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Ninja ZX-6R
Ninja ZX-6R ABS
Motorcycle
Service Manual

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Table of Contents

   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 (see chapter 17). Subthrottle valve actuator trouble Inspect (see chapter 17). Intake air pressure sensor #1 trouble Inspect (see chapter 17). Intake air pressure sensor #2 trouble Inspect (see chapter 17).
  • Page 124: Poor Running Or No Power At High Speed

    3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Other: Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight, and examine leads for signs of burning or fraying (see chapter 3). Poor Running or No Power at High Speed Symptoms or Possible Causes Actions...
  • Page 125 FUEL SYSTEM (DFI) 3-37 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Miscellaneous: Subthrottle sensor trouble Inspect (see chapter 17). Subthrottle valve actuator trouble Inspect (see chapter 17). Throttle valves will not fully open Inspect throttle cables and lever linkage (see chapter 3).
  • Page 126: Warning Indicator Light (led)

    3-38 FUEL SYSTEM (DFI) Warning Indicator Light (LED) Yellow Engine Warning/Red Warning Indicator Light (LED) Inspection Yellow Engine Warning Indicator Light (LED) [A] Red Warning Indicator Light (LED) [B] ○ In this model, the above mentioned warning indicator lights (LED) go on or blink by the data sent from the ECU. •...
  • Page 127: Ecu

    FUEL SYSTEM (DFI) 3-39 ECU Identification ○ Most countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU with each other and use only the ECU for your model. Other- wise, the motorcycle cannot clear the regulation. ECU Identification Part Number [A] Specification...
  • Page 128: Ecu Installation

    ○ Install: Lower Guard [A] Upper Guard [B] ○ Tighten the new screws [C] using the Kawasaki genuine screws of which threads are coated with locking agent. • Connect the ECU connectors [A]. • Hold the main harness to the clamp [B].
  • Page 129: Ecu Power Supply Inspection

    FUEL SYSTEM (DFI) 3-41 ECU Power Supply Inspection • Remove the front seat cover (see Seat Cover Removal in the Frame chapter). • Visually inspect the ECU connectors. If the connector is clogged with mud or dust, blow it off with compressed air.
  • Page 130 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 (black) [B] with the needle adapter set.
  • Page 131 FUEL SYSTEM (DFI) 3-43 ECU Power Source Circuit 1. ECU 2. Joint Connector C 3. Frame Ground 2 4. Frame Ground 3 5. Frame Ground 1 6. Engine Ground 7. Battery 12 V 8 Ah 8. Starter Relay 9. Main Fuse 30 A 10.
  • Page 132: 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 133 FUEL SYSTEM (DFI) 3-45 CAN Communication Line CAN Communication Line Circuit 1. ECU 2. KIBS Hydraulic Unit (Equipped Models) 3. Meter Unit...
  • Page 134: 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 135: Fuel Line

    FUEL SYSTEM (DFI) 3-47 Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Fuel Tank Bolts [A] Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) ○ Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of the throttle body assy.
  • Page 136: Fuel Flow Rate Inspection

    3-48 FUEL SYSTEM (DFI) Fuel Line NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. • Turn the ignition switch off. If the fuel pressure is much higher than specified, replace the fuel pump because the fuel pressure regulator in the fuel pump have been clogged or stuck.
  • Page 137 FUEL SYSTEM (DFI) 3-49 Fuel Line • Open the fuel tank cap [A] to lower the pressure in the tank. • Remove the 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 138: Fuel Pump

    3-50 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions, creating the potential for serious burns. Make sure the area is well venti- lated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 139: 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 140: Fuel Pump Operating Voltage Inspection

    3-52 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Operating Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Remove the front seat (see Front Seat Removal in the Frame chapter). • Disconnect the fuel pump lead connector and connect the measuring adapter [A] between these connectors as shown.
  • Page 141: Pressure Regulator Removal

    FUEL SYSTEM (DFI) 3-53 Fuel Pump Pressure Regulator Removal ○ The pressure regulator [A] is built into the fuel pump and can not be removed. Fuel Filter Cleaning ○ The fuel filter [A] is built into the fuel pump and can not be cleaned or checked.
  • Page 142 3-54 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Circuit 1. ECU 2. Joint Connector C 3. Frame Ground 2 4. Engine Ground 5. Battery 12 V 8 Ah 6. Stater Relay 7. Main Fuse 30 A 8. ECU Fuse 15 A 9.
  • Page 143: Fuel Injectors

    FUEL SYSTEM (DFI) 3-55 Fuel Injectors Fuel Injector Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Fuel Injector Audible Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) •...
  • Page 144: 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 off. • Remove the air cleaner drain hose and breather hose (see Air Cleaner Housing Removal). •...
  • Page 145: Fuel Injector Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-57 Fuel Injectors Fuel Injector Output Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Remove the ECU (see ECU Removal). ○ Do not disconnect the ECU connector. •...
  • Page 146: Fuel Injector Fuel Line Inspection

    3-58 FUEL SYSTEM (DFI) 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 ECU Connector (Gray) Fuel Injector Connector...
  • Page 147 FUEL SYSTEM (DFI) 3-59 Fuel Injectors ○ Watch the gauge for at least 6 seconds. If the pressure holds steady, the fuel line is good. If the pressure drops at once or if bubbles are found in the area, the fuel line is leaking. Replace the delivery pipe assy, injectors and related parts.
  • Page 148 3-60 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Circuit 1. ECU 2. Joint Connector C 3. Frame Ground 2 4. Engine Ground 5. Battery 12 V 8 Ah 6. Starter Relay 7. Main Fuse 30 A 8. ECU Fuse 15 A 9.
  • Page 149: Throttle Grip And Cables

    FUEL SYSTEM (DFI) 3-61 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 150: Throttle Body Assy

