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Kawasaki Ninja ZX-6R Service Manual

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Table of Contents
Ninja ZX-6R
Ninja ZX-6R ABS
Motorcycle
Service Manual

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  Also See for Kawasaki Ninja ZX-6R

  Summary of Contents for Kawasaki Ninja ZX-6R

  • Page 1 Ninja ZX-6R Ninja ZX-6R 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 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 ticular interest for more efficient and con- maintenance. • venient operation. Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and • Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 11 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................1-10 Unit Conversion Table ......................1-13...
  • 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 ZX636ED (US and CA Models) Left Side View ZX636ED (US and CA Models) Right Side View...
  • Page 18 1-8 GENERAL INFORMATION Model Identification ZX636ED (EUR Models) Left Side View ZX636ED (EUR Models) Right Side View...
  • Page 19 GENERAL INFORMATION 1-9 Model Identification ZX636FD (EUR Models) Left Side View ZX636FD (EUR Models) Right Side View Frame Number Engine Number...
  • Page 20: General Specifications

    1-10 GENERAL INFORMATION General Specifications Items ZX636ED/FD Dimensions Overall Length 2 085 mm (82.09 in.) Overall Width 705 mm (27.8 in.) Overall Height 1 115 mm (43.90 in.) Wheelbase 1 395 mm (54.92 in.) Road Clearance 130 mm (5.12 in.) Seat Height 830 mm (32.7 in.) Curb Mass:...
  • Page 21 GENERAL INFORMATION 1-11 General Specifications Items ZX636ED/FD Valve Timing: Intake: Open 44° (BTDC) Close 67° (ABDC) Duration 291° Exhaust: Open 58° (BBDC) Close 20° (ATDC) Duration 258° 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 22 1-12 GENERAL INFORMATION General Specifications Items ZX636ED/FD Front Suspension: Type Telescopic fork (upside-down) Wheel Travel 120 mm (4.72 in.) Rear Suspension: Type Swingarm (uni-trak) Wheel Travel 134 mm (5.28 in.) Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 8 Ah Headlight:...
  • Page 23: Unit Conversion Table

    GENERAL INFORMATION 1-13 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 25: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-11 Special Tools .......................... 2-13 Periodic Maintenance Procedures..................2-14 Fuel System (DFI)........................ 2-14 Air Cleaner Element Replacement..................2-14 Idle Speed Inspection ....................... 2-15 Idle Speed Adjustment......................
  • Page 26 2-2 PERIODIC MAINTENANCE Steering ..........................2-53 Steering Play Inspection ....................2-53 Steering Play Adjustment....................2-54 Steering Stem Bearing Lubrication ................... 2-55 Electrical System ......................... 2-56 Lights and Switches Operation Inspection................ 2-56 Headlight Aiming Inspection ..................... 2-58 Sidestand Switch Operation Inspection ................2-59 Engine Stop Switch Operation Inspection.................
  • Page 27: 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 *A: Service at number of years shown or indicated odometer reading intervals, whichever comes first.
  • Page 28 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart Odometer Reading (*B) × 1 000 km (× 1 000 mile) year (*A) Page Items (0.6) (3.8) (7.6) (11.4) (15.2) Wheel bearing damage 2-35 Final Drive Drive chain lubrication condition (*C) 2-36 : every 600 km (400 mile) Drive chain slack (*C) 2-36 : every 1 000 km (600 mile)
  • Page 29: Torque And Locking Agent

    PERIODIC MAINTENANCE 2-5 Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.
  • Page 30: Periodic Maintenance

