Download  Print this page
   
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
666
667
668
669
670
671
672
673
674
675
676
677
678
679
680
681
682
683
684
685
686
687
688
689
690
691
692
693
694
695
696
697
698
699
700
701
702
703
704
705
706
707
708
709
710
711
712
713
714
715
716
717
718
719
720
721
722
723
724
725
726
727
728
729
730
731
732
733
734
735
736
737
738
739

Advertisement

Ninja ZX-10R
Ninja ZX-10R ABS
Motorcycle
Service Manual

Advertisement

Table of Contents

   Summary of Contents for Kawasaki Ninja ZX-10R

  • Page 1 Ninja ZX-10R Ninja ZX-10R 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 Self-Diagnosis System...
  • 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: Country And Area Codes

    LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: Emission Control Information

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

    Be alert for problems and non-scheduled maintenance. • NOTICE Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and NOTICE is used to address practices not testers that are necessary when servicing related to personal injury.
  • Page 10 NOTE ○ This note symbol indicates points of par- ticular interest for more efficient and con- venient operation. • Indicates a procedural step or work to be done. ○ Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE.
  • Page 11: Table Of Contents

    Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................1-11 Technical Information-Sport-Kawasaki TRaction Control System (S-KTRC) ......1-14 Technical Information-Power Mode ..................1-17 Technical Information-Kawasaki Intelligent anti-lock Brake System (KIBS/ZX1000K model only) ............................. 1-19 Unit Conversion Table ......................1-23...
  • Page 12: 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 13 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 14 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.
  • Page 15 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 16 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.
  • Page 17: Model Identification

    GENERAL INFORMATION 1-7 Model Identification ZX1000JBF (US and CA Models) Left Side View ZX1000JBF (US and CA Models) Right Side View...
  • Page 18 1-8 GENERAL INFORMATION Model Identification ZX1000JBF (EUR Models) Left Side View ZX1000JBF (EUR Models) Right Side View...
  • Page 19 GENERAL INFORMATION 1-9 Model Identification ZX1000KBF (US and CA Models) Left Side View ZX1000KBF (US and CA Models) Right Side View...
  • Page 20 1-10 GENERAL INFORMATION Model Identification ZX1000KBF (EUR Models) Left Side View ZX1000KBF (EUR Models) Right Side View Frame Number Engine Number...
  • Page 21: General Specifications

    GENERAL INFORMATION 1-11 General Specifications Items ZX1000JBF/KBF Dimensions Overall Length 2 075 mm (81.69 in.) Overall Width 715 mm (28.1 in.) Overall Height 1 115 mm (43.90 in.) Wheelbase 1 425 mm (56.10 in.) Road Clearance 135 mm (5.31 in.) Seat Height 813 mm (32.0 in.) Curb Mass:...
  • Page 22 1-12 GENERAL INFORMATION General Specifications Items ZX1000JBF/KBF Exhaust: Open 74° (BBDC) Close 39° (ATDC) Duration 293° Lubrication System Forced lubrication (wet sump with oil cooler) Engine Oil: Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity...
  • Page 23 GENERAL INFORMATION 1-13 General Specifications Items ZX1000JBF/KBF Rear Suspension: Type Swingarm (horizontal back-link) Wheel Travel 140 mm (5.51 in.) Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery: (ZX1000J Model) 12 V 6 Ah 12 V 8.6 Ah (ZX1000K Model) Headlight: Type...
  • Page 24: Technical Information-sport-kawasaki Traction Control System (s-ktrc)

    1-14 GENERAL INFORMATION Technical Information-Sport-Kawasaki TRaction Control System (S-KTRC) Overview S-KTRC is a highly sophisticated system based on MotoGP racing technology. Unlike the KTRC system used on the GTR1400 ABS (Concours 14 ABS in N. America), which is designed to offer rider reassurance when traversing slippery surfaces, S-KTRC, is designed to maximize forward motion, allowing riding at the edge of traction.
  • Page 25 The wheel rotation sensor converts front and rear wheel rotation speed to a pulse signal and transmits it to the FI ECU. As for the KIBS (Kawasaki Intelligent anti-lock Brake Sys- tem) equipped model, a pulse signal is transmitted via the KIBS ECU.
  • Page 26 1-16 GENERAL INFORMATION Technical Information-Sport-Kawasaki TRaction Control System (S-KTRC) 6. Multifunction Meter The multifunction meter receives a mode-switching signal and displays the mode [A], and transmits it to the FI ECU by the CAN system. When a failure occurs in the system, the multifunction me- ter displays the warning indication by blinking the warning indicator light (yellow LED) [B] and mode indicator symbol.
  • Page 27: Technical Information-power Mode

    GENERAL INFORMATION 1-17 Technical Information-Power Mode The rider can choose from three engine power modes to suit their preferences and road conditions. The FI ECU controls the engine power by adjusting fuel injection, air intake, and ignition timing. It enables three-mode selection: Full Power (Mode F), Middle Power (Mode M), and Low Power (Mode In addition, combining each mode with each S-KTRC setting allows the rider to have more choices to be able to interact with various conditions.
  • Page 28 1-18 GENERAL INFORMATION Technical Information-Power Mode Mode F: The highest engine power output is achieved. The rider can use the full power of the engine. Mode M: The throttle response is less sharp compared to mode F. Depending on the throttle application, full power can be accessed temporarily.
  • Page 29 (KIBS/ZX1000K model only) Overview Kawasaki Intelligent anti-lock Brake System (KIBS) offers enhanced braking stability (ABS perfor- mance equivalent to the current model) to supersport models, which pitch more than most motorcycles and also offers high-precision front and rear brake pressure control (high-precision ABS) for sport rid- ing.
  • Page 30 1-20 GENERAL INFORMATION Technical Information-Kawasaki Intelligent anti-lock Brake System (KIBS/ZX1000K model only) 3. KIBS Hydraulic Unit The KIBS hydraulic unit consists of the hydraulic unit and KIBS ECU and has the front caliper hydraulic pressure sen- sor built-in. When receiving a signal from the KIBS ECU, the hydraulic unit increases or decreases the front and rear brake hy- draulic pressure.
  • Page 31 GENERAL INFORMATION 1-21 Technical Information-Kawasaki Intelligent anti-lock Brake System (KIBS/ZX1000K model only) KIBS Control 1. ABS performance equivalent to the current model (enhanced braking stability) By monitoring front caliper hydraulic pressure, KIBS regulates pressure increases reducing the ten- dency of the rear to lift. Before the ABS system fully reacts, KIBS system prevents the pressure from increasing too quickly thus suppressing rear lift.
  • Page 32 1-22 GENERAL INFORMATION Technical Information-Kawasaki Intelligent anti-lock Brake System (KIBS/ZX1000K model only) 3. Rear brake control enhancement during engine braking By recognizing rear wheel slip due to engine brake force during aggressive throttle operation, and at high rpm or downshifting, the KIBS system prevents unnecessary ABS intervention to the rear wheel...
  • Page 33: Unit Conversion Table

    GENERAL INFORMATION 1-23 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 35 PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-12 Special Tools .......................... 2-14 Periodic Maintenance Procedures..................2-15 Fuel System (DFI)........................ 2-15 Throttle Control System Inspection................... 2-15 Engine Vacuum Synchronization Inspection..............2-15 Idle Speed Inspection .......................
  • Page 36 2-2 PERIODIC MAINTENANCE Steering Damper Oil Leak Inspection ................2-40 Electrical System ......................... 2-41 Lights and Switches Operation Inspection................ 2-41 Headlight Aiming Inspection ..................... 2-43 Headlight Aiming Adjustment.................... 2-43 Sidestand Switch Operation Inspection ................2-44 Engine Stop Switch Operation Inspection................. 2-45 Others ..........................
  • Page 37: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. Periodic Inspection FREQUENCY Whichever * ODOMETER READING comes ×...
  • Page 38: Periodic Maintenance

    2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page Every ITEM (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Wheel bearing damage - • • • year 2-29 inspect Final Drive Drive chain lubrication...
  • Page 39 PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page ITEM Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Sidestand switch operation • • • year 2-44 - inspect Engine stop switch •...
  • Page 40: Torque And Locking Agent

    2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.
  • Page 41 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Cooler Mounting Bolts 106 in·lb L, S Water Hose Fitting Bolts 87 in·lb 87 in·lb Coolant Drain Bolt (Cylinder) Water Passage Plugs Engine Top End Air Suction Valve Cover Bolts 87 in·lb Camshaft Cap Bolts 106 in·lb...
  • Page 42 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Oil Drain Bolt Engine Removal/Installation Adjusting Collar Locknut Left Front Engine Mounting Bolt Lower Engine Mounting Bolt 87 in·lb Lower Engine Mounting Nut R, S Middle Engine Mounting Bolt 87 in·lb Middle Engine Mounting Nut R, S...
  • Page 43 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Transmission Case Bearing Holder Bolts (L = 14) 0.50 43 in·lb Transmission Case Bolts Torque Limiter Shaft Plug Starter Clutch Shaft Holder Bolt 87 in·lb Starter Clutch Shaft Bolt Wheels/Tires Front Axle Clamp Bolts Front Axle Nut...
  • Page 44 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Swingarm Pivot Shaft Swingarm Pivot Shaft Nut 11.0 Tie-Rod Nuts Rocker Arm Nut Rear Shock Absorber Nut (Upper) Steering Steering Stem Head Nut Steering Stem Nut Left Switch Housing Screws 0.36 31 in·lb Right Switch Housing Screws...
  • Page 45 PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Stator Coil Bolts 106 in·lb Timing Rotor Bolt 106 in·lb Water Temperature Sensor Brush Holder Screw 0.39 34 in·lb Engine Ground Terminal Bolt 87 in·lb Front Brake Light Switch Screw 0.12 11 in·lb Left Switch Housing Screws...
  • Page 46: Specifications

    2-12 PERIODIC MAINTENANCE 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) – – – Throttle Body Vacuum 30.7 ±1.33 kPa (230 ±10 mmHg) at idle speed –...
  • Page 47 PERIODIC MAINTENANCE 2-13 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 25 ∼...
  • Page 48: Special Tools

    2-14 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers: Throttle Sensor Setting Adapter: 57001-143 57001-1538 Steering Stem Nut Wrench: Extension Tube: 57001-1100 57001-1578 Jack: Pilot Screw Adjuster, D: 57001-1238 57001-1588 Oil Filter Wrench: Jack Attachment: 57001-1249 57001-1608 Vacuum Gauge: 57001-1369...
  • Page 49: Periodic Maintenance Procedures

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Fuel System (DFI) Throttle Control System Inspection • Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Standard: •...
  • Page 50 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove: Intake Air Pressure Sensor Hose [A] Air Intake Valve Hose [B] (Other than US, CA and CAL Models) Rubber Caps [C] • For CAL and SEA Models, remove the vacuum hoses. NOTE ○...
  • Page 51 PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Connect the following parts temporarily. Intake Air Temperature Sensor [A] ECU [B] Secondary Fuel Hose [C] (see Fuel Hose Replacement) NOTE ○ Be sure to connect the intake air temperature sensor. When the ignition switch is turned ON without the in- take air temperature sensor, the ECU detects the ser- vice code 13.
  • Page 52 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures If any vacuum is not within specifications, adjust the by- pass screws [A]. View from Front [B] Special Tool - Pilot Screw Adjuster, D [C]: 57001-1588 • Adjust the each vacuum (#1 ∼ #4) to the standard value. •...
  • Page 53: Idle Speed Inspection

    PERIODIC MAINTENANCE 2-19 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 54: Idle Speed Adjustment

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Adjustment NOTE ○ This motorcycle is equipped with the idle speed control valve. The idle speed is adjusted automatically at the specified value (1 100 r/min (rpm)) by the idle speed control valve system. Therefore, it is not necessary to adjust the idle speed normally.
  • Page 55: Evaporative Emission Control System Inspection (cal And Sea Models)

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Evaporative Emission Control System Inspection (CAL and SEA Models) • Inspect the canister as follows. ○ Remove the upper fairing assembly (see Upper Fairing Assembly Removal in the Frame chapter). ○ Remove the canister [A]. ○...
  • Page 56: Cooling System

    2-22 PERIODIC MAINTENANCE 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 sidestand). If the coolant level is lower than the “L”...
  • Page 57: Engine Top End

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted when the engine is cold (at room temperature). • Remove: Crankshaft Sensor Cover (see Crankshaft Sensor Re- moval in the Electrical System chapter) Cylinder Head Cover (see Cylinder Head Cover Re- moval in the Engine Top End chapter) •...
  • Page 58: Valve Clearance Adjustment

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures ○ When positioning #1 piston TDC at the end of the compression stroke: Intake Valve Clearance of #1 and #3 Cylinders Exhaust Valve Clearance of #1 and #2 Cylinders Measuring Valve [A] ○ When positioning #4 piston TDC at the end of the compression stroke: Intake Valve Clearance of #2 and #4 Cylinders Exhaust Valve Clearance of #3 and #4 Cylinders...
  • Page 59 PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Adjustment Shims Thickness Part Number Mark 1.300 92180-0108 1.325 92180-0109 1.350 92180-0110 1.375 92180-0111 1.400 92180-0112 1.425 92180-0113 1.450 92180-0114 1.475 92180-0115 1.500 92180-0116 1.525 92180-0117 1.550 92180-0118 1.575 92180-0119 1.600 92180-0120 1.625 92180-0121 1.650 92180-0122 1.675...
  • Page 60: Air Suction System Damage Inspection

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTICE Be sure to remeasure the clearance after selecting a shim. The clearance can be out of the specified range because of the shim tolerance. ○ If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance.
  • Page 61: Clutch

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures • Start the engine and run it at idle speed. • Plug the air switching valve hose end [A] with your finger and feel vacuum pulsing in the hose. If there is no vacuum pulsation, check the hose line for leak.
  • Page 62: Wheels/tires

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Push the release lever [A] toward the front of the motor- cycle until it becomes hard to turn. ○ At this time, the release lever should have the proper an- gle shown. 60° [B] If the angle is wrong, check the clutch and release parts for wear.
  • Page 63: Tire Tread Wear Inspection

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Tire Tread Wear Inspection As the tire tread wears down, the tire becomes more sus- ceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn).
  • Page 64: Final Drive

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Raise the rear wheel off the ground with the stand (see Rear Wheel Removal in the Wheels/Tires chapter). • Inspect the roughness of the rear wheel bearing by mov- ing [A] the wheel. •...
  • Page 65: Drive Chain Slack Inspection

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Drive Chain Slack Inspection NOTE ○ Check the slack with the motorcycle setting on its side- stand. ○ Clean the chain if it is dirty, and lubricate it if it appears dry. • Check the wheel alignment (see Wheel Alignment Inspec- tion).
  • Page 66: Wheel Alignment Inspection

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures • 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. Wheel Alignment Inspection •...
  • Page 67: Chain Guide Wear Inspection

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures WARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control. Inspect the chain for damage and proper adjustment before each ride.
  • Page 68: Brake Hose And Pipe Damage And Installation Condition Inspection

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Damage and Installation Condition Inspection • Inspect the brake hoses, pipes and fittings for deteriora- tion, cracks and signs of leakage. ○ The high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly main- tained.
  • Page 69: Brake Pad Wear Inspection

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures • Follow the procedure below to install the front/rear brake fluid reservoir cap correctly. ○ First, tighten the brake fluid reservoir cap [B] clockwise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].
  • Page 70: Suspension

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures If it does not, adjust the brake light switch. • Remove the front footpeg bracket (see Brake Pedal Re- moval in the Brakes chapter). • Remove the front footpeg bracket (see Brake Pedal Re- moval in the Brakes chapter).
  • Page 71: Front Fork Oil Leak Inspection

    PERIODIC MAINTENANCE 2-37 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 72: Steering

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Play Inspection • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter). • Raise the front wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 •...
  • Page 73: Steering Stem Bearing Lubrication

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures • Install the claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of steering stem locknut [C]. • Hand tighten the steering stem locknut until it touches the claw washer.
  • Page 74: Steering Damper Oil Leak Inspection

    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Damper Oil Leak Inspection • Visually inspect the steering damper [A] for oil leakage. If the oil leakage is found on it, replace the steering damper with a new one (see Steering Damper Re- moval/Installation in the Steering chapter).
  • Page 75: Electrical System

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step • Set the gear position in the neutral position. • Turn the ignition switch to ON. • The following lights should go on according to below table. [A] City Light (LED) Goes on [B] Taillight (LED)
  • Page 76 2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Turn the ignition switch to OFF. • The all lights should go off. ○ For models equipped with an immobilizer system, warn- ing indicator light (Red LED) will blinks. Refer to the Im- mobilizer System (Equipped Models) section in the Elec- trical System chapter.
  • Page 77: Headlight Aiming Inspection

    PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Fourth Step • Set the dimmer switch [A] to low beam position. • Start the engine. • The low beam headlight should go on. If the low beam headlight does not go on, inspect or re- place the following parts.
  • Page 78: Sidestand Switch Operation Inspection