    3-62 FUEL SYSTEM (DFI) 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 explo- sive under certain conditions, creating the potential...
  • Page 151: Throttle Body Assy Installation

    FUEL SYSTEM (DFI) 3-63 Throttle Body Assy • Disconnect the adjusting screw [A] from the clamp. • Remove the throttle body assy from the throttle body assy holders. • Remove: Bolt [A] Holder Plate [B] Throttle Cable Lower Ends • After removing the throttle body assy, stuff pieces of lint -free, clean cloth into the throttle body assy holders.
  • Page 152: Throttle Body Assy Disassembly

    3-64 FUEL SYSTEM (DFI) Throttle Body Assy Throttle Body Assy Disassembly 1. Throttle Body Assy 2. Subthrottle Valve Actuator 3. Main Throttle Sensor 4. Subthrottle Sensor 5. Fuel Injectors 6. Delivery Pipe Assy 7. Intake Air Pressure Sensor #1 8. Intake Air Pressure Sensor #2 NOTICE Do not remove, disassemble or adjust the main throttle sensor, subthrottle sensor, subthrottle...
  • Page 153: Throttle Body Assy Assembly

    FUEL SYSTEM (DFI) 3-65 Throttle Body Assy • Remove the fuel injectors [A] from the delivery pipe assy [B]. NOTE ○ Do not damage the insertion portions of the injectors when they are pulled out from the delivery pipe assy. NOTICE Never drop the fuel injector especially on a hard surface.
  • Page 154: Air Cleaner

    3-66 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 155: Air Cleaner Housing Installation

    FUEL SYSTEM (DFI) 3-67 Air Cleaner • Loosen the air cleaner housing clamp bolt [A] on both sides. • Disconnect the air switching valve hose [A] from the air cleaner housing [B]. Air Cleaner Housing Installation • Install the clamp bolt heads [A] outside as shown. •...
  • Page 156: Air Cleaner Housing Disassembly

    3-68 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/Installation in the Self-Diagnosis System chapter) Clamps [A] Ducts [B] Air Cleaner Element [C] (see Air Cleaner Element Re- placement in the Periodic Maintenance chapter) Air Cleaner Housing Assembly...
  • Page 157 FUEL SYSTEM (DFI) 3-69 Air Cleaner • Install: Air Cleaner Frame Gasket [A] Pads [B] Air Cleaner Element Gasket [C] Air Cleaner Element [D] Air Cleaner Case Gasket [E] Upper Air Cleaner Housing [F] Air Cleaner Housing Assembly Screws [G] •...
  • Page 158: Air Line

    3-70 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) • Free the leads [A]. •...
  • Page 159: Air Intake Duct Assembly

    FUEL SYSTEM (DFI) 3-71 Air Line Air Intake Duct Assembly • Assembly is the reverse of disassembly. • Fit the projections [A] of the holder [B] to the hole of the air intake ducts. • Tighten: Torque - Air Intake Duct Assembly Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb) •...
  • Page 160: Fuel Tank

    3-72 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions, creating the potential for serious burns. Make sure the area is well venti- lated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 161 FUEL SYSTEM (DFI) 3-73 Fuel Tank • Remove: Fuel Tank Bolts [A] • Slide the dust cover [A]. • Open the clamp [B]. • Disconnect: Battery (–) Terminal [C] Fuel Pump Lead Connector [D] Fuel Tank Drain Hose [E] Fuel Tank Breather Hose [F] •...
  • Page 162: Fuel Tank Installation

    3-74 FUEL SYSTEM (DFI) Fuel Tank • Pull the fuel hose joint [A] out of the outlet pipe. 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 163 FUEL SYSTEM (DFI) 3-75 Fuel Tank • When installing the pad [A] and hooks [B], install them as shown. 16 mm (0.63 in.) [C] View A [D] View B [E] • Remove the vinyl bag on the pipe and fuel hose joint. •...
  • Page 164: Fuel Tank And Cap Inspection

    3-76 FUEL SYSTEM (DFI) Fuel Tank • 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. WARNING Leaking fuel can cause a fire or explosion resulting in serious burns.
  • Page 165: Evaporative Emission Control System (cal Model)

    FUEL SYSTEM (DFI) 3-77 Evaporative Emission Control System (CAL Model) The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.
  • Page 167 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Special Tools and Sealant ...................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal ..................
  • Page 168: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 169 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Heat Insulation Plate Bolt 0.40 35 in·lb Radiator Upper Bolts 87 in·lb Coolant By-pass Fitting Bolt 0.90 78 in·lb Water Hose Clamp Screws 0.31 27 in·lb Oil Cooler Mounting Bolts Water Temperature Sensor 106 in·lb Thermostat Housing Cover Bolts...
  • Page 170: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart 1. Radiator 2. Radiator Fan 3. Radiator Cap 4. Radiator Overflow Hose 5. Reserve Tank Overflow Hose 6. Reserve Tank 7. Air Bleeder Hose 8. Oil Cooler Intake Hose 9. Oil Cooler 10. Water Pump 11.
  • Page 171 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 172: 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 173: Special Tools And Sealant

    COOLING SYSTEM 4-7 Special Tools and Sealant Bearing Driver Set: Liquid Gasket, TB1211F: 57001-1129 92104-0004 Oil Seal Driver 37.5: 57001-1660...
  • Page 174: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the upper fairing assembly (see Upper Fairing Assembly Removal 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 175: 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 176: 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 177: Water Pump Housing Assembly

    COOLING SYSTEM 4-11 Water Pump • Take the oil seal [A] out of the housing [B] with a hook [C]. Water Pump Housing Assembly NOTICE Do not reuse the mechanical seal and oil seal. • Apply high-temperature grease to the oil seal lips [A]. •...
  • Page 178: Radiator