    2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Top End Air Suction Valve Cover Bolts 87 in·lb Breather Hose Fitting Camshaft Cap Bolts 106 in·lb Camshaft Chain Tensioner Cap Bolt Camshaft Chain Tensioner Mounting Bolts 97 in·lb Camshaft Sprocket Bolts Coolant Drain Bolt (Cylinder)
  • Page 31 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Filter Holder Bolt Oil Jet Nozzles 0.30 26 in·lb Oil Pan Bolts 87 in·lb Oil Passage Plug Oil Passage Plugs (Taper) Oil Pressure Relief Valve Oil Pressure Switch Oil Pressure Switch Terminal Bolt 0.15 13 in·lb...
  • Page 32 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Transmission Case Bolts (M8) Wheels/Tires Front Axle Clamp Bolts Front Axle 13.0 93.7 Rear Axle Nut 13.0 93.7 Final Drive Chain Guide Bolts 106 in·lb Engine Sprocket Cover Bolts (L = 45 mm) 87 in·lb Engine Sprocket Cover Bolts (L = 55 mm) 87 in·lb...
  • Page 33 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Bracket Nut Swingarm Pivot Adjusting Collar Locknut 10.0 Swingarm Pivot Shaft Swingarm Pivot Shaft Nut 11.0 79.7 Tie-Rod Nuts Rocker Arm Bolt Upper Front Fork Clamp Bolts Upper Rear Shock Absorber Nut Steering Handlebar Clamp Bolts...
  • Page 34 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Pressure Switch Oil Pressure Switch Terminal Bolt 0.15 13 in·lb Oxygen Sensor (Equipped Models) Regulator/Rectifier Bracket Screws 0.12 11 in·lb Right Switch Housing Screws 0.36 31 in·lb Sidestand Switch Bolt 0.90 78 in·lb...
  • Page 35: Specifications

    PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 1 300 ±50 r/min (rpm) – – – Throttle Body Vacuum 33.4 ±1.33 kPa (251 ±10 mmHg) at idle speed –...
  • Page 36 2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive 30 ∼ 40 mm (1.2 ∼ 1.6 in.) Drive Chain Slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Drive Chain Wear (20-link 319 mm (12.6 in.) Length) Standard Chain: Make...
  • Page 37: Special Tools

    PERIODIC MAINTENANCE 2-13 Special Tools Inside Circlip Pliers: Vacuum Gauge: 57001-143 57001-1369 Steering Stem Nut Wrench: Throttle Sensor Setting Adapter: 57001-1100 57001-1538 Jack: Extension Tube: 57001-1238 57001-1578 Oil Filter Wrench: Jack Attachment: 57001-1249 57001-1608 Pilot Screw Adjuster, C: 57001-1292...
  • Page 38: Periodic Maintenance Procedures

    Install a new element [A] so that the screen side [B] faces upward. NOTICE Use only the recommended air cleaner element (Kawasaki part number 11013-0036). Using another air cleaner element will wear the engine prema- turely or lower the engine performance. •...
  • Page 39: Idle Speed Inspection

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Idle Speed Inspection • Start the engine and warm it up thoroughly. • With the engine idling, turn the handlebar to both sides [A]. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed, or damaged.
  • Page 40: Engine Vacuum Synchronization Inspection

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures If necessary, adjust the throttle cable as follows. • Loosen the locknuts [A] [B]. • Screw both throttle cable adjusters [C] [D] to give the throttle grip plenty of play. • Turn the decelerator cable adjuster [C] until it has no play when the throttle grip is completely closed.
  • Page 41 PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Plug the air switching valve hose end [A] and air cleaner housing fitting [B]. • Install the air cleaner housing (see Air Cleaner Housing Installation in the Fuel System (DFI) chapter). • Connect the following parts temporarily. Fuel Pump Lead Connector [A] Extension Tube [B] Special Tool - Extension Tube: 57001-1578...
  • Page 42 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures If any vacuum is not within specifications, adjust the by- pass screws [A]. View from Rear [B] Special Tool - Pilot Screw Adjuster, C [C]: 57001-1292 • Adjust the each vacuum (#1 ∼ #4) to the standard value. •...
  • Page 43: Fuel System

