] between these connectors.
  • Page 152: Intake Air Pressure Sensor #2 Output Voltage Inspection

    3-66 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #2 (Service Code 16) Intake Air Pressure Sensor #2 Output Voltage Inspection • Measure the output voltage at the intake air pressure sen- sor #2 in the same way as input voltage inspection, note the following.
  • Page 153 FUEL SYSTEM (DFI) 3-67 Intake Air Pressure Sensor #2 (Service Code 16) Intake Air Pressure Sensor #2 Circuit 1. Water Proof Joint 1 2. Water Proof Joint 2 3. Intake Air Pressure Sensor #2 4. ECU...
  • Page 154: Crankshaft Sensor (service Code 21)

    3-68 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) The crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no sig- nals. Crankshaft Sensor Removal/Installation • Refer to the Crankshaft Sensor Removal/Installation in the Electrical System chapter. Crankshaft Sensor Resistance Inspection •...
  • Page 155: Speed Sensor (service Code 24)

    FUEL SYSTEM (DFI) 3-69 Speed Sensor (Service Code 24) Speed Sensor Removal/Installation • Refer to the Speed Sensor Removal/Installation in the Electrical System chapter. Speed Sensor Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. •...
  • Page 156: Speed Sensor Output Voltage Inspection

    3-70 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) Speed Sensor Output Voltage Inspection • Raise the rear wheel off the ground with the stand. • Measure the output voltage at the speed sensor in the same way as input voltage inspection, note the following. ○...
  • Page 157 FUEL SYSTEM (DFI) 3-71 Speed Sensor (Service Code 24) Speed Sensor Circuit 1. Speed Sensor 2. Water Proof Joint 1 3. Water Proof Joint 2 4. ECU...
  • Page 158: Vehicle-down Sensor (service Code 31)

    3-72 FUEL SYSTEM (DFI) 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 the signal changes.
  • Page 159: Vehicle-down Sensor Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-73 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Disconnect the vehicle-down sensor connector and con- nect the harness adapter [A] between these connectors as shown.
  • Page 160: Vehicle-down Sensor Output Voltage Inspection

    3-74 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Output Voltage Inspection • Remove the vehicle-down sensor (see Vehicle-down Sensor Removal). • Connect the harness adapter [A] to the vehicle-down sen- sor connectors as shown. Special Tool - Measuring Adapter: 57001-1700 Main Harness [B] Vehicle-down Sensor [C] •...
  • Page 161 FUEL SYSTEM (DFI) 3-75 Vehicle-down Sensor (Service Code 31) If the reading is within the standard, remove the ECU and check the wiring for continuity between main harness con- nectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→ Vehicle-down Sensor Connector [B] Y/G lead (ECU terminal 19) [C] G lead (ECU terminal 33) [D]...
  • Page 162: Subthrottle Sensor (service Code 32)

    3-76 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) The subthrottle sensor is a rotating variable resistor that change 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 163: Subthrottle Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-77 Subthrottle Sensor (Service Code 32) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→ Subthrottle Sensor Connector [B] BL lead (ECU terminal 5) [C] G lead (ECU terminal 33) [D]...
  • Page 164 3-78 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) • Measure the output voltage with the engine stopped with the connector joined. • Turn the ignition switch on. • Measure the output voltage when the subthrottle valve is completely closed by turning the lever [A] fully counter- clockwise [B].
  • Page 165: Subthrottle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-79 Subthrottle Sensor (Service Code 32) Subthrottle Sensor 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: G lead [C] ←→...
  • Page 166: Oxygen Sensor - Not Activated (service Code 33)

    3-80 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection • Turn the ignition switch off. • Remove the right frame cover (see Frame Cover Removal in the Frame chapter).
  • Page 167 FUEL SYSTEM (DFI) 3-81 Oxygen Sensor - not activated (Service Code 33) • Remove the fuel outlet hose (see Fuel Hose Replacement in the Periodic Maintenance chapter). • Connect the following parts temporary. Fuel Pump Lead Connector [A] Fuel Level Sensor Lead Connector [B] Extension Tube [C] Special Tool - Extension Tube: 57001-1578 •...
  • Page 168 3-82 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33) Oxygen Sensor Circuit 1. Ignition Switch 10. Starter Relay 2. Water Proof Joint 2 11. Main Fuse 30 A 3. Oxygen Sensor 12. ECU Fuse 15 A 4. Joint Connector E 13.
  • Page 169: Exhaust Butterfly Valve Actuator Sensor (service Code 34, Zr800a/b Models)

    FUEL SYSTEM (DFI) 3-83 Exhaust Butterfly Valve Actuator Sensor (Service Code 34, ZR800A/B Models) Exhaust Butterfly Valve Actuator Sensor Removal/Installation The exhaust butterfly valve actuator sensor is built in the exhaust butterfly valve actuator. So, the sensor itself can not be removed. Remove the exhaust butterfly valve actu- ator (see Exhaust Butterfly Valve Actuator Removal).
  • Page 170: Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection

    3-84 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator Sensor (Service Code 34, ZR800A/B Models) Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection NOTE ○ Before this inspection, confirm the pulley [A] is original position (see Exhaust Butterfly Valve Actuator Installa- tion).
  • Page 171: Exhaust Butterfly Valve Actuator Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-85 Exhaust Butterfly Valve Actuator Sensor (Service Code 34, ZR800A/B Models) Exhaust Butterfly Valve Actuator Sensor Resistance Inspection • Turn the ignition switch off. • Disconnect the exhaust butterfly valve actuator sensor connector (3 pins connector) [A]. •...
  • Page 172: Immobilizer Amplifier (service Code 35)

    3-86 FUEL SYSTEM (DFI) Immobilizer Amplifier (Service Code 35) Antenna Resistance Inspection • Turn the ignition switch off. • Remove the fuel tank (see Fuel Tank Removal). • Disconnect the antenna lead connector [A]. • Measure the antenna resistance. Antenna Resistance Connections: BK lead ←→...
  • Page 173: Blank Key Detection (service Code 36)

    FUEL SYSTEM (DFI) 3-87 Blank Key Detection (Service Code 36) • This code appears in the following conditions. ○ The transponder [A] in the ignition key is malfunction. ○ When the spare key of unregistration is used. ○ When the ignition key is registered in the registered ECU. •...
  • Page 174 11. ECU Fuse 15 A 2. Joint Connector E 12. ECU Main Relay 3. ECU 13. Relay Box 4. Immobilizer/Kawasaki Diagnostic System Con- 14. Fuse Box 1 nector 15. Ignition Fuse 15 A 5. Frame Ground 1 16. Red Warning Indicator Light (LED) 6.
  • Page 175: Ecu Communication Error (service Code 39)

    FUEL SYSTEM (DFI) 3-89 ECU Communication Error (Service Code 39) ECU Communication Line Inspection ○ When the data is not sent from the ECU to the meter unit for more than about 10 seconds, the service code 39 is displayed. ○...
  • Page 176: Stick Coils #1, #2, #3, #4 (service Code 51, 52, 53, 54)

    3-90 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 Stick Coil Removal/Installation •...
  • Page 177 FUEL SYSTEM (DFI) 3-91 Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) • Turn the ignition switch off. If the input voltage is out of the standard, check the wiring for continuity (see wiring diagram in this section). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).
  • Page 178: Radiator Fan Relay (service Code 56)

    3-92 FUEL SYSTEM (DFI) Radiator Fan Relay (Service Code 56) Radiator Fan Relay Removal/Installation ○ The radiator fan relay is built in the relay box [A]. • Refer to the Relay Box Removal in the Electrical System chapter. Radiator Fan Relay Inspection •...
  • Page 179: Subthrottle Valve Actuator (service Code 62)

    FUEL SYSTEM (DFI) 3-93 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal NOTICE Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy especially on a hard surface.
  • Page 180: Subthrottle Valve Actuator Input Voltage Inspection

    3-94 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Disconnect the subthrottle valve actuator harness con- nector and connect the harness adapter [A] between these connectors as shown.
  • Page 181 FUEL SYSTEM (DFI) 3-95 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Circuit 1. Subthrottle Valve Actuator 2. ECU...
  • Page 182: Exhaust Butterfly Valve Actuator (service Code 63, Zr800a/b Models)

    3-96 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator (Service Code 63, ZR800A/B Models) Exhaust Butterfly Valve Actuator Removal NOTICE Never drop the exhaust butterfly valve actuator es- pecially on a hard surface. Such a shock to the ac- tuator can damage it. •...
  • Page 183 FUEL SYSTEM (DFI) 3-97 Exhaust Butterfly Valve Actuator (Service Code 63, ZR800A/B Models) • Install the pulley [A] on the actuator as shown. • Tighten the pulley bolt [B] while holding the pulley with the suitable tool [C]. Torque - Exhaust Butterfly Valve Actuator Pulley Bolt: 4.9 N·m (0.50 kgf·m, 43 in·lb) NOTICE If the pulley bolt is tightened without holding, the...
  • Page 184: Exhaust Butterfly Valve Actuator Inspection

    3-98 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator (Service Code 63, ZR800A/B Models) If the position is not within the specified angle above, ad- just the angle as follows. ○ Disconnect: 2 Pins Connector 3 Pins Connector ○ Connect the 12 V battery to the 2 pins connector termi- nals.
  • Page 185: Exhaust Butterfly Valve Actuator Resistance Inspection

    FUEL SYSTEM (DFI) 3-99 Exhaust Butterfly Valve Actuator (Service Code 63, ZR800A/B Models) Exhaust Butterfly Valve Actuator Resistance Inspection • Turn the ignition switch off. • Disconnect the exhaust butterfly valve actuator lead con- nector (2 pins connector) [A]. • Set the hand tester to the ×...
  • Page 186: Air Switching Valve (service Code 64)

    3-100 FUEL SYSTEM (DFI) Air Switching Valve (Service Code 64) Air Switching Valve Removal/Installation • Refer to the Air Switching Valve Removal/Installation in the Engine Top End chapter. Air Switching Valve Inspection • Refer to the Air Switching Valve Unit Test in the Electrical System chapter.
  • Page 187: Oxygen Sensor Heater (service Code 67)

    FUEL SYSTEM (DFI) 3-101 Oxygen Sensor Heater (Service Code 67) Oxygen Sensor Heater Removal/Installation The oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see Oxygen Sensor Removal in the Electrical System chapter).
  • Page 188 3-102 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67) If the fuse and wiring are good, remove the ECU and check the wiring for continuity between main harness con- nectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→...
  • Page 189: Oxygen Sensor - Incorrect Output Voltage (service Code 94)

    FUEL SYSTEM (DFI) 3-103 Oxygen Sensor - Incorrect Output Voltage (Service Code 94) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection • Turn the ignition switch off. • Remove the right frame cover (see Frame Cover Removal in the Frame chapter).
  • Page 190 3-104 FUEL SYSTEM (DFI) Oxygen Sensor - Incorrect Output Voltage (Service Code 94) • Remove the fuel outlet hose (see Fuel Hose Replacement in the Periodic Maintenance chapter). • Connect the following parts temporary. Fuel Pump Lead Connector [A] Fuel Level Sensor Lead Connector [B] Extension Tube [C] Special Tool - Extension Tube: 57001-1578 •...
  • Page 191 FUEL SYSTEM (DFI) 3-105 Oxygen Sensor - Incorrect Output Voltage (Service Code 94) Oxygen Sensor Circuit 1. Ignition Switch 10. Starter Relay 2. Water Proof Joint 2 11. Main Fuse 30 A 3. Oxygen Sensor 12. ECU Fuse 15 A 4.
  • Page 192: Warning Indicator Light (led)

    3-106 FUEL SYSTEM (DFI) Warning Indicator Light (LED) Yellow Engine Warning Indicator Light (LED) Inspection Yellow Engine Warning Indicator Light (LED) [A] • Refer to the Electronic Combination Meter Unit Inspection in the Electrical System chapter. Warning Indicator Light (LED) Circuit 1.
  • Page 193: Ecu

    FUEL SYSTEM (DFI) 3-107 ECU Identification ○ Most countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU with each other and use only the ECU for your model. Other- wise, the motorcycle cannot clear the regulation. ECU Identification (ZR800A/B Models) Part Number [A] Specification...
  • Page 194: Ecu Installation

    3-108 FUEL SYSTEM (DFI) ECU Installation • Connect the ECU connectors [A]. • Install the ECU [B] (in Rubber Protector [C]). • Insert the slits of the rubber protector to the projections [D]. ECU Power Supply Inspection • Remove the relay box (see Relay Box Removal in the Electrical System chapter).
  • Page 195 FUEL SYSTEM (DFI) 3-109 If the wiring is good, check the power source voltage of the ECU. NOTE ○ Be sure the battery is fully charged. • Connect the ECU connectors. • Connect a digital meter [A] to the connector [B] with the needle adapter set.
  • Page 196 3-110 FUEL SYSTEM (DFI) ECU Power Source Circuit 1. Ignition Switch 2. Frame Ground 1 3. Joint Connector E 4. ECU 5. Joint Connector D 6. Frame Ground 4 7. Frame Ground 3 8. Engine Ground 9. Battery 12 V 8 Ah 10.
  • Page 197: Dfi Power Source

    FUEL SYSTEM (DFI) 3-111 DFI Power Source ECU Fuse Removal • Refer to the 30 A Main/10 A ECU Fuse Removal in the Electrical System chapter. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 198: Fuel Line

    3-112 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Outlet Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) ○ Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of the throttle body assy.
  • Page 199: Fuel Flow Rate Inspection

    FUEL SYSTEM (DFI) 3-113 Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure with the engine idling. Fuel Pressure (with Engine Idling) Standard: 294 kPa (3.0 kgf/cm², 43 psi) NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications.
  • Page 200 3-114 FUEL SYSTEM (DFI) Fuel Line • Open the fuel tank cap [A] to lower the pressure in the tank. • Remove the fuel outlet hose from the fuel pump (see Fuel Tank Removal). ○ Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump.
  • Page 201: Fuel Pump

    FUEL SYSTEM (DFI) 3-115 Fuel Pump Fuel Pump Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions, creating the potential for serious burns. Make sure the area is well venti- lated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 202: Fuel Pump Installation

    3-116 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Installation • Remove dirt or dust from the fuel pump [A] by lightly ap- plying compressed air. • Replace the fuel pump gasket with a new one. • Check that the fuel pump terminal [A] and band [B] are in place.
  • Page 203: Fuel Pump Operating Voltage Inspection

    FUEL SYSTEM (DFI) 3-117 Fuel Pump Fuel Pump Operating Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Remove the right subframe cover (see Subframe Cover Removal in the Frame chapter). •...
  • Page 204: Pressure Regulator Removal