    4-12 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Coolant Reserve Tank (see Coolant Reserve Tank Re- moval) •...
  • Page 179: 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. • Tighten the radiator fan mounting bolts. • When installing the pads [B], install it so that the corners [C] align.
  • Page 180: 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 181: Heat Insulation Plate Removal

    COOLING SYSTEM 4-15 Radiator Heat Insulation Plate Removal • Remove: Radiator (see Radiator and Radiator Fan Removal) • Open the clamps [A]. • Open the clamp [A]. • Free the lead from the clamp [B]. • Free the right switch housing lead and front wheel rotation sensor lead from the clamp on the right side of the heat insulation plate.
  • Page 182: Thermostat

    4-16 COOLING SYSTEM Thermostat Thermostat Removal • Remove the oil cooler (see Oil Cooler Removal in the En- gine Lubrication System chapter) • Loosen the water hose clamp screw [A]. • Disconnect the water hose [B]. • Remove: Thermostat Housing Cover Bolts [C] Thermostat Housing Cover [D] Thermostat Thermostat Installation...
  • Page 183 COOLING SYSTEM 4-17 Thermostat • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water. ○ The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [B] in the water so that the heat sen- sitive portions [C] are located in almost the same depth.
  • Page 184: Hoses And Pipes

    4-18 COOLING SYSTEM Hoses and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). •...
  • Page 185: Water Temperature Sensor

    COOLING SYSTEM 4-19 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 187 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Cylinder Compression Exhaust System Identification ... Measurement ......5-25 Specifications ........Cylinder Head Removal ....5-26 Special Tools and Sealant ....Cylinder Head Installation .... 5-26 Clean Air System....... 5-11 Cylinder Head Warp Inspection ...
  • Page 188: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 189 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 Cylinder Head Cover Bolts 87 in·lb 3 Spark Plugs 115 in·lb 4 Breather Hose Fitting 5 Camshaft Sprocket Bolts 6 Camshaft Cap Bolts 106 in·lb 7 Upper Camshaft Chain Guide Bolts...
  • Page 190 5-4 ENGINE TOP END Exploded View...
  • Page 191 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Exhaust Butterfly Valve Actuator Pulley Bolt 0.50 43 in·lb Exhaust Butterfly Valve Actuator Mounting 0.44 38 in·lb Screws Muffler Body Mounting Bolt Muffler Body End Cover Bolts 0.71 62 in·lb Premuffler Chamber Mounting Bolt Premuffler Chamber Bracket Bolt...
  • Page 192: Exhaust System Identification

    5-6 ENGINE TOP END Exhaust System Identification Exhaust Pipe Mark Position [A] Premuffler Chamber Mark Position [A]...
  • Page 193 ENGINE TOP END 5-7 Exhaust System Identification Muffler Body Mark Position [A] Exhaust Pipe [A] with Hole [B] for Oxygen Sensor [C] Honeycomb Type Catalyst Position [A]...
  • Page 194: Specifications

    5-8 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: 33.343 ∼ 33.457 mm (1.3127 ∼ 1.3172 in.) Exhaust 33.24 mm (1.309 in.) 34.743 ∼ 34.857 mm (1.3678 ∼ 1.3723 in.) Intake 34.64 mm (1.364 in.) 0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.) Camshaft Journal/Camshaft 0.17 mm (0.0067 in.) Cap Clearance...
  • Page 195: Special Tools And Sealant

    ENGINE TOP END 5-9 Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter Holder Bar: 57001-221 57001-1128 Valve Spring Compressor Assembly: Valve Spring Compressor Adapter, 20: 57001-241 57001-1154 Valve Seat Cutter, 45° - 24.5: Valve Seat Cutter, 45° - 30: 57001-1113 57001-1187 Valve Seat Cutter, 32°...
  • Page 196 5-10 ENGINE TOP END Special Tools and Sealant Valve Seat Cutter Holder, 4: L-Shape Hose: 57001-1275 57001-1606 Valve Seat Cutter, 60° - 25: Valve Guide Driver Attachment, C: 57001-1328 57001-1624 Valve Seat Cutter, 60° - 27: Spacer: 57001-1409 57001-1786 Valve Guide Driver: Liquid Gasket, TB1211F: 57001-1564 92104-0004...
  • Page 197: 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 Cover [B] (Both Sides) • Remove the air suction valve [A] on both sides. Air Suction Valve Installation •...
  • Page 198: 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 199: 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 200: 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 201 ENGINE TOP END 5-15 Cylinder Head Cover • Install the cylinder head cover. • Install the rubber washers [A] with the metal side faces upward. • Tighten the cover bolts following the specified tightening sequence. Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 202: 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 203: Camshaft Chain Tensioner Installation

    ENGINE TOP END 5-17 Camshaft Chain Tensioner • Remove: Spring [A] Rod [B] • Remove: Camshaft Chain Tensioner Mounting Bolts [A] Camshaft Tensioner Body [B] Camshaft Chain Tensioner Installation • Replace the O-ring [A] with a new one. • Apply grease to the new O-ring. •...
  • Page 204: Camshaft, Camshaft Chain

    5-18 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove the cylinder head cover (see Cylinder Head Cover Removal). • Remove the timing inspection cap [A] and starter clutch bolt cap [B] on the starter clutch cover [C]. • Using a wrench on the starter clutch bolt [A], turn the crankshaft clockwise until the line [B] (TDC mark for #1,4 pistons) on the starter clutch is aligned with the notches...
  • Page 205: Camshaft Installation