    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 44: Fuel Hose Replacement

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check that the fuel hose is routed according to Cable, Wire, and Hose Routing section in the Appendix chapter. Replace the hose if it has been sharply bent or kinked. Hose Joints [A] Fuel Hose [B] •...
  • Page 45 PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • Pull the fuel hose joint [A] out of the delivery pipe [B]. WARNING Fuel is flammable and explosive under certain con- ditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
  • Page 46: Evaporative Emission Control System Inspection (Cal Model)

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Evaporative Emission Control System Inspection (CAL Model) • Inspect the canister as follows. ○ Remove the purge valve from the canister bracket (see Purge Valve Removal/Installation in the Self-Diagnosis System chapter). ○ Disconnect the hoses [A]. ○...
  • Page 47: Cooling System

    PERIODIC MAINTENANCE 2-23 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 48 2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Radiator Cap [A] ○ Remove the radiator cap in two steps. First turn the cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap.
  • Page 49 PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Water and Coolant Mixture Ratio (Recommended) Soft Water: Coolant: Freezing Point: –35°C (–31°F) Total Amount: 2.5 L (2.6 US qt) NOTE ○ Choose a suitable mixture ratio by referring to the coolant manufacturer’s directions. •...
  • Page 50: Water Hose And O-Ring Replacement

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Water Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Oil Cooler [A] (see Oil Cooler Removal in the Engine Lubrication System chapter) Thermostat Housing Cover [B] (see Thermostat Housing Removal in the Cooling System chapter)
  • Page 51: Engine Top End

    PERIODIC MAINTENANCE 2-27 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 the cylinder head cover (see Cylinder Head Cover Removal in the Engine Top End chapter). •...
  • Page 52: Valve Clearance Adjustment

    2-28 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 53 PERIODIC MAINTENANCE 2-29 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 54: Air Suction System Damage Inspection

    2-30 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 55: Clutch

    PERIODIC MAINTENANCE 2-31 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 56: Engine Lubrication System

    2-32 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 57: Oil Filter Replacement

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures • Pour in the specified type and amount of oil. Recommended Engine Oil Type: API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity: SAE 10W-40 Capacity: 2.8 L (3.0 US qt) (when filter is not removed) 3.1 L (3.3 US qt) (when filter is removed) 3.6 L (3.8 US qt) (when engine is completely dry)
  • Page 58: Wheels/Tires

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheels/Tires Air Pressure Inspection • Remove the air valve cap. • Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours).
  • Page 59: Wheel Bearing Damage Inspection

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures WARNING Some replacement tires may adversely affect han- dling and cause an accident resulting in serious in- jury or death. To ensure proper handling and sta- bility, use only the recommended standard tires for replacement, inflated to the standard pressure.
  • Page 60: Final Drive

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Final Drive Drive Chain Lubrication Condition Inspection • If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. •...
  • Page 61: Drive Chain Slack Adjustment

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Drive Chain Slack Adjustment • Remove the cotter pin [A], and loosen the rear axle nut [B]. • Loosen the both chain adjuster locknuts [C]. If the chain is too loose, turn out the left and right chain adjusters [D] evenly.
  • Page 62: Wheel Alignment Inspection

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel Alignment Inspection • Check that the notch [A] on the left alignment indicator [B] aligns with the same swingarm mark or position [C] that the right alignment indicator notch aligns with. If they do not, adjust the chain slack and align the wheel alignment (see Drive Chain Slack Adjustment).
  • Page 63: Chain Guide Wear Inspection

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Chain Guide Wear Inspection • Remove the swingarm (see Swingarm Removal in the Suspension chapter). • Visually inspect the chain guide [A]. Replace the chain guide if it shows any signs of abnormal wear or damage. Brakes Brake System Brake Fluid Leak (Brake Hose and Pipe) Inspection...
  • Page 64: Brake Fluid Level Inspection

    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Damage and Installation Condi- tion Inspection • For KIBS equipped models, remove the air cleaner hous- ing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). • Inspect the brake hoses, pipe and fittings for deteriora- tion, cracks and signs of leakage.
  • Page 65: Brake Fluid Change