    3-118 FUEL SYSTEM (DFI) Fuel Pump Pressure Regulator Removal ○ The pressure regulator [A] is built into the fuel pump [B] and can not be removed. Pump Screen, Fuel Filter Cleaning ○ The pump screen [A] and fuel filter [B] are built into the pump and can not be cleaned or checked.
  • Page 205 FUEL SYSTEM (DFI) 3-119 Fuel Pump Fuel Pump Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Frame Ground 1 4. Joint Connector E 5. ECU 6. Joint Connector D 7. Frame Ground 3 8. Engine Ground 9. Battery 12 V 8 Ah 10.
  • Page 206: Fuel Injectors

    3-120 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Fuel Injector Audible Inspection NOTE ○ Be sure the battery is fully charged. • Start the engine, and let it idle. • Apply the tip of a screwdriver [A] to the fuel injector [B]. Put the grip end onto your ear, and listen whether the fuel injector is clicking or not.
  • Page 207: Fuel Injector Power Source Voltage Inspection

    FUEL SYSTEM (DFI) 3-121 Fuel Injectors Fuel Injector Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Disconnect the injector connector and connect the har- ness adapter [A] between these connectors as shown. Main Harness [B] Fuel Injector #1 [C] Special Tool - Measuring Adapter: 57001-1700...
  • Page 208: Fuel Injector Output Voltage Inspection

    3-122 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Output Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Remove the ECU (see ECU Removal). ○ Do not disconnect the ECU connector. •...
  • Page 209: Fuel Injector Fuel Line Inspection

    FUEL SYSTEM (DFI) 3-123 Fuel Injectors If the reading is out of the specification, remove the ECU and check the wiring for continuity between main harness connectors. ○ Disconnect the ECU and injector connectors. Wiring Inspection ECU Connector [A] ←→ Fuel Injector Connector [B] For Fuel Injector #1 [C] BL/BK lead (ECU terminal 36) [D] For Fuel Injector #2...
  • Page 210 3-124 FUEL SYSTEM (DFI) Fuel Injectors ○ Watch the gauge for at least 6 seconds. If the pressure holds steady, the fuel line is good. If the pressure drops at once or if bubbles are found in the area, the fuel line is leaking. Replace the delivery pipe assy, injectors and related parts.
  • Page 211: Throttle Grip And Cables

    FUEL SYSTEM (DFI) 3-125 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 212: Throttle Body Assy

    3-126 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection/Adjustment • Refer to the Idle Speed Inspection/Adjustment in the Pe- riodic Maintenance chapter. Synchronization Inspection/Adjustment • Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter. Throttle Body Assy Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions, creating the potential...
  • Page 213 FUEL SYSTEM (DFI) 3-127 Throttle Body Assy • Remove: Throttle Body Cover Mounting Bolt [A] Quick Rivet [B] Right Throttle Body Cover [C] • Remove: Throttle Body Cover Mounting Bolt [A] Left Throttle Body Cover [B] • Remove the intake air pressure sensor #1/#2 (see Intake Air Pressure Sensor #1/#2 Removal).
  • Page 214 3-128 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the throttle cable upper ends [A]. • Remove: Fuel Tank Bracket (see Air Cleaner Element Replace- ment in the Periodic Maintenance chapter) Air Cleaner Housing Mounting Bolt [A] (Both Sides) • Loosen the air duct clamp bolts [A].
  • Page 215: Throttle Body Assy Installation

    FUEL SYSTEM (DFI) 3-129 Throttle Body Assy Throttle Body Assy Installation • Apply a thin coating of grease to the throttle cable lower ends. • Fit the accelerator cable end [A] and the decelerator cable end [B] into the throttle pulley. •...
  • Page 216: Throttle Body Assy Disassembly

    3-130 FUEL SYSTEM (DFI) Throttle Body Assy • Apply a thin coating of grease to the throttle cable upper ends. • Install the upper ends of the throttle cables in the grip. • Fit the projection [A] of the right switch housing into the hole [B] of the handlebars.
  • Page 217: Throttle Body Assy Assembly

    FUEL SYSTEM (DFI) 3-131 Throttle Body Assy • Remove the throttle body assy (see Throttle Body Assy Removal). • Cut the band [A]. • Remove the delivery pipe assy mounting screws [B] to pull out the injectors from the throttle body assy together with the delivery pipe assy [C].
  • Page 218 3-132 FUEL SYSTEM (DFI) Throttle Body Assy • Replace the dust seals [A] with new ones. • Apply engine oil to the new dust seals. • Install the injectors along with the delivery pipe assy to the throttle body. • Tighten: Torque - Delivery Pipe Assy Mounting Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb)
  • Page 219: Air Cleaner

    FUEL SYSTEM (DFI) 3-133 Air Cleaner Air Cleaner Element Removal/Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Element Inspection • Remove the air cleaner element (see Air Cleaner Element Replacement in the Periodic Maintenance chapter). •...
  • Page 220: Fuel Tank

    3-134 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 221 FUEL SYSTEM (DFI) 3-135 Fuel Tank • Open the fuel tank cap [A] to lower the pressure in the tank. ○ During tank removal, keep the tank cap open to release pressure in the tank. This makes fuel spillage less. •...
  • Page 222: Fuel Tank Installation

    3-136 FUEL SYSTEM (DFI) Fuel Tank • Pull the joint lock [A] fully as shown. NOTICE Prying or excessively widening the joint lock ends for fuel hose removal will permanently deform the joint lock, resulting in a loose or incomplete lock that may allow fuel to leak and create the potential for a fire explosion.
  • Page 223 FUEL SYSTEM (DFI) 3-137 Fuel Tank • When installing the dampers [A], position the thick side [B] to frame side [C]. • Remove the vinyl bag on the pipe and fuel hose joint. • Check the joint lock for deformation and wear. If the joint lock is deformed, replace the fuel hose with a new one.
  • Page 224: Fuel Tank And Cap Inspection

    3-138 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank and Cap Inspection • Open the tank cap. • 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] in the tank are not clogged.
  • Page 225 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Special Tools ......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal/Installation ..............Water Pump..........................
  • Page 226: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 227 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Thermostat Bracket Bolt 0.70 61 in·lb Reserve Tank Bolts 87 in·lb Thermostat Housing Screws 0.27 23 in·lb Thermostat Housing Clamp Bolt 0.70 61 in·lb Water Temperature Sensor 106 in·lb Radiator Bolts 0.70 61 in·lb...
  • Page 228: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart...
  • Page 229 COOLING SYSTEM 4-5 Coolant Flow Chart 1. Front 8. Radiator 2. Reserve Tank 9. Cylinder Head Jacket 3. Reserve Tank Overflow Hose 10. Cylinder Jacket 4. Reserve Tank Hose 11. Oil Filter 5. Radiator Cap 12. Water Pump 6. Thermostat Housing 13.
  • Page 230: Specifications

    4-6 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type (Recommended) Permanent type 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 231: Special Tools

    COOLING SYSTEM 4-7 Special Tools Bearing Driver Set: Oil Seal Driver: 57001-1129 57001-1660...
  • Page 232: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the left side fairing (see Side Fairing Removal in the Frame chapter). • Visually inspect the coolant [A] in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting.
  • Page 233: 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 234: 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 Inspection •...
  • Page 235: 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 NOTICE Do not reuse the mechanical seal and oil seal. • Apply high-temperature grease to the oil seal lips [A]. •...
  • Page 236: Radiator

    4-12 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove the side fairings (see Side Fairing Removal in the Frame chapter). • Disconnect the radiator fan motor lead connector [A]. •...
  • Page 237: Radiator And Radiator Fan Installation

    COOLING SYSTEM 4-13 Radiator Radiator and Radiator Fan Installation • Installation is the reverse of removal. • Install the rubber dampers [A] and radiator bracket collars [B] as shown. Larger [C] Smaller [D] • Run the radiator fan motor lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
  • Page 238: Radiator Cap Inspection

    4-14 COOLING SYSTEM Radiator NOTICE When cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage: Keep the steam gun [A] away more than 0.5 m (1.6 ft) [B] from the radiator core. Hold the steam gun perpendicular [C] (not oblique [D]) to the core surface.
  • Page 239: Thermostat

    COOLING SYSTEM 4-15 Thermostat Thermostat Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove the side fairings (see Side Fairing Removal in the Frame chapter). • Loosen the water hose clamp screws [A]. • Disconnect the water hoses [B].
  • Page 240: Thermostat Inspection

    4-16 COOLING SYSTEM Thermostat Thermostat Inspection • Remove the thermostat (see Thermostat Removal), and inspect the thermostat valve [A] at room temperature. If the valve is open, replace the thermostat with a new one. • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water.
  • Page 241: Hose And Pipes

    COOLING SYSTEM 4-17 Hose and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). •...
  • Page 242: Water Temperature Sensor

    4-18 COOLING SYSTEM Water Temperature Sensor NOTICE The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it. Water Temperature Sensor Removal/Installation • Refer to the Water Temperature Sensor Removal/Instal- lation in the Fuel System (DFI) chapter.
  • Page 243 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Valves ..........5-27 Exhaust System......... Valve Clearance Inspection ..5-27 Specifications ........5-10 Valve Clearance Adjustment..5-27 Special Tools and Sealant ....5-12 Valve Removal ......5-27 Clean Air System....... 5-14 Valve Installation ......
  • Page 244: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 245 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Suction Valve Cover Bolts 87 in·lb Cylinder Head Cover Bolts 87 in·lb Camshaft Cap Bolts (L = 45 mm) 106 in·lb Camshaft Cap Bolts (L = 40 mm) 106 in·lb Spark Plugs 115 in·lb...
  • Page 246 5-4 ENGINE TOP END Exploded View ZR800A/B Models...
  • Page 247 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 Muffler Body Mounting Bolts Muffler Body End Cover Bolts 97 in·lb Exhaust Butterfly Valve Cover Bolt...
  • Page 248 5-6 ENGINE TOP END Exploded View ZR800C/D Models...
  • Page 249 ENGINE TOP END 5-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Muffler Body Mounting Bolts Muffler Body End Cover Bolts 97 in·lb Muffler Body Cover Bolts 0.70 61 in·lb Exhaust Pipe Manifold Holder Nuts Muffler Body Clamp Bolt R: Replacement Parts S: Follow the specified tightening sequence.
  • Page 250: Exhaust System

    5-8 ENGINE TOP END Exhaust System Exhaust System...
  • Page 251 ENGINE TOP END 5-9 Exhaust System Manifold Mark Position [A] Honeycomb Type Catalyst Position [A] Muffler Body Mark Position [A] Manifold [A] with Hole [B] for Oxygen Sensor [C].
  • Page 252: Specifications

    5-10 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: 35.742 ∼ 35.858 mm (1.4072 ∼ 1.4117 in.) Exhaust 35.64 mm (1.403 in.) 35.942 ∼ 36.058 mm (1.4150 ∼ 1.4196 in.) Intake 35.84 mm (1.411 in.) 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.) Camshaft Journal, Camshaft 0.16 mm (0.0063 in.) Cap Clearance...
  • Page 253 ENGINE TOP END 5-11 Specifications Item Standard Service Limit Cylinder, Pistons 70.992 ∼ 71.008 mm (2.7950 ∼ 2.7956 in.) 71.11 mm (2.7996 in.) Cylinder Inside Diameter 70.974 ∼ 70.984 mm (2.7942 ∼ 2.7946 in.) 70.82 mm (2.7882 in.) Piston Diameter 0.008 ∼...
  • Page 254: Special Tools And Sealant

    5-12 ENGINE TOP END Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 32° - 30: 57001-221 57001-1120 Valve Spring Compressor Assembly: Valve Seat Cutter, 60° - 30: 57001-241 57001-1123 Piston Pin Puller Assembly: Valve Seat Cutter Holder Bar: 57001-910 57001-1128 Valve Seat Cutter, 45°...
  • Page 255 ENGINE TOP END 5-13 Special Tools and Sealant Valve Guide Arbor, 4: Valve Seat Cutter, 60° - 25: 57001-1273 57001-1328 Valve Guide Reamer, 4: Valve Guide Driver: 57001-1274 57001-1564 Valve Seat Cutter Holder, 4: Valve Guide Driver Attachment, C: 57001-1275 57001-1624 Compression Gauge Adapter, M10 ×...
  • Page 256: Clean Air System

    5-14 ENGINE TOP END Clean Air System Air Suction Valve Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Side Fairings (see Side Fairing Removal in the Frame chapter) • Disconnect the hose [A]. •...
  • Page 257: Air Suction Valve Inspection

    ENGINE TOP END 5-15 Clean Air System Air Suction Valve Inspection • Remove the air suction valve (see Air Suction Valve Re- moval). • Visually inspect the reeds for cracks, folds, warps, heat damage or other damage. If there is any doubt as to the condition of the reeds [A], replace the air suction valve as an assembly.
  • Page 258: Air Switching Valve Unit Test

    5-16 ENGINE TOP END Clean Air System Air Switching Valve Unit Test • Refer to the Air Switching Valve Unit Test in the Electrical System chapter. Clean Air System Hose Inspection • Be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the air cleaner housing, air switching valve and air suction valve covers.
  • Page 259: Cylinder Head Cover

    ENGINE TOP END 5-17 Cylinder Head Cover Cylinder Head Cover Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Thermostat Housing (see Thermostat Removal in the Cooling System chapter) Coolant Reserve Tank (see Coolant Change in the Peri- odic Maintenance chapter) Stick Coils (see Stick Coil Removal in the Electrical Sys- tem chapter)
  • Page 260 5-18 ENGINE TOP END Cylinder Head Cover • Tighten the cover bolts following the specified tightening sequence. Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the removed parts (see appropriate chapters).
  • Page 261: Camshaft Chain Tensioner

    ENGINE TOP END 5-19 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal NOTICE This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below.
  • Page 262: Camshaft, Camshaft Chain

    5-20 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) 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 263: Camshaft, Camshaft Cap Wear Inspection

    ENGINE TOP END 5-21 Camshaft, Camshaft Chain • Position the crankshaft at #1, 4 piston TDC. • Pull the tension side (exhaust side) [A] of the chain taut to install the chain. • Engage the camshaft chain with the camshaft sprockets so that the timing marks on the sprockets are positioned as shown.
  • Page 264: Camshaft Runout Inspection

    5-22 ENGINE TOP END Camshaft, Camshaft Chain If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer. Camshaft Journal Diameter 23.950 ∼ 23.972 mm (0.9429 ∼ 0.9438 in.) Standard: Service Limit: 23.92 mm (0.942 in.) If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again.
  • Page 265: Cylinder Head