    ENGINE TOP END 5-19 Camshaft, Camshaft Chain • Remove the camshaft chain tensioner (see Camshaft Chain Tensioner Removal). • Loosen the upper camshaft chain guide bolts and camshaft cap bolts as shown sequence [1 ∼ 20], and remove them. • Remove: Upper Camshaft Chain Guide [A] Camshaft Caps [B]...
  • Page 206 5-20 ENGINE TOP END Camshaft, Camshaft Chain • Install the camshaft sprockets as shown. #4 Cam Positions [A] Intake Camshaft Sprocket [B] Exhaust Camshaft Sprocket [C] ○ The intake camshaft sprocket and exhaust camshaft sprocket are identical. • Apply a non-permanent locking agent to the threads of the camshaft sprocket bolts and tighten them.
  • Page 207 ENGINE TOP END 5-21 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. ○...
  • Page 208 5-22 ENGINE TOP END Camshaft, Camshaft Chain • Replace the O-rings with new ones. • Apply grease to the new O-rings • Install: O-rings [A] Dowel Pins [B] O-rings [C] Dowel Pins [D] • Install the camshaft caps and upper camshaft chain guide [A] as shown.
  • Page 209: Camshaft, Camshaft Cap Wear Inspection

    ENGINE TOP END 5-23 Camshaft, Camshaft Chain • Install the camshaft chain tensioner (see Camshaft Chain Tensioner Installation). • Turn the crankshaft 2 turns clockwise to allow the ten- sioner to expand and recheck the camshaft chain timing. • Replace the O-ring of the timing inspection cap and starter clutch bolt cap with new ones.
  • Page 210: Camshaft Runout Inspection

    5-24 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Runout Inspection • Remove the camshafts (see Camshaft Removal). • Set the camshaft in a camshaft alignment jig or on V blocks. • Measure the runout with a dial gauge [A] at the specified place as shown.
  • Page 211: Cylinder Head

    ENGINE TOP END 5-25 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 212: Cylinder Head Removal

    5-26 ENGINE TOP END Cylinder Head Cylinder Head Removal • Remove: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) Thermostat Housing (see Thermostat Removal in the Cooling System chapter) Cylinder Head Cover (see Cylinder Head Cover Re- moval) Camshafts (see Camshaft Removal) Coolant Drain Bolt (Cylinder) [A] Washer [B]...
  • Page 213 ENGINE TOP END 5-27 Cylinder Head • Tighten the M9 cylinder head bolts following the tightening sequence [1 ∼10]. ○ First, tighten the bolts with 15 N·m (1.5 kgf·m, 11 ft·lb) of torque. ○ Next, in accordance with the following table tighten the bolts with the specified torque.
  • Page 214: Cylinder Head Warp Inspection

    5-28 ENGINE TOP END Cylinder Head • Replace the washer [A] with a new one. • Tighten: Torque - Coolant Drain Bolt (Cylinder) [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the removed parts (see appropriate chapters). Cylinder Head Warp Inspection •...
  • Page 215: Valves

    ENGINE TOP END 5-29 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. NOTE ○ Mark and record the valve lifter and shim locations so they can be installed in their original positions.
  • Page 216: Valve Guide Installation

    5-30 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 217: Valve Seat Inspection

    ENGINE TOP END 5-31 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: 0.08 ∼ 0.16 mm (0.0031 ∼ 0.0063 in.) Exhaust 0.03 ∼ 0.10 mm (0.0012 ∼ 0.0039 in.) Intake Service Limit: Exhaust...
  • Page 218 5-32 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 219 ENGINE TOP END 5-33 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 220 5-34 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 221 ENGINE TOP END 5-35 Valves...
  • Page 222: Throttle Body Assy Holder

    5-36 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] Throttle Body Assy Holder Bolts [B] Throttle Body Assy Holders [C] Throttle Body Assy Holder Installation •...
  • Page 223: Muffler

    ENGINE TOP END 5-37 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 the lower ends of the exhaust butterfly valve ca- bles from the pulley of the muffler body (see Exhaust But- terfly Valve Cable Removal).
  • Page 224: Muffler Body Installation

    5-38 ENGINE TOP END Muffler Muffler Body Installation • Replace the premuffler chamber gasket [A] with a new one. • Install the muffler body gasket to the premuffler chamber [B] until it is bottomed so that the chamfer side [C] faces muffler body [D].
  • Page 225: Premuffler Chamber Removal

    ENGINE TOP END 5-39 Muffler Premuffler Chamber Removal • Remove: Muffler Body (see Muffler Body Removal) Cotter Pin [A] • Loosen the rear axle nut [B]. • Loosen the both chain adjuster locknuts [C]. • Remove the drive chain from the rear sprocket. •...
  • Page 226: Premuffler Chamber Installation

    5-40 ENGINE TOP END Muffler Premuffler Chamber Installation • Replace the exhaust pipe gasket [A] with a new one. • Install the exhaust pipe gasket to the exhaust pipe [B] until it is bottomed so that the chamfer side [C] faces premuffler chamber [D].
  • Page 227: Exhaust Pipe Removal

    ENGINE TOP END 5-41 Muffler Exhaust Pipe Removal • Remove: Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter) Oxygen Sensor (Equipped Models) (see Oxygen Sen- sor Removal (Equipped Models) in the Electrical System chapter) Exhaust Pipe Clamp Bolt [A] •...
  • Page 228: Exhaust Pipe Installation

    5-42 ENGINE TOP END Muffler Exhaust Pipe Installation • Replace the exhaust pipe gaskets [A] [B] with new ones. • Install the exhaust pipe gasket [B] to the exhaust pipe [C] until it is bottomed so that the chamfer side [D] faces premuffler chamber [E].
  • Page 229: Exhaust Butterfly Valve Cable Removal

    ENGINE TOP END 5-43 Muffler Exhaust Butterfly Valve Cable Removal • Remove the front seat (see Front Seat Removal in the Frame chapter). • Open the clamp [A] and free the cables. • Slide the dust cover [B]. • Loosen the locknut [A], and turn the adjuster [B] to give the cable plenty of play.
  • Page 230: Exhaust Butterfly Valve Cable Installation