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ The left adjuster [A] and right adjuster [B] can move the direction of the headlight beam to up, down, left and right by turning each adjuster itself as the below table. Turning Direction Moving Direction of of Adjuster Headlight Beam...
  • Page 79: Engine Stop Switch Operation Inspection

    PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures Sidestand Switch Operation Sidestand Gear Position Clutch Lever Engine Start Engine Run Neutral Released Starts Continue running Neutral Pulled in Starts Continue running In Gear Released Does not start Continue running In Gear Pulled in Starts Continue running Down...
  • Page 80: Others

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Second Step • Turn the engine stop switch to run position [A]. • Push the starter button and start the engine. • Turn the engine stop switch to stop position. • Immediately the engine should be stop. If the engine does not stop, inspect the engine stop switch (see Switch Inspection in the Electrical System chapter).
  • Page 81: Bolts, Nuts And Fasteners Tightness Inspection

    PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures • With the cable disconnected at both ends, the inner cable should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.
  • Page 82 2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Bolt, Nut and Fastener to be checked Engine: Clutch Lever Pivot Bolt Locknut Engine Mounting Bolts and Nuts Exhaust Pipe Clamp Bolt Exhaust Pipe Holder Nuts Muffler Body Clamp Bolt Muffler Body Mounting Bolt Premuffler Chamber Bracket Bolt Premuffler Chamber Mounting Bolt Radiator Bolts...
  • Page 83: Replacement Parts

    Discard the air cleaner element [A], and install a new el- ement so that the screen side [B] faces upward. NOTICE Use only the recommended air cleaner element (Kawasaki part number 11013-0041). Using another air cleaner element will wear the engine prema- turely or lower the engine performance. •...
  • Page 84 2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the fuel hose [A] with a new one. • Run the fuel hose correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Insert [B] the fuel hose joint [C] straight onto the delivery pipe until the hose joint clicks.
  • Page 85 PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures • Turn [A] the driver to disconnect the joint lock [B]. • Pull the fuel hose joint [C] out of the delivery pipe. NOTICE When pulling out the fuel hose joint, do not apply strong force to the delivery pipe [D] on the nozzle assy.
  • Page 86: Coolant Change

    2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Push and pull [A] the fuel hose joint [B] back and forth more than two times and make sure it is locked and does not come off. NOTICE When pushing and pulling the fuel hose joint, do not apply strong force to the delivery pipe [C] on the nozzle assy.
  • Page 87 PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures • Remove: Coolant Reserve Tank Mounting Bolt [A] Cap [B] • Pour the coolant into a container. • Install the coolant reserve tank [C]. • Tighten the drain bolt with new gasket. Torque - Coolant Drain Bolt (Water Pump): 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 88: Radiator Hose And O-ring Replacement

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Thermostat Housing [A] (see Thermostat Removal in the Cooling System chapter) Oil Cooler [B] (see Oil Cooler Removal in the Engine Lubrication System chapter)
  • Page 89: Engine Oil Change

    PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the engine oil drain bolt [A] to drain the oil. ○ The oil in the oil filter can be drained by removing the filter (see Oil Filter Replacement).
  • Page 90: Oil Filter Replacement

    2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Oil Filter Replacement • Drain the engine oil (see Engine Oil Change). • Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). • Remove the oil filter [A] with the oil filter wrench [B]. Special Tool - Oil Filter Wrench: 57001-1249 •...
  • Page 91: Brake Hose And Pipe Replacement

    PERIODIC MAINTENANCE 2-57 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 Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Brake Hose Fitting Bolt [A] Brake Hose Banjo Bolts [B] Bolt [C]...
  • Page 92 2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • For KIBS equipped models; note the following. • Remove: Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Rear Fender Front (see Rear Fender Front Removal in the Frame chapter) Rear Shock Absorber (see Rear Shock Absorber Re-...
  • Page 93 PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures...
  • Page 94: Brake Fluid Change

    2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Change NOTE ○ The procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is the same as for the front brake. • Level the brake fluid reservoir. •...
  • Page 95: Master Cylinder Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures • Follow the procedure below to install the front/rear brake fluid reservoir cap correctly. ○ First, tighten the front/rear brake fluid reservoir cap [B] clockwise [C] by hand until slight resistance is felt indi- cating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].
  • Page 96 2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Master Cylinder Disassembly • Remove the rear master cylinder (see Rear Master Cylin- der Removal in the Brakes chapter). • Remove the circlip [A], connector [B] and O-ring [C]. Special Tool - Inside Circlip Pliers: 57001-143 •...
  • Page 97: Caliper Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-63 Periodic Maintenance Procedures Caliper Rubber Parts Replacement Front Caliper Disassembly • Remove: Front Caliper (see Front Caliper Removal in the Brakes chapter) Brake Pads (see Front Brake Pad Removal in the Brakes chapter) • Remove: Front Caliper Assembly Bolts [A] •...
  • Page 98 2-64 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the dust seals [A] and fluid seals [B]. • Remove the bleed valve [C] and rubber cap [D]. • Repeat the previous step to remove the pistons from the other side of the caliper body. NOTE ○...
  • Page 99 PERIODIC MAINTENANCE 2-65 Periodic Maintenance Procedures • Install the pad spring [A] as shown. • Install the brake pads (see Front Brake Pad Installation in the Brakes chapter). • Wipe up any spilled brake fluid on the caliper with wet cloth.
  • Page 100 2-66 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Caliper Assembly • 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 101: Spark Plug Replacement

    PERIODIC MAINTENANCE 2-67 Periodic Maintenance Procedures Spark Plug Replacement • Remove the stick coils (see Stick Coil Removal in the Electrical System chapter). • Remove the spark plugs using the 16 mm (0.63 in.) plug wrench [A] vertically. • Replace the spark plug with new ones. Standard Spark Plug Type: NGK CR9EIA-9...
  • Page 103 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........Fuel Injector Output Voltage DFI System........3-10 Inspection........3-58 DFI Parts Location......3-20 Fuel Injector Fuel Line Inspection 3-60 Specifications ........3-23 Throttle Grip and Cables ....3-62 Special Tools and Sealant ....
  • Page 104 3-2 FUEL SYSTEM (DFI) Vacuum Chamber Removal Fuel Tank and Cap Inspection ..3-84 (Other than US, CA and CAL Fuel Tank Cleaning ...... 3-84 Models) ........3-78 Evaporative Emission Control System Vacuum Chamber Installation (CAL and SEA Models)....3-85 (Other than US, CA and CAL Parts Removal/Installation ...
  • Page 105: Exploded View

    FUEL SYSTEM (DFI) 3-3 Exploded View This page intentionally left blank.
  • Page 106 3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 107 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Cleaner Housing Assembly Screws 0.11 10 in·lb Air Cleaner Housing Clamp Bolts 0.20 18 in·lb Air Cleaner Housing Duct Screws 0.11 10 in·lb Air Intake Duct Assembly Screws 0.15 13 in·lb Air Intake Solenoid Valve Nut...
  • Page 108 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 109 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bracket Screw 0.35 30 in·lb Delivery Pipe Assy Mounting Screws 3.43 0.35 30 in·lb Fitting Retainer Screws 2.06 0.21 18 in·lb Fitting Screws 3.43 0.35 30 in·lb Idle Speed Control Valve Actuator Retainer 2.06 0.21 18 in·lb...
  • Page 110 3-8 FUEL SYSTEM (DFI) Exploded View...
  • Page 111 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Exhaust Butterfly Valve Actuator Mounting Screws 0.12 11 in·lb Exhaust Butterfly Valve Actuator Pulley Bolt 0.50 43 in·lb 3. Other than CAL and SEA Models 4. CAL and SEA Models...
  • Page 112: Dfi System

    3-10 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 113 FUEL SYSTEM (DFI) 3-11 DFI System 1. ECU 2. Battery 3. Vehicle-down Sensor 4. Exhaust Butterfly Valve Actuator 5. Vacuum Chamber (Other than US, CA and CAL Models) 6. Air Intake Valve Actuator (Other than US, CA and CAL Models) 7.
  • Page 114 3-12 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram Part Names 1. Air Intake Solenoid Valve (Other than US, CA and CAL Models) 2. Front Wheel Rotation Sensor...
  • Page 115 26. Oxygen Sensor (Equipped Models) 27. Joint Connector E 28. ECU 29. Rear Wheel Rotation Sensor 30. Exhaust Butterfly Valve Actuator 31. Kawasaki Diagnostic System/Immobilizer (Equipped Models) Connector 32. Engine Ground 33. Battery 34. Starter Relay 35. Main Fuse 30 A 36.
  • Page 116 3-14 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram (KIBS Equipped Models)
  • Page 117 24. Gear Position Switch 25. Oxygen Sensor (Equipped Models) 26. Joint Connector E 27. ECU 28. Exhaust Butterfly Valve Actuator 29. Kawasaki Diagnostic System/Immobilizer (Equipped Models) Connector 30. Engine Ground 31. Battery 32. Starter Relay 33. Main Fuse 30 A 34.
  • Page 118 3-16 FUEL SYSTEM (DFI) DFI System ○ Color Codes: BK: Black GY: Gray PU: Purple BL: Blue LB: Light Blue R: Red BR: Brown LG: Light Green V: Violet CH: Chocolate W: White O: Orange DG: Dark Green P: Pink Y: Yellow G: Green...
  • Page 119 FUEL SYSTEM (DFI) 3-17 DFI System This page intentionally left blank.
  • Page 120 3-18 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Subthrottle Valve Actuator: Y/BK 2. Subthrottle Valve Actuator: BK/O 3. Unused 4. Front Wheel Rotation Sensor Signal: G/Y 5. Unused 6. Starter Lockout Switch: R/G 7. Gear Position Switch: G/R 8.
  • Page 121 71. Fuel Pump Relay: BR/Y 72. Secondary Fuel Injector #2: O/G 73. Engine Ground: BK/Y 74. Engine Ground: BK/Y 75. Unused 76. Oxygen Sensor Heater (Equipped Models): R 77. Unused 78. Stick Coil #3: BK/W *: KDS (Kawasaki Diagnostic System)
  • Page 122: Dfi Parts Location

    Primary Fuel Injectors #1, #2, #3, #4 [B] Battery [A] Exhaust Butterfly Valve Actuator [B] ECU Fuse 15 A [C] Kawasaki Diagnostic System/Immobilizer (Equipped Models) Connector [D] Vehicle-down Sensor [E] ECU [A] Relay Box [B] (Fuel Pump Relay, Radiator Fan Relay)
  • Page 123 FUEL SYSTEM (DFI) 3-21 DFI Parts Location Secondary Fuel Injectors #1, #2, #3, #4 [A] Intake Air Temperature Sensor [B] Crankshaft Sensor [A] Gear Position Switch [A] Ignition Key [A] (Transponder, Immobilizer System Equipped Models) Immobilizer Antenna [B] (Equipped Models) Ignition Switch [C] Warning Indicator Light (LED) [D] Immobilizer Amplifier [A] (Equipped Models)
  • Page 124 3-22 FUEL SYSTEM (DFI) DFI Parts Location Oxygen Sensor [A] (Equipped Models) Front Wheel Rotation Sensor [A] Rear Wheel Rotation Sensor [A]...
  • Page 125: Specifications

    FUEL SYSTEM (DFI) 3-23 Specifications Item Standard Digital Fuel Injection System Idle Speed 1 100 ±50 r/min (rpm) Throttle Body Assy: Throttle Valve Dual throttle valve Bore 47 mm (1.85 in.) Throttle Body Vacuum 30.7 ±1.33 kPa (230 ±10 mmHg) 0 ∼...
  • Page 126: Special Tools And Sealant

    3-24 FUEL SYSTEM (DFI) Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Fuel Pressure Gauge Adapter: 57001-125 57001-1593 Hand Tester: Fuel Hose: 57001-1394 57001-1607 Needle Adapter Set: Measuring Adapter: 57001-1457 57001-1700 Extension Tube: Liquid Gasket, TB1211: 57001-1578 56019-120...
  • Page 127: Dfi Servicing Precautions

    FUEL SYSTEM (DFI) 3-25 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 128 3-26 FUEL SYSTEM (DFI) 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 129: Troubleshooting The Dfi System

    FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (immobilizer equipped mod- els), water temperature warning indicator and oil pressure warning indicator. Outline When a problem occurs with DFI system, the warning in- dicator light (LED) [A] and FI warning symbol [B] goes on to alert the rider.
  • Page 130 ECU are not erased to preserve the problem 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 injectors (primary and secondary) and ignition system.
  • Page 131 FUEL SYSTEM (DFI) 3-29 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 132 3-30 FUEL SYSTEM (DFI) Troubleshooting the DFI System • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. •...
  • Page 133: Inquiries To Rider

    FUEL SYSTEM (DFI) 3-31 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 134 3-32 FUEL SYSTEM (DFI) Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. □ □ □ □ □ □...
  • Page 135 FUEL SYSTEM (DFI) 3-33 Troubleshooting the DFI System □ Poor running spark plug loose (tighten it). □ or no power at spark plug dirty, broken, or gap maladjusted (remedy it). high speed □ spark plug incorrect (replace it). □ knocking (fuel poor quality or incorrect, → use high-octane gasoline). □...
  • Page 136: Dfi System Troubleshooting Guide

    3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system.
  • Page 137 FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Fuel filter or pump screen clogged Inspect and replace fuel pump (see chapter 3). Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3).
  • Page 138 3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Fuel pump trouble Inspect (see chapter 3). Fuel injector trouble Inspect (see chapter 3). Main throttle sensor trouble Inspect (see chapter 17). Subthrottle sensor trouble Inspect (see chapter 17). Subthrottle valve actuator trouble Inspect (see chapter 17).
  • Page 139: Poor Running Or No Power At High Speed

    FUEL SYSTEM (DFI) 3-37 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Intake air pressure sensor #2 trouble Inspect (see chapter 17). Water temperature sensor trouble Inspect (see chapter 17). Intake air temperature sensor trouble Inspect (see chapter 17). Other: Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight,...
  • Page 140 3-38 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Intake air pressure sensor #1 trouble Inspect (see chapter 17). Intake air pressure sensor #2 trouble Inspect (see chapter 17). Water temperature sensor trouble Inspect (see chapter 17). Intake air temperature sensor trouble Inspect (see chapter 17).
  • Page 141: Warning Indicator Light (led)

    FUEL SYSTEM (DFI) 3-39 Warning Indicator Light (LED) Light (LED) Inspection ○ The warning indicator light (LED) [A] is used for the FI in- dicator, immobilizer indicator (immobilizer equipped mod- els), water temperature warning indicator and oil pressure warning indicator. ○...
  • Page 142: Ecu

    3-40 FUEL SYSTEM (DFI) 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 can not clear the regulation. ECU Identification Part Number [A] Specification...
  • Page 143: Ecu Power Supply Inspection

    FUEL SYSTEM (DFI) 3-41 ECU Power Supply Inspection • Remove the upper air cleaner housing (see Air Cleaner Element Replacement in the Periodic Maintenance chap- ter). • Visually inspect the ECU connectors. If the connector is clogged with mud or dust, blow it off with compressed air.
  • Page 144 3-42 FUEL SYSTEM (DFI) 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 (gray) [B] with the needle adapter set.
  • Page 145 FUEL SYSTEM (DFI) 3-43 ECU Power Source Circuit 1. Ignition Switch 2. Joint Connector E 3. ECU 4. Engine Ground 5. Battery 6. Starter Relay 7. Main Fuse 30 A 8. ECU Fuse 15 A 9. Frame Ground 2 10. Frame Ground 1 11.
  • Page 146: Can Communication Line

    3-44 FUEL SYSTEM (DFI) CAN Communication Line CAN Communication Line Resistance Inspection ○ In this model, resistors for CAN communication line are built in the ECU [A] and meter unit. • Refer to the Meter Unit Inspection in the Electrical System chapter for the resistor in the meter unit.
  • Page 147 FUEL SYSTEM (DFI) 3-45 CAN Communication Line CAN Communication Line Circuit 1. Meter Unit 2. Joint Connector C 3. Joint Connector D 4. ECU 5. Kawasaki Diagnostic System/Immobilizer (Equipped Models) Connector 6. KIBS Hydraulic Unit (Equipped Models)
  • Page 148: Dfi Power Source

    3-46 FUEL SYSTEM (DFI) DFI Power Source ECU Fuse Removal • Refer to the 30 A Main/15 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 149: Fuel Line

    FUEL SYSTEM (DFI) 3-47 Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Fuel Tank Covers (see Fuel Tank Removal) Fuel Tank Bolts (see Fuel Tank Removal) Primary Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) ○...
  • Page 150: Fuel Flow Rate Inspection

    3-48 FUEL SYSTEM (DFI) 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 151 FUEL SYSTEM (DFI) 3-49 Fuel Line • Open the fuel tank cap [A] to lower the pressure in the tank. • Remove the primary fuel 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 152: Fuel Pump

    3-50 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump 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 153: Fuel Pump Installation

    FUEL SYSTEM (DFI) 3-51 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 154: Pressure Regulator Removal

    3-52 FUEL SYSTEM (DFI) Fuel Pump • Disconnect the fuel pump lead connector and connect the harness adapter [A] between these connectors as shown in the figure. Main Harness [B] Fuel Pump [C] Special Tool - Measuring Adapter: 57001-1700 • Connect a digital meter [D] to the harness adapter leads.
  • Page 155: Fuel Filter Cleaning

    FUEL SYSTEM (DFI) 3-53 Fuel Pump Fuel Filter Cleaning ○ The fuel filter [A] is built into the fuel pump and can not be cleaned or checked. If the fuel filter is suspected of clogging or being damaged, replace it with the fuel pump as a set. Fuel Pump Circuit 1.
  • Page 156: Fuel Injectors

    3-54 FUEL SYSTEM (DFI) Fuel Injectors Primary Fuel Injector Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Secondary Fuel Injector Removal/Installation • Refer to the Nozzle Assy Disassembly/Assembly. Fuel Injector Audible Inspection NOTE ○ Be sure the battery is fully charged. ○...
  • Page 157: Fuel Injector Resistance Inspection

    FUEL SYSTEM (DFI) 3-55 Fuel Injectors Fuel Injector Resistance Inspection For Primary Fuel Injectors • Remove the air cleaner housing (see Air Cleaner Housing Removal). • Disconnect the primary fuel injector connector [A]. • Connect a digital meter to the terminals in each primary fuel injector [A].
  • Page 158: Fuel Injector Power Source Voltage Inspection

    3-56 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. For Primary Fuel Injectors • Remove the air cleaner housing (see Air Cleaner Housing Removal).
  • Page 159 FUEL SYSTEM (DFI) 3-57 Fuel Injectors For Secondary Fuel Injectors • Remove the fuel tank (see Fuel Tank Removal). • Disconnect the injector connector and connect the har- ness adapter [A] between these connectors as shown in the figure. Main Harness [B] Secondary Fuel Injector #1 [C] Special Tool - Measuring Adapter: 57001-1700 •...
  • Page 160: Fuel Injector Output Voltage Inspection

    3-58 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Output Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. • Remove the ECU (see ECU Removal). ○ Do not disconnect the ECU connector. •...
  • Page 161 FUEL SYSTEM (DFI) 3-59 Fuel Injectors If the reading is out of the specification, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and injector connector. Wiring Continuity Inspection (Primary Fuel Injectors) ECU Connector (Gray) [A] ←→...
  • Page 162: Fuel Injector Fuel Line Inspection

    3-60 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Fuel Line Inspection • Remove: Fuel Tank (see Fuel Tank Removal) Air Cleaner Housing (see Air Cleaner Housing Removal) Primary and Secondary Fuel Hoses (see Fuel Hose Re- placement in the Periodic Maintenance chapter) ○...
  • Page 163 FUEL SYSTEM (DFI) 3-61 Fuel Injectors Fuel Injector Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Secondary Fuel Injector #1 4. Secondary Fuel Injector #2 5. Secondary Fuel Injector #3 6. Secondary Fuel Injector #4 7. Primary Fuel Injector #1 8.
  • Page 164: Throttle Grip And Cables

    3-62 FUEL SYSTEM (DFI) 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 165: Throttle Body Assy

    FUEL SYSTEM (DFI) 3-63 Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance 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 ex- plosive under certain conditions, creating the...
  • Page 166: Throttle Body Assy Installation

    3-64 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the caps [A]. • Loosen the throttle body assy holder clamp bolts [A]. • Remove the throttle body assy [A] from the throttle body assy holders. • Disconnect: Main Throttle Sensor Connector [B] Subthrottle Sensor Connector [C] •...
  • Page 167: Throttle Body Assy Disassembly

    FUEL SYSTEM (DFI) 3-65 Throttle Body Assy • Install the throttle body assy holder clamp bolt heads [A] outside as shown in the figure. • Tighten: Torque - Throttle Body Assy Holder Clamp Bolts: 2.0 N·m (0.20 kgf·m, 18 in·lb) •...
  • Page 168: Throttle Body Assy Assembly

    3-66 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the throttle body assy (see Throttle Body Assy Removal). • Remove the screws [A] to pull out the primary fuel injec- tors [B] from the throttle body assy together with the de- livery pipe assy [C].
  • Page 169 FUEL SYSTEM (DFI) 3-67 Throttle Body Assy • Replace the dust seals [A] with new ones. • Apply engine oil to the new dust seals. • Install the primary fuel injectors along with the delivery pipe assy to the throttle body. •...
  • Page 170: Nozzle Assy

    3-68 FUEL SYSTEM (DFI) Nozzle Assy Nozzle Assy Removal • Remove the fuel tank (see Fuel Tank Removal). • Disconnect the secondary fuel hose [A] from the delivery pipe assy of the nozzle assy [B] (see Fuel Hose Replace- ment in the Periodic Maintenance chapter). •...
  • Page 171: Nozzle Assy Assembly

    FUEL SYSTEM (DFI) 3-69 Nozzle Assy Nozzle Assy Assembly • Before assembling, blow away dirt or dust from the deliv- ery pipes [A] by applying compressed air [B]. • Replace the O-rings [A] of the joint pipe [B] with new ones. •...
  • Page 172: Air Cleaner

    3-70 FUEL SYSTEM (DFI) 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 173: Air Cleaner Housing Installation

    FUEL SYSTEM (DFI) 3-71 Air Cleaner • Remove: ECU (see ECU Removal) Air Cleaner Element (see Air Cleaner Element Replace- ment in the Periodic Maintenance chapter) Air Cleaner Drain Hose [A] Breather Hose [B] • Loosen the air cleaner housing clamp bolts [A]. •...
  • Page 174: Air Cleaner Housing Disassembly

    3-72 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Housing Disassembly • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) Intake Air Temperature Sensor (see Intake Air Temper- ature Sensor Removal in the Self-Diagnosis System chapter) Nozzle Assy (see Nozzle Assy Removal) Screws [A] Ducts [B] Hose [C]...
  • Page 175 FUEL SYSTEM (DFI) 3-73 Air Cleaner • Install: Air Cleaner Gasket [A] Duct [B] Air Cleaner Frame Gasket [C] Air Cleaner Element Gasket [D] Air Cleaner Element [E] Air Cleaner Case Gasket [F] Damper [G] • Install the air cleaner housing (see Air Cleaner Housing Installation).
  • Page 176: Air Line

    3-74 FUEL SYSTEM (DFI) Air Line Air Intake Duct Removal • Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Meter Bracket (see Meter Unit Removal/Installation in the Electrical System chapter) Immobilizer Amplifier [A] (Equipped Models) (see Immo- bilizer System Parts Replacement in the Electrical Sys- tem chapter) Air Intake Duct Mounting Bolts [B] (Both Sides)
  • Page 177: Air Intake Duct Assembly

    FUEL SYSTEM (DFI) 3-75 Air Line Air Intake Duct Assembly • Install the dampers [A] and seal [B] as shown in the figure. • Fit the holder [C] to the air intake ducts [D]. Projections [E] and Holes [F] Grooves [G] and Ribs [H] •...
  • Page 178: Air Intake Duct Assembly (other Than Us, Ca And Cal Models)

    3-76 FUEL SYSTEM (DFI) Air Line • Remove the shaft [A] of the air intake valve actuator. • Remove: Pad [A] Screws [B] Air Intake Valve [C] Air Intake Duct Assembly (Other than US, CA and CAL Models) • Install the seals [A] as shown in the figure. •...
  • Page 179: Air Intake Solenoid Valve Removal (other Than Us, Ca And Cal Models)

    FUEL SYSTEM (DFI) 3-77 Air Line • Hang the shaft [A] to the air intake valve securely. • Fit the projections [A] of the air intake valve actuator [B] to the grooves [C]. • Turn the air intake valve actuator clockwise (90°). •...
  • Page 180: Vacuum Chamber Removal (other Than Us, Ca And Cal Models)

    3-78 FUEL SYSTEM (DFI) Air Line Vacuum Chamber Removal (Other than US, CA and CAL Models) • Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Bolt [A] Hoses [B] Vacuum Chamber [C] Vacuum Chamber Installation (Other than US, CA and CAL Models) •...
  • Page 181: Fuel Tank

    FUEL SYSTEM (DFI) 3-79 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 182 3-80 FUEL SYSTEM (DFI) Fuel Tank • Remove: Bolts [A] Fuel Tank Covers (Both Sides) [B] ○ Clear the hook fastener [C], projections [D] and hook por- tion [E]. ○ Remove the relay box [A] from the left fuel tank cover [B]. •...
  • Page 183 FUEL SYSTEM (DFI) 3-81 Fuel Tank • Disconnect: Battery (–) Terminal Fuel Pump Lead Connector [A] • Be sure to place a piece of cloth around the fuel hose joint. • Insert a thin blade screwdriver [A] into the slit [B] on the joint lock [C].
  • Page 184: Fuel Tank Installation

    3-82 FUEL SYSTEM (DFI) Fuel Tank • For the California and Southeast Asia models, note the following. NOTICE For the California and Southeast Asia models, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capac- ity is greatly reduced.
  • Page 185 FUEL SYSTEM (DFI) 3-83 Fuel Tank • For the California and Southeast Asia models, note the following. ○ To prevent the gasoline from flowing into or out of the canister, hold the separator perpendicular to the ground. ○ Connect the hoses according to the diagram of the evap- orative emission control system.
  • Page 186: Fuel Tank And Cap Inspection

    3-84 FUEL SYSTEM (DFI) Fuel Tank ○ Insert the hook portion [A] of the fuel tank into the slot [B] of the fuel tank cover. ○ Insert the projections [C] into the holes [D], and then at- tach the hook fastener [E] to the hook fastener [F] on the fuel tank.
  • Page 187: Evaporative Emission Control System (cal And Sea Models)

    FUEL SYSTEM (DFI) 3-85 Evaporative Emission Control System (CAL and SEA Models) The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.
  • Page 188: Separator Operation Test

    3-86 FUEL SYSTEM (DFI) Evaporative Emission Control System (CAL and SEA Models) Separator Operation Test WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 189: Canister Inspection

    FUEL SYSTEM (DFI) 3-87 Evaporative Emission Control System (CAL and SEA Models) Canister Inspection • Refer to the Evaporative Emission Control System In- spection (CAL and SEA Models) in the Periodic Mainte- nance chapter. 1. Green Hoses (Purge) 2. Fittings 3.
  • Page 191 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 ..................Coolant Reserve Tank Installation ..................
  • Page 192: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 193 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Water Hose Clamp Screws 0.31 27 in·lb Water Pipe Mounting Bolt 87 in·lb Water Pump Cover Bolts 87 in·lb L (2) Coolant Drain Bolt (Water Pump) 87 in·lb Impeller Bolt 87 in·lb Water Temperature Sensor 106 in·lb...
  • Page 194: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart 1. Radiator 2. Radiator Fan 3. Water Pump 4. Oil Cooler 5. Oil Cooler Inlet Hose 6. Oil Cooler Outlet Hose 7. Cylinder Jacket 8. Cylinder Head Jacket 9. Thermostat Housing 10. Air Bleeder Hose 11.
  • Page 195 COOLING SYSTEM 4-5 Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 196: Specifications

    4-6 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type (Recommended) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point –35°C (–31°F) Total Amount...
  • Page 197: Special Tools

    COOLING SYSTEM 4-7 Special Tools Bearing Driver Set: Oil Seal Driver 37.5: 57001-1129 57001-1660...
  • Page 198: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the right lower fairing (see Lower Fairing Re- moval in the Frame chapter). • Visually inspect the coolant in the reserve tank [A]. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded.
  • Page 199: 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 200: 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 201: 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 new oil seal lips [A]. •...
  • Page 202: Radiator

    4-12 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal • Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Coolant Reserve Tank (see Coolant Reserve Tank Re- moval)
  • Page 203: Radiator And Radiator Fan Installation

    COOLING SYSTEM 4-13 Radiator Radiator and Radiator Fan Installation If the radiator bracket [A] was removed, install it. • Install the radiator fan to the radiator. • Run the radiator fan motor lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). •...
  • Page 204: 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 205: Thermostat

    COOLING SYSTEM 4-15 Thermostat Thermostat Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Throttle Body Assy Holder Clamp [A] Water Temperature Sensor Connector [B] (Disconnect)
  • Page 206: Thermostat Inspection

    4-16 COOLING SYSTEM Thermostat ○ Install the thermostat [A] in the housing so that the air bleeder hole [B] is on top. • Tighten: Torque - Thermostat Cap Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) • Install the thermostat assembly to the cylinder head. •...
  • Page 207: Hoses And Pipes

    COOLING SYSTEM 4-17 Hoses and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). •...
  • Page 208: Water Temperature Sensor

    4-18 COOLING SYSTEM Water Temperature Sensor Water Temperature Sensor Removal/Installation • Refer to the Water Temperature Sensor Removal/Instal- lation in the Self-Diagnosis System chapter. Water Temperature Sensor Inspection • Refer to the Water Temperature Sensor Inspection in the Electrical System chapter.
  • Page 209 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Cylinder Compression Exhaust System Identification ... Measurement ......5-24 Specifications ........Cylinder Head Removal ....5-24 Special Tools and Sealant ....Cylinder Head Installation .... 5-25 Clean Air System....... 5-11 Cylinder Head Warp Inspection ...
  • Page 210: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 211 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb 1 Air Suction Valve Cover Bolts 87 in·lb 2 Camshaft Cap Bolts 106 in·lb 3 Camshaft Chain Tensioner Cap Bolt 4 Camshaft Chain Tensioner Mounting Bolts 87 in·lb 5 Camshaft Sprocket Bolts 6 Coolant Drain Bolt (Cylinder) 87 in·lb...
  • Page 212 5-4 ENGINE TOP END Exploded View...
  • Page 213 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Muffler Body Mounting Bolt Premuffler Chamber Mounting Bolt R: Replacement Parts...
  • Page 214: Exhaust System Identification

    5-6 ENGINE TOP END Exhaust System Identification Exhaust Pipe Mark Position [A] Premuffler Chamber Mark Position [A]...
  • Page 215 ENGINE TOP END 5-7 Exhaust System Identification Muffler Body Mark Position [A] Premuffler Chamber [A] with Hole [B] for Oxygen Sensor [C] Honeycomb Type Catalyst Position [A]...
  • Page 216: Specifications

    5-8 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: 35.043 ∼ 35.157 mm (1.3796 ∼ 1.3841 in.) Exhaust 34.94 mm (1.376 in.) 38.243 ∼ 38.357 mm (1.5056 ∼ 1.5101 in.) Intake 38.14 mm (1.502 in.) 0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.) Camshaft Journal/Camshaft 0.17 mm (0.0067 in.) Cap Clearance...
  • Page 217: Special Tools And Sealant

    ENGINE TOP END 5-9 Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 32° - 28: 57001-221 57001-1119 Valve Spring Compressor Assembly: Valve Seat Cutter Holder Bar: 57001-241 57001-1128 Valve Spring Compressor Adapter, 25: Valve Seat Cutter, 32° - 33: 57001-1019 57001-1199 Valve Seat Cutter, 45°...
  • Page 218 5-10 ENGINE TOP END Special Tools and Sealant Valve Guide Arbor, 4.5: Compression Gauge Adapter, M10 × 1.0: 57001-1331 57001-1601 Valve Guide Reamer, 4.5: L-Shape Hose: 57001-1333 57001-1606 Valve Seat Cutter, 60° - 33: Washer: 57001-1334 57001-1612 Valve Guide Driver: Liquid Gasket, TB1211F: 57001-1564 92104-0004...
  • Page 219: Clean Air System

    ENGINE TOP END 5-11 Clean Air System Air Suction Valve Removal • Remove: Air Switching Valve (see Air Switching Valve Removal) Air Suction Valve Cover Bolts [A] (Both Sides) Air Suction Valve Covers [B] (Both Sides) • Remove the air suction valves [A] on both sides. Air Suction Valve Installation •...
  • Page 220: Air Suction Valve Inspection

    5-12 ENGINE TOP END Clean Air System Air Suction Valve Inspection • Remove the air suction valve (see Air Suction Valve Re- moval). • Visually inspect the reeds [A] for cracks, folds, warps, heat damage or other damage. If there is any doubt as to the condition of the reeds, re- place the air suction valve as an assembly.
  • Page 221: Air Switching Valve Operation Test

    ENGINE TOP END 5-13 Clean Air System Air Switching Valve Operation Test • Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter. Air Switching Valve Unit Test • Refer to the Air Switching Valve Unit Test in the Electrical System chapter.
  • Page 222: Cylinder Head Cover

    5-14 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal • Remove: Air Suction Valves (see Air Suction Valve Removal) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Stick Coils (see Stick Coil Removal in the Electrical Sys- tem chapter) •...
  • Page 223 ENGINE TOP END 5-15 Cylinder Head Cover • Be sure to install the following parts. Dowel Pins [A] Plug Hole Gaskets [B] • Install the cylinder head cover. • Install the rubber washers [A] with the metal side faces upward. •...
  • Page 224: Camshaft Chain Tensioner