    ENGINE TOP END 5-23 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) Stick Coils (see Stick Coil Removal in the Electrical Sys- tem chapter)
  • Page 266: Cylinder Head Removal

    5-24 ENGINE TOP END Cylinder Head Cylinder Head Removal • Remove: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) Cylinder Head Cover (see Cylinder Head Cover Re- moval) Camshafts (see Camshaft Removal) • Drain the coolant from the cylinder. ○...
  • Page 267 ENGINE TOP END 5-25 Cylinder Head • Tighten the M10 cylinder head bolts following the tighten- ing sequence [1 ∼10]. ○ First, tighten the bolts with 10 N·m (1.0 kgf·m, 15 ft·lb) of torque. ○ Next, in accordance with the following table tighten the bolts with the specified torque.
  • Page 268: Cylinder Head Warp Inspection

    5-26 ENGINE TOP END Cylinder Head • Install: Front Camshaft Chain Guide [A] Rear Camshaft Chain Guide [B] New O-rings [C] Collar [D] ○ Apply grease to the new O-ring. • Tighten: Torque - Front Camshaft Chain Guide Bolt (Upper) [E]: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Camshaft Chain Guide Bolt (Lower) [F]: 12 N·m (1.2 kgf·m, 106 in·lb)
  • Page 269: Valves

    ENGINE TOP END 5-27 Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove: Cylinder Head (see Cylinder Head Removal) Valve Lifter and Shim ○...
  • Page 270: Valve Guide Installation

    5-28 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). NOTICE Do not heat the cylinder head with a torch. This will warp the cylinder head.
  • Page 271: Valve-to-guide Clearance Measurement (wobble Method)

    ENGINE TOP END 5-29 Valves Valve-to-Guide Clearance Measurement (Wobble Method) If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. • Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface.
  • Page 272: Valve Seat Repair

    5-30 ENGINE TOP END Valves Valve Seat Repair • Repair the valve seat with the valve seat cutters [A]. Special Tools - Valve Seat Cutter Holder Bar [B]: 57001 -1128 Valve Seat Cutter Holder, 4 [C]: 57001-1275 [For Exhaust Valve Seat] Valve Seat Cutter, 45°...
  • Page 273 ENGINE TOP END 5-31 Valves Operating Procedures • Clean the seat area carefully. • Coat the seat with machinist’s dye. • Fit a 45° cutter into the holder and slide it into the valve guide. • Press down lightly on the handle and turn it right or left. Grind the seating surface only until it is smooth.
  • Page 274 5-32 ENGINE TOP END Valves If the outside diameter [A] of the seating surface is too large, make the 32° grind described below. If the outside diameter of the seating surface is within the specified range, measure the seat width as described be- low.
  • Page 275 ENGINE TOP END 5-33 Valves • Lap the valve to the seat, once the seat width and outside diameter are within the ranges specified above. ○ Put a little coarse grinding compound on the face of the valve in a number of places around the valve head. ○...
  • Page 276 5-34 ENGINE TOP END Valves...
  • Page 277: Cylinder, Pistons

    ENGINE TOP END 5-35 Cylinder, Pistons Cylinder Removal • Remove the cylinder head (see Cylinder Head Removal). • Loosen the water hose clamp screw [A]. • Remove: Water Pipe Bolt [B] Water Pipe [C] and Water Hose Cylinder [D] Cylinder Installation NOTE ○...
  • Page 278: Piston Removal

    5-36 ENGINE TOP END Cylinder, Pistons Piston Removal • Remove the cylinder (see Cylinder Removal). • Place a clean cloth under the pistons and remove the pis- ton pin snap ring [A] from the outside of each piston. • Remove the piston pins. Special Tool - Piston Pin Puller Assembly [A]: 57001-910 •...
  • Page 279: Cylinder Wear Inspection

    ENGINE TOP END 5-37 Cylinder, Pistons • Do not mix up the top and second ring. • Install the top ring [A] so that the “1R” mark [B] faces up. • Install the second ring [C] so that the “2R” mark [D] faces ○...
  • Page 280: Piston Ring, Piston Ring Groove Wear Inspection

    5-38 ENGINE TOP END Cylinder, Pistons Piston Ring, Piston Ring Groove Wear Inspection • 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 281: Piston Ring End Gap Inspection

    ENGINE TOP END 5-39 Cylinder, Pistons Piston Ring End Gap Inspection • 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 282: Throttle Body Holder

    5-40 ENGINE TOP END Throttle Body Holder Throttle Body Holder Installation • Apply grease to the new O-rings [A]. • Be sure to install the O-rings. • Install the holders [B] as shown. Clamp [C] • Tighten: Torque - Throttle Body Assy Holder Bolts [D]: 13 N·m (1.3 kgf·m, 115 in·lb) •...
  • Page 283: Muffler

    ENGINE TOP END 5-41 Muffler WARNING The muffler can become extremely hot during nor- mal operation and cause severe burns. Do not re- move the muffler while it is hot. Muffler Body Removal ZR800A/B Models • Remove the right frame cover (see Frame Cover Removal in the Frame chapter).
  • Page 284 5-42 ENGINE TOP END Muffler • Loosen the locknuts [A]. • Remove the exhaust butterfly valve cable lower ends [B] from the pulley [C]. ZR800C/D Models • Remove: Muffler Body Cover Bolts [A] Muffler Body Cover [B] • Loosen the clamp bolt [A]. •...
  • Page 285: Muffler Body Installation

    ENGINE TOP END 5-43 Muffler Muffler Body Installation ZR800A/B Models • Replace the muffler body gasket [A] and nut [B] with new ones. • Install the muffler body gasket until it is bottomed so that the inside chamfer side faces rear [C]. •...
  • Page 286 5-44 ENGINE TOP END Muffler • Adjust the exhaust butterfly cables (see Exhaust Butterfly Valve Cable Installation). • Thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts and nut. ZR800C/D Models • Replace the muffler body gasket [A] and nut [B] with new ones.
  • Page 287: Exhaust Pipe Removal

    ENGINE TOP END 5-45 Muffler • When installing the pads, note the following. ○ Install the pads [A] first. Next, install the pad [B] as shown. Muffler Body Cover [C] • Install the muffler body cover [A]. • Tighten: Torque - Muffler Body Cover Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb) L = 27 mm (1.06 in.) [B] L = 14 mm (0.55 in.) [C]...
  • Page 288: Exhaust Pipe Installation

    5-46 ENGINE TOP END Muffler Exhaust Pipe Installation • Replace the exhaust pipe gaskets [A] and muffler body gasket with new ones and install them. • Install the exhaust pipe [B]. • Tighten the exhaust pipe manifold holder nuts [C] follow- ing the specified tightening sequence.
  • Page 289: Exhaust Butterfly Valve Cable Installation (zr800a/b Models)

    ENGINE TOP END 5-47 Muffler • Remove: Clamp [A] Exhaust Butterfly Valve Cable Upper Ends [B] • Remove: Exhaust Butterfly Valve Cable Lower Ends (see Muffler Body Removal) Exhaust Butterfly Valve Cables Exhaust Butterfly Valve Cable Installation (ZR800A/B Models) • Confirm whether pulley [A] is an angle as shown.
  • Page 290 5-48 ENGINE TOP END Muffler • Stretch the open cable (white) [A] first by using the ad- juster [B]. ○ Turn the adjuster counterclockwise until the play of the open cable becomes no play. Locknut of White [C] NOTICE To keep the correct exhaust butterfly valve position, adjust the open cable first.
  • Page 291 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool and Sealant ......................Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Clutch Cable Removal ...................... Clutch Cable Installation ....................Clutch Cable Lubrication....................
  • Page 292: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 293 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Lever Clamp Bolts 97 in·lb Oil Filler Plug 0.20 18 in·lb Clutch Cover Mounting Bolts 97 in·lb Clutch Spring Bolts 0.90 78 in·lb Clutch Hub Nut 13.8 CL: Apply cable lubricant. EO: Apply engine oil.
  • Page 294: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch 37.7 ∼ 38.3 mm (1.48 ∼ 1.51 in.) Clutch Plate Assembly Length – – – 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) Friction Plate Thickness 2.4 mm (0.094 in.) Friction and Steel Plate Warp...
  • Page 295: Special Tool And Sealant

    CLUTCH 6-5 Special Tool and Sealant Clutch Holder: Liquid Gasket, TB1211F: 57001-1243 92104-0004...
  • Page 296: Clutch Lever And Cable

    6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Cable Removal •...
  • Page 297: Clutch Cover

    CLUTCH 6-7 Clutch Cover Clutch Cover Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Right Subframe Cover (see Subframe Cover Removal in the Frame chapter) Right Lower Fairing (see Lower Fairing Removal (ZR800A/B Models) in the Frame chapter) Clutch Cable Lower End [A] Clutch Cover Mounting Bolts [B]...
  • Page 298: 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 299: Clutch Removal

    CLUTCH 6-9 Clutch Clutch Removal • Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with Thrust Bearing, Pusher [C], Spring and Washer) • Remove: Friction Plates and Steel Plates Clutch Hub Nut [A] ○...
  • Page 300 6-10 CLUTCH Clutch ○ Install the spacer [A] so that the tapered side [B] faces inward. ○ Install the spacer [A] so that the “OUTSIDE” mark [B] faces outward. ○ Replace the clutch hub nut with a new one. ○ Holding the clutch hub, tighten the clutch hub nut.
  • Page 301: Clutch Plate Assembly Inspection

    CLUTCH 6-11 Clutch • Align the mark [A] of the clutch spring plate [B] with the groove [C] of the clutch hub. • Install: Clutch Spring Plate Clutch Springs • Tighten: Torque - Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) •...
  • Page 302: Clutch Plate, Wear, Damage Inspection

    6-12 CLUTCH Clutch Clutch Plate, Wear, Damage Inspection • Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. • Measure the thickness of each friction plate [A] at several points. If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones.
  • Page 303 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealant ...................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ Oil Pan Removal .......................
  • Page 304: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 305 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Jet Nozzle Bolts 0.70 61 in·lb Oil Filler Plug 0.20 18 in·lb Oil Filter Oil Filter Holder Oil Pressure Switch Terminal Bolt 0.20 18 in·lb Oil Pressure Switch Oil Passage Plugs Oil Pipe Holder Bolts 115 in·lb...
  • Page 306: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 307 ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart 1. Camshaft Oil Passage 2. Oil Filter 3. Oil Jet 4. Crankshaft Oil Passage 5. Oil Pressure Switch 6. Breather Hose 7. Drive Shaft Oil Passage 8. Oil Pipe 9. Main Oil Passage 10.
  • Page 308: Specifications

    7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity: 3.1 L (3.3 US gt) (when filter is not removed) 3.4 L (3.6 US gt) (when filter is removed) 3.8 L (4.0 US gt) (when engine is completely dry) Between upper and lower level lines (Wait 2 ∼...
  • Page 309: Special Tools And Sealant

    ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Outside Circlip Pliers: Oil Pressure Gauge Adapter, PT3/8: 57001-144 57001-1233 Oil Pressure Gauge, 10 kgf/cm²: Liquid Gasket, TB1211: 57001-164 56019-120...
  • Page 310: Engine Oil And Oil Filter

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter according to the periodic maintenance chart.
  • Page 311: Oil Pan

    ENGINE LUBRICATION SYSTEM 7-9 Oil Pan Oil Pan Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Lower Fairings (see Lower Fairing Removal (ZR800A/B Models) in the Frame chapter) Muffler Body (see Muffler Body Removal in the Engine Top End chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter)
  • Page 312: Oil Pressure Relief Valve

    7-10 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Refer to the Oil Pan Removal. Oil Pressure Relief Valve Installation • Refer to the Oil Pan Installation. Oil Pressure Relief Valve Inspection • Check to see if the valve [A] slides smoothly when push- ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure.
  • Page 313: 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 the water pipe bolts [A]. •...
  • Page 314: Oil Pump Drive Gear Removal

    7-12 ENGINE LUBRICATION SYSTEM Oil Pump • Replace the O-ring [A] with a new one. • Apply grease to the O-ring. • Install: Pins [B] Water Pump Body [C] • Install the impeller [A], washer and bolt [B]. • Tighten: Torque - Water Pump Impeller Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 315: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pressure Measurement Oil Pressure Measurement • Remove the right lower fairing (see Lower Fairing Re- moval (ZR800A/B Models) in the Frame chapter). • Remove the oil passage plug, and attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT3/8: 57001 -1233...
  • Page 316: Oil Pressure Switch

    7-14 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Right Lower Fairing (see Lower Fairing Removal (ZR800A/B Models) in the Frame chapter) Switch Cover [A] Switch Terminal Bolt [B] Oil Pressure Switch [C]...
  • Page 317 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 318: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 319 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Engine Bracket Bolts 97 in·lb Upper Engine Bracket Bolts Subframe Bolts Adjusting Collar Locknuts Front Engine Mounting Bolts Upper Adjusting Collar 87 in·lb Middle Engine Mounting Nut Rear Engine Bracket Bolts Lower Engine Mounting Nut 10 Lower Adjusting Collar 0.50...
  • Page 320: Special Tool

    8-4 ENGINE REMOVAL/INSTALLATION Special Tool Engine Mount Nut Wrench: 57001-1450...
  • Page 321: 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 Motorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to hold the front brake when removing the engine.
  • Page 322: Front Engine Bracket Bolts

    8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove the engine sprocket [A] (see Engine Sprocket Removal in the Final Drive chapter). • Disconnect: Crankshaft Sensor Lead Connector and Oil Pressure Switch Lead Terminal (see Crankshaft Sensor Removal in the Electrical System chapter) Starter Motor Cable (see Starter Motor Removal in the Electrical System chapter) Alternator Lead Connector (see Alternator Cover Re-...
  • Page 323: Upper Engine Bracket Bolts

    ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Remove the right front engine mounting bolt [A]. • Using the nut wrench [A], loosen the lock nut [B]. Special Tool - Engine Mount Nut Wrench: 57001-1450 • Using the Hexagon Wrench, turn the upper adjusting col- lar [A] counterclockwise to make the gap between the en- gine and upper adjusting collar.
  • Page 324 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Using the nut wrench [A], loosen the locknut [B]. Special Tool - Engine Mount Nut Wrench: 57001-1450 • Using the Hexagon Wrench, turn the lower adjusting col- lar [A] counterclockwise to make the gap between the en- gine and lower adjusting collar.
  • Page 325: Engine Installation

    ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation Engine Installation • Support the engine with a suitable stand. ○ Put a plank onto the suitable stand for engine balance. • Screw the lower adjusting collar [A] to the frame. • Screw the upper adjusting collar [B] to the subframe. •...
  • Page 326 8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Install the engine mounting bolts and nuts, following the specified installing sequence. ○ 1st, install the rear engine bracket [A] and tighten the bolts [B] temporarily. ○ 2nd, install the left upper engine bracket [C], left subframe [D] and spherical washers [E] so that the spherical side faces inward and tighten the bolts [F] [G] [H] [I] temporar- ily.
  • Page 327 ENGINE REMOVAL/INSTALLATION 8-11 Engine Removal/Installation ○ 16th, loosen the subframe bolt [T], and tighten the sub- frame bolt [T]. Torque - Subframe Bolt [T]: 25 N·m (2.5 kgf·m, 18 ft·lb) ○ 17th, loosen the subframe bolt [U], and tighten the sub- frame bolt [U].
  • Page 328: In·lb

    8-12 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Install the front engine bracket and horn. • Tighten: Torque - Front Engine Bracket Bolts: 11 N·m (1.1 kgf·m, 97 in·lb) • When installing the trim [A], note the following. ○ Touch the trim to the horn bracket [B]. •...
  • Page 329 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................... 9-15 Crankshaft Removal ......................9-15 Crankshaft Installation ...................... 9-15 Connecting Rod Removal ....................9-15 Connecting Rod Installation ....................
  • Page 330: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 331 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Jet Nozzle Bolts 0.70 61 in·lb Crankcase Bolts (M6) 106 in·lb Crankcase Bolts (M7) Side Breather Plate Bolts 0.60 52 in·lb Connecting Rod Big End Nuts See the text ←...
  • Page 332 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 333 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Shift Drum Bearing Holder Screw 0.60 52 in·lb Shift Drum Bearing Holder Bolt 106 in·lb Shift Drum Cam Holder Bolt 106 in·lb Neutral Switch Shift Lever Bolt 0.70 61 in·lb Gear Positioning Lever Bolt 106 in·lb Shift Shaft Return Spring Pin...
  • Page 334: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Bend – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.2/100 mm (0.008/3.94 in.) 0.13 ∼ 0.38 mm Connecting Rod Big End Side Clearance 0.58 mm (0.0051 ∼...
  • Page 335 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit 0.020 ∼ 0.044 mm Crankshaft Main Bearing Insert/Journal 0.07 mm (0.0008 ∼ 0.0017 in.) Clearance (0.0028 in.) 32.984 ∼ 33.000 mm Crankshaft Main Journal Diameter: 32.96 mm (1.2986 ∼ 1.2992 in.) (1.2976 in.) 32.984 ∼...
  • Page 336: Special Tools And Sealant

    9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealant Bearing Puller: Flywheel Holder: 57001-135 57001-1313 Outside Circlip Pliers: Liquid Gasket, TB1216B: 57001-144 92104-1064 Bearing Puller Adapter: Liquid Gasket, TB1207B: 57001-317 92104-2068 Bearing Driver, 32: 57001-382...
  • Page 337: 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: Oil Pressure Switch Terminal (see Oil Pressure Switch Removal in the Engine Lubrication System chapter) Crankshaft Sensor (see Crankshaft Sensor Removal in the Electrical System chapter)
  • Page 338: In·lb

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Assembly NOTICE 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. • Using a high flash-point solvent, clean off the mating sur- faces of the crankcase halves and wipe dry.
  • Page 339: In·lb

    CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting • Install the side breather plate [A]. • Apply a non-permanent locking agent to the threads of the side breather plate bolts [B] and tighten them. Torque - Side Breather Plate Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) •...
  • Page 340 9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. • Apply liquid gasket [A] to the mating surface of the lower crankcase half.
  • Page 341 CRANKSHAFT/TRANSMISSION 9-13 Crankcase Splitting • Tighten the M9 crankcase bolts following the tightening sequence [1 ∼10]. L = 81 mm (3.19 in.) [1 ∼ 6] L = 95 mm (3.74 in.) [7 ∼ 10] ○ First, tighten the bolts with 10 N·m (1.0 kgf·m, 89 ft·lb) of torque.
  • Page 342 9-14 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Tighten the upper crankcase bolts in the order listed. Torque - Crankcase Bolts (M8) [A]: 27 N·m (2.8 kgf·m, 20 ft·lb) Crankcase Bolts (M7) [B] [C]: 20 N·m (2.0 kgf·m, 15 ft·lb) Crankcase Bolts (M6) [D] [E] [F]: 12 N·m (1.2 kgf·m, 106 in·lb) L= 85 mm (3.35 in.) [B] L= 50 mm (1.97 in.) [C]...
  • Page 343: Crankshaft And Connecting Rods

    CRANKSHAFT/TRANSMISSION 9-15 Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft [A]. Crankshaft Installation NOTICE If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.
  • Page 344 9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Apply molybdenum disulfide oil solution [A] to the inner surfaces of upper and lower bearing inserts. • Do not apply any grease or oil to the cap inside and cap insert outside [B]. •...
  • Page 345 CRANKSHAFT/TRANSMISSION 9-17 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 346 9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Dent both bolt head and bolt tip with a punch as shown. • Before tightening, use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt stretch. Connecting Rod [A] Mark here with a punch [B].
  • Page 347: Crankshaft/connecting Rod Cleaning

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods • Apply a small amount of molybdenum disulfide oil solution to the following. Threads [A] of Nuts and Bolts Seating Surfaces [B] of Nuts and Connecting Rods • Install new bolts in the connecting rods. •...
  • Page 348: Connecting Rod Twist Inspection

    9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Twist Inspection • With the big-end arbor [A] still on V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being paralleled with the surface plate over a 100 mm (3.94 in.) length of the arbor to de- termine the amount of connecting rod twist.
  • Page 349 CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods If the clearance is within the standard, no bearing replace- ment is required. If the clearance is between 0.072 mm (0.0028 in.) and the service limit (0.11 mm, 0.0043 in.), replace the bear- ing inserts [A] with inserts painted blue [B]. Check in- sert/crankpin clearance with the plastigage.
  • Page 350: Crankshaft Side Clearance Inspection

    9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Measure the connecting rod big end inside diameter, and mark each connecting rod big end in accordance with the inside diameter. • Tighten the connecting rod big end nuts to the specified torque (see Connecting Rod Installation). NOTE ○...
  • Page 351: Crankshaft Runout Inspection

    CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rods Crankshaft Runout Inspection • 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 Inspection •...
  • Page 352 9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. ○ Crankcase Main Bearing Inside Diameter Marks: “ ” or no mark. • Tighten the crankcase bolts to the specified torque (see Crankcase Assembly).
  • Page 353: In·lb

    CRANKSHAFT/TRANSMISSION 9-25 Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal/Installation in the Electrical System chapter. Starter Motor Clutch Inspection • Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Starter Idle Gear and Shaft •...
  • Page 354: Transmission

    9-26 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal • Remove: Shift Lever Bolt [A] Shift Lever [B] If the tie-rod is removed from the shift pedal and shift lever, note the following. ○ The following portions have left-hand threads. Locknut [C] of Shift Lever Side Ball Joint [D] of Shift Lever •...
  • Page 355: External Shift Mechanism Removal

    CRANKSHAFT/TRANSMISSION 9-27 Transmission External Shift Mechanism Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Shift Lever (see Shift Pedal Removal) Clutch (see Clutch Removal in the Clutch chapter) Oil Pipe Holder Bolts [A] Oil Pipe Holders [B] Oil Pipe [C] and O-rings •...
  • Page 356: External Shift Mechanism Inspection

    9-28 CRANKSHAFT/TRANSMISSION Transmission External Shift Mechanism Inspection • Examine the shift shaft [A] for any damage. If the shaft is bent, straighten or replace it. If the serration [B] are damaged, replace the shaft. If the springs [C] are damaged in any way, replace them. If the shift mechanism arm [D] is damaged in any way, replace the shaft.
  • Page 357: Transmission Shaft Disassembly

    CRANKSHAFT/TRANSMISSION 9-29 Transmission • Install the drive shaft and output shaft into the upper crankcase half. • Apply engine oil to the bearings. ○ The bearing set pins and rings must match properly with the holes or grooves in the bearing outer races. When they are properly matched, there is no clearance [A] be- tween the crankcase and the bearing outer races.
  • Page 358: Transmission Shaft Assembly

    9-30 CRANKSHAFT/TRANSMISSION Transmission • Remove the collar [A] together with the ball bearing [B] from output shaft. Special Tool - Bearing Puller [C]: 57001-135 • Discard the bearing. Transmission Shaft Assembly • Install the new ball bearing [A] and collar [B] (output shaft) on the each shafts, using the bearing driver.
  • Page 359 CRANKSHAFT/TRANSMISSION 9-31 Transmission • The drive shaft gears can be recognized by size: the gear with the smallest diameter is 1st gear, and the largest one is 6th gear. Be sure that all parts are put back in the cor- rect sequence and all circlips and washers are properly in place.
  • Page 360 9-32 CRANKSHAFT/TRANSMISSION Transmission 1. Needle Bearing 17. Ball Bearing 2. Circlip 18. Drive Shaft 3. Bearing Outer Race 19. Nut 4. Thrust Washer, 30 mm (1.18 in.) 20. Collar 5. 2nd Gear 21. Oil Seal 6. Circlip, 29 mm (1.14 in.) 22.
  • Page 361: Shift Drum And Fork Removal

    CRANKSHAFT/TRANSMISSION 9-33 Transmission Shift Drum and Fork Removal • Remove: Lower Crankcase Half (see Crankcase Splitting) Transmission Shafts Gear Positioning Lever [A] (see External Shift Mecha- nism Removal) Bolt [B] and Screw [C] Shift Drum Bearing Holder [D] • Pull out the shift rods [E], and take off the shift forks. •...
  • Page 362: Shift Fork Bending Inspection

    9-34 CRANKSHAFT/TRANSMISSION Transmission Shift Fork Bending Inspection • Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90°...
  • Page 363 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 ....................10-7 Rear Wheel Removal......................10-7 Rear Wheel Installation..................... 10-8 Wheel Inspection ......................10-10 Axle Inspection........................
  • Page 364: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 365 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolt Front Axle 11.0 79.7 Rear Axle Nut 11.0 79.7 4. ABS Equipped Models G: Apply grease. HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 366: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 1.0 mm (0.04 in.) Axle Runout/100 mm TIR 0.03 mm (0.0012 in.) or less TIR 0.2 mm (0.008 in.) (3.94 in.)
  • Page 367: Special Tools

    WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: Bearing Remover Shaft, 13: 57001-1129 57001-1377 Jack: Jack Attachment: 57001-1238 57001-1608 Bearing Remover Head, 20 × 22: 57001-1293...
  • Page 368: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Front Caliper Mounting Bolts [A] (Both Sides) Front Caliper [B] (Both Sides) ○ ZR800A/B/D Models [C] ○ ZR800C Model [D] • For ABS equipped models, remove the front wheel rota- tion sensor (see Front Wheel Rotation Sensor Removal in the Brake chapter).
  • Page 369: Front Wheel Installation

    WHEELS/TIRES 10-7 Wheels (Rims) Front Wheel Installation NOTE ○ The direction of the wheel rotation [A] is shown by an arrow [B] on the wheel hub. • Check the wheel rotation mark on the front wheel and install it. • Apply high-temperature grease to the grease seal lips.
  • Page 370: Rear Wheel Installation

    10-8 WHEELS/TIRES Wheels (Rims) • Remove: Cotter Pin [A] Axle Nut [B] Washer Axle [C] (from Right Side) Wheel Alignment Indicator [D] (Both Sides) • For ABS equipped models, remove the rear wheel rota- tion sensor from the caliper bracket (see Rear Wheel Ro- tation Sensor Removal in the Brakes chapter).
  • Page 371 WHEELS/TIRES 10-9 Wheels (Rims) • Bend the cotter pin [A] over the nut [B]. WARNING A loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper torque and install a new cotter pin. •...
  • Page 372: Wheel Inspection

    10-10 WHEELS/TIRES Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground (see Front/Rear Wheel Removal). • Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings (see Hub Bearing Removal/Installation). •...
  • Page 373: Balance Inspection

    WHEELS/TIRES 10-11 Wheels (Rims) Balance Inspection • Remove the front and rear wheels (see Front/Rear Wheel Removal). • Support the wheel so that it can be spun freely. • Spin the wheel lightly, and mark [A] the wheel at the top when the wheel stops.
  • Page 374 30 g (1.06 oz.) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20, and 30 grams (0.35, 0.71, and 1.06 oz.) sizes. An imbalance of less than 10 grams (0.35 oz.) will not usually affect running stability.
  • Page 375: Tires

    WHEELS/TIRES 10-13 Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove: Wheels (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...
  • Page 376 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 377: 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 378: Hub Bearing

    10-16 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheels (see Front/Rear Wheel Removal), and take out the following. Collars [A] Coupling [B] (Out of rear hub) Grease Seals [C] Front Wheel [D] Rear Wheel [E] • Use the bearing remover to remove the hub bearings [A]. NOTICE Do not lay the wheel on the ground with the disc facing down.
  • Page 379: Hub Bearing Inspection

    WHEELS/TIRES 10-17 Hub Bearing • Replace the grease seals with new ones. • Press in the grease seals [A] so that the seal surface is flush [B] with the end of the hole. ○ Apply high-temperature grease to the grease seal lips. Special Tool - Bearing Driver Set [C]: 57001-1129 •...
  • Page 381 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 382: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 383 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 17.0 Chain Adjuster Locknuts 16.5 1.68 12.2 Rear Axle Nut 11.0 79.7 Rear Sprocket Nuts HG: Apply high-temperature grease. HO: Apply heavy oil.
  • Page 384: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain 20 ∼ 30 mm (0.8 ∼ 1.2 in.) Drive Chain Slack – – – Drive Chain Wear (20-link Length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 319 mm (12.6 in.) Standard Chain: Make ENUMA...
  • Page 385: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...
  • Page 386: 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 387 FINAL DRIVE 11-7 Drive Chain • Grind [A] the pin head to make it flat. • Set the cutting and riveting pin [B] as shown. • Screw the pin holder until it touches chain pin. • Be sure that the cutting pin hits center of chain pin. •...
  • Page 388 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 389 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 390: Sprocket, Coupling

    11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove: Left Frame Cover (see Frame Cover Removal in the Frame chapter) Engine Sprocket Cover Bolts [A] Bracket [B] Engine Sprocket Cover [C] • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer.
  • Page 391: Rear Sprocket Removal