    5-44 ENGINE TOP END Muffler Exhaust Butterfly Valve Cable Installation • Confirm whether pulley [A] is an angle shown. 41.7° ±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.
  • Page 231 ENGINE TOP END 5-45 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 233 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 234: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 235 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Lever Clamp Bolts 0.80 69 in·lb Clutch Hub Nut 13.8 Clutch Stopper Bolts 0.90 78 in·lb Clutch Cover Bolts (M6, L = 40 mm) 87 in·lb Oil Filler Plug –...
  • Page 236: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch 40.5 ∼ 41.3 mm (1.59 ∼ 1.63 in.) Clutch Plate Assembly Length – – – 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) Friction Plate Thickness 2.5 mm (0.098 in.) Friction and Steel Plate Warp...
  • Page 237: Special Tool And Sealant

    CLUTCH 6-5 Special Tool and Sealant Clutch Holder: Clutch Plate Holder: 57001-1243 57001-1788 Crankcase Splitting Tool Assembly: Liquid Gasket, TB1211F: 57001-1362 92104-0004...
  • Page 238: 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 239: 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 [A] (see Cable Removal) Clutch Cover Bolts [B] Bracket [C] •...
  • Page 240: Release Shaft Installation

    6-8 CLUTCH Clutch Cover Release Shaft Installation • Apply grease to the oil seal lips on the upper ridge of the clutch cover. • Apply engine oil to the needle bearings in the hole of the clutch cover. • Apply molybdenum disulfide grease to the pusher-holding portion [A] on the release shaft.
  • Page 241: Clutch Cover Assembly

    CLUTCH 6-9 Clutch Cover 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. • Install the needle bearings [A] and oil seal [B] position as shown.
  • Page 242: Clutch Removal

    6-10 CLUTCH Clutch Clutch Removal • Remove: Clutch Cover (see Clutch Cover Removal) Starter Clutch Bolt Cap [A] • Using a wrench on the starter clutch bolt, turn the crank- shaft clockwise until the clutch stopper bolts [A] reaches the position as shown. •...
  • Page 243: Clutch Installation

    CLUTCH 6-11 Clutch • Hold the sub clutch hub [A] steady with the clutch holder [B], and remove the nut [C] and washers. Special Tool - Clutch Holder: 57001-1243 ○ Use the clutch holder with sharpened hook nose by grind- ing.
  • Page 244 6-12 CLUTCH Clutch • Engage the clutch housing gear [A] and oil pump drive gear [B] with the crankshaft primary gear [C] and oil pump drive gear [D]. • Apply engine oil to the sleeve [A] and needle bearing [B]. •...
  • Page 245 CLUTCH 6-13 Clutch • Install the friction plates [A] and steel plates [B] alternately as shown. Thick Steel Plate [C] NOTICE If new dry friction plates and steel plates are in- stalled, apply engine oil to the surfaces of each plate to avoid clutch plate seizure.
  • Page 246 6-14 CLUTCH Clutch • Be sure to install the spring seats on the clutch pressure plate. • Install: Clutch Springs Clutch Stopper Plate [A] • Tighten the clutch stopper bolts by hand. ○ Hold the clutch pressure plate by hand while tightening the clutch stopper bolts.
  • Page 247: Clutch Plate Assembly Length Measurement

    CLUTCH 6-15 Clutch Clutch Plate Assembly Length Measurement • Assemble the following parts. Clutch Hub [A] Friction Plates [B] Steel Plates [C] Clutch Pressure Plate [D] Spring Seats [E] Clutch Springs [F] Clutch Stopper Plate [G] Clutch Stopper Bolts [H] Torque - Clutch Stopper Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) •...
  • Page 248: Clutch Spring Free Length Measurement

    6-16 CLUTCH Clutch Clutch Spring Free Length Measurement • Measure the free length of the clutch springs [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 48.38 mm (1.905 in.) Service Limit: 46.3 mm (1.82 in.) Clutch Housing Finger Inspection •...
  • Page 249 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............................ 7-10 Oil Pan Removal .......................
  • Page 250: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 251 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Bleed Bolt 87 in·lb Oil Cooler/Oil Filter Case Mounting Bolts Oil Cooler Mounting Bolts Oil Filter Holder Bolt Oil Filter G, R Oil Filter Guard Bolts 0.41 35 in·lb Oil Jet Nozzles 0.30...
  • Page 252: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 253 ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart 1. Intake Camshaft 2. Exhaust Camshaft 3. Camshaft Oil Passage 4. Oil Filter 5. Oil Cooler 6. Oil Jet 7. Oil Pressure Switch 8. Drive Shaft Oil Passage 9. Output Shaft Oil Passage 10.
  • Page 254 7-6 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1. Blowby Gas...
  • Page 255: Specifications

    ENGINE LUBRICATION SYSTEM 7-7 Specifications Item Standard Engine Oil Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 2.8 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) Between upper and lower level lines (Wait 2 ∼...
  • Page 256: Special Tools And Sealant

    7-8 ENGINE LUBRICATION SYSTEM Special Tools and Sealant Outside Circlip Pliers: Oil Pressure Gauge Adapter, PT3/8: 57001-144 57001-1233 Oil Pressure Gauge, 10 kgf/cm²: Liquid Gasket, TB1211: 57001-164 56019-120...
  • Page 257: Engine Oil And Oil Filter

    ENGINE LUBRICATION SYSTEM 7-9 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 258: Oil Pan

    7-10 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Oil Pan Bolts [A] Clamps [B] Oil Pan [C] Front [D]...
  • Page 259: Oil Pressure Relief Valve