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures • Check that the brake fluid level in the rear brake reservoir [A] is above the lower level line [B]. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C]. ○...
  • Page 66 2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the rubber cap [A] from the bleed valve on the caliper. • Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container. •...
  • Page 67: Brake Hose And Pipe Replacement

    PERIODIC MAINTENANCE 2-43 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 68 2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures • For KIBS equipped models; note the following. NOTE ○ When removing the brake pipes and hoses on the hy- draulic unit, remove them according to each assembly of the exploded view in the Brakes chapter. •...
  • Page 69 PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures...
  • Page 70: Master Cylinder Rubber Parts Replacement

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). • Remove the seal cover [A], circlip [B], connector [C] and O-ring [D].
  • Page 71: Caliper Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures Master Cylinder Assembly • Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. NOTICE Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts.
  • Page 72 2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Using compressed air, remove the pistons. ○ Cover the caliper opening with a clean heavy cloth [A]. ○ Lightly apply compressed air [B] to the oil passage. WARNING The piston in the brake caliper can crush hands and fingers.
  • Page 73 PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures Rear Caliper Disassembly • Remove: Rear Caliper (see Rear Caliper Removal in the Brakes chapter) Brake Pads (see Rear Brake Pad Removal in the Brakes chapter) Rear Caliper Pin Bolt [A] Caliper Bracket [B] •...
  • Page 74 2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the fluid seal [A] with a new one. ○ Apply silicone grease to the fluid seal, and install it into the cylinder by hand. • Replace the dust seal [B] with a new one. ○...
  • Page 75: Brake Pad Wear Inspection

    PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures Brake Pad Wear Inspection • Remove the brake pads (see Front/Rear Brake Pad Re- moval in the Brakes chapter). • Check the lining thickness [A] of the pads in each caliper. If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set.
  • Page 76: Suspension

    2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures If it does not go on, inspect or replace the following parts. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Brake Light (LED) (see Tail/Brake Light (LED) Removal Installation in the Electrical System chapter) Main Fuse 30 A and Brake Light/Horn Fuse 7.5 A (see Fuse Inspection in the Electrical System chapter) Front Brake Light Switch [A] (see Switch Inspection in...
  • Page 77: Steering

    PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures 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. Rocker Arm Operation Inspection •...
  • Page 78: Steering Play Adjustment

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Play Adjustment • Remove: Steering Stem Head with Handlebars (see Handlebar Removal in the Steering chapter). Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) • Bend the claws [A] of the claw washer straighten. •...
  • Page 79: Steering Stem Bearing Lubrication

    PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures Steering Stem Bearing Lubrication • Remove the steering stem (see Stem, Stem Bearing Re- moval in the Steering chapter). • Using a high flash-point solvent, wash the upper and lower ball bearings [A] in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt.
  • Page 80: Electrical System

    2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step • Set the gear position in the neutral position. • Turn the ignition switch on. • The following lights should go on according to below table. City Lights [A] Go on Taillight (LED) [B]...
  • Page 81 PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures • Turn the ignition switch off. • The all lights should go off. ○ For models equipped with an immobilizer system, red warning indicator light (LED) will blinks. Refer to the Im- mobilizer System (Equipped Models) section in the Elec- trical System chapter).
  • Page 82: Headlight Aiming Inspection

    2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Set the dimmer switch to high beam position. • The low beam [A] and high beam [B] headlights should go on. • The blue high beam indicator light (LED) [C] should go on. If the high beam headlight and/or blue high beam indicator light (LED) does not go on, inspect or replace the following parts.
  • Page 83: Sidestand Switch Operation Inspection

    PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures Sidestand Switch Operation Inspection • Raise the rear wheel off the ground with the stand (see Rear Wheel Removal in the Wheels/Tires chapter). • Inspect the sidestand switch [A] operation accordance to below table. Sidestand Switch Operation Gear Clutch...
  • Page 84: Engine Stop Switch Operation Inspection

    2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the sidestand switch operation does not work, inspect or replace the following parts. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Ignition Fuse 15 A (see Fuse Inspection in the Electrical System chapter)
  • Page 85: Spark Plug Replacement