    FINAL DRIVE 11-11 Sprocket, Coupling • Be sure to install the dowel pins [A]. • Install the engine sprocket cover [A]. • Install the bracket [B] as shown, and tighten the cover bolts [C]. Torque - Engine Sprocket Cover Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb) •...
  • Page 392: Coupling Installation

    11-12 FINAL DRIVE Sprocket, Coupling Coupling Installation • Apply high-temperature grease to the following. Coupling Grease Seal Lips [A] Coupling Internal Surface [B] • Replace the O-ring [A] with a new one. • Apply grease to the O-ring. • Install the collar [B]. Coupling Bearing Removal •...
  • Page 393: Coupling Bearing Inspection

    FINAL DRIVE 11-13 Sprocket, Coupling • Replace the grease seal with a new one. • Press in the grease seal so that the seal surface is flush with the end of the hole. ○ Apply high-temperature grease to the grease seal lips. Special Tool - Bearing Driver Set: 57001-1129 Coupling Bearing Inspection Since the coupling bearing is made to extremely close...
  • Page 394: Rear Sprocket Warp Inspection

    11-14 FINAL DRIVE Sprocket, Coupling Rear Sprocket Warp Inspection • Raise the rear wheel off the ground with the stand so that it will turn freely. • Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown, and rotate [C] the rear wheel to measure the sprocket runout (warp).
  • Page 395 BRAKES 12-1 Brakes Table of Contents Exploded View........................12-4 Specifications ......................... 12-14 Special Tools .......................... 12-15 Brake Lever, Brake Pedal....................... 12-16 Brake Lever Position Adjustment..................12-16 Brake Pedal Position Inspection ..................12-16 Brake Pedal Position Adjustment..................12-16 Brake Pedal Removal ....................... 12-16 Brake Pedal Installation ....................
  • Page 396 12-2 BRAKES Brake Hose and Pipe Inspection..................12-35 Anti-Lock Brake System (Equipped Models) ................12-36 ABS Servicing Precautions ....................12-39 ABS Troubleshooting Outline.................... 12-41 Inquiries to Rider....................... 12-44 Self-diagnosis Outline ....................... 12-46 Self-diagnosis Procedures ....................12-46 Service Code Clearing Procedures................... 12-47 How to Read Service Codes.....................
  • Page 397 BRAKES 12-3 This page intentionally left blank.
  • Page 398: Exploded View

    12-4 BRAKES Exploded View ZR800A Model...
  • Page 399 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts Front Master Cylinder Reservoir Cap Screws 0.15 13 in·lb Brake Lever Pivot Bolt 0.10 8.9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Brake Light Switch Screw 0.12 11 in·lb Front Master Cylinder Clamp Bolts...
  • Page 400 12-6 BRAKES Exploded View ZR800C Model...
  • Page 401 BRAKES 12-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts Front Master Cylinder Reservoir Cap Screws 0.15 13 in·lb Brake Lever Pivot Bolt 0.10 8.9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Master Cylinder Clamp Bolts 97 in·lb Front Brake Light Switch Screw 0.12...
  • Page 402 12-8 BRAKES Exploded View...
  • Page 403 BRAKES 12-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts Rear Master Cylinder Mounting Bolts Brake Pedal Bolt 0.90 78 in·lb Rear Master Cylinder Push Rod Locknut 17.2 1.75 12.7 Rear Caliper Pin Bolt Rear Brake Disc Mounting Bolts Rear Brake Pad Pin 17.2 1.75...
  • Page 404 12-10 BRAKES Exploded View ABS Equipped Models...
  • Page 405 BRAKES 12-11 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts Front Master Cylinder Reservoir Cap Screws 0.15 13 in·lb Brake Lever Pivot Bolt 0.10 8.9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Master Cylinder Clamp Bolts 97 in·lb Front Brake Light Switch Screw 0.12...
  • Page 406 12-12 BRAKES Exploded View ABS Equipped Models...
  • Page 407 BRAKES 12-13 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts (ABS Hydraulic Unit) Brake Hose Banjo Bolts Rear Caliper Pin Bolt Bleed Valve 0.80 69 in·lb Rear Brake Pad Pin Plug 0.25 22 in·lb Rear Brake Pad Pin 17.2 1.75 12.7...
  • Page 408: Specifications

    12-14 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 5-way adjustable (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 40 mm (1.57 in.) below footpeg –...
  • Page 409: Special Tools

    BRAKES 12-15 Special Tools Hand Tester: 57001-1394...
  • Page 410: Brake Lever, Brake Pedal

    12-16 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder.
  • Page 411: Brake Pedal Installation

    BRAKES 12-17 Brake Lever, Brake Pedal • Remove: Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] Brake Pedal Bolt [E] Brake Pedal [F] Brake Pedal Installation • Apply grease to the inside of the bushing [A]. •...
  • Page 412: Calipers

    12-18 BRAKES Calipers Front Caliper Removal ZR800A/B/D Models • 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. NOTICE Do not loosen the caliper assembly bolts.
  • Page 413: Front Caliper Disassembly

    BRAKES 12-19 Calipers Rear Caliper • Install: Rubber Boot [A] Guide [B] • Fit the rear brake pads [A] to the guide [B]. • Apply silicone grease to the rear caliper pin bolt. • Tighten: Torque - Caliper Mounting Bolts: Front: 25 N·m (2.5 kgf·m, 18 ft·lb) Rear: 22 N·m (2.2 kgf·m, 16 ft·lb) Rear Caliper Pin Bolt: 27 N·m (2.8 kgf·m, 20 ft·lb)
  • Page 414: Rear Caliper Assembly

    12-20 BRAKES Calipers Rear Caliper Assembly • Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter. Caliper Fluid Seal Damage Inspection The fluid seal (piston seal) [A] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- perature of the discs or the brake fluid to increase.
  • Page 415: Caliper Dust Seal Damage Inspection

    BRAKES 12-21 Calipers Caliper Dust Seal Damage Inspection • Check that the dust seals [A] are not cracked, worn, swollen, or otherwise damaged. If they show any damage, replace the dust seals with new ones. Pistons [B] Fluid Seals [C] ○...
  • Page 416: Caliper Piston And Cylinder Damage Inspection

    12-22 BRAKES Calipers Caliper Piston and Cylinder Damage Inspection • Visually inspect the pistons [A] and cylinder surfaces [B]. Replace the caliper if the cylinder and piston are badly scores or rusty. ○ ZR800A/B/D Models [C] ○ ZR800C Model [D] Front Caliper Holder Shaft Wear Inspection (ZR800C Model) The caliper body must slide smoothly on the caliper holder...
  • Page 417: Rear Caliper Holder Wear Inspection

    BRAKES 12-23 Calipers Rear Caliper Holder Wear Inspection The caliper body must slide smoothly on the rear caliper pin bolt [A] and sleeve [B]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature.
  • Page 418: Front Brake Pad Removal

    12-24 BRAKES Brake Pads Front Brake Pad Removal ZR800A/B/D Models • Remove: Pad Pin [A] Pad Spring [B] Brake Pads [C] ZR800C Model • Remove the pad pin plug [A]. • Loosen the pad pin [A]. • Remove the caliper mounting bolts [B]. •...
  • Page 419 BRAKES 12-25 Brake Pads • Set: Inside Pad [A] Pad Spring [B] ○ Push down the pin holder [C] and insert the pad pin. Torque - Front Brake Pad Pin: 17.2 N·m (1.75 kgf·m, 12.7 ft·lb) WARNING After servicing, it takes several applications of the brake lever before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death.
  • Page 420: Rear Brake Pad Removal

    12-26 BRAKES Brake Pads Rear Brake Pad Removal • Unscrew the pad pin plug [A]. • Loosen the pad pin [A]. • Unscrew the bolt [B]. • Remove: Pad Pin [A] Brake Pads [B] Rear Brake Pad Installation • Push the caliper piston in by hand as far as they will go. •...
  • Page 421: Brake Pad Wear Inspection

    BRAKES 12-27 Brake Pads • Set: Inside Pad [A] Pad Pin [B] • Install the caliper (see Caliper Installation). • Tighten the pad pin and plug. Torque - Rear Brake Pad Pin: 17.2 N·m (1.75 kgf·m, 12.7 ft·lb) Rear Brake Pad Pin Plug: 2.5 N·m (0.25 kgf·m, 22 in·lb) WARNING After servicing, it takes several applications of the...
  • Page 422: Master Cylinder

    12-28 BRAKES Master Cylinder Front Master Cylinder Removal • Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder (see Brake Hose and Pipe Re- moval/Installation). • 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 423: Rear Master Cylinder Installation

    BRAKES 12-29 Master Cylinder • Remove: Cotter Pin [A] Joint Pin [B] Bolt [C] Rear Master Cylinder [D] • Slide out the clamp [E]. • Pull off the reservoir hose lower end, and drain the brake fluid into a container. Rear Master Cylinder Installation •...
  • Page 424: Master Cylinder Inspection (visual Inspection)

    12-30 BRAKES Master Cylinder Master Cylinder Inspection (Visual Inspection) • Remove the master cylinders (see Front/Rear Master Cylinder Removal). • Disassemble the front and rear master cylinders (see Master Cylinder Rubber Parts Replacement in the Peri- odic Maintenance chapter). • Check that there are no scratches, rust or pitting on the inner wall [A] of each master cylinder and on the outside of each piston [B].
  • Page 425: Brake Disc

    BRAKES 12-31 Brake Disc Brake Disc Removal • Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Remove the brake disc mounting bolts, and take off the disc. ○ Remove the sensor rotor (ABS equipped models). • Remove the gaskets.
  • Page 426: Brake Fluid

    12-32 BRAKES 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 427 BRAKES 12-33 Brake Fluid • Bleed the brake line and the caliper. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].
  • Page 428 12-34 BRAKES Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. • Never reuse old brake fluid. • Do not use fluid from a container that has been left unsealed or that has been open for a long time. •...
  • Page 429: Brake Hose

    BRAKES 12-35 Brake Hose Brake Hose and Pipe Removal/Installation • Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter. Brake Hose and Pipe Inspection • Refer to the Brake Hose and Pipe Damage and Instal- lation Condition Inspection in the Periodic Maintenance chapter.
  • Page 430: Anti-lock Brake System (equipped Models)

    12-36 BRAKES Anti-Lock Brake System (Equipped Models) Parts Location 1. ABS Kawasaki Self-diagnosis System Connector 2. Fuse Box 1 3. Yellow ABS Indicator Light (LED) 4. Front Wheel Rotation Sensor Rotor 5. Front Wheel Rotation Sensor 6. ABS Hydraulic Unit 7.
  • Page 431 8. Battery 12 V 8 Ah 19. Meter Unit 9. Starter Relay 20. Joint Connector C 10. Main Fuse 30 A 21. Front Wheel Rotation Sensor 11. ABS Kawasaki Self-diagnosis System Connector ○ Color Codes: BK: Black GY: Gray PU: Purple...
  • Page 432 2. Unused 3. Unused 4. Front and Rear Brake Light Switch Signal: BL/R 5. ABS Kawasaki Self-diagnosis System Terminal: P 6. Power Supply to Rear Wheel Rotation Sensor: W/G 7. Power Supply: BR/W 8. Power Supply to Front Wheel Rotation Sensor: W/BK 9.
  • Page 433: Abs Servicing Precautions

    BRAKES 12-39 Anti-Lock Brake System (Equipped Models) ABS Servicing Precautions There are a number of important precautions that should be followed servicing the ABS system. ○ This ABS system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 434 12-40 BRAKES Anti-Lock Brake System (Equipped Models) WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If any of the brake line fittings, including the ABS hydraulic unit joint nuts, or the bleed valve is opened at any time, the air must be bled completely from the brake line.
  • Page 435: Abs Troubleshooting Outline

    BRAKES 12-41 Anti-Lock Brake System (Equipped Models) ○ The yellow ABS indicator light (LED) may come on if the engine is run with the motorcycle on its stand and the transmission in gear. If the indicator light comes on, just turn the ignition switch off, then clear service code 42, which indicates a “Faulty front wheel rotation sensor”.
  • Page 436 12-42 BRAKES Anti-Lock Brake System (Equipped Models) Even when the ABS is operating normally, the yellow ABS indicator light (LED) may light up under the conditions listed below. Turn the ignition switch off to stop the indicator light. If the motorcycle runs without erasing the service code, the light may light up again.
  • Page 437 BRAKES 12-43 Anti-Lock Brake System (Equipped Models) ABS Diagnosis Flow Chart...
  • Page 438: Inquiries To Rider

    12-44 BRAKES Anti-Lock Brake System (Equipped Models) Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of condition the rider is dissatisfied with. ○ Try to find out exactly what problem occurs under exactly what conditions by asking the rider; know- ing this information may help you reproduce the problem in the shop.
  • Page 439 BRAKES 12-45 Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 1...
  • Page 440: Self-diagnosis Outline

    12-46 BRAKES Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 2 Self-diagnosis Outline When the yellow ABS indicator light (LED) has blinked or come on, the ABS hydraulic unit mem- orizes and stores the service code for the service person to troubleshoot easily. The service code memory is powered directly by the battery and cannot be canceled by the ignition switch.
  • Page 441: Service Code Clearing Procedures

    BRAKES 12-47 Anti-Lock Brake System (Equipped Models) • The ABS hydraulic unit can be store the service codes including previous ones. • To read out the current service code, erase the stored service codes once prior reading the service code (see Service Code Clearing Procedures).
  • Page 442 12-48 BRAKES Anti-Lock Brake System (Equipped Models) Erasing of Service Code...
  • Page 443 BRAKES 12-49 Anti-Lock Brake System (Equipped Models) Self-diagnosis Flow Chart...
  • Page 444: How To Read Service Codes

    12-50 BRAKES Anti-Lock Brake System (Equipped Models) How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the yellow ABS indicator light (LED) as shown below. ○ Read 10th digit and unit digit as the yellow ABS indicator light (LED) blinks. ○...
  • Page 445: Service Code Table

    BRAKES 12-51 Anti-Lock Brake System (Equipped Models) Service Code Table Service Yellow ABS Indicator Problems Light State Code Light (LED) Stays on* (Error function Main harness, meter unit, wheel rotation – after the ignition switch sensor(s) or ABS unit abnormal turned on) Does not go on (When the Main harness, meter unit or ABS unit...
  • Page 446: Yellow Abs Indicator Light (led) Inspection