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Screen [A] • Remove the oil pressure relief valve [A].
  • Page 260: Oil Pressure Relief Valve Installation

    7-12 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Installation • Apply a non-permanent locking agent to the threads of the oil pressure relief valve [A], and tighten it. NOTICE Do not apply too much non-permanent locking agent to the threads.
  • Page 261: Oil Pressure Relief Valve Inspection

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pressure Relief Valve Oil Pressure Relief Valve Inspection • Remove the oil pressure relief valve (see Oil Pressure Relief Valve Removal). • Check to see if the valve [A] slides smoothly when push- ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure.
  • Page 262: Oil Pump

    7-14 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Water Pump Cover Bolts [A] Water Pump Cover [B] •...
  • Page 263: Oil Pump Installation

    ENGINE LUBRICATION SYSTEM 7-15 Oil Pump Oil Pump Installation • Install the outer rotor [A] into the crankcase. • Install the pin [B] and inner rotor [C] to the oil (water) pump shaft [D], and install the assy. ○ Turn the pump shaft so that the slot [E] in its shaft fits onto the projection [F] of the pump drive gear shaft.
  • Page 264: Oil Pump Drive Gear Removal

    7-16 ENGINE LUBRICATION SYSTEM Oil Pump • Align the line [A] of the water pump cover and the white mark [B] of the water hose [C]. • Install the water hose clamp [D] as shown. • Tighten: Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m, 27 in·lb) Oil Pump Drive Gear Removal •...
  • Page 265: Oil Pump Drive Gear Shaft Installation

    ENGINE LUBRICATION SYSTEM 7-17 Oil Pump Oil Pump Drive Gear Shaft Installation • Apply molybdenum disulfide grease [A] to the oil pump drive gear shaft. • Apply molybdenum disulfide oil solution [B] to the crankcase. • Install the oil pump drive gear shaft and washer [C] as shown.
  • Page 266: Oil Cooler

    7-18 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Starter Motor (see Starter Motor Removal in the Electri- cal System chapter) •...
  • Page 267: Oil Cooler/oil Filter Case Removal

    ENGINE LUBRICATION SYSTEM 7-19 Oil Cooler Oil Cooler/Oil Filter Case Removal • Remove: Oil Filter (see Oil Filter Replacement in the Periodic Maintenance chapter) Oil Cooler (see Oil Cooler Removal) Oil Filter Guard Bolts [A] Oil Filter Guard [B] • Remove: Oil Cooler/Oil Filter Case Mounting Bolts [A] •...
  • Page 268 7-20 ENGINE LUBRICATION SYSTEM Oil Cooler If the oil filter holder bolt [A] was removed, install it. ○ Apply a non-permanent locking agent to the threads of the oil filter holder bolt, and tighten it. Torque - Oil Filter Holder Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) •...
  • Page 269: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-21 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 270: Oil Pressure Switch

    7-22 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the right lower fairing (see Lower Fairing Re- moval in the Frame chapter). •...
  • Page 271 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 272: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 273 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Adjusting Collar Locknuts Right Front Engine Mounting Bolt Left Front Engine Mounting Bolt Adjusting Collars 87 in·lb S, (M) Middle Engine Mounting Nut R, S Lower Engine Mounting Nut R, S S: Follow the specified tightening sequence.
  • Page 274: Special Tool

    8-4 ENGINE REMOVAL/INSTALLATION Special Tool Engine Mount Nut Wrench: 57001-1450...
  • Page 275: 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 276 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Free the lead from the clamps [A]. • Disconnect the sidestand switch lead connector [B]. • Remove the engine ground cable terminal bolt [A]. • Remove: Bolt [A] • Support the engine with a suitable stand [A]. ○...
  • Page 277: Engine Installation

    ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Remove: Right Front Engine Mounting Bolt [A] Middle Engine Mounting Nut [B] Lower Engine Mounting Nut NOTE ○ Hold the mounting bolt not to turn when loosening the middle and lower engine mounting nuts. •...
  • Page 278 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Install the adjusting collars [A] to the frame until end of the threads. • Replace the engine mounting nuts with new ones. • Support the engine with a suitable stand. ○ Put a plank onto the suitable stand for engine balance. ○...
  • Page 279 ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation ○ Second, tighten the left front engine mounting bolt [A]. Frame [B] Engine [C] Torque - Left Front Engine Mounting Bolt: 44 N·m (4.5 kgf·m, 32 ft·lb) ○ Third, tighten the lower engine mounting bolt [A] coun- terclockwise until the adjusting collar [B] touches [C] the frame [D].
  • Page 280 8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Run the leads, cables and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Install the removed parts (see appropriate chapters). • Adjust: Throttle Cables (see Throttle Control System Inspection in the Periodic Maintenance chapter) Clutch Cable (see Clutch Operation Inspection in the Pe- riodic Maintenance chapter)
  • Page 281 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........Starter Idle Gear and Starter Clutch .. 9-32 Specifications ........Starter Idle Gear Removal ... 9-32 Special Tools and Sealants ....Starter Idle Gear Installation ..9-32 Crankcase ......... 9-11 Starter Clutch Removal....9-34 Crankcase Splitting ......
  • Page 282: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 283 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Breather Hose Fitting Transmission Case Bolts (M8) Transmission Case Bolt (M6) 87 in·lb Bearing Holder Screws 0.50 43 in·lb Oil Jet Nozzles 0.30 26 in·lb Race Holder Screws 0.50 43 in·lb Breather Plate Bolts 87 in·lb Oil Passage Plugs (Taper)
  • Page 284 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 285 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Gear Positioning Lever Bolt 106 in·lb Shift Drum Cam Holder Bolt 106 in·lb Gear Position Switch Screws 0.30 26 in·lb Shift Shaft Return Spring Pin Starter Clutch Cover Bolts (L = 30 mm) 87 in·lb Starter Clutch Cover Bolt (L = 20 mm) 87 in·lb...
  • Page 286: 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 287 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, Yellow – – – 1.495 ∼ 1.499 mm (0.05886 ∼ 0.05902 in.) Black, Green – – – 1.499 ∼ 1.503 mm (0.05902 ∼ 0.05917 in.) Blue, Purple –...
  • Page 288 9-8 CRANKSHAFT/TRANSMISSION Specifications Connecting Rod Big End Bearing Insert Selection Con-rod Big End Bearing Insert Crankpin Diameter Inside Diameter Marking Size Color Part Number Marking ○ None Brown 92139-0167 None None Black 92139-0166 ○ ○ ○ None Blue 92139-0165 Crankshaft Main Bearing Insert Selection Crankcase Main Crankshaft Main Bearing Insert*...
  • Page 289 CRANKSHAFT/TRANSMISSION 9-9 Special Tools and Sealants Outside Circlip Pliers: Grip: 57001-144 57001-1591 Piston Pin Puller Assembly: Rotor Holder: 57001-910 57001-1666 Piston Ring Compressor Grip: Stopper: 57001-1095 57001-1679 Piston Ring Compressor Belt, 67 ∼ 79: Rotor Holder Attachment: 57001-1097 57001-1689 Bearing Driver Set: Liquid Gasket, TB1211F: 57001-1129 92104-0004...
  • Page 290: Special Tools And Sealants