    PERIODIC MAINTENANCE 2-61 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 plugs with new ones. Standard Spark Plug Type: NGK CR9E...
  • Page 86: Condition Of Bolts, Nuts And Fasteners Tightness Inspection

    2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cables: Lubricate with Rust Inhibitor. Clutch Cable Throttle Cables • Lubricate the cables by seeping the oil between the cable and housing. ○ The cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant.
  • Page 87 PERIODIC MAINTENANCE 2-63 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 89 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........Fuel Injector Power Source DFI System........Voltage Inspection..... 3-56 DFI Parts Location......3-18 Fuel Injector Output Voltage Specifications ........3-22 Inspection........3-57 Special Tools and Sealant ....3-23 Fuel Injector Fuel Line Inspection 3-58 DFI Servicing Precautions ....
  • Page 90: Exploded View

    3-2 FUEL SYSTEM (DFI) Exploded View...
  • Page 91: Exploded View

    FUEL SYSTEM (DFI) 3-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Cleaner Housing Assembly Screws 0.12 11 in·lb Air Intake Duct Assembly Screws 0.15 13 in·lb Air Intake Duct Mounting Bolts 87 in·lb Air Cleaner Housing Clamp Bolts 0.20 18 in·lb 5.
  • Page 92 3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 93 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Intake Air Temperature Sensor Screw 0.12 11 in·lb Throttle Case Screws 0.36 31 in·lb Throttle Cable Holder Plate Bolt 0.40 35 in·lb Throttle Body Assy Holder Bolts 106 in·lb Throttle Body Assy Holder Clamp Bolts 0.30 26 in·lb...
  • Page 94 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 95 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Crankshaft Sensor Bolts 0.60 52 in·lb Water Temperature Sensor 106 in·lb Exhaust Butterfly Valve Actuator Mounting Screws 0.44 38 in·lb Exhaust Butterfly Valve Actuator Pulley Bolt 0.50 43 in·lb Fuel Pump Bolts 87 in·lb L, S...
  • Page 96: Dfi System

    3-8 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 97 FUEL SYSTEM (DFI) 3-9 DFI System 1. ECU 2. Battery 12 V 8 Ah 3. Intake Air Temperature Sensor 4. Subthrottle Valve Actuator 5. Subthrottle Sensor 6. Fuel Injectors 7. Delivery Pipe Assy 8. Vehicle-down Sensor 9. Fuel Filter 10. Pressure Regulator 11.
  • Page 98 3-10 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 99 Part Names 1. ECU 2. Joint Connector C 3. Rear Wheel Rotation Sensor 4. Exhaust Butterfly Valve Actuator 5. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector 6. Frame Ground 2 7. Frame Ground 3 8. Frame Ground 1 9. Engine Ground 10.
  • Page 100 3-12 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram (KIBS Equipped Models)
  • Page 101 Part Names 1. ECU 2. Joint Connector C 3. Rear Wheel Rotation Sensor 4. Exhaust Butterfly Valve Actuator 5. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector 6. Frame Ground 2 7. Frame Ground 3 8. Frame Ground 1 9. Engine Ground 10.
  • Page 102 3-14 FUEL SYSTEM (DFI) DFI System ○ Color Codes: BK: Black GY: Gray PU: Purple BL: Blue LB: Light Blue R: Red BR: Brown V: Violet LG: Light Green CH: Chocolate O: Orange W: White DG: Dark Green P: Pink Y: Yellow G: Green...
  • Page 103 FUEL SYSTEM (DFI) 3-15 DFI System This page intentionally left blank.
  • Page 104 3-16 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Subthrottle Valve Actuator: P/BL 2. Exhaust Butterfly Valve Actuator (+): W/BL 3. Exhaust Butterfly Valve Actuator Sensor: GY 4. Power Supply to Sensors: BL 5. Fuel Pump Relay: BR/Y 6.
  • Page 105 59. Crankshaft Sensor (–): Y/BK 60. Crankshaft Sensor (+): Y 61. Purge Valve (CAL Model): R/Y 62. Air Switching Valve: R/BL 63. Unused 64. Unused 65. Ground for Ignition System: BK/Y 66. Stick Coil #3: BK/O *: KDS (Kawasaki Diagnostic System)
  • Page 106: Dfi Parts Location