    12-52 BRAKES Anti-Lock Brake System (Equipped Models) Yellow ABS Indicator Light (LED) Inspection ○ In this model, the yellow ABS indicator light (LED) [A] goes on or blinks by the control of the ABS hydraulic unit. Yellow ABS Indicator Light (LED) Stays ON (Error func- tion after the ignition switch turned on - No Service Code) •...
  • Page 447 BRAKES 12-53 Anti-Lock Brake System (Equipped Models) Step 3-2 • Check for continuity between the terminal 9 (BK) [A] of the ABS hydraulic unit connector and a frame ground [B]. If there is no continuity, repair or replace the main har- ness.
  • Page 448 12-54 BRAKES Anti-Lock Brake System (Equipped Models) Step 2 • Disconnect the ABS hydraulic unit connector [A] and check the yellow ABS indicator light (LED) for function. ○ The yellow ABS indicator light (LED) should goes on when the ignition switch turned on. If the indicator does not goes on, go to next step.
  • Page 449: Abs Unit Solenoid Valve Inspection (service Code 13, 14, 17, 18)

    BRAKES 12-55 Anti-Lock Brake System (Equipped Models) ABS Unit Solenoid Valve Inspection (Service Code 13, 14, 17, 18) ○ These codes indicate there is a problem in the solenoid valves, which integrated into the ABS Hydraulic Unit. Therefore the solenoid valves cannot be checked directly. •...
  • Page 450: Abs Motor Inspection (service Code 35)

    12-56 BRAKES Anti-Lock Brake System (Equipped Models) Step 3 • Measure the front and rear wheel rotation sensor air gaps (see Wheel Rotation Sensor Air Gap Inspection). If the air gap is not within the specification, recheck the hub bearing, sensor, sensor rotor and sensor installation condition.
  • Page 451: Front Or Rear Wheel Rotation Sensor Wiring Inspection (service Code 43)

    BRAKES 12-57 Anti-Lock Brake System (Equipped Models) Step 3 • Check the front and rear tire/wheel conditions for tire pres- sure, tire size/types, abnormal wear and deformations (see Wheels/Tires in the Periodic Maintenance chapter). If the tire and/or wheel are in bad condition, correct them if necessary and recheck.
  • Page 452 12-58 BRAKES Anti-Lock Brake System (Equipped Models) Step 2-1 • Disconnect the rear wheel rotation sensor connector. • Recheck the continuity between the terminal 9 (BK) [A] and terminal 6 (W/G) [B] of the ABS hydraulic unit con- nector. If there is continuity, repair or replace the main harness. If there is no continuity, replace the rear wheel rotation sensor.
  • Page 453: Rear Wheel Rotation Sensor Wiring Inspection (service Code 45)

    BRAKES 12-59 Anti-Lock Brake System (Equipped Models) Step 6 • Connect the front wheel rotation sensor connector. • Connect the 4.5 ∼ 5.0 V DC power (e.g. three AA dry battery in series [A]) between the terminal 17 (BK/W) (–) [B] and terminal 8 (W/BK) (+) [C] of the ABS hydraulic unit connector to measure DC amperage.
  • Page 454 12-60 BRAKES Anti-Lock Brake System (Equipped Models) Step 2 • Check for continuity between the terminal 9 (BK) [A] and terminal 6 (W/G) [B] of the ABS hydraulic unit connector. If there is continuity, go to next step. If there is no continuity, go to step 3. Step 2-1 •...
  • Page 455: Power Supply Voltage Abnormal Inspection (service Code 52: Low Voltage) (service Code 53: High Voltage)

    BRAKES 12-61 Anti-Lock Brake System (Equipped Models) Step 5 • With disconnecting the rear wheel rotation sensor con- nector [A], check for continuity between the terminal 15 (BK/O) [B] of the ABS hydraulic unit connector [C] and terminal 1 (BK/O) [D] of the rear wheel rotation sensor connector (main harness side).
  • Page 456: Abs Hydraulic Unit Internal Error Inspection (service Code 55)

    12-62 BRAKES Anti-Lock Brake System (Equipped Models) Step 3 • Disconnect the ABS hydraulic unit connector. • Check the voltage between the terminal 9 (BK) (–) [A] and terminal 18 (R/W) (+) [B] of the ABS hydraulic unit connector. Special Tool - Hand Tester: 57001-1394 ○...
  • Page 457: Abs Hydraulic Unit Removal

    BRAKES 12-63 Anti-Lock Brake System (Equipped Models) ABS Hydraulic Unit Removal NOTICE The ABS hydraulic unit [A] has been adjusted and set with precision at the factory. Therefore, it should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface.
  • Page 458 12-64 BRAKES Anti-Lock Brake System (Equipped Models) • Remove the brake hose banjo bolts [A] while holding the ABS hydraulic unit [B] with a suitable plier [C]. • Remove: Bolt [A] ABS Hydraulic Unit Assembly [B] • Remove: Bolts [A] Bracket [B] ABS Hydraulic Unit [C] NOTICE...
  • Page 459: Abs Hydraulic Unit Installation

    BRAKES 12-65 Anti-Lock Brake System (Equipped Models) ABS Hydraulic Unit Installation • Installation is the reverse of removal. NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • When installing the hoses and pipes, avoid sharp bend- ing, kinking, flatting or twisting, and run the hoses accord- ing to Cable, Wire, and Hose Routing section in the Ap- pendix chapter.
  • Page 460: Front Wheel Rotation Sensor Removal

    12-66 BRAKES Anti-Lock Brake System (Equipped Models) Front Wheel Rotation Sensor Removal NOTICE The wheel rotation sensor should be handled care- fully, never struck sharply, as with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made.
  • Page 461: Rear Wheel Rotation Sensor Installation

    BRAKES 12-67 Anti-Lock Brake System (Equipped Models) • Remove: Right Side Cover (see Side Cover Removal in the Frame chapter) • Disconnect the connector [A]. • Remove: Clamp [A] Bolts [B] Screw [C] • Remove: Clamp [A] Brake Hose Banjo Bolt [B] •...
  • Page 462: Wheel Rotation Sensor Inspection

    12-68 BRAKES Anti-Lock Brake System (Equipped Models) Wheel Rotation Sensor Inspection • Remove the front wheel rotation sensor [A] from the front fork. • Remove the rear wheel rotation sensor [B] from the caliper bracket. • Visually inspect the wheel rotation sensors. Replace the wheel rotation sensor if it is cracked, bent, or otherwise damaged.
  • Page 463: Wheel Rotation Sensor Rotor Inspection

    BRAKES 12-69 Anti-Lock Brake System (Equipped Models) Wheel Rotation Sensor Rotor Inspection • Remove: Wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter) Brake Disc Mounting Bolts [A] Sensor Rotor [B] Front Wheel [C] Rear Wheel [D] • Visually inspect the wheel rotation sensor rotor. If the rotor is deformed or damaged (chipped teeth [A]), replace the sensor rotor with a new one.
  • Page 465 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-8 Special Tools .......................... 13-10 Front Fork ..........................13-13 Rebound Damping Force Adjustment (ZR800A/B Models, Right Front Fork Only)..13-13 Spring Preload Adjustment (ZR800A/B Models)............... 13-13 Front Fork Removal (Each Fork Leg) ................13-14 Front Fork Installation .......................
  • Page 466: Exploded View

    13-2 SUSPENSION Exploded View ZR800A/B Models...
  • Page 467 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Front Fork Clamp Bolts Front Fork Top Plugs 22.5 2.29 16.6 Piston Rod Nuts Lower Front Fork Clamp Bolts 20.5 2.09 15.1 Cylinder Units Front Axle Clamp Bolt 7. Inner Tube (ABS Equipped Models) AD: Apply adhesive (see the text).
  • Page 468 13-4 SUSPENSION Exploded View ZR800C/D Models...
  • Page 469 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Front Fork Clamp Bolts Front Fork Top Plugs 22.5 2.29 16.6 Piston Rod Nut Lower Front Fork Clamp Bolts 20.5 2.09 15.1 Piston Rod Rubber Nut Piston Rod Assy Stopper 17.5 1.78 12.9...
  • Page 470 13-6 SUSPENSION Exploded View...
  • Page 471 SUSPENSION 13-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Swingarm Pivot Shaft Nut 11.0 79.7 Swingarm Pivot Shaft 87 in·lb Swingarm Pivot Shaft Locknut Rear Shock Absorber Nut (Upper) Rear Shock Absorber Nut (Lower) Rocker Arm Nut Tie-Rod Nuts 8.
  • Page 472: Specifications

    13-8 SUSPENSION Specifications Item Standard Front Fork (ZR800A/B Models, Per One Unit) Fork Inner Tube Diameter 41 mm (1.6 in.) Air Pressure Atmospheric pressure (Non-adjustable) Rebound Damper Setting (Right Front 12th click from the 1st click of the fully clockwise Fork Only) position (Usable range: 0 ←→...
  • Page 473 SUSPENSION 13-9 Specifications Item Standard Spring Preload Setting Position (ZR800A/B Models): Standard Spring length: 175.2 mm (6.90 in.) Spring length: 170.2 ∼ 180.2 mm (6.70 ∼ 7.09 in.) Usable Range (stronger to weaker) Spring Preload Setting Position (ZR800C/D Models): Standard 4th position 1st ∼...
  • Page 474: Special Tools

    13-10 SUSPENSION 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: Fork Piston Rod Puller, M10 × 1.0: 57001-1129 57001-1298 Jack: Fork Spring Stopper: 57001-1238 57001-1374...
  • Page 475 SUSPENSION 13-11 Special Tools Hook Wrench T=3.2 R37: Needle Bearing Driver, 17/ 18: 57001-1539 57001-1609 Fork Spring Compressor: Needle Bearing Driver, 28: 57001-1540 57001-1610 Fork Spring Compressor: Spacer, 57001-1587 57001-1636 Swingarm Pivot Nut Wrench: Spacer 28: 57001-1597 57001-1663 Jack Attachment: Fork Spring Compressor: 57001-1608 57001-1685...
  • Page 476 13-12 SUSPENSION Special Tools Bar: Fork Piston Rod Stopper Holder: 57001-1751 57001-1789 Fork Spring Compressor: 57001-1771...
  • Page 477: Front Fork

    SUSPENSION 13-13 Front Fork Rebound Damping Force Adjustment (ZR800A/B Models, Right Front Fork Only) • To adjust the rebound damping force, turn the rebound damping adjuster [A]. ○ The standard adjuster setting is the 12th click from the fully clockwise position. ○...
  • Page 478: Front Fork Removal (each Fork Leg)

    13-14 SUSPENSION Front Fork Front Fork Removal (Each Fork Leg) • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Front Fender (see Front Fender Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Loosen the upper front fork clamp bolt [A] and fork top plug [B] beforehand if the fork leg is to be disassembled.
  • Page 479 SUSPENSION 13-15 Front Fork • Install the clamps [A] as shown. NOTE ○ Set the clamps so that the cutout [B] of the upper side does not touch the tongue shape of stopper, pull up the outer tube [C] to hold it by the clamps, and then tighten the two bolts [D].
  • Page 480 13-16 SUSPENSION Front Fork • Lift up the suitable jack until the piston rod nut [A] comes out. • Insert the fork spring stopper [B] between the piston rod nut and the holder [C] while holding up the top plug [D]. Special Tool - Fork Spring Stopper: 57001-1374 •...
  • Page 481 SUSPENSION 13-17 Front Fork • Hold the fork tube upright, press the inner tube [A] and the piston rod all the way down. • Pour in the type and amount of fork oil specified. Recommended Oil KHL15-10 or equivalent Amount (Per Side): When changing oil: Approx.
  • Page 482 13-18 SUSPENSION Front Fork • Screw the fork piston rod puller onto the end of the piston rod. Special Tool - Fork Piston Rod Puller, M12 × 1.25: 57001 -1289 • Pull the puller up above the outer tube top. •...
  • Page 483 SUSPENSION 13-19 Front Fork • Hold up the fork piston rod puller. • Insert the fork spring stopper [A] between the piston rod nut [B] and the holder [C] while holding up the fork piston rod puller [D]. Special Tool - Fork Spring Stopper: 57001-1374 •...
  • Page 484 13-20 SUSPENSION Front Fork If using the spring compressor (57001-1587). • Install the clamps [A] as shown. NOTE ○ Set the clamps so that the cutout [B] of the upper side does not touch the tongue shape of stopper, pull up the outer tube [C] to hold it by the clamps, and then tighten the two bolts [D].
  • Page 485 SUSPENSION 13-21 Front Fork • Set the holder bar [A] and compression shafts [B]. • Screw in the nuts [A] until the piston rod nut [B] comes out. ○ Hold up the top plug [C] while screwing in the nut. •...
  • Page 486 13-22 SUSPENSION Front Fork • Screw the rod nut [A] onto the piston rod [B] as shown. 12 mm (0.47 in.) or more [C] • Drain the fork oil into a suitable container and remove the spring seat. ○ Using the piston rod puller [A], pump the piston rod [B] up and down at least ten times to expel the oil from the fork.
  • Page 487 SUSPENSION 13-23 Front Fork Oil Level (fully compressed, without spring) Standard: Right Front Fork 106 ±2 mm (4.17 ±0.08 in.) (from the top of the outer tube) Left Front Fork 109 ±2 mm (4.29 ±0.08 in.) (from the top of the outer tube) NOTE ○...
  • Page 488 13-24 SUSPENSION Front Fork • Install the clamps [A] as shown. Special Tools - Fork Spring Compressor: 57001-1540 Fork Spring Compressor: 57001-1587 NOTE ○ Set the clamps so that the cutouts [B] do not fit the hole [C] of the washer [D], pull up the outer tube [E] to hold it by the clamps, and then tighten the two bolts [F].
  • Page 489: Front Fork Oil Change (zr800c/d Models)

    SUSPENSION 13-25 Front Fork • Check the distance between the bottom end [A] of the top plug and rebound damping adjuster [B] with a pair of vernier caliper (Right Front Fork Only). 13 mm (0.51 in.) [C] • Replace the O-ring [A] on the top plug [B] with a new one. •...
  • Page 490 13-26 SUSPENSION Front Fork • While holding up the top plug [A] by one person, push down [B] the fork spring compressor and insert the fork spring stopper [C] between the piston rod nut [D] and the spacer [E]. Special Tool - Fork Spring Stopper: 57001-1374 •...
  • Page 491 SUSPENSION 13-27 Front Fork • Hold the fork tube upright, press the outer tube [A] and the piston rod all the way down. • Pour in the type and amount of fork oil specified. Recommended Oil KHL15-10 or equivalent Amount: When changing oil: Approx.
  • Page 492 13-28 SUSPENSION Front Fork • Screw on the rod nut [A] fully to the piston rod [B]. • Screw the fork piston rod puller onto the end of the piston rod. Special Tool - Fork Piston Rod Puller, M10 × 1.0: 57001 -1298 •...
  • Page 493 SUSPENSION 13-29 Front Fork • Replace the O-ring [A] on the top plug [B] with a new one. • Apply grease to the new O-ring. • Screw in the top plug stopped onto the piston rod. • Holding the top plug [A] with a wrench [B], tighten the piston rod nut [C] against the top plug.
  • Page 494 13-30 SUSPENSION Front Fork • Using the fork piston rod stopper holder [A], remove the piston rod assy stopper [B]. Special Tool - Fork Piston Rod Stopper Holder: 5700-1789 NOTE ○ Install the fork piston rod stopper holder so that the long side [C] faces upward.
  • Page 495 SUSPENSION 13-31 Front Fork • Screw the adjust nut [A] onto the compression shaft as shown. About 40 mm (1.57 in.) [B] • Screw the locknut [C]. • Set the other side compression shaft same process. • Install the spacer [A] with the flat surface [B] facing up- ward.
  • Page 496: Front Fork Disassembly