    9-10 CRANKSHAFT/TRANSMISSION Special Tools and Sealants Liquid Gasket, TB1216B: 92104-1064...
  • Page 291: Crankcase

    CRANKSHAFT/TRANSMISSION 9-11 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: Crankshaft Sensor (see Crankshaft Sensor Removal in the Electrical System chapter) Starter Clutch (see Starter Clutch Removal) Cylinder Head (see Cylinder Head Removal in the En-...
  • Page 292: Crankcase Assembly

    9-12 CRANKSHAFT/TRANSMISSION 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 293 CRANKSHAFT/TRANSMISSION 9-13 Crankcase • Press 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 hose fitting [B] and tighten it. View from Upside [C] Torque - Breather Hose Fitting: 15 N·m (1.5 kgf·m, 11 ft·lb) •...
  • Page 294 9-14 CRANKSHAFT/TRANSMISSION Crankcase • Press the new needle bearing [A] for the shift shaft so that its marked side faces outside [B] and its surface [C] is flush with the end of the hole. • Install the new oil seal [D] so that its surface [E] is flush with the end of the hole.
  • Page 295 CRANKSHAFT/TRANSMISSION 9-15 Crankcase • Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket, coating area. Dry them with a clean cloth. • Apply liquid gasket [A] to the mating surface of the lower crankcase half.
  • Page 296 9-16 CRANKSHAFT/TRANSMISSION Crankcase • The M8 bolts [A] has a copper plated washer [B], replace it with a new one. • Apply molybdenum disulfide oil solution to both sides [C] of the washers and threads [D] of M8 bolts. • Tighten the lower crankcase bolts using the following steps.
  • Page 297: 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 298: Connecting Rod Removal

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts. • Install the crankshaft [A] with the camshaft chain [B] hang- ing on it. • Install the connecting rod big end caps (see Connecting Rod Installation).
  • Page 299: Connecting Rod Installation

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods Connecting Rod Installation NOTICE To minimize vibration, the connecting rods should have the same weight mark. Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] ○ Diameter Mark [D]: “ ” or no mark NOTICE If the connecting rods, big end bearing inserts, or crankshaft are replaced with new ones, select the...
  • Page 300 9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods NOTICE The connecting rod bolts are designed to stretch when tightened. Never reuse the connecting rod bolts. See the table below for correct bolt and nut usage. NOTICE Be careful not to overtighten the nuts. The bolts must be positioned on the seating surface correctly to prevent the bolt heads from hitting the crankcase.
  • Page 301 CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods • Dent both bolt head and bolt tip with a punch as shown. • Before tightening, use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt stretch. Connecting Rod [A] Dent here with a punch [B].
  • Page 302: Crankshaft/connecting Rod Cleaning

    9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • First, tighten the nuts with 12.8 N·m (1.3 kgf·m, 113 in·lb) of torque. • Next, tighten the nuts 175°. ○ Using a torque angle gauge [A], tighten the nuts specified angle. Connecting Torque + Angle Bolt Rod Assy N·m (kgf·m, in·lb)
  • Page 303: Connecting Rod Big End Side Clearance Inspection

    CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rods Connecting Rod Big End Side Clearance Inspection • Measure connecting rod big end side clearance. ○ Insert a thickness gauge [A] between the big end and ei- ther crank web to determine clearance. Connecting Rod Big End Side Clearance 0.13 ∼...
  • Page 304 9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods If any crankpin has worn past the service limit, replace the crankshaft with a new one. If the measured crankpin diameters [A] are not less than the service limit, but do not coincide with the original di- ameter markings [B] on the crankshaft, make new marks on it.
  • Page 305: Crankshaft Side Clearance Inspection

    CRANKSHAFT/TRANSMISSION 9-25 Crankshaft and Connecting Rods Crankshaft Side Clearance Inspection • Insert a thickness gauge [A] between the thrust washer [B] on the crankcase and the crank web [C] at the #3 main journal to determine clearance. If the clearance exceeds the service limit, replace the thrust washers as a set and check the width of the crank- shaft #3 main journal.
  • Page 306 9-26 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods If the clearance is within the standard, no bearing replace- ment is required. If the clearance is between 0.061 mm (0.0024 in.) and the service limit (0.09 mm, 0.0035 in.), replace the bearing in- serts [A] with inserts painted blue and purple [B].
  • Page 307 CRANKSHAFT/TRANSMISSION 9-27 Crankshaft and Connecting Rods Crankcase Main Crankshaft Main Bearing Insert* Bearing Inside Journal Diameter Part Number Journal Nos. Size Color Diameter Marking Marking 92139-0247 1, 5 Brown ○ 92139-0250 2, 4 Yellow 92139-0253 92139-0246 1, 5 Black None 92139-0249 2, 4 Green...
  • Page 308: Pistons