    5-16 ENGINE TOP END 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 225: Camshaft Chain Tensioner Installation

    ENGINE TOP END 5-17 Camshaft Chain Tensioner Camshaft Chain Tensioner Installation • Replace the O-ring [A] with a new one. • Apply grease to the new O-ring. • Release the stopper [B] and push the push rod [C] into the interior of the tensioner body [D] so that the position of the push rod is 3 or 4 notches [E] as shown in the figure.
  • Page 226: Camshaft, Camshaft Chain

    5-18 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) • Using a wrench on the timing rotor bolt [A], turn the crank- shaft clockwise until the line [B] (TDC mark for #1,4 pis- tons) on the timing rotor [C] is aligned with the mating sur- face [D] of the crankcase.
  • Page 227: Camshaft Installation

    ENGINE TOP END 5-19 Camshaft, Camshaft Chain • Remove: Camshaft Sprocket Bolts [A] Camshaft Sprockets NOTICE The crankshaft may be turned while the camshafts are removed. Always pull the chain taut while turn- ing the crankshaft. This avoids kinking the chain on the lower (crankshaft) sprocket.
  • Page 228 5-20 ENGINE TOP END Camshaft, Camshaft Chain • Pull the tension side (exhaust side) [A] of the chain taut to install the chain. • Engage the camshaft chain with the sprockets so that tim- ing marks on the sprockets are positioned as shown in the figure.
  • Page 229: Camshaft, Camshaft Cap Wear Inspection

    ENGINE TOP END 5-21 Camshaft, Camshaft Chain • Install the ten dowel pins on the marks [A]. • Install the camshaft cap, following the identification No. [B] and upper camshaft chain guide [C]. • First tighten the all camshaft cap bolts evenly to seat the camshaft in place, then tighten all bolts following the spec- ified tightening sequence.
  • Page 230: 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 23.940 ∼ 23.962 mm (0.9425 ∼ 0.9434 in.) Standard: Service Limit: 23.91 mm (0.9413 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 231: Camshaft Chain Installation

    ENGINE TOP END 5-23 Camshaft, Camshaft Chain • Remove the crankshaft sprocket [A]. • Pull out the camshaft chain [B] downward. Camshaft Chain Installation • Install the camshaft chain from head side. • Install the crankshaft sprocket [A] on the crankshaft [B] with their teeth [C] aligned.
  • Page 232: Cylinder Head

    5-24 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove the spark plugs (see Spark Plug Replacement in the Periodic Maintenance chapter). •...
  • Page 233: Cylinder Head Installation

    ENGINE TOP END 5-25 Cylinder Head • Remove the front camshaft chain guide bolt (upper) [A]. • Remove: Front Camshaft Chain Guide Bolt (Lower) [A] Collar Front Camshaft Chain Guide [B] Dowel Pin [C] Rear Camshaft Chain Guide [D] • Loosen the M6 and M10 cylinder head bolts as shown sequence [1 ∼...
  • Page 234: Cylinder Head Warp Inspection

    5-26 ENGINE TOP END Cylinder Head • Install: Dowel Pin [A] Rear Camshaft Chain Guide [B] Front Camshaft Chain Guide [C] New O-ring [D] Collar [E] • Tighten: Torque - Front Camshaft Chain Guide Bolt (Upper) [F]: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Camshaft Chain Guide Bolt (Lower) [G]: 12 N·m (1.2 kgf·m, 106 in·lb) •...
  • Page 235: Valves

    ENGINE TOP END 5-27 Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the valve lifter and shim. ○ Mark and record the valve lifter and shim locations so they can be installed in their original positions.
  • Page 236: 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 237: Valve Seat Inspection

    ENGINE TOP END 5-29 Valves NOTE ○ The reading is not actual valve/valve guide clearance because the measuring point is above the guide. Valve/Valve Guide Clearance (Wobble Method) Standard: 0.03 ∼ 0.12 mm (0.0012 ∼ 0.0047 in.) Exhaust 0.03 ∼ 0.13 mm (0.0012 ∼ 0.0051 in.) Intake Service Limit: Exhaust...
  • Page 238 5-30 ENGINE TOP END Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
  • Page 239 ENGINE TOP END 5-31 Valves • Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range.
  • Page 240 5-32 ENGINE TOP END Valves If the seat width is too wide, make the 60° [A] grind de- scribed below. If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 60° angle until the seat width is within the specified range.
  • Page 241 ENGINE TOP END 5-33 Valves...
  • Page 242: Throttle Body Assy Holder

    5-34 ENGINE TOP END Throttle Body Assy Holder Throttle Body Assy Holder Removal • Remove: Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Clamps [A] • Loosen the throttle body assy holder bolts as shown se- quence [1 ∼...
  • Page 243: Muffler

    ENGINE TOP END 5-35 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 • Remove: Bolts [A] Muffler Body Cover [B] •...
  • Page 244: Premuffler Chamber Removal

    5-36 ENGINE TOP END Muffler • Thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts. • Install the removed parts (see appropriate chapters). Premuffler Chamber Removal • Remove: Muffler Body (see Muffler Body Removal) Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Front Seat (see Front Seat Removal in the Frame chap-...
  • Page 245: Premuffler Chamber Installation

    ENGINE TOP END 5-37 Muffler • Loosen the exhaust pipe clamp bolt [A]. • Remove the bolt [B]. • Pull out the premuffler chamber backward from the ex- haust pipe. Premuffler Chamber Installation • Replace the premuffler chamber gasket [A] with a new one.
  • Page 246: Exhaust Pipe Removal

    5-38 ENGINE TOP END Muffler • Install the removed parts (see appropriate chapters). • Thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts. Exhaust Pipe Removal • Remove: Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter) Exhaust Pipe Clamp Bolt [A] (Loosen) •...
  • Page 247: Exhaust Butterfly Valve Cable Removal

    ENGINE TOP END 5-39 Muffler • Install the removed parts (see appropriate chapters). • Thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts and nuts. Exhaust Butterfly Valve Cable Removal • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter).
  • Page 248 5-40 ENGINE TOP END Muffler • Loosen the locknuts [A], and turn the adjusters [B] to give the cable plenty of play. • Remove the clamp [A]. • Remove the upper ends [B] of the exhaust butterfly valve cables from the pulley [C]. •...
  • Page 249: Exhaust Butterfly Valve Cable Installation

    ENGINE TOP END 5-41 Muffler Exhaust Butterfly Valve Cable Installation • Confirm whether pulley [A] is an angle shown in the figure. 41.7° ±0.7° [B] ○ This position is original position of the pulley. NOTE ○ Correct the position electrically after confirming use is discontinued and there is no damage when differing from the angle of shown in the figure.
  • Page 250 5-42 ENGINE TOP END Muffler • Install the upper ends of the exhaust butterfly valve ca- bles to the pulley of the exhaust butterfly valve actuator, following the specified installing sequence. ○ First, install the close cable (black) [A]. ○ Second, install the open cable (white) [B].
  • Page 251 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool and Sealant ......................Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Cable Removal ......................... Cable Installation ......................Cable Lubrication ......................Clutch Lever Installation....................
  • Page 252: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 253 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Lever Clamp Bolts 0.80 69 in·lb Clutch Cover Bolts 87 in·lb Oil Filler Plug – – – Hand-tighten Clutch Cover Plate Bolts 87 in·lb Clutch Spring Bolts 97 in·lb Sub Clutch Hub Bolts Clutch Hub Nut 13.3...
  • Page 254: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch Spring Plate Free Play (Usable Range) 0.05 ∼ 0.70 mm (0.002 ∼ 0.028 in.) – – – Clutch Plate Assembly Length (Reference) 53.5 mm (2.11 in.)
  • Page 255: Special Tool And Sealant

    CLUTCH 6-5 Special Tool and Sealant Clutch Holder: Liquid Gasket, TB1211F: 57001-1243 92104-0004...
  • Page 256: Clutch Lever And Cable

    6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Cable Removal •...
  • Page 257: 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 Lower Fairing (see Lower Fairing Removal in the Frame chapter) Clutch Cable Lower End (see Cable Removal) Clutch Cover Bolts [A] •...
  • Page 258: Release Shaft Removal

    6-8 CLUTCH Clutch Cover ○ Tighten the bolt (L = 45 mm, 1.8 in.) [A] together with the clutch cable bracket [B] as shown in the figure. Release Shaft Removal NOTICE Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary.
  • Page 259: Clutch Cover Assembly

    CLUTCH 6-9 Clutch Cover • Remove: Bolts [A] Plate [B] Pads Needle Bearings [C] Clutch Cover Assembly • Replace the needle bearings and oil seal with new ones. NOTE ○ Install the needle bearings so that the manufacture’s mark face out. •...
  • Page 260: Clutch Removal

    6-10 CLUTCH Clutch Clutch Removal • Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs (with Clutch Spring Holders) Clutch Spring Plate [B] Pusher [C] • Remove: Friction Plates (10) [A] Steel Plates (9) [B] Spring [C] Spring Seat [D] •...
  • Page 261: Clutch Installation

    CLUTCH 6-11 Clutch • Remove: Torque Limiter Springs [A] Sub Clutch Hub [B] Clutch Hub [C] Spacer [D] ○ Remove the sub clutch hub bolts [E] as necessary. If the oil pump drive gear is to be disassembled, loosen the oil pump drive gear bolt [A] (Left-hand Threads). •...
  • Page 262 6-12 CLUTCH Clutch • Install the clutch housing [A]. ○ Fit the holes [B] and projections [C]. ○ Engage the clutch housing gear and the crankshaft pri- mary gear. • Install the spacer [A] and the clutch hub [B]. ○ Turn the stepped side [C] of the spacer to outside.
  • Page 263 CLUTCH 6-13 Clutch ○ Third Torque Limiter Spring [A] Tang [B] ○ Fourth Torque Limiter Spring [A] Tang [B] • Replace the clutch hub nut [A] with a new one. • Hold the sub clutch hub [B] steady with the clutch holder [C], and tighten the clutch hub nut.
  • Page 264: Spring Plate Free Play Measurement

    6-14 CLUTCH Clutch • Install the last friction plate (48 lining blocks) [A] fitting the tangs in the grooves in the housing as shown in the figure. • Apply molybdenum disulfide grease to the pusher [A]. • Install the pusher to the drive shaft [B] direction as shown in the figure.
  • Page 265: Spring Plate Free Play Adjustment

    CLUTCH 6-15 Clutch • Engage the clutch hub with the sub clutch hub. • To measure the free play, set a dial gauge [A] against the raised center [B] of the clutch spring plate. • Move the clutch housing gear back and forth [C]. The dif- ference between the highest and lowest gauge readings is the amount of free play.
  • Page 266: Clutch Plate, Wear, Damage Inspection

    6-16 CLUTCH Clutch Clutch Plate Assembly Length (Reference Information) • Assemble the following parts. Clutch Hub [A] Spring Seat [B] Spring [C] Sub Clutch Hub [D] Sub Clutch Hub Bolts [E] New Friction Plates [F] Steel Plates [G] Spring Plate [H] Clutch Springs [I] Clutch Spring Holders [J] Clutch Spring Bolts [K]...
  • Page 267: Clutch Spring Free Length Measurement

    CLUTCH 6-17 Clutch Clutch Spring Free Length Measurement • Measure the free length of the clutch springs [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 43.5 mm (1.71 in.) Service Limit: 42.1 mm (1.66 in.) Clutch Housing Finger Inspection •...
  • Page 269 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 270: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 271 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Cooler Mounting Bolts 106 in·lb L, S Oil Pressure Switch Oil Pressure Switch Terminal Bolt 0.15 13 in·lb Oil Pump Drive Chain Guide Bolt 87 in·lb Oil Pump Drive Gear Bolt 87 in·lb L, Lh Oil Passage Plug (Taper)
  • Page 272: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1. Oil Screen 9. Crankshaft Oil Passage 2. Oil Pump 10. Oil Pressure Switch 3. Oil Pressure Relief Valve 11. Camshaft Oil Passages 4. Oil Filter 12. Drive Shaft Oil Passage 5. Oil Pipe 13.
  • Page 273: Specifications

    ENGINE LUBRICATION SYSTEM 7-5 Specifications Item Standard Engine Oil Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 2.9 L (3.1 US qt) (when filter is not removed) 3.3 L (3.5 US qt) (when filter is removed) 3.7 L (3.9 US qt) (when engine is completely dry) Level Between upper and lower level lines...
  • Page 274: Special Tools And Sealant

    7-6 ENGINE LUBRICATION SYSTEM Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: Outside Circlip Pliers: 57001-164 57001-144 Oil Pressure Gauge Adapter, PT3/8: Liquid Gasket, TB1211: 57001-1233 56019-120...
  • Page 275: Engine Oil And Oil Filter

    ENGINE LUBRICATION SYSTEM 7-7 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 276: Oil Pan

    7-8 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Removal • Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Oil Filter (see Oil Filter Replacement in the Periodic Maintenance chapter) Oil Pan Bolts [A] Clamp [B]...
  • Page 277 ENGINE LUBRICATION SYSTEM 7-9 Oil Pan • Replace the O-rings [A] [B] with new ones, and apply grease to them. • Install the O-rings. ○ Turn the chamfered side [C] downward. • Install the oil screen [D]. ○ Fit the claws [E] to the crankcase rib [F]. •...
  • Page 278: Oil Pressure Relief Valve

    7-10 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Pressure Relief Valve [A] Oil Pressure Relief Valve Installation • Apply a non-permanent locking agent to the threads of the oil pressure relief valve, and tighten it.
  • Page 279: Oil Pump

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pump Oil Pump Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Sidestand Switch Lead Connector [A] (Disconnect) Bolt [B] and Water Pipe [C] Water Pump Cover Bolts [D] Water Pump Cover [E] Water Hose Clamp Screw [F] (Loosen)
  • Page 280: Oil Pump Drive Gear Removal/installation

    7-12 ENGINE LUBRICATION SYSTEM Oil Pump • Replace the O-ring [A] with a new one. • Apply grease to the new O-ring. • Install the oil (water) pump body [B]. • Apply coolant to the surface of the rubber seal [A] on the impeller.
  • Page 281: Oil Pump Drive Gear Installation

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump Oil Pump Drive Gear Installation • Install is the reverse of removal. Note the following. ○ First, engage the oil pump chain [A] to the gears, and then install the oil pump drive gear [B]. ○...
  • Page 282: Oil Cooler

    7-14 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Lower Fairings (see Lower Fairing Removal in the Frame chapter) Water Hose Ends [A] •...
  • Page 283: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-15 Oil Pressure Measurement Oil Pressure Measurement • Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Oil Passage Plug [A] • 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 284: Oil Pressure Switch

    7-16 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal • Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Switch Cover [A] Switch Terminal Bolt [B] Oil Pressure Switch [C] Oil Pressure Switch Installation •...
  • Page 285 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 286: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 287 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Adjusting Collar Locknut Left Front Engine Mounting Bolt Lower Engine Mounting Bolt 87 in·lb Lower Engine Mounting Nut R, S Middle Engine Mounting Bolt 87 in·lb Middle Engine Mounting Nut R, S Right Front Engine Mounting Bolt M: Apply molybdenum disulfide grease.
  • Page 288: Special Tool

    8-4 ENGINE REMOVAL/INSTALLATION Special Tool Engine Mount Nut Wrench: 57001-1450...
  • Page 289: 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 290 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove the engine ground cable terminal bolt [A]. • Disconnect: Water Temperature Sensor Connector [B] Starter Motor Cable [C] (see Starter Motor Removal in the Electrical System chapter) • Free the lead from the clamps [A]. •...
  • Page 291 ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Remove: Left Front Engine Mounting Bolt [A] Middle Engine Mounting Nut [B] Lower Engine Mounting Nut [C] • Remove: Right Front Engine Mounting Bolt [A] • Using the nut wrench [A], loosen the locknut [B]. Special Tool - Engine Mount Nut Wrench: 57001-1450 •...
  • Page 292: Engine Installation

    8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Installation • Apply molybdenum disulfide grease to the threads of the adjusting collars [A]. • Install the adjusting collars to crankcase backside until end of the threads. • Install the adjusting collar [A] to the frame until end of the threads.
  • Page 293 ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation • Install the engine mounting bolts and nuts, following the specified installing sequence. ○ First, install and tighten the following bolts temporarily. Middle Engine Mounting Bolt [A] Lower Engine Mounting Bolt [B] Left Front Engine Mounting Bolt [C] Right Front Engine Mounting Bolt [D] ○...
  • Page 294 8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation ○ Third, insert the middle [A] and lower [B] engine mount- ing bolts to the adjusting collars [C], and tighten the bolts counterclockwise. NOTE ○ Tighten the bolts until the clearance [D] between the frame and collar come to 0 mm (0 in.). Torque - Middle Engine Mounting Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) Lower Engine Mounting Bolt: 9.8 N·m (1.0 kgf·m,...
  • Page 295 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........Balancer Adjustment....9-33 Specifications ........Balancer Damper Inspection..9-33 Special Tools and Sealants ....Torque Limiter........9-34 Crankcase ......... 9-10 Torque Limiter Removal ....9-34 Crankcase Splitting ...... 9-10 Torque Limiter Installation .... 9-34 Crankcase Assembly ....
  • Page 296: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 297 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Balanser Shaft Clamp Bolt 87 in·lb Balanser Shaft Clamp Lever Bolt Bearing Holder Bolts Breather Hole Plug Breather Plate Bolts 87 in·lb Connecting Rod Big End Nuts see the text MO, R Coolant Drain Bolt (Cylinder) 87 in·lb...
  • Page 298 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 299 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Sprocket Nut 14.8 Gear Position Switch Screws 0.30 26 in·lb Gear Positioning Lever Bolt 106 in·lb Shift Drum Cam Holder Bolt Shift Pedal Mounting Bolt Shift Ratchet Assembly Holder Bolts Shift Shaft Return Spring Pin Transmission Case Bearing Holder Bolts 0.50...
  • Page 300: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankcase, 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 (0.0051 ∼ 0.0150 in.) Connecting Rod Big End Side 0.58 mm Clearance...
  • Page 301 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankshaft Main Bearing Insert Thickness: 1.491 ∼ 1.495 mm (0.05870 ∼ 0.05886 in.) Brown – – – 1.495 ∼ 1.499 mm (0.05886 ∼ 0.05902 in.) Black – – – 1.499 ∼ 1.503 mm (0.05902 ∼ 0.05917 in.) Blue –...
  • Page 302 9-8 CRANKSHAFT/TRANSMISSION Specifications Connecting Rod Big End Bearing Insert Selection Connecting Rod Big Bearing Insert Crankpin Diameter End Inside Diameter Marking Size Color Part Number Marking ○ None Brown 92139-0721 None None Black 92139-0720 ○ ○ ○ None Blue 92139-0719 Crankshaft Main Bearing Insert Selection Crankcase Main Crankcase Main...
  • Page 303: Special Tools And Sealants

    CRANKSHAFT/TRANSMISSION 9-9 Special Tools and Sealants Outside Circlip Pliers: Bearing Driver Set: 57001-144 57001-1129 Piston Pin Puller Assembly: Liquid Gasket, TB1216B: 57001-910 92104-1064 Piston Ring Compressor Grip: Liquid Gasket, TB1207B: 57001-1095 92104-2068 Piston Ring Compressor Belt, 67 ∼ 79: 57001-1097...
  • Page 304: Crankcase

    9-10 CRANKSHAFT/TRANSMISSION Crankcase 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: Cylinder Head (see Cylinder Head Removal in the En- gine Top End chapter) Starter Motor (see Starter Motor Removal in the Electri- cal System chapter)
  • Page 305: Crankcase Assembly

    CRANKSHAFT/TRANSMISSION 9-11 Crankcase 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. • With a high-flash point solvent, clean off the mating sur- faces of the crankcase halves and wipe dry.
  • Page 306 9-12 CRANKSHAFT/TRANSMISSION Crankcase • Install the fitting [A] until it is bottomed. Special Tool - Bearing Driver Set: 57001-1129 • Apply a non-permanent locking agent to the threads of the breather plug [B] and tighten it. Torque - Breather Plug: 15 N·m (1.5 kgf·m, 11 ft·lb) View from Upside [C] •...
  • Page 307 CRANKSHAFT/TRANSMISSION 9-13 Crankcase • Install the needle bearing [A] so that its surface is flush with the end of hole [B]. • Replace the output shaft oil seal [C] and the shift shaft oil seal [D] with new ones, and install them. •...
  • Page 308 9-14 CRANKSHAFT/TRANSMISSION Crankcase • Using a cleaning fluid, clean off any oil or dirt on the mat- ing surface of the crankcase halves. • Apply liquid gasket to the mating surface of the lower crankcase half as shown in the figure. Sealant - Liquid Gasket, TB1216B [A]: 92104-1064 Liquid Gasket, TB1207B [B]: 92104-2068 NOTE...
  • Page 309 CRANKSHAFT/TRANSMISSION 9-15 Crankcase • The M8 bolt [A] has a copper plated washer [B], replace them with new ones. • Apply molybdenum disulfide oil to both sides [C] of the washers and threads [D]. • Tighten the lower crankcase bolts with the following pro- cedures.
  • Page 310 9-16 CRANKSHAFT/TRANSMISSION Crankcase • Tighten the upper crankcase bolts with the following pro- cedures. ○ Replace the M8 bolt washers with new ones. ○ Install the M8 bolts [A] and washers. ○ Install the M7 bolt [B]. ○ Tighten: Torque - Upper Crankcase Bolts (M8): 27 N·m (2.8 kgf·m, 20 ft·lb) Upper Crankcase Bolt (M7): 20 N·m (2.0 kgf·m, 15 ft·lb)
  • Page 311: Crankshaft And Connecting Rods

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove: Connecting Rod Big End Nuts [A] Connecting Rod Big End Caps [B] NOTE ○ Mark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions.
  • Page 312: Connecting Rod Removal

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Apply molybdenum disulfide grease to the grooved side [A] of the thrust washers. • Insert the thrust washers into the groove of the #3 main journal [B]. ○ Turn the oil groove side of the thrust washer to the crank- shaft.
  • Page 313 CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods ○ When installing the inserts [A], be careful not to damage the insert surface with the edge of the connecting rod [B] or the cap [C]. One way to install inserts is as follows. Installation [D] to Cap Installation [E] to Connecting Rod Push [F]...
  • Page 314 9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods (1) Bolt Length Measurement Method • Be sure to clean the bolts, nuts, and connecting rods thoroughly with a high-flash point solvent, because the new connecting rods, bolts, and nuts are treated with an anti-rust solution.
  • Page 315: Crankshaft/connecting Rod Cleaning

    CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods (2) Rotation Angle Method If you do not have a point micrometer, you may tighten the nuts using the “Rotation Angle Method”. • Be sure to clean the bolts, nuts and connecting rods thor- oughly with a high-flash point solvent, because the new connecting rods, bolts and nuts are treated with an anti -rust solution.
  • Page 316: Connecting Rod Bend Inspection

    9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Bend Inspection • Remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap. • Select an arbor [A] of the same diameter as the connect- ing rod big end, and insert the arbor through the connect- ing rod big end.
  • Page 317: Connecting Rod Big End Bearing Insert/crankpin Wear Inspection

    CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection • Remove the connecting rod big end (see Connecting Rod Removal). • Cut strips of plastigage to crankpin width. Place a strip on the crankpin parallel to the crankshaft installed in the correct position.
  • Page 318: Crankshaft Side Clearance Inspection

    9-24 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 319: Crankshaft Runout Inspection

    CRANKSHAFT/TRANSMISSION 9-25 Crankshaft and Connecting Rods • Measure the width [A] of the crankshaft #3 main journal [B]. If the measurement exceeds the standard, replace the crankshaft. Crankshaft #3 Main Journal Width 23.49 ∼ 23.54 mm (0.9248 ∼ 0.9268 in.) Standard: Crankshaft Runout Inspection •...
  • Page 320 9-26 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Main Journal Diameter 34.984 ∼ 35.000 mm (1.3773 ∼ 1.3780 in.) Standard: Service Limit: 34.96 mm (1.3764 in.) If any journal has worn past the service limit, replace the crankshaft with a new one. If the measured journal diameters [C] are not less than the service limit, but do not coincide with the original diameter markings [D] on the crankshaft, make new marks on it.
  • Page 321: Pistons

    CRANKSHAFT/TRANSMISSION 9-27 Pistons Piston Removal • Remove: Crankshaft (see Crankshaft Removal) • Remove the piston together with the connecting rod to the cylinder head side. NOTICE Discard the connecting rod bolts and nuts. To pre- vent damage to the crankpin surfaces, do not al- low the connecting rod bolts to bump against the crankpins.
  • Page 322: Piston Installation

    9-28 CRANKSHAFT/TRANSMISSION Pistons Piston Installation • Apply molybdenum disulfide oil to the oil ring expander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] not butt together. • Apply molybdenum disulfide oil to the oil ring steel rails, and install the oil ring steel rails, one above the expander and one below it.
  • Page 323: Cylinder (upper Crankcase) Wear Inspection

    CRANKSHAFT/TRANSMISSION 9-29 Pistons • Apply molybdenum disulfide oil to the cylinder bore and piston skirt. • Install the piston with its marking hollow [A] facing exhaust side. • Using the piston ring compressor assembly [B] to install the piston from the cylinder head side. Special Tools - Piston Ring Compressor Grip: 57001-1095 67 ∼...
  • Page 324: Piston Ring, Piston Ring Groove Wear Inspection

    9-30 CRANKSHAFT/TRANSMISSION 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 325: Piston Ring End Gap Inspection

    CRANKSHAFT/TRANSMISSION 9-31 Pistons Piston Ring End Gap Inspection • Place the piston ring [A] inside the cylinder (upper crankcase), using the piston to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. •...
  • Page 326: Balancer

    9-32 CRANKSHAFT/TRANSMISSION Balancer Balancer Removal • Remove: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) Oil Pan (see Oil Pan Removal in the Engine Lubrication System chapter) • Remove: Balancer Shaft Clamp Lever Bolt [A] Balancer Shaft Clamp Bolt [B] Balancer Shaft Clamp Lever [C] Balancer Shaft [D] Balancer Shaft Oil Seal...
  • Page 327: Balancer Installation

    CRANKSHAFT/TRANSMISSION 9-33 Balancer Balancer Installation • Position the crankshaft at #2, 3 positions TDC or at #1, 4 positions TDC. • Install the balancer assembly as follows. ○ Align the punch mark [A] on the weight and the projection [B] on the crankcase. ○...
  • Page 328: Torque Limiter

    9-34 CRANKSHAFT/TRANSMISSION Torque Limiter Torque Limiter Removal • Remove: Starter Motor (see Starter Motor Removal in the Electri- cal System chapter) Throttle Body Assy Holder [A] Breather Hose [B] • Roll up the heat insulation rubber plate [C]. • Remove: Torque Limiter Cover Bolts [A] Torque Limiter Cover [B] •...
  • Page 329 CRANKSHAFT/TRANSMISSION 9-35 Torque Limiter • Replace the torque limiter cover with a new one. • Using a cleaning fluid, clean off any oil or dirt on the mat- ing surface of the crankcase. And then dry it with a clean cloth.
  • Page 330: Starter Clutch

    9-36 CRANKSHAFT/TRANSMISSION Starter Clutch Starter Clutch Removal • Remove: Torque Limiter (see Torque Limiter Removal) Transmission Assy (see Transmission Assy Removal) Starter Clutch Shaft Holder Bolt [A] Starter Clutch Shaft Bolt [B] Starter Clutch Shaft Holder [C] • Remove the starter clutch shaft [A] using a suitable M8 bolt [B].
  • Page 331: Starter Clutch Assembly

    CRANKSHAFT/TRANSMISSION 9-37 Starter Clutch Starter Clutch Assembly • Install the one-way clutch [A] to the driven gear. ○ Face the circlip side of the one-way clutch to inside. • Install the new snap ring [B] to the one-way clutch. • Install the drive gear [C] while turn it counterclockwise [D].
  • Page 332: Transmission

    9-38 CRANKSHAFT/TRANSMISSION Transmission Transmission Assy Removal • Remove: Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter) Gear Position Switch (see Gear Position Switch Re- moval in the Electrical System chapter) Collar [A] O-ring [B] • Remove: Clutch (see Clutch Removal in the Clutch chapter) Shift Shaft Assembly (see External Shift Mechanism Re- moval) If the transmission assy is to be disassembled, remove...
  • Page 333: Transmission Assy Assembly

    CRANKSHAFT/TRANSMISSION 9-39 Transmission Transmission Assy Assembly • Install the ball bearing [A] until it is bottomed. ○ Turn the oil seal side to the bottom. Special Tool - Bearing Driver Set: 57001-1129 • Install the bearing holder [B]. ○ Turn the flat side to the bottom. •...
  • Page 334: Transmission Assy Installation

    9-40 CRANKSHAFT/TRANSMISSION Transmission • Install the following parts as shown in the figure. Spring [A] Washer [B] Gear Positioning Lever [C] • Tighten: Torque - Gear Positioning Lever Bolt [D]: 12 N·m (1.2 kgf·m, 106 in·lb) • Install the shift ratchet assembly (see External Shift Mech- anism Installation).
  • Page 335: Transmission Shaft Removal

    CRANKSHAFT/TRANSMISSION 9-41 Transmission • Install: Shift Shaft (see External Shift Mechanism Installation) Shift Lever (see Shift Lever Installation) • Set the gear positioning lever to the neutral position. • Check that the drive and output shaft turn freely. • Apply grease to the O-ring [A] and install it to its position on the output shaft [B].
  • Page 336 9-42 CRANKSHAFT/TRANSMISSION Transmission • Replace any circlips removed with new ones. • Install the circlips [A] so that the opening [B] of it is aligned with spline grooves [C]. • Install the circlips so that the mark [D] on them faces to each gear side.
  • Page 337 CRANKSHAFT/TRANSMISSION 9-43 Transmission 1. 1st Gear 11. Toothed Washer 2. 2nd Gear 12. Toothed Bushing, L = 15 mm (0.60 in.) 3. 3rd Gear 13. Toothed Washer 4. 4th Gear 14. Circlip (Turn the punch mark to the washer.) 15. Bushing, 31 mm (1.2 in.) 5.
  • Page 338: Shift Drum And Fork Removal

    9-44 CRANKSHAFT/TRANSMISSION Transmission Shift Drum and Fork Removal • Refer to the Transmission Assy Disassembly. Shift Drum and Fork Installation • Refer to the Transmission Assy Assembly. Shift Drum Disassembly • Remove the shift drum (see Transmission Assy Disas- sembly). •...
  • Page 339: Shift Fork Guide Pin/drum Groove Wear Inspection

    CRANKSHAFT/TRANSMISSION 9-45 Transmission Shift Fork Guide Pin/Drum Groove Wear Inspection • Measure the diameter of each shift fork guide pin [A], and measure the width [B] of each shift drum groove. If the guide pin on any shift fork is less than the service limit, the fork must be replaced.
  • Page 340: External Shift Mechanism

    9-46 CRANKSHAFT/TRANSMISSION External Shift Mechanism Shift Pedal Removal • Remove: Shift Lever Bolt [A] Front Footpeg Bracket Bolts [B] If the tie-rod [C] is to be removed from the shift pedal and the shift lever, loosen the tie-rod locknuts [D]. ○...
  • Page 341: External Shift Mechanism Removal

    CRANKSHAFT/TRANSMISSION 9-47 External Shift Mechanism External Shift Mechanism Removal • Remove: Shift Lever (see Shift Pedal Removal) Oil Pump Drive Gear (see Oil Pump Drive Gear Re- moval/Installation in the Engine Lubrication System chapter) Circlip [A] Washer [B] Special Tool - Outside Circlip Pliers: 57001-144 •...
  • Page 342 9-48 CRANKSHAFT/TRANSMISSION External Shift Mechanism • Assemble: Ratchet [A] Pawls [B] Pins [C] Springs [D] • Install the shift ratchet assembly [A] to the holder [B] as shown in the figure. • Install the shift ratchet assembly to the shift drum cam [C]. ○...
  • Page 343: External Shift Mechanism Inspection

    CRANKSHAFT/TRANSMISSION 9-49 External Shift Mechanism • Replace the circlip [A] with a new one. • Install: Washer [B] Circlip Special Tool - Outside Circlip Pliers: 57001-144 ○ Fit the circlip into the groove of the shift shaft securely. External Shift Mechanism Inspection •...
  • Page 345 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-7 Rear Wheel Removal......................10-8 Rear Wheel Installation..................... 10-8 Wheel Inspection ......................10-10 Axle Inspection........................
  • Page 346: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 347 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolts Front Axle Nut 13.0 Rear Axle Nut 13.0 AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 348: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 1.0 mm (0.04 in.) Axle Runout/100 mm (3.94 in.) TIR 0.03 mm (0.0012 in.) or less TIR 0.2 mm (0.008 in.) Wheel Balance 10 g (0.35 oz.) or less...
  • Page 349: Special Tools

    WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: Bearing Remover Shaft, 13: 57001-1129 57001-1377 Jack: Jack Attachment: 57001-1238 57001-1608 Bearing Remover Head, 25 × 28: 57001-1346...
  • Page 350: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Front Caliper Mounting Bolts [A] (Both Sides) Front Caliper [B] (Both Sides) • Loosen: Front Axle Clamp Bolts [A] (Right Side) Front Axle [B] • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter).
  • Page 351: 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 spoke. • Check the wheel rotation mark on the front wheel and install it. • Apply high-temperature grease to the grease seal lips.
  • Page 352: Rear Wheel Removal

    10-8 WHEELS/TIRES Wheels (Rims) Rear Wheel Removal • Raise the rear wheel off the ground with the stand [A]. • Remove: Cotter Pin [A] Rear Axle Nut [B] Washer [C] Rear Axle [D] (from Right Side) • Remove the rear wheel rotation sensor from the caliper bracket (see Rear Wheel Rotation Sensor Removal in the Brakes chapter).
  • Page 353 WHEELS/TIRES 10-9 Wheels (Rims) • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. ○...
  • Page 354: Wheel Inspection

    10-10 WHEELS/TIRES Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 • Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings (see Hub Bearing Removal/Installation).
  • Page 355: 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 356: Balance Weight Installation

    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 357: Tires

    WHEELS/TIRES 10-13 Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove: Wheels (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...
  • Page 358 10-14 WHEELS/TIRES Tires • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull [B] the valve stem through the rim from the inside out until it snaps into place.
  • Page 359: Tire Repair

    Also, permanent (internal) repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire. For these reasons, Kawasaki does not recommend temporary (exter- nal) repair. Only appropriate permanent (internal) repairs are recommended. Repair methods may vary slightly from make to make.
  • Page 360: Hub Bearing

    10-16 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheels (see Front/Rear Wheel Removal), and take out the following. Collars Coupling (Out of rear hub) Grease Seals • Use the bearing remover to remove the hub bearings [A]. NOTICE Do not lay the wheel on the ground with the disc facing down.
  • Page 361: Hub Bearing Lubrication

    WHEELS/TIRES 10-17 Hub Bearing Hub Bearing Lubrication NOTE ○ Since the hub bearings are packed with grease and sealed, lubrication is not required.
  • Page 363 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View ........................11-2 Specifications ........................11-4 Special Tools .......................... 11-5 Drive Chain..........................11-6 Drive Chain Slack Inspection .................... 11-6 Drive Chain Slack Adjustment ..................11-6 Wheel Alignment Inspection/Adjustment ................11-6 Drive Chain Wear Inspection .................... 11-6 Drive Chain Lubrication.....................
  • Page 364: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 365 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Sprocket Cover Bolts 87 in·lb Engine Sprocket Nut 14.8 Rear Axle Nut 13.0 Rear Sprocket Nuts HG: Apply high-temperature grease. HO: Apply heavy oil. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil solution.
  • Page 366: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain 25 ∼ 35 mm (1.0 ∼ 1.4 in.) Drive Chain Slack – – – Drive Chain Wear (20-link Length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) Standard Chain: Make ENUMA...
  • Page 367: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...
  • Page 368: Drive Chain

    11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection/Adjustment •...
  • Page 369 FINAL DRIVE 11-7 Drive Chain Body [A] Handlebar [B] Cutting and Riveting Pin [C] For Cutting [D] For Riveting [E] Plate Holder (A) [F] Plate Holder (B) [G] Gauge [H] • Grind [A] the pin head to make it flat. •...
  • Page 370 11-8 FINAL DRIVE Drive Chain • Set the plate holder (A) [A] and plate holder (B) [B] on the body. • Fit the plate holder (A) to the link plate. • Turn the pin holder by hand until the plate holder (B) touches the other link plate.
  • Page 371 FINAL DRIVE 11-9 Drive Chain • Turn the wrench clockwise until the tip of riveting pin hits of the link pin. • Rivet it. • Same work for the other link pin. • After staking, check the staked area of the link pin for cracks.
  • Page 372: Sprocket, Coupling

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

    FINAL DRIVE 11-11 Sprocket, Coupling • Install: Pin [A] Chain Guide [B] Engine Sprocket Cover [C] • Tighten: Torque - Engine Sprocket Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Rear Sprocket Removal • Remove the rear wheel (see Rear Wheel Removal in the Wheels/Tires chapter).
  • Page 374: Coupling Bearing Removal

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

    FINAL DRIVE 11-13 Sprocket, Coupling Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances, the clearance can not normally be measured. NOTE ○ It is not necessary to remove the coupling bearing for inspection. If the bearing is removed, it will need to be replaced with a new one.
  • Page 377 BRAKES 12-1 Brakes Table of Contents Exploded View ........12-2 Brake Disc Removal ....12-25 Specifications ........12-10 Brake Disc Installation ....12-25 Special Tools ........12-11 Brake Disc Wear Inspection..12-25 Brake Lever, Brake Pedal....12-12 Brake Disc Warp Inspection..12-26 Brake Lever Position Adjustment.
  • Page 378: Exploded View

    12-2 BRAKES Exploded View...
  • Page 379 BRAKES 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.12 11 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Brake Disc Mounting Bolts Front Brake Light Switch Screw 0.12 11 in·lb Front Brake Pad Pins...
  • Page 380 12-4 BRAKES Exploded View...
  • Page 381 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valve 0.80 69 in·lb Brake Hose Banjo Bolts Brake Pedal Mounting Bolt 0.90 78 in·lb Brake Disc Mounting Bolts Rear Brake Pad Pin Rear Brake Pad Pin Plug 0.25 22 in·lb Rear Caliper Pin Bolt Rear Master Cylinder Mounting Bolts...
  • Page 382 12-6 BRAKES Exploded View KIBS Equipped Models...
  • Page 383 BRAKES 12-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts Brake Pipe Joint Nuts 3. KIBS Hydraulic Unit L: Apply a non-permanent locking agent. R: Replacement Parts NOTE ○ When disassembling the brake hose and pipe, disassemble them by the unit as shown in the exploded view.
  • Page 384 12-8 BRAKES Exploded View KIBS Equipped Models...
  • Page 385 BRAKES 12-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts Brake Pipe Joint Nuts 3. KIBS Hydraulic Unit 4. Rear Wheel Rotation Sensor L: Apply a non-permanent locking agent. R: Replacement Parts NOTE ○ When disassembling the brake hose and pipe, disassemble them by the unit as shown in the exploded view.
  • Page 386: Specifications

    12-10 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 6-way adjustable (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 65 mm (2.6 in.) below top of –...
  • Page 387: Special Tools

    BRAKES 12-11 Special Tools Jack: Jack Attachment: 57001-1238 57001-1608 Hand Tester: 57001-1394...
  • Page 388: Brake Lever, Brake Pedal

    12-12 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 6 positions so that the brake lever position can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever.
  • Page 389: Brake Pedal Installation

    BRAKES 12-13 Brake Lever, Brake Pedal • Remove: Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] • Remove the brake pedal mounting bolt [E] and take out the brake pedal. Brake Pedal Installation •...
  • Page 390 12-14 BRAKES Brake Lever, Brake Pedal • Assemble: Front Footpeg Bracket [A] Rear Master Cylinder [B] Foot Guard [C] Cable Guide [D] Torque - Rear Master Cylinder Mounting Bolts [E]: 25 N·m (2.5 kgf·m, 18 ft·lb) ○ Run the exhaust butterfly valve cables to the cable guide. ○...
  • Page 391: Calipers

    BRAKES 12-15 Calipers Front Caliper Removal • Remove: Bolt [A] Front Wheel Rotation Sensor [B] • Loosen the banjo bolt [C] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [D], and detach the caliper [E] from the disc.
  • Page 392: Caliper Installation

    12-16 BRAKES Calipers • Unscrew the banjo bolt and remove the brake hose from the caliper (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter). NOTICE Immediately wash away any brake fluid that spills. NOTE ○ If the caliper is to be disassembled after removal and if compressed air is not available, disassemble the caliper before the brake hose is removed (see Caliper Rubber Parts Replacement in the Periodic Maintenance chap-...
  • Page 393: Caliper Fluid Seal Damage

    BRAKES 12-17 Calipers Caliper Fluid Seal Damage 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 394: Rear Caliper Holder Shaft Wear

    12-18 BRAKES Calipers Rear Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts [A]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and con- stant drag on the disc will raise brake and brake fluid tem- perature.
  • Page 395: Brake Pads

    BRAKES 12-19 Brake Pads Front Brake Pad Removal • Loosen the pad pins [A]. • Remove the front caliper with the hose installed (see Front Caliper Removal). • Remove: Pad Pins Brake Pads Front Brake Pad Installation • Check that the pad spring [A] is in place on the caliper. •...
  • Page 396: Rear Brake Pad Installation

    12-20 BRAKES Brake Pads Rear Brake Pad Installation • Check that the pad spring is in place on the caliper. • Push the caliper piston in as far as it will go. • Install the piston side pad [A] first, and then another pad. ○...
  • Page 397: Master Cylinder

    BRAKES 12-21 Master Cylinder Front Master Cylinder Removal • Remove the reservoir mounting bolt and nut [A]. • Unscrew the banjo bolt [A] and remove the brake hose from the master cylinder (see Brake Hose and Pipe Re- placement in the Periodic Maintenance chapter). •...
  • Page 398: Rear Master Cylinder Removal

    12-22 BRAKES Master Cylinder • Install the master cylinder clamp [A] so that the arrow mark [B] faces upward. • Set the front master cylinder to match its mating surface [A] to the punch mark [B] of the handlebar. • Tighten the upper clamp bolt first, and then the lower clamp bolt.
  • Page 399: Rear Master Cylinder Installation

    BRAKES 12-23 Master Cylinder • Slide the clamp [A]. • Pull off the reservoir hose lower end [B], and drain the brake fluid into a container. Rear Master Cylinder Installation • Replace the washers that are on each side of hose fitting with new ones.
  • Page 400: Master Cylinder Inspection (visual Inspection)

    12-24 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 401: Brake Disc

    BRAKES 12-25 Brake Disc Brake Disc Removal • Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Unscrew the mounting bolts [A], and take off the disc [B]. Brake Disc Installation • Replace the gaskets with new ones. •...
  • Page 402: Brake Disc Warp Inspection

    12-26 BRAKES Brake Disc Brake Disc Warp Inspection • Raise the wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 ○ For front disc inspection, turn the handlebar fully to one side. • Set up a dial gauge against the disc [A] as shown in the figure and measure disc runout, while turning [B] the wheel by hand.
  • Page 403: Brake Fluid

    BRAKES 12-27 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 404 12-28 BRAKES Brake Fluid • Bleed the brake line and the master cylinder. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].
  • Page 405 BRAKES 12-29 Brake Fluid • Follow the procedure below to install the front/rear brake fluid reservoir cap correctly. ○ First, tighten the brake fluid reservoir cap [B] clockwise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].
  • Page 406 12-30 BRAKES Brake Fluid • Install the stopper and screw. • Tighten: Torque - Front Brake Reservoir Cap Stopper Screw: 1.2 N·m (0.12 kgf·m, 11 in·lb) • Tighten the bleed valve, and install the rubber cap. Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb) •...
  • Page 407: Brake Hose

    BRAKES 12-31 Brake Hose Brake Hose Removal/Installation • Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter. Brake Hose Inspection • Refer to the Brake Hose and Pipe Damage and Instal- lation Condition Inspection in the Periodic Maintenance chapter.
  • Page 408: Kibs (equipped Models)

    Front Wheel Rotation Sensor Rotor [B] Rear Wheel Rotation Sensor [C] Rear Wheel Rotation Sensor Rotor [D] ABS Indicator Light (LED) [E] KIBS Indicator Light (Yellow LED with KIBS Symbol) [F] KIBS Hydraulic Unit [G] Fuse Box 3 [H] KIBS Kawasaki Self-Diagnosis System Connector [I]...
  • Page 409 2. Front Wheel Rotation Sensor 13. Fuse Box 3 3. Front Brake Light Switch 14. Frame Grounds 4. Joint Connector C 15. KIBS Kawasaki Self-diagnosis System Connector 5. Joint Connector D 16. KIBS Hydraulic Unit 6. ECU 17. Ignition Fuse 15 A 7.
  • Page 410 12-34 BRAKES KIBS (Equipped Models) KIBS Hydraulic Unit Terminal Names 1. Ground: BK 2. CAN Communication Line (High): GY/BL 3. Front Wheel Rotation Sensor Signal Input: Y 4. Power Supply: BR/W 5. KIBS Kawaski Self-Daignosis System Terminal: P 6. Front and Rear Brake Light Switch Signal: BL/R 7.
  • Page 411: Kibs Servicing Precautions

    Be sure to check for fluid leak- age, and bleed the brake line thoroughly. ○ Connect the KIBS Kawasaki Self-Diagnosis System con- nector cover to the original position when the cover is dis- connected. KIBS Kawasaki Self-Diagnosis System Connector Color...
  • Page 412 12-36 BRAKES KIBS (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 KIBS hydraulic unit joint nuts, or the bleed valve is opened at any time, the air must be bled completely from the brake line.
  • Page 413: Kibs Troubleshooting Outline

    BRAKES 12-37 KIBS (Equipped Models) KIBS Troubleshooting Outline When an abnormality in the system occurs, the ABS indi- cator light (LED) and KIBS indicator light (LED) light up and the KIBS warning symbol are displayed on the LCD (Liquid Crystal Display) to alert the rider. In addition, the nature of the fault is stored in the memory of the KIBS hydraulic unit and FI ECU, and when in the self-diagnosis mode, the ser- vice code [A] is displayed on the LCD by the “b”...
  • Page 414 12-38 BRAKES KIBS (Equipped Models) • Visually inspect the wiring for signs of burning or fraying. If any wiring is poor, replace the damaged wiring. • Pull each connector apart and inspect it for corrosion, dirt and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it.
  • Page 415 BRAKES 12-39 KIBS (Equipped Models) KIBS Diagnosis Flow Chart...
  • Page 416: Inquiries To Rider

    12-40 BRAKES KIBS (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 417 BRAKES 12-41 KIBS (Equipped Models) Pre-Diagnosis Inspection 1...
  • Page 418: Self-diagnosis Outline

    12-42 BRAKES KIBS (Equipped Models) Pre-Diagnosis Inspection 2 Self-diagnosis Outline Refer to the Self-Diagnosis System chapter for the self-diagnosis or service code.
  • Page 419: Abs And Kibs Indicator Lights (led) Inspection

    BRAKES 12-43 KIBS (Equipped Models) ABS and KIBS Indicator Lights (LED) Inspection ○ In this model, the ABS indicator light (LED) [A] and KIBS indicator light (LED) [B] go on or blink by the data sent from the KIBS hydraulic unit. •...
  • Page 420 12-44 BRAKES KIBS (Equipped Models) • Remove: Bolts [A] Cover [B] ○ Clear the projection [C] from the bracket. • Clean the KIBS hydraulic unit. NOTICE Clean all fittings on the KIBS hydraulic unit and the rear master cylinder because dirt around the banjo bolts could contaminate the brake fluid in the line during removal/installation.
  • Page 421: Kibs Hydraulic Unit Installation

    BRAKES 12-45 KIBS (Equipped Models) • Loosen the brake pipe joint nuts [A]. • Take the KIBS hydraulic unit [B] together with the bracket off the brake pipes. NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately.
  • Page 422: Front Wheel Rotation Sensor Removal

    12-46 BRAKES KIBS (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 423: Rear Wheel Rotation Sensor Removal

    BRAKES 12-47 KIBS (Equipped Models) Rear 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 424: Wheel Rotation Sensor Inspection

    12-48 BRAKES KIBS (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 425: Kibs Solenoid Valve Relay Fuse (20 A) Removal

    BRAKES 12-49 KIBS (Equipped Models) • 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. If there is iron or other magnetic deposits [B], remove the deposits.
  • Page 427 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-9 Rebound Damping Force Adjustment................13-9 Compression Damping Force Adjustment ................ 13-9 Spring Preload Adjustment ....................13-10 Front Fork Removal (Each Fork Leg) ................13-10 Front Fork Installation (Each Fork Leg) ................
  • Page 428: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 429 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Clamp Bolts (Upper) Front Fork Clamp Bolts (Lower) Front Fork Top Plugs Piston Rod Guide Case Front Axle Clamp Bolts AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.
  • Page 430 13-4 SUSPENSION Exploded View...
  • Page 431 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Nut (Lower) Rear Shock Absorber Bracket Nut Swingarm Pivot Adjusting Collar Locknut 10.0 Swingarm Pivot Shaft Swingarm Pivot Shaft Nut 11.0 Tie-Rod Nuts Rocker Arm Nut Rear Shock Absorber Nut (Upper) G: Apply grease.
  • Page 432: Specifications

    13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Diameter 43 mm (1.7 in.) Air Pressure Atmospheric pressure (Non-adjustable) Rebound Damper Setting 3 3/4 turns out from the fully clockwise position (Usable Range: 0 ←→ 5 1/2 turns out) Compression Damper Setting 4 1/2 turns out from the fully clockwise position (Usable Range: 0 ←→...
  • Page 433: Special Tools

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Fork Oil Level Gauge: 57001-143 57001-1290 Oil Seal & Bearing Remover: Bearing Remover Shaft, 13: 57001-1058 57001-1377 Bearing Driver Set: Fork Oil Seal Driver, 43: 57001-1129 57001-1530 Jack: Hook Wrench T=3.2 R37: 57001-1238 57001-1539 Bearing Remover Head, 15 ×...
  • Page 434 13-8 SUSPENSION Special Tools Swingarm Pivot Nut Wrench: Spacer 28: 57001-1597 57001-1663 Jack Attachment: Needle Bearing Driver, 20 & Spacer, 28: 57001-1608 57001-1678 Needle Bearing Driver, 17/ 18: Top Plug Wrench (45 mm): 57001-1609 57001-1741 Needle Bearing Driver, 28: Rod Guide Case Wrench, 35 mm: 57001-1610 57001-1758...
  • Page 435: Front Fork

    SUSPENSION 13-9 Front Fork Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebound damping adjuster [A]. ○ The standard adjuster setting is the 3 3/4 turns out from the fully clockwise position. WARNING If both adjusters are not adjusted equally, handling may be impaired and a hazardous condition may result.
  • Page 436: Spring Preload Adjustment

    13-10 SUSPENSION Front Fork Spring Preload Adjustment • To adjust the spring preload, turn the spring preload ad- juster [A]. ○ The standard adjuster setting is the 6 turns in from the fully counterclockwise position. WARNING If both adjusters are not adjusted equally, handling may be impaired and a hazardous condition may result.
  • Page 437: Front Fork Installation (each Fork Leg)

    SUSPENSION 13-11 Front Fork Front Fork Installation (Each Fork Leg) • Install the fork so that the top plug end [A] as shown in the figure. 11 mm (0.43 in.) [B] Steering Stem Head [C] • Tighten: Torque - Front Fork Clamp Bolts (Lower): 23 N·m (2.3 kgf·m, 17 ft·lb) NOTE ○...
  • Page 438: Front Fork Oil Change

    13-12 SUSPENSION Front Fork Front Fork Oil Change • Remove the front fork (see Front Fork Removal (Each Fork Leg)). • Turn the spring preload adjuster fully counterclockwise for removing the piston rod assy easily. • Hold the inner tube lower end in a vise. •...
  • Page 439 SUSPENSION 13-13 Front Fork • Remove: Piston Rod Assy [A] Collar [B] Fork Spring [C] Fork Spring Guide [D] • Drain the fork oil into a suitable container [A]. ○ Pump the inner tube up and down at least ten times to expel the oil from the fork.
  • Page 440 13-14 SUSPENSION Front Fork • Insert the piston rod assy into the inner tube. NOTE ○ Lifting the outer tube, and insert the piston rod assy. NOTICE When inserting, be careful not to damage the piston ring [A]. • Hold the inner tube bottom by a vise. •...
  • Page 441 SUSPENSION 13-15 Front Fork • Install the piston rod nut [A] until it is bottomed. • Install: Compression Damping Adjuster Rod (Outside) [B] Rebound Damping Adjuster Rod (Inside) [C] • Replace the O-ring [A] with a new one. • Apply grease to the new O-ring. •...
  • Page 442: Front Fork Disassembly

    13-16 SUSPENSION Front Fork • Lift the outer tube. • Using the wrench, tighten the top plug temporary. Special Tool - Top Plug Wrench (45 mm): 57001-1741 • Install the front fork (see Front Fork Installation (Each Fork Leg)). NOTE ○...
  • Page 443: Inner Tube Inspection

    SUSPENSION 13-17 Front Fork • Apply grease to the oil seal lips. • Install the oil seal [A] so that the stamp side faces lower side. • Install the washer [B] so that the chamfer side faces upper side. • Install the guide bushing [C] so that the slit of it is posi- tioned perpendicular to the traveling direction.
  • Page 444: Dust Seal Inspection

    13-18 SUSPENSION Front Fork Dust Seal Inspection • Inspect the dust seals [A] for any signs of deterioration or damage. Replace it if necessary. Spring Tension Inspection • Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced.
  • Page 445: Rear Shock Absorber

    SUSPENSION 13-19 Rear Shock Absorber Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebound damping adjuster [A] to the desired position. ○ The standard adjuster setting is the 1 3/4 turns out from the fully clockwise position. Rebound Damping Force Adjustment Adjuster Damping...
  • Page 446: Spring Preload Adjustment

    13-20 SUSPENSION Rear Shock Absorber • To adjust the low speed compression damping force, turn the inside damping adjuster with a flat-head screwdriver to the desired position. ○ The standard adjuster setting is the 1 3/4 turns out from the fully clockwise position. Low Speed Compression Damping Force Adjustment Adjuster Damping...
  • Page 447: Rear Shock Absorber Removal

    SUSPENSION 13-21 Rear Shock Absorber • 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. Special Tools - Hook Wrench T=3.2 R37: 57001-1539 Hook Wrench R=35: 57001-1580 If the spring action feels too soft or too stiff, adjust it.
  • Page 448: Rear Shock Absorber Installation

    13-22 SUSPENSION Rear Shock Absorber • Remove: Upper Rear Shock Absorber Nut and Bolt [A] • Remove the rear shock absorber upward. Rear Shock Absorber Installation • Replace the rear shock absorber nuts and tie-rod nuts with new ones. • Tighten: Torque - Rear Shock Absorber Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb)
  • Page 449: Swingarm

    SUSPENSION 13-23 Swingarm Swingarm Removal • Remove: Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Mud Guard with Rear Brake Hose (see Mud Guard Re- moval in the Frame chapter) Rocker Arm (see Rocker Arm Removal) • Remove: Brake Hose Clamp Bolt [A] •...
  • Page 450: Swingarm Installation

    13-24 SUSPENSION Swingarm Swingarm Installation • Visually inspect the chain guide [A]. Replace the chain guide if it shows any signs of abnormal wear or damage. ○ Apply a non-permanent locking agent to the threads of the chain guide bolt [B]. •...
  • Page 451: Swingarm Bearing Removal

    SUSPENSION 13-25 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 452: Swingarm Bearing, Sleeve Inspection

    13-26 SUSPENSION Swingarm 32 mm (1.26 in.) [A] 1 mm (0.04 in.) [B] 1.5 mm (0.06 in.) [C] 9.5 mm (0.37 in.) [D] 27.5 mm (1.08 in.) [E] Needle Bearings [F] Grease Seals [G] Ball Bearing [H] Circlip [I] Swingarm Bearing, Sleeve Inspection NOTICE Do not remove the bearings for inspection.
  • Page 453: Swingarm Bearing Lubrication

    SUSPENSION 13-27 Swingarm • Turn the bearing in the swingarm back and forth [A] while checking for plays, roughness, or binding. If bearing play, roughness, or binding is found, replace the bearing. • Examine the bearing seal [B] for tears or leakage. If the seal is torn or is leaking, replace the bearing.
  • Page 454: Tie-rod, Rocker Arm

    13-28 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal • Squeeze the brake lever slowly and hold it with a band [A]. • Remove the front footpeg bracket bolts [A]. • Raise the rear wheel off the ground with the jack (see Rear Shock Absorber Removal).
  • Page 455: Rocker Arm Installation

    SUSPENSION 13-29 Tie-Rod, Rocker Arm Rocker Arm Installation • Replace the tie-rod nut, rear shock absorber nut and rocker arm nut with new ones. • Apply grease to the inside of the oil seals. • Tighten: Torque - Rocker Arm Nut: 34 N·m (3.5 kgf·m, 25 ft·lb) Tie-Rod Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear Shock Absorber Nut (Lower): 34 N·m (3.5 kgf·m, 25 ft·lb)
  • Page 456: Tie-rod And Rocker Arm Bearing Installation

    13-30 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Installation • Replace the needle bearings [A] and oil seals with new ones. • Apply plenty of grease to the lips of the oil seals. • Install the needle bearings and oil seals position as shown in the figure.
  • Page 457: Rocker Arm/tie-rod Bearing, Sleeve Inspection

    SUSPENSION 13-31 Tie-Rod, Rocker Arm Rocker Arm/Tie-Rod Bearing, Sleeve Inspection NOTICE Do not remove the bearings for inspection. Re- moval may damage them. • Visually inspect the rocker arm, or tie-rod sleeves [A] and needle bearings [B]. • The rollers in a needle bearing normally wear very little, and wear is difficult to measure.
  • Page 459 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Specifications ......................... 14-4 Special Tools .......................... 14-5 Steering ..........................14-6 Steering Inspection ......................14-6 Steering Adjustment......................14-6 Steering Damper ........................14-7 Damping Force Adjustment ....................14-7 Steering Damper Removal....................14-7 Steering Damper Installation..................... 14-7 Steering Damper Oil Leak Inspection ................
  • Page 460: Exploded View

    14-2 STEERING Exploded View...
  • Page 461 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Steering Stem Head Nut Steering Stem Nut Left Switch Housing Screws 0.36 31 in·lb Right Switch Housing Screws 0.36 31 in·lb Front Fork Clamp Bolts (Upper) Handlebar Clamp Bolts Handlebar Positioning Bolts 87 in·lb Throttle Case Screws 0.36...
  • Page 462: Specifications

    14-4 STEERING Specifications Item Standard Steering Damper Damper Setting 18th click from the first click of the fully clockwise position (Usable Range: 0 ←→ 18 Clicks)
  • Page 463: Special Tools

    STEERING 14-5 Special Tools Bearing Puller: Steering Stem Bearing Driver, 42.5: 57001-135 57001-1344 Head Pipe Outer Race Press Shaft: Steering Stem Bearing Driver Adapter, 41.5: 57001-1075 57001-1345 Steering Stem Nut Wrench: Head Pipe Outer Race Driver, 55: 57001-1100 57001-1446 Bearing Driver Set: 57001-1129...
  • Page 464: Steering Inspection

    14-6 STEERING 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 465: Steering Damper

    STEERING 14-7 Steering Damper Damping Force Adjustment • To adjust the damping force, turn the damping adjuster [A] until you feel a click. ○ The standard adjuster setting is the 18th click from the 1st of the fully clockwise position. If the damping feels too soft or too stiff, adjust it in accordance with the following table.
  • Page 466: Steering Stem

    14-8 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Upper Fairing Assembly (see Upper Fairing Assembly 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) Steering Stem Head with Handlebars (see Handlebar Removal)
  • Page 467: Stem, Stem Bearing Installation

    STEERING 14-9 Steering Stem • Remove the lower ball bearing [A] from the steering stem. • Remove the lower bearing inner race (with its grease seal) [A] which is pressed onto the steering stem [B] with the bearing puller [C] and adapter [D]. Special Tool - Bearing Puller: 57001-135 Stem, Stem Bearing Installation •...
  • Page 468 14-10 STEERING Steering Stem • Install the steering stem [A] through the head pipe and install the upper bearing [B] and inner race [C] on it. • Install: Stem Cap [D] Steering Stem Nut [E] • Settle the bearings in place as follows. ○...
  • Page 469: Steering Stem Bearing Lubrication

    STEERING 14-11 Steering Stem • Install the stem head. • Install the washer, and temporary tighten the stem head nut. • Install the front forks (see Front Fork Installation in the Suspension chapter). NOTE ○ Tighten the front fork clamp bolts (upper) first, next the stem head nut, last the front fork clamp bolts (lower).
  • Page 470: Handlebar

    14-12 STEERING Handlebar Handlebar Removal • Remove: Steering Damper (see Steering Damper Removal) Clutch Lever Clamp Bolts [A] Clutch Lever Assembly [B] Left Switch Housing [C] Handlebar Weight [D] Left Handlebar Grip [E] • Remove: Front Master Cylinder [A] (see Front Master Cylinder Re- moval in the Brakes chapter) Right Switch Housing [B] Throttle Case [C]...
  • Page 471: Handlebar Installation

    STEERING 14-13 Handlebar Handlebar Installation • Apply a non-permanent locking agent to the threads of the handlebar positioning bolts and tighten them. Torque - Handlebar Positioning Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the steering stem head with handlebars. •...
  • Page 472 14-14 STEERING Handlebar • Install the throttle cable tips. • Install the throttle case. ○ Fit the projection [A] into a hole [B] in the handlebar. • Tighten: Torque - Throttle Case Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb) • Install: Clutch Lever Assembly (see Clutch Lever Installation in the Clutch chapter)
  • Page 473 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Seats ............................15-8 Front Seat Removal ......................15-8 Front Seat Installation ....................... 15-8 Rear Seat Removal......................15-8 Rear Seat Installation......................15-8 Fairings........................... 15-9 Lower Fairing Removal ..................... 15-9 Lower Fairing Installation ....................15-9 Upper Fairing Assembly Removal ..................
  • Page 474: Exploded View

    15-2 FRAME Exploded View...
  • Page 475 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fender Mounting Bolts 0.40 35 in·lb Front Footpeg Bracket Bolts Rear Footpeg Bracket Bolts Rear Frame Front Bolts Rear Frame Rear Bolts Sidestand Bolt Sidestand Bracket Bolts Sidestand Nut R, S Sidestand Switch Bolt 0.90...
  • Page 476 15-4 FRAME Exploded View...
  • Page 477 FRAME 15-5 Exploded View 1. US, CA and CAL Models L: Apply a non-permanent locking agent. R. Replacement Parts...
  • Page 478 15-6 FRAME Exploded View...
  • Page 479 FRAME 15-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Windshield Mounting Bolts 0.12 11 in·lb...
  • Page 480: Seats

    15-8 FRAME Seats Front Seat Removal • Remove: Rear Seat (see Rear Seat Removal) Upper Seat Cover (see Seat Cover Removal) • Remove the front seat bolts [A]. • Remove the front seat backward to clear the seat hooks. Front Seat Installation •...
  • Page 481: Fairings

    FRAME 15-9 Fairings Lower Fairing Removal • Remove the quick rivets [A]. • Remove: Quick Rivets [A] Bolts [B] ○ Pull up the core by the flat-head screwdriver (–), and then remove the quick rivet. • Clear the hook portions on the upper edges [C] from the slots, and remove the left lower fairing [D].
  • Page 482: Upper Fairing Assembly Installation

    15-10 FRAME Fairings • Disconnect: Regulator/Rectifier Connectors [A] Headlight Lead Connector [B] • Remove the fuse box [C]. • Open the clamp [D]. • Disconnect: City Light Lead Connector [A] Headlight Lead Connector [B] • Open the clamps [C]. • For models equipped with an evaporative emission con- trol system, note the following.
  • Page 483: Upper Fairing Assembly Disassembly

    FRAME 15-11 Fairings Upper Fairing Assembly Disassembly • Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal) Headlight (see Headlight Removal/Installation in the Electrical System chapter) City Light (LED) (see City Light (LED) Removal/Installa- tion in the Electrical System chapter) •...
  • Page 484: Center Inner Fairing Installation

    15-12 FRAME Fairings Center Inner Fairing Installation • Installation is the reverse of removal. Note the following. ○ Insert the hook portion [A] of the center inner fairing into the slot [B].
  • Page 485: Seat Covers

    FRAME 15-13 Seat Covers Seat Cover Removal • Remove: Rear Seat (see Rear Seat Removal) • Remove the bolts [A]. • Remove the upper seat cover backward [B] to clear the hook portions. • Remove: Front Seat (see Front Seat Removal) Quick Rivets [A] Bolts [B] Seat Covers [C]...
  • Page 486: Fenders

    15-14 FRAME Fenders Front Fender Removal • Remove: Bolts [A] with Washers (Both Sides) Reflectors (Both Sides, US, CA, CAL and AU Models) Front Fender [B] • Take the brake hose off the clamp [C] (both sides). Front Fender Installation •...
  • Page 487: Flap And Rear Fender Rear Installation

    FRAME 15-15 Fenders • Remove: Bolts [A] and Bracket Flap [B] Lower Pipe [C] • Remove the bolts [A] and the brackets [B]. • Pull out the upper pipes. • Remove the bolt [C], and take off the rear fender rear from the tool kit case [D].
  • Page 488: Rear Fender Front Removal

    15-16 FRAME Fenders ○ Install the bracket [A] on the upper pipes as shown in the figure. Rear Fender Front Removal • Remove: Flap and Rear Fender Rear (see Flap and Rear Fender Rear Removal) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery (see Battery Removal in the Electrical System chapter)
  • Page 489: Frame

    FRAME 15-17 Frame Rear Frame Rear Removal • Remove: Flap and Rear Fender Rear (see Flap and Rear Fender Rear Removal) Rear Frame Rear Bolts [A] Rear Frame Rear [B] Rear Frame Rear Installation • Apply a non-permanent locking agent to the threads of the rear frame rear bolts and tighten them.
  • Page 490: Windshield

    15-18 FRAME Windshield Windshield Removal • Remove: Bolts [A] and Washers Windshield [B] Windshield Installation • Tighten: Torque - Windshield Mounting Bolts: 1.2 N·m (0.12 kgf·m, 11 in·lb)
  • Page 491: Guard

    FRAME 15-19 Guard Mud Guard Removal • Remove: Mud Guard Mounting Bolts [A] Clamp (Right Side) Brake Hose Banjo Bolt of Rear Caliper Side (see Rear Caliper Removal in the Brakes chapter) Mud Guard [B] Mud Guard Installation • Installation is the reverse of removal. Note the following. ○...
  • Page 492: Sidestand

    15-20 FRAME Sidestand Sidestand Removal • Raise the rear wheel off the ground with the stand [A]. • Remove: Sidestand Switch Bolt [A] Sidestand Switch [B] • Remove: Spring [A] Sidestand Nut [B] Sidestand Bolt [C] Sidestand [D] Sidestand Installation •...
  • Page 493: Footpeg

    FRAME 15-21 Footpeg Footpeg Height Adjustment ○ The front footpeg can be adjusted within 2 positions in height to suit the rider’s preference. Footpeg [A] Bolts [B] Bolt Holes [C] Footpeg Position 1 [D] Footpeg Position 2 [E] • Remove the bolts [A]. •...
  • Page 495 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-4 Specifications ......................... 16-10 Special Tools and Sealant ...................... 16-11 Parts Location......................... 16-12 Wiring Diagram (US, CA and CAL without KIBS Models) ............16-15 Wiring Diagram (US, CA and CAL with KIBS Models) ............16-18 Wiring Diagram (Other than US, CA and CAL without KIBS Models) ........
  • Page 496 16-2 ELECTRICAL SYSTEM Brush Lead Inspection ...................... 16-50 Right-hand End Cover Inspection ..................16-50 Starter Relay Inspection....................16-50 Lighting System ........................16-52 Headlight Beam Horizontal Adjustment ................16-52 Headlight Beam Vertical Adjustment................. 16-52 Headlight Bulb Replacement .................... 16-52 Headlight Removal/Installation ..................16-53 City Light (LED) Removal/Installation ................
  • Page 497 ELECTRICAL SYSTEM 16-3 This page intentionally left blank.
  • Page 498: Exploded View

    16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 499 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb License Plate Light Mounting Screws 0.12 11 in·lb Meter Unit Mounting Screws 0.12 11 in·lb Tail/Brake Light Mounting Screws 0.12 11 in·lb Rear Turn Signal Light Lens Screws 0.10 8.9 in·lb 5.
  • Page 500 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 501 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Alternator Cover Bolts 87 in·lb Alternator Lead Holding Plate Bolt 87 in·lb Alternator Rotor Bolt 15.8 Crankshaft Sensor Bolts 0.60 52 in·lb Crankshaft Sensor Cover Bolts 87 in·lb Fuel Pump Bolts 87 in·lb L, S Gear Position Switch Screws...
  • Page 502 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 503 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brush Holder Screw 0.39 34 in·lb Engine Ground Terminal Bolt 87 in·lb Front Brake Light Switch Screw 0.12 11 in·lb Left Switch Housing Screws 0.36 31 in·lb Right Switch Housing Screws 0.36 31 in·lb Sidestand Switch Bolt...
  • Page 504: Specifications

    16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery (Wet) Model Name: ZX1000J Model YTZ7S (F) ZX1000K Model YTZ10S Capacity: ZX1000J Model 12 V 6 Ah ZX1000K Model 12 V 8.6 Ah Voltage 12.8 V or more Charging System Type Three-phase AC Alternator Output Voltage...
  • Page 505: Special Tools And Sealant

    ELECTRICAL SYSTEM 16-11 Special Tools and Sealant Hand Tester: Grip: 57001-1394 57001-1591 Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: Rotor Holder: 57001-1405 57001-1666 Peak Voltage Adapter: Rotor Holder Attachment: 57001-1415 57001-1689 Lead Wire - Peak Voltage Adapter: Key Registration Adapter: 57001-1449 57001-1746 Key Registration Unit:...
  • Page 506: Parts Location

    16-12 ELECTRICAL SYSTEM Parts Location 1. Timing Rotor 2. Crankshaft Sensor 3. Horn 4. Oil Pressure Switch 5. Rear Brake Light Switch 6. Oxygen Sensor (Equipped Models) 7. Alternator 8. Stator Coil 9. Gear Position Switch 10. Sidestand Switch 11. Immobilizer Amplifier (Equipped Models) 12.
  • Page 507 ELECTRICAL SYSTEM 16-13 Parts Location 15. Relay Box 16. Starter Lockout Switch 17. Ignition Switch 18. Immobilizer Antenna (Equipped Models, Included in Ignition Switch) 19. Meter Unit 20. Front Brake Light Switch 21. ECU 22. Air Switching Valve 23. Stick Coils 24.
  • Page 508 16-14 ELECTRICAL SYSTEM Parts Location 34. Fuel Reserve Switch (Included in Fuel Pump)
  • Page 509: Wiring Diagram (us, Ca And Cal Without Kibs Models)

    ELECTRICAL SYSTEM 16-15 Wiring Diagram (US, CA and CAL without KIBS Models) This page intentionally left blank.
  • Page 510 16-16 ELECTRICAL SYSTEM Wiring Diagram (US, CA and CAL without KIBS Models)
  • Page 511 ELECTRICAL SYSTEM 16-17 Wiring Diagram (US, CA and CAL without KIBS Models)
  • Page 512: Wiring Diagram (us, Ca And Cal With Kibs Models)

    16-18 ELECTRICAL SYSTEM Wiring Diagram (US, CA and CAL with KIBS Models)
  • Page 513 ELECTRICAL SYSTEM 16-19 Wiring Diagram (US, CA and CAL with KIBS Models)
  • Page 514: Wiring Diagram (other Than Us, Ca And Cal Without Kibs Models)

    16-20 ELECTRICAL SYSTEM Wiring Diagram (Other than US, CA and CAL without KIBS Models)
  • Page 515 ELECTRICAL SYSTEM 16-21 Wiring Diagram (Other than US, CA and CAL without KIBS Models)
  • Page 516: Wiring Diagram (other Than Us, Ca And Cal With Kibs Models)

    16-22 ELECTRICAL SYSTEM Wiring Diagram (Other than US, CA and CAL with KIBS Models)
  • Page 517 ELECTRICAL SYSTEM 16-23 Wiring Diagram (Other than US, CA and CAL with KIBS Models)
  • Page 518: Precautions

    16-24 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 519: Electrical Wiring

    ELECTRICAL SYSTEM 16-25 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 520: Battery

    16-26 ELECTRICAL SYSTEM Battery Battery Removal • Turn off the ignition switch. • Remove the front seat (see Front Seat Removal in the Frame chapter). • Slide the red cap [A]. • Disconnect the negative (–) cable [B] and then positive (+) cable [C].
  • Page 521: Interchange

    ELECTRICAL SYSTEM 16-27 Battery NOTICE This battery is designed to sustain no unusual deterioration if refresh-charged according to the method specified above. However, the battery’s performance may be reduced no- ticeably if charged under conditions other than given above. Never remove the seal cap during refresh charge.
  • Page 522: Refreshing Charge

    If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on. Terminal Voltage: 12 V or lower Charging Method: 0.6 A × 20 h Kawasaki-recommended chargers: Battery Mate 150-9 OptiMate PRO 4-S/PRO S/PRO 2 Yuasa MB-2040/2060 Christie C10122S •...
  • Page 523 ELECTRICAL SYSTEM 16-29 Battery • After recharging, record [A] the charging date and the name of person in charge of this job to the battery recharg- ing record label [B] if necessary.
  • Page 524: Charging System

    16-30 ELECTRICAL SYSTEM Charging System Alternator Cover Removal • Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Bolt [A] • Bring the heat insulator plate [B] forward. ○...
  • Page 525: Stator Coil Installation

    ELECTRICAL SYSTEM 16-31 Charging System Stator Coil Installation • Apply a non-permanent locking agent to the threads of the stator coil bolts and tighten them. Torque - Stator Coil Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) • Apply silicone sealant to the circumference of the alterna- tor lead grommet [A], and fit the grommet into the notch of the cover securely.
  • Page 526 16-32 ELECTRICAL SYSTEM 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 527: Charging Voltage Inspection

    ELECTRICAL SYSTEM 16-33 Charging System Charging Voltage Inspection • Check the battery condition (see Charging Condition In- spection). • Warm up the engine to obtain actual alternator operating conditions. • Remove the front seat (see Front Seat Removal in the Frame chapter).
  • Page 528 16-34 ELECTRICAL SYSTEM Charging System • To check the alternator output voltage, do the following procedures. ○ Turn the ignition switch to OFF. ○ Remove the left upper inner fairing (see Upper Inner Fair- ing Removal in the Frame chapter). ○...
  • Page 529: 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 530 16-36 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 2. Load 3. Regulator/Rectifier 4. Alternator 5. Frame Ground 6. Starter Relay 7. Main Fuse 30 A 8. Battery...
  • Page 531: Ignition System

    ELECTRICAL SYSTEM 16-37 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 532: Crankshaft Sensor Installation

    16-38 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Installation • Apply a non-permanent locking agent to the crankshaft sensor bolts [A]. • Tighten: Torque - Crankshaft Sensor Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) • Apply silicone sealant to the circumference of the crank- shaft sensor lead grommet [B], and fit the grommet into the notch of the crankcase securely.
  • Page 533: Crankshaft Sensor Peak Voltage Inspection

    ELECTRICAL SYSTEM 16-39 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 534: Stick Coil Installation

    16-40 ELECTRICAL SYSTEM Ignition System Stick Coil Installation • Apply a thin coat of grease [A] to the stick coils for easy installation. • Insert the stick coils so that the coil heads align with the lines [B] on the cylinder head cover. NOTICE Do not tap the coil head while installing the coil.
  • Page 535: Stick Coil Primary Peak Voltage Inspection

    ELECTRICAL SYSTEM 16-41 Ignition System Stick Coil Primary Peak Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove the stick coils (see Stick Coil Removal). ○ Do not remove the spark plugs. • Connect the ECU to the harness. •...
  • Page 536: Spark Plug Condition Inspection

    16-42 ELECTRICAL SYSTEM Ignition System Spark Plug Condition Inspection • Remove the spark plugs (see Spark Plug Replacement in the Periodic Maintenance chapter). • Visually inspect the spark plugs. If the spark plug center electrode [A] and/or side elec- trode [B] are corroded or damaged, or if the insulator [C] is cracked, replace the plug.
  • Page 537: Ic Igniter Inspection

    ELECTRICAL SYSTEM 16-43 Ignition System 3rd Check • Inspect the engine for its secure stop after the following operations are completed. • Run the engine to the following conditions. Condition: Transmission Gear → 1st Position Clutch Lever → Release Sidestand → Up •...
  • Page 538 16-44 ELECTRICAL SYSTEM Ignition System...
  • Page 539 ELECTRICAL SYSTEM 16-45 Ignition System Ignition System Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Stick Coils 4. Spark Plugs 5. Crankshaft Sensor 6. Primary Fuel Injectors 7. Secondary Fuel Injectors 8. Gear Position Switch 9. Sidestand Switch 10. Joint Connector E 11.
  • Page 540: Electric Starter System

    16-46 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Thermostat (see Thermostat Removal in the Cooling System chapter) • Slide out the rubber cap [A]. • Remove: Starter Motor Cable Terminal Nut [B] Starter Motor Mounting Bolts [C]...
  • Page 541: Starter Motor Disassembly

    ELECTRICAL SYSTEM 16-47 Electric Starter System Starter Motor Disassembly • Remove the starter motor (see Starter Motor Removal). • Take off the starter motor through bolts [A] and remove the both end covers [B]. • Pull out the armature [A] out of the yoke [B]. NOTE ○...
  • Page 542 16-48 ELECTRICAL SYSTEM Electric Starter System • Install: Brush Springs [A] Negative Brush Assy [B] ○ Turn the stopper side [C] to inside. • Tighten: Torque - Brush Holder Screw: 3.8 N·m (0.39 kgf·m, 34 in·lb) • Install the brushes onto the brush springs. •...
  • Page 543: Brush Inspection

    ELECTRICAL SYSTEM 16-49 Electric Starter System • Tighten: Torque - Starter Motor Through Bolts [A]: 5.0 N·m (0.51 kgf·m, 44 in·lb) Brush Inspection • Measure the length of each brush [A]. If any is worn down to the service limit, replace the brush assy.
  • Page 544: Brush Lead Inspection

    16-50 ELECTRICAL SYSTEM Electric Starter System Brush Lead Inspection • Using the × 1 Ω hand tester range, measure the resis- tance as shown. Right-hand End Cover and Negative Brushes [A] Terminal Bolt and Positive Brushes [B] Special Tool - Hand Tester: 57001-1394 If there is not close to zero ohms, the brush lead has an open.
  • Page 545 ELECTRICAL SYSTEM 16-51 Electric Starter System Electric Starter Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Gear Position Switch 5. Sidestand Switch 6. Joint Connector E 7. Joint Connector B 8. Battery 9. Main Fuse 30 A 10.
  • Page 546: Lighting System

    16-52 ELECTRICAL SYSTEM Lighting System This motorcycle adopt the daylight system and have a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off.
  • Page 547: Headlight Removal/installation

    ELECTRICAL SYSTEM 16-53 Lighting System • Connect the headlight connector. • Install the cover [A], and turn it clockwise until the mark [B] aligns to the projection [C]. • After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter). ○...
  • Page 548: License Plate Light Bulb Replacement

    16-54 ELECTRICAL SYSTEM Lighting System • Remove: Tail/Brake Light Mounting Screws [A] Bolts [B] and Brackets [C] Bolt [D] • Remove the tail/brake light [A]. ○ Bring down the rear fender rear [B] lightly to clear the hook [C] from the tail/brake light. •...
  • Page 549 ELECTRICAL SYSTEM 16-55 Lighting System Headlight/Tail Light Circuit 1. Ignition Switch 2. Joint Connector A 3. Tail/Brake Light (LED) 4. License Plate Light 12 V 5 W 5. Joint Connector B 6. Battery 7. Main Fuse 30 A 8. Starter Relay 9.
  • Page 550: Rear Turn Signal Light Bulb Replacement

    16-56 ELECTRICAL SYSTEM Lighting System Rear Turn Signal Light Bulb Replacement Other than US, CA and CAL Models • Remove the upper seat cover (see Seat Cover Removal in the Frame chapter). • Disconnect the tail/brake light connector [A]. • Turn the socket [A] counterclockwise and remove the socket together with the bulb.
  • Page 551: Turn Signal Relay Inspection

    ELECTRICAL SYSTEM 16-57 Lighting System US, CA and CAL Models • Remove: Screw [A] Rear Turn Signal Light Lens [B] • Push and turn the turn signal light bulb [A] counterclock- wise and remove it. • Replace the bulb with a new one. •...
  • Page 552 16-58 ELECTRICAL SYSTEM Lighting System • Connect one 12 V battery and turn signal lights as indi- cated in the figure, and count how many times the lights blink for one minute. Turn Signal Relay [A] Turn Signal Lights [B] 12 V Battery [C] If the lights do not blink as specified, replace the turn sig- nal relay.
  • Page 553 ELECTRICAL SYSTEM 16-59 Lighting System Turn Signal Light Circuit 1. Ignition Switch 2. Joint Connector A 3. Rear Right Turn Signal Light 12 V 10 W 4. Rear Left Turn Signal Light 12 V 10 W 5. Joint Connector B 6.
  • Page 554: Air Switching Valve

    16-60 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Operation Test • Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter. Air Switching Valve Unit Test • Remove the air switching valve (see Air Switching Valve Removal in the Engine Top End chapter).
  • Page 555 ELECTRICAL SYSTEM 16-61 Air Switching Valve Air Switching Valve Circuit 1. ECU 2. Air Switching Valve 3. Ignition Switch 4. Joint Connector F 5. Joint Connector A 6. Fuse Box 1 7. Ignition Fuse 15 A 8. Relay Box 9. ECU Main Relay 10.
  • Page 556: Air Intake Solenoid Valve

    16-62 ELECTRICAL SYSTEM Air Intake Solenoid Valve Air Intake Solenoid Valve Operation Test • Start the engine and run it at idle speed. • Check the air intake valve [A] as follows. ○ When the engine is running, the air intake valve is lifting ○...
  • Page 557 ELECTRICAL SYSTEM 16-63 Air Intake Solenoid Valve • Disconnect the 12 V battery. • Blow the air to the inlet air duct [A] again, and make sure flow the blown air from the outlet air duct [B]. If the air intake solenoid valve does not operate as de- scribed, replace it with a new one.
  • Page 558: Radiator Fan System

    16-64 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Inspection • Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). • Disconnect the connector [A]. • Using an auxiliary leads, supply battery power to the fan motor.
  • Page 559: Meter, Gauge, Indicator Unit

    ELECTRICAL SYSTEM 16-65 Meter, Gauge, Indicator Unit Meter Unit Removal/Installation • Remove the upper fairing assembly (see Upper Fairing Assembly Removal in the Frame chapter). • Remove the bolt [A] (other than US, CA and CAL models). • Slide back the dust cover and disconnect the meter unit connector [B].
  • Page 560: Meter Operation Inspection

    16-66 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Operation Inspection Check 1-1: Switching Inspection • Turn the ignition switch to ON and check the following. ○ The all LCD segments [A] appear for 3 seconds. ○ The warning indicator light (Red LED) [B] goes on for 3 seconds and then goes off in a moment after that goes off.
  • Page 561 ELECTRICAL SYSTEM 16-67 Meter, Gauge