    13-32 SUSPENSION Front Fork • Screw the nuts [A] onto the compression shafts [B] as shown. About 15 mm (0.59 in.) [C] • Screw the piston rod assy stopper [D]. • Remove the following special tools. Fork Spring Compressors • Remove the top plug.
  • Page 497 SUSPENSION 13-33 Front Fork • Separate the inner tube from the outer tube as follows. ○ Slide up the dust seal [A]. ○ Remove the retaining ring [B] from the outer tube. ○ Holding the outer tube [A] by hand, pull the inner tube [B] several times to pull out the outer tube.
  • Page 498: Front Fork Assembly

    13-34 SUSPENSION Front Fork Front Fork Assembly Other than ZR800C/D Models Left Front Fork • Using a high flash-point solvent, clean off any oil or dirt that may be on the adhesive coating area. Dry them with a clean cloth. •...
  • Page 499: Inner Tube, Outer Tube Inspection

    SUSPENSION 13-35 Front Fork Inner Tube, Outer Tube Inspection • Visually inspect the inner tube [A]. If there is any damage, replace the inner tube. Since damage to the inner tube damages the oil seal, and dust seal replace the oil seal and dust seal whenever the inner tube is replaced.
  • Page 500: Rear Shock Absorber

    13-36 SUSPENSION Rear Shock Absorber Rebound Damping Force Adjustment (ZR800A/B Models) • To adjust the rebound damping force, turn the lower damping adjuster [A]. ○ The standard adjuster setting is the 1 1/4 turns out from the fully clockwise position. Rebound Damping Force Adjustment Adjuster Damping...
  • Page 501: Spring Preload Adjustment (zr800c/d Models)

    SUSPENSION 13-37 Rear Shock Absorber • Remove: Bolts [A] Screw [B] • To adjust the spring preload, turn in the adjusting nut to the desired position and tighten the locknut by using hook wrenches [A] with the rear shock absorber attached the frame.
  • Page 502: Rear Shock Absorber Removal

    13-38 SUSPENSION Rear Shock Absorber • Using the hook wrench [A], turn the adjusting nut [B] to adjust the spring preload. ○ The standard adjuster setting is 4th position. Spring Preload Setting Standard Position: 4th position Adjustable Range: 1st to 7th position •...
  • Page 503: Rear Shock Absorber Installation

    SUSPENSION 13-39 Rear Shock Absorber • Remove the upper shock absorber nut and bolt [A]. • Remove the shock absorber [B] from downside. Rear Shock Absorber Installation • Replace the rear shock absorber nuts (upper and lower) and tie-rod nut with new ones. •...
  • Page 504 13-40 SUSPENSION Rear Shock Absorber ZR800C/D Models WARNING Since the rear shock absorber contains nitrogen gas, do not incinerate the rear shock absorber with- out first releasing the gas or it may explode. Before a rear shock absorber is scrapped, drill a hole at the point [A] shown to release the nitrogen gas com- pletely.
  • Page 505: Swingarm

    SUSPENSION 13-41 Swingarm Swingarm Removal • Remove: Frame Covers (see Frame Cover Removal in the Frame chapter) Chain Cover (see Drive Chain Removal in the Final Drive chapter) • Raise the rear wheel off the ground with jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 •...
  • Page 506: Swingarm Installation

    13-42 SUSPENSION Swingarm • Remove: Swingarm Pivot Shaft Nut [A] Swingarm Pivot Shaft [B] Swingarm Swingarm Installation • Replace the following parts with a new one. Lower Shock Absorber Nut Upper Tie-Rod Nut • Place the collar [A] on the stopper [B] inside the frame [C]. •...
  • Page 507: Swingarm Bearing Removal

    SUSPENSION 13-43 Swingarm Swingarm Bearing Removal • Remove: Swingarm (see Swingarm Removal) Collar [A] Oil Seals [B] Sleeve [C] Circlip [D] (Right Side) Special Tool - Inside Circlip Pliers: 57001-143 • Remove the ball bearing and needle bearings. Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058 Swingarm Bearing Installation •...
  • Page 508: Swingarm Bearing, Sleeve Inspection

    13-44 SUSPENSION Swingarm • Install the needle bearings [A], ball bearing [B] and oil seals [C] position as shown. Circlip [D] 23.5 ±0.4 mm (0.93 ±0.02 in.) [E] 6 ±0.4 mm (0.24 ±0.02 in.) [F] Swingarm Bearing, Sleeve Inspection NOTICE Do not remove the bearings for inspection.
  • Page 509: Swingarm Bearing Lubrication

    SUSPENSION 13-45 Swingarm Swingarm Bearing Lubrication NOTE ○ Since the bearings are packed with grease and sealed, lubrication is not required. Chain Guide Inspection • Refer to the Chain Guide Wear Inspection in the Periodic Maintenance chapter.
  • Page 510: Tie-rod, Rocker Arm

    13-46 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal • Squeeze the brake lever slowly and hold it with a band [A]. • Raise the rear wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 • Remove: Upper Tie-Rod Nut and Bolt [A] Lower Tie-Rod Nut and Bolt [B]...
  • Page 511: Tie-rod And Rocker Arm Bearing Removal

    SUSPENSION 13-47 Tie-Rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Removal • Remove: Tie-Rods (see Tie-Rod Removal) Rocker Arm (see Rocker Arm Removal) Sleeves [A] Oil Seals [B] Swingarm [C] (see Swingarm Removal) • Remove the needle bearings [D], using a suitable tool. Tie-Rod and Rocker Arm Bearing Installation •...
  • Page 512: Rocker Arm/tie-rod Bearing, Sleeve Inspection

    13-48 SUSPENSION Tie-Rod, Rocker Arm NOTE ○ Install the needle bearings so that the marked side faces in. Needle Bearings [A] Oil Seals [B] Front [C] Right Side [D] Left Side [E] Rear Shock Absorber [F] Tie-Rods [G] Rocker Arm [H] 7.5 mm (0.30 in.) [I] 5.0 ±0.4 mm (0.20 ±0.02 in.) [J] 5.5 mm (0.22 in.) [K]...
  • Page 513 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 ................... 14-8 Steering Stem Warp Inspection ..................
  • Page 514: Exploded View

    14-2 STEERING Exploded View...
  • Page 515 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Handlebar Holder Bolts Rear View Mirror Locknut (Upper) Rear View Mirror Nut (Lower) Switch Housing Screws 0.36 31 in·lb Upper Front Fork Clamp Bolts Steering Stem Head Bolt 11.0 79.7 Lower Handlebar Holder Nuts Steering Stem Nut Lower Front Fork Clamp Bolts...
  • Page 516: Special Tools

    14-4 STEERING Special Tools 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 Steering Stem Bearing Driver, 42.5: 57001-1344...
  • Page 517: Steering Inspection

    STEERING 14-5 Steering Steering Inspection • Refer to the Steering Play Inspection in the Periodic Main- tenance chapter. Steering Adjustment • Refer to the Steering Play Adjustment in the Periodic Maintenance chapter.
  • Page 518: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Bolts [A] Clamp [B] Clamp [C] (ABS Equipped Models) Bracket [D] Handlebars (see Handlebar Removal) Steering Stem Head (see Steering Play Adjustment in the Periodic Maintenance chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter)
  • Page 519: Stem, Stem Bearing Installation

    STEERING 14-7 Steering Stem • Remove the lower ball bearing inner race (with its oil seal) [A] which is pressed onto the steering stem with a suitable commercially available chisel [B]. Stem, Stem Bearing Installation • Replace the bearing outer races with new ones. •...
  • Page 520: Steering Stem Bearing Lubrication

    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. Afterward tighten it again with specified torque using a steering stem nut wrench [A].
  • Page 521: Steering Stem Warp Inspection

    STEERING 14-9 Steering Stem Steering Stem Warp Inspection • Whenever the steering stem is removed, or if the steering can not be adjusted for smooth action, check the steering stem for straightness. If the steering stem [A] is bent, replace the steering stem. Stem Cap Deterioration, Damage Inspection Replace the stem cap if its oil seal [A] shows damage.
  • Page 522: Handlebar

    14-10 STEERING Handlebar Handlebar Removal • Remove: Clutch Lever Clamp Bolts [A] Clutch Lever Assembly [B] Left Switch Housing [C] Handlebar Weight [D] Handlebar Grip [E] • Remove: Front Master Cylinder [A] (see Front Master Cylinder Re- moval in the Brakes chapter) Right Switch Housing [B] Handlebar Weight [C] Throttle Grip [D]...
  • Page 523 STEERING 14-11 Handlebar • Put the upper handlebar holder [A] on the flat surface to confirm the installation direction. Front [B] Rear [C] • When installing the lower handlebar holders, install the upper handlebar holder [A] and handlebar holder bolts [B] temporarily as shown.
  • Page 524 14-12 STEERING Handlebar • Using a high flash-point solvent, clean of any oil or dirt that may be on the adhesive coating area. Dry them with a clean cloth. • Apply adhesive cement to the left side of the handlebars. •...
  • Page 525 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 Upper Fairing Removal ..................... 15-9 Upper Fairing Disassembly....................15-9 Upper Fairing Assembly....................
  • Page 526: Exploded View

    15-2 FRAME Exploded View...
  • Page 527 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear View Mirror Locknut (Upper) Rear View Mirror Nut (Lower) Turn Signal Light Mounting Screws 0.12 11 in·lb Front Fender Bolts 0.40 35 in·lb Lh: Left-hand Threads...
  • Page 528 15-4 FRAME Exploded View...
  • Page 529 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Footpeg Bracket Bolts Side Stand Switch Bolt 0.90 78 in·lb Side Stand Bolt Side Stand Nut Lower Fairing Mounting Bolts 87 in·lb Lower Fairing Bracket Bolts 87 in·lb 7. ZR800A/B Models G: Apply grease.
  • Page 530 15-6 FRAME Exploded View...
  • Page 531 FRAME 15-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb License Plate Light Mounting Screws 0.12 11 in·lb Turn Signal Light Mounting Screws 0.12 11 in·lb 3. AU Model...
  • Page 532: Seats

    15-8 FRAME Seats Rear Seat Removal • Insert the ignition switch key [A] into the seat lock, turning the key clockwise, pulling the front part of the seat [B] up, and pull the seat forward. Rear Seat Installation • Insert the rear seat hook [A] into the bracket [B] of the frame.
  • Page 533: Fairings

    FRAME 15-9 Fairings Upper Fairing Removal • Remove: Bolts [A] Meter Cover [B] • Remove: Bolts [A] Bracket [B] • Remove the bolts [C] and pull out the upper fairing [D] forward. • Disconnect: Headlight Lead Connectors [A] City Light Lead Connectors [B] Left and Right Turn Signal Light Lead Connectors [C] •...
  • Page 534: Upper Fairing Assembly

    15-10 FRAME Fairings Upper Fairing Assembly • Check the pads [A] are in place on the upper fairing. • Installation is the reverse of removal. Upper Fairing Installation • Connect: City Light Lead Connectors Headlight Lead Connectors Left and Right Turn Signal Light Lead Connectors •...
  • Page 535: Ignition Switch Cover Installation

    FRAME 15-11 Fairings Ignition Switch Cover Installation • Check that the pad [A] is in place on the ignition switch cover [B]. 10 mm (0.39 in.) [C] • Fit the hooks [A] of the ignition switch cover [B] on the ribs [C] of the tank cover.
  • Page 536: Middle Fairing Removal

    15-12 FRAME Fairings • When installing the hook fasteners [A], align the edge of the hook fasteners with the lines [B] of the fuel tank. • Check that the grommets [A] are in place on the fuel tank and tank cover. •...
  • Page 537: Side Fairing Removal

    FRAME 15-13 Fairings • Check that the grommet [A] is in place on the fuel tank. • Insert the tabs [B] into the slots [C]. • Fit the hook fasteners [D]. • Insert the projection [E] into the hole [F]. •...
  • Page 538: Lower Fairing Removal (zr800a/b Models)

    15-14 FRAME Fairings Lower Fairing Removal (ZR800A/B Models) • Remove the bolts [A]. • Clear the projection [B] and remove the lower fairing [C]. Lower Fairing Installation (ZR800A/B Models) • Check that the grommets [A] are in place on the lower fairing [B] and bracket.
  • Page 539: Side Covers

    FRAME 15-15 Side Covers Side Cover Removal • Remove: Seats (see Rear/Front Seat Removal) Bolt [A] with washer • Pull the side cover [B] evenly outward to clear the projec- tions [C]. • Pull the side cover backward to clear the hook fasteners [D] and projections [E].
  • Page 540: Side Cover Installation

    15-16 FRAME Side Covers Side Cover Installation • Check that the pads [A] and damper [B] are in place on the side covers as follows. ○ Install the adhesive surface of the damper to the adhesive surface of the pad. Left Side Cover [C] Right Side Cover [D] 10 mm (0.39 in.) [E]...
  • Page 541 FRAME 15-17 Side Covers • Check that the grommets [A] and pad [B] are in place. • Insert the projections [C] into the hole [D]. • Fit the hook fasteners [E]. • Insert the projections [F] into the holes [G]. •...
  • Page 542: Seat Covers

    15-18 FRAME Seat Covers Seat Cover Removal • Remove: Seats (see Rear/Front Seat Removal) Bolts [A] • Pull the seat cover [B] backward to clear the hooks [C]. Seat Cover Installation • Check that the pads [A] are in place on the seat cover. •...
  • Page 543: Fenders