    9-28 CRANKSHAFT/TRANSMISSION 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 309: Piston Installation

    CRANKSHAFT/TRANSMISSION 9-29 Pistons Piston Installation NOTE ○ If a new piston is used, use new piston ring. • Apply molybdenum disulfide oil solution to the oil ring ex- pander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] not butt together. •...
  • Page 310: Cylinder (upper Crankcase) Wear Inspection

    9-30 CRANKSHAFT/TRANSMISSION Pistons • Apply molybdenum disulfide oil solution to the cylinder bore and piston skirt. • Install the piston with its dent mark [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 311: Piston Ring Groove Width Inspection

    CRANKSHAFT/TRANSMISSION 9-31 Pistons Piston Ring Groove Width Inspection • Measure the piston ring groove width. ○ Use a vernier caliper at several points around the piston. Piston Ring Groove Width Standard: 0.82 ∼ 0.84 mm (0.0323 ∼ 0.0331 in.) Top [A] Second [B] 0.82 ∼...
  • Page 312: Starter Idle Gear And Starter Clutch

    9-32 CRANKSHAFT/TRANSMISSION Starter Idle Gear and Starter Clutch Starter Idle Gear Removal • Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Idle Gear Cover Bolts [A] Idle Gear Cover [B] • Remove the idle gear (starter motor side) [A] with the shaft [B].
  • Page 313 CRANKSHAFT/TRANSMISSION 9-33 Starter Idle Gear and Starter Clutch • Install the idle gear (starter clutch side) [A] on the shaft. ○ Engage the idle gear with the starter clutch gear. • Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area.
  • Page 314: Starter Clutch Removal

    9-34 CRANKSHAFT/TRANSMISSION Starter Idle Gear and Starter Clutch Starter Clutch Removal • Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Starter Clutch Cover (see Starter Idle Gear Removal) Idle Gear (Starter Clutch Side) (see Starter Idle Gear Removal) •...
  • Page 315: Starter Clutch Assembly

    CRANKSHAFT/TRANSMISSION 9-35 Starter Idle Gear and Starter Clutch Starter Clutch Assembly • Install the one-way clutch [A] so that its circlip side [B] faces inward. • Install the new snap ring. • Push the starter clutch gear [A] in and turn it counterclock- wise [B] and install it.
  • Page 316 9-36 CRANKSHAFT/TRANSMISSION Starter Idle Gear and Starter Clutch ○ Examine the starter clutch gear [A] as well. Replace the clutch gear if it is worn or damaged.
  • Page 317: Transmission

    CRANKSHAFT/TRANSMISSION 9-37 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) Transmission Case Bolts [A]...
  • Page 318 9-38 CRANKSHAFT/TRANSMISSION Transmission • Press the ball bearing [A] in the transmission case [B] so that the stepped side faces outside until it is bottomed. Special Tool - Bearing Driver Set: 57001-1129 • Install the bearing holder [C] as shown. •...
  • Page 319: Transmission Assy Installation

    CRANKSHAFT/TRANSMISSION 9-39 Transmission • Install the drive shaft [A] and output shaft [B] as a set in the transmission case [C]. • Install the shift forks as shown. ○ The shift fork [D] for drive shaft gears has the short ears. ○...
  • Page 320: Transmission Shaft Removal

    9-40 CRANKSHAFT/TRANSMISSION Transmission • Install the gear positioning lever (see External Shift Mech- anism Installation). • Set the gear positioning lever to the neutral position [A]. • Check that the drive and output shaft turn freely. • Apply grease to the new O-ring [A] and install it to its po- sition on the output shaft [B].
  • Page 321 CRANKSHAFT/TRANSMISSION 9-41 Transmission • Replace any circlips removed with new ones. • Install the circlip [A] on the drive shaft [B] so that the punch mark [C] faces the washer [D] and position the opening [E] as shown. • Install the circlip [A] on the output shaft [B] so that the punch mark [C] faces the washer [D] and position the opening [E] as shown.
  • Page 322 9-42 CRANKSHAFT/TRANSMISSION Transmission • Fit the steel balls into the 5th gear holes in the output shaft. 5th Gear [A] Output Shaft [B] Steel Balls [C] NOTICE Do not apply grease to the balls to hold them in place. This will cause the positive neutral finder mechanism to malfunction.
  • Page 323 CRANKSHAFT/TRANSMISSION 9-43 Transmission 1. 1st Gear 14. Toothed Washer, 40 mm (1.57 in.) 2. 2nd Gear 15. Circlip 3. 3rd Gear 16. Steel Ball 4. 4th Gear 17. Bushing 5. 5th Gear 18. Washer, 32 mm (1.26 in.) 6. 6th (Top) Gear 19.
  • Page 324: 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 325: 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 of each shift drum groove [B]. If the guide pin on any shift fork is less than the service limit, the fork must be replaced.
  • Page 326: External Shift Mechanism

    9-46 CRANKSHAFT/TRANSMISSION External Shift Mechanism Shift Pedal Removal • Remove: Shift Lever Bolt [A] Shift Lever [B] If the tie-rod is removed from the shift pedal and shift lever, note the following. ○ The following portions have left-hand threads. Shift Lever Side of Tie-Rod Locknut [C] of Shift Lever Side Ball Joint [D] of Shift Lever •