    3-18 FUEL SYSTEM (DFI) DFI Parts Location Main Throttle Sensor [A] Subthrottle Sensor [B] Subthrottle Valve Actuator [C] Intake Air Pressure Sensor #2 [D] Stick Coils #1, #2, #3, #4 [E] Air Switching Valve [F] Intake Air Pressure Sensor #1 [G] Water Temperature Sensor [A] Fuel Injectors #1, #2, #3, #4 [B] Battery 12 V 8 Ah [A]...
  • Page 107 FUEL SYSTEM (DFI) 3-19 DFI Parts Location Vehicle-down Sensor [A] Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector [B] Fuel Pump [A] Intake Air Temperature Sensor [A] Crankshaft Sensor [A] Gear Position Switch [A]...
  • Page 108 3-20 FUEL SYSTEM (DFI) DFI Parts Location Fuse Box 1 [A] Ignition Key [A] (Transponder, Immobilizer System Equipped Models) Immobilizer Antenna [B] (Equipped Models) Ignition Switch [C] Yellow Engine Warning Indicator Light (LED) [D] Immobilizer Amplifier [A] (Equipped Models) Oxygen Sensor [A] (Equipped Models) Front Wheel Rotation Sensor [A]...
  • Page 109 FUEL SYSTEM (DFI) 3-21 DFI Parts Location Rear Wheel Rotation Sensor [A] Purge Valve [A] (CAL Model)
  • Page 110: Specifications

    3-22 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 300 ±50 r/min (rpm) Throttle Body Assy: Throttle Valve Dual throttle valve Bore 38 mm (1.5 in.) Throttle Body Vacuum 33.4 ±1.33 kPa (251 ±10 mmHg) 0 ∼...
  • Page 111: Special Tools And Sealant

    FUEL SYSTEM (DFI) 3-23 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 112: Dfi Servicing Precautions

    3-24 FUEL SYSTEM (DFI) DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 113 FUEL SYSTEM (DFI) 3-25 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 [A].
  • Page 114: Troubleshooting The Dfi System

    3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System Outline When a problem occurs with DFI system, the yellow en- gine warning indicator light (LED) [A] goes on to alert the rider. For models equipped with an immobilizer system, the red warning indicator light (LED) [A] and immobilizer warning symbol [B] blink, when a problem occurs in the system.
  • Page 115 (LED) goes off. But the service codes stored in memory of the ECU are not erased to preserve the problem history. The problem history can be referred using the KDS (Kawasaki Diagnostic System) when solv- ing unstable problems. When the motorcycle is down, the vehicle-down sensor operates and the ECU shuts off the fuel pump relay, fuel injectors and ignition system.
  • Page 116 3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System • When checking the DFI parts, use a digital meter which can be read two decimal place voltage or resistance. ○ The DFI part connectors [A] have seals [B], including the ECU. When measuring the input or output voltage with the connector joined, use the needle adapter set [C].
  • Page 117 FUEL SYSTEM (DFI) 3-29 Troubleshooting the DFI System • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. •...
  • Page 118: Inquiries To Rider

    3-30 FUEL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.
  • Page 119 FUEL SYSTEM (DFI) 3-31 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. □ □ □ □ □ □...
  • Page 120 3-32 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ □ □ Poor running very low idle speed, very high idle speed, rough idle speed. at low speed □ battery voltage is low (charge the battery). □ spark plug loose (tighten it). □...
  • Page 121: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system.
  • Page 122 3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Intake air pressure sensor #1 trouble Inspect (see chapter 17).
  • Page 123 FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Subthrottle sensor trouble Inspect