    FRAME 15-19 Fenders Front Fender Removal • Free the brake hoses [A] from the clamps [B]. • Remove: Bolts [C] with Washers (Both Sides) Front Fender [D] Front Fender Installation • Install the front fender to the front fork. • Tighten: Torque - Front Fender Bolts: 3.9 N·m (0.40 kgf·m, 35 in·lb) •...
  • Page 544: Rear Fender Installation

    15-20 FRAME Fenders • Remove the seat lock cable tip [A]. • Pull out the bracket [B]. • Remove: Bracket [C] Key Cylinder [D] Rear Fender Installation • Installation is the reverse of removal. • Install the removed parts (see appropriate chapters). •...
  • Page 545 FRAME 15-21 Fenders • Remove the bolts [A]. • Remove: Trims [A] Bracket [B] • Remove the bolts [A]. • Remove: Bolts [A] License Plate Bracket [B] Pad [C] Flap Bracket [D] • Remove: (For AU model) Bolts [A] License Plate Bracket [B] Pad [C] Flap Bracket [D] Flap [E]...
  • Page 546: Flap Installation

    15-22 FRAME Fenders • Remove: Screw [A] Washers [B] Rear Turn Signal Light Assembly [C] • Remove: Screws [A] Washers [B] Dampers [C] License Plate Light Assembly [D] Flap [E] Flap Installation • Installation is the reverse of removal. ○ Check that the grommet [A] is in place on the flap bracket [B].
  • Page 547: Frame

    FRAME 15-23 Frame Frame Inspection • Visually inspect the frame for cracks, dents, bending, or warp. ○ If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident resulting in injury or death. If the frame is bent, dented, cracked, or warped, replace it.
  • Page 548: Side Stand

    15-24 FRAME Side Stand Side Stand Removal • Raise the rear wheel off the ground with the stand. • Remove: Side Stand Switch Bolt [A] Side Stand Switch [B] Spring [C] Side Stand Nut [D] Side Stand Bolt [E] Side Stand [F] Side Stand Installation •...
  • Page 549: Frame Cover

    FRAME 15-25 Frame Cover Subframe Cover Removal • Remove: Side Cover (see Side Cover Removal) Bolts [A] with Washers • Clear the tabs [B] on the subframe cover [C] by pulling up the lower part of the subframe cover. • Clear the tabs [D] on the subframe cover and remove the subframe cover.
  • Page 550: Frame Cover Removal

    15-26 FRAME Frame Cover Frame Cover Removal • Check that the pads [A] are in place on the frame cover. Left Frame Cover [B] Right Frame Cover [C] • When installing the grommet [A], face the thick side to- ward the inside [B] of the left frame cover [C]. •...
  • Page 551: Rear View Mirrors

    FRAME 15-27 Rear View Mirrors Rear View Mirror Removal • Slide the dust cover [A]. • Loosen the rear view mirror locknut (upper) [B], and re- move the rear view mirror stay [C] from the rear view mir- ror nut (lower) [D]. ○...
  • Page 553 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-3 Specifications ......................... 16-10 Special Tools and Sealant ...................... 16-11 Parts Location......................... 16-13 Wiring Diagram (ZR800A without GPS Unit)................16-16 Wiring Diagram (ZR800A with GPS Unit)................16-18 Wiring Diagram (ZR800B without GPS Unit)................16-20 Wiring Diagram (ZR800B with GPS Unit)................
  • Page 554 16-2 ELECTRICAL SYSTEM Starter Motor Disassembly....................16-53 Starter Motor Assembly ....................16-54 Brush Inspection ....................... 16-55 Commutator Cleaning and Inspection................16-55 Armature Inspection......................16-56 Brush Lead Inspection ...................... 16-56 Brush Plate and Terminal Bolt Inspection ................. 16-56 Starter Relay Inspection....................16-57 Lighting System ........................
  • Page 555: Exploded View

    ELECTRICAL SYSTEM 16-3 Exploded View This page intentionally left blank.
  • Page 556 16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 557 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Turn Signal Light Mounting Screws 0.12 11 in·lb Meter Mounting Screws 0.12 11 in·lb Meter Assembly Screws 0.43 0.044 3.8 in·lb Front Brake Light Switch Screw 0.12 11 in·lb License Plate Light Mounting Screws 0.12 11 in·lb...
  • Page 558 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 559 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oxygen Sensor Water Temperature Sensor 106 in·lb Stator Coil Bolts 106 in·lb Alternator Rotor Bolt 15.8 Starter Motor Clutch Bolts 106 in·lb Timing Rotor Bolt Starter Motor Mounting Bolts 97 in·lb Crankshaft Sensor Cover Bolts 97 in·lb...
  • Page 560 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 561 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Starter Relay Cable Terminal Bolts 0.40 35 in·lb Starter Motor Cable Terminal Nut 0.50 43 in·lb Starter Relay Bracket Bolts 0.70 61 in·lb Side Stand Switch Bolt 0.90 78 in·lb Regulator/Rectifier Bracket Bolts 0.70 61 in·lb...
  • Page 562: Specifications

    16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name FTX9-BS Capacity 12 V 8 Ah Voltage 12.6 V or more Gross Weight 3.0 kg (6.6 lb) Electrolyte Volume 0.41 L (25 cu in.) Charging System Type Three-phase AC Alternator Output Voltage 39 V or more at 4 000 r/min (rpm) 0.05 ∼...
  • Page 563 ELECTRICAL SYSTEM 16-11 Special Tools and Sealant Hand Tester: Flywheel & Pulley Holder: 57001-1394 57001-1605 Peak Voltage Adapter: Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: 57001-1415 57001-1615 Lead Wire - Peak Voltage Adapter: Stopper: 57001-1449 57001-1679 Key Registration Unit: Rotor Holder: 57001-1582 57001-1690...
  • Page 564: Special Tools And Sealant

    16-12 ELECTRICAL SYSTEM Special Tools and Sealant Liquid Gasket, TB1211F: 92104-0004...
  • Page 565: Parts Location

    ELECTRICAL SYSTEM 16-13 Parts Location This page intentionally left blank.
  • Page 566 16-14 ELECTRICAL SYSTEM Parts Location...
  • Page 567 8. Speed Sensor 9. Frame Ground 10. Fuse Box 2 11. Battery 12 V 8 Ah 12. Relay Box 13. Immobilizer/Kawasaki Diagnostic System Connector 14. ECU 15. Fuse Box 1 16. Starter Relay 17. Side Stand Switch 18. Neutral Switch 19.
  • Page 568: Wiring Diagram (zr800a Without Gps Unit)

    16-16 ELECTRICAL SYSTEM Wiring Diagram (ZR800A without GPS Unit)
  • Page 569 ELECTRICAL SYSTEM 16-17 Wiring Diagram (ZR800A without GPS Unit)
  • Page 570: Wiring Diagram (zr800a With Gps Unit)

    16-18 ELECTRICAL SYSTEM Wiring Diagram (ZR800A with GPS Unit)
  • Page 571 ELECTRICAL SYSTEM 16-19 Wiring Diagram (ZR800A with GPS Unit)
  • Page 572: Wiring Diagram (zr800b Without Gps Unit)

    16-20 ELECTRICAL SYSTEM Wiring Diagram (ZR800B without GPS Unit)
  • Page 573 ELECTRICAL SYSTEM 16-21 Wiring Diagram (ZR800B without GPS Unit)
  • Page 574: Wiring Diagram (zr800b With Gps Unit)

    16-22 ELECTRICAL SYSTEM Wiring Diagram (ZR800B with GPS Unit)
  • Page 575 ELECTRICAL SYSTEM 16-23 Wiring Diagram (ZR800B with GPS Unit)
  • Page 576: Wiring Diagram (zr800c)

    16-24 ELECTRICAL SYSTEM Wiring Diagram (ZR800C)
  • Page 577 ELECTRICAL SYSTEM 16-25 Wiring Diagram (ZR800C)
  • Page 578: Wiring Diagram (zr800d)

    16-26 ELECTRICAL SYSTEM Wiring Diagram (ZR800D)
  • Page 579 ELECTRICAL SYSTEM 16-27 Wiring Diagram (ZR800D)
  • Page 580: Precautions

    16-28 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○...
  • Page 581: Electrical Wiring

    ELECTRICAL SYSTEM 16-29 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 582: Battery

    16-30 ELECTRICAL SYSTEM Battery Battery Removal • Turn the ignition switch off. • Remove: Seats (see Rear/Front Seat Removal in the Frame chap- ter) Band [A] • Remove the Fuse Box [B] from the battery case. • Take out the battery [C] from the battery case. •...
  • Page 583: Battery Activation

    ELECTRICAL SYSTEM 16-31 Battery Battery Activation Electrolyte Filling • Make sure that the model name [A] of the electrolyte con- tainer matches the model name [B] of the battery. These names must be the same. Battery Model Name ZR800A/B: FTX9-BS NOTICE Each battery comes with its own specific elec- trolyte container;...
  • Page 584 16-32 ELECTRICAL SYSTEM Battery • Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery. Hold the container level, push down to break the seals of all six cells. You will see air bubbles rising into each cell as the ports fill.
  • Page 585 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: Battery Mate 150-9 OptiMate PRO 4-S/PRO S/PRO2 Yuasa MB-2040/2060...
  • Page 586: Precautions

    16-34 ELECTRICAL SYSTEM Battery Precautions 1) No need of topping-up No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that. 2) Refreshing charge.
  • Page 587: Refreshing Charge

    ELECTRICAL SYSTEM 16-35 Battery If the reading is 12.6 V or more, no refresh charge is re- quired, however, if the read is below the specified, refresh charge is required. Battery Terminal Voltage Standard: 12.6 V or more Terminal Voltage (V) [A] Battery Charge Rate (%) [B] Refresh charge is required [C] Good [D]...
  • Page 588: Charging System

    16-36 ELECTRICAL SYSTEM Charging System Alternator Cover Removal • Remove: Left Frame Cover (see Frame Cover Removal in the Frame chapter) Left Lower Fairing (see Lower Fairing Removal (ZR800A/B Models) in the Frame chapter) • Free the hoses [A]. • Disconnect the alternator lead connector [B].
  • Page 589: Stator Coil Removal

    ELECTRICAL SYSTEM 16-37 Charging System Stator Coil Removal • Remove: Alternator Cover (see Alternator Cover Removal) Holding Plate Bolt [A] and Plate Alternator Lead Grommet [B] Stator Coil Bolts [C] Stator Coil [D] Stator Coil Installation • Apply a non-permanent locking agent to the threads of the stator coil bolts and tighten them.
  • Page 590: Alternator Rotor Installation

    16-38 ELECTRICAL SYSTEM Charging System • Using the flywheel puller [A], remove the alternator rotor [B] from the crankshaft. Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: 57001-1615 NOTICE Do not attempt to strike the alternator rotor itself. Striking the rotor can cause the magnets to lose their magnetism.
  • Page 591 ELECTRICAL SYSTEM 16-39 Charging System • Using a cleaning fluid, clean off any oil or dirt on the washer [A] and dry it with a clean cloth. • Install the washer. NOTE ○ Confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque.
  • Page 592: Charging Voltage Inspection

    16-40 ELECTRICAL SYSTEM Charging System Charging Voltage Inspection • Check the battery condition (see Charging Condition In- spection). • Warm up the engine to obtain actual alternator operating conditions. • Take out the battery from the rear fender with the cables connected (see Battery Removal).
  • Page 593 ELECTRICAL SYSTEM 16-41 Charging System • To check the alternator output voltage, do the following procedures. ○ Turn the ignition switch off. ○ Remove the left frame cover (see Frame Cover Removal in the Frame chapter). ○ Disconnect the alternator lead connector [A]. ○...
  • Page 594: Regulator/rectifier Inspection

    NOTICE Use only Kawasaki Hand Tester 57001-1394 for this test. A tester other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large capacity battery is used, the regulator/rectifier will be damaged.
  • Page 595 ELECTRICAL SYSTEM 16-43 Charging System Charging System Circuit 1. Ignition Switch 2. Load 3. Frame Ground 3 4. Engine Ground 5. Battery 12 V 8 Ah 6. Main Fuse 30 A 7. Starter Relay 8. Alternator 9. Regulator/Rectifier...
  • Page 596: Ignition System

    16-44 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. NOTICE Do not disconnect the battery cables or any other electrical connections when the ignition switch is...
  • Page 597: Crankshaft Sensor Installation

    ELECTRICAL SYSTEM 16-45 Ignition System Crankshaft Sensor Installation • Run the crankshaft sensor lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Tighten: Torque - Crankshaft Sensor Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) • Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area.
  • Page 598: Crankshaft Sensor Peak Voltage Inspection

    16-46 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak Voltage Inspection NOTE ○ Be sure the battery is fully charged. ○ Using the peak voltage adapter [A] is more reliable way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements. •...
  • Page 599: Stick Coil Removal

    ELECTRICAL SYSTEM 16-47 Ignition System Stick Coil Removal NOTICE Never drop the stick coils especially on a hard sur- face. Such a shock to the stick coils can damage it. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Side Fairings (see Side Fairing Removal in the Frame chapter)
  • Page 600: Stick Coil Inspection

    16-48 ELECTRICAL SYSTEM Ignition System Stick Coil Inspection • Remove the stick coils (see Stick Coil Removal). • Measure the primary winding resistance [A] as follows. ○ Connect the hand tester between the coil terminals. ○ Set the tester to the × 1 Ω range, and read the tester. •...
  • Page 601: Spark Plug Removal

    ELECTRICAL SYSTEM 16-49 Ignition System WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • Turn the ignition switch and the engine stop switch on. • Pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measure the primary peak voltage.
  • Page 602: Ic Igniter Inspection

    16-50 ELECTRICAL SYSTEM Ignition System 2nd Check • Start the engine to the following conditions. Condition: Transmission Gear → 1st Position Clutch Lever → Pulled in Side Stand → Up ○ Turn the ignition switch on and push the starter button. ○...
  • Page 603 ELECTRICAL SYSTEM 16-51 Ignition System...
  • Page 604 16-52 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Engine Stop Switch 11. Joint Connector E 21. Relay Box 2. Stick Coils 12. ECU 22. Starter Lockout Switch 3. Vehicle-down Sensor 13. Frame Ground 1 23. Ignition Fuse 15 A 4.
  • Page 605: Electric Starter System

    ELECTRICAL SYSTEM 16-53 Electric Starter System Starter Motor Removal NOTICE Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • Remove the throttle body assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter). •...
  • Page 606: Starter Motor Assembly

    16-54 ELECTRICAL SYSTEM Electric Starter System ○ The brush plate [A] and brushes come off with the right -hand end cover [B]. • Remove the terminal locknut [A] and terminal bolt [B], and then remove the brush with the brush plate [C] from the right-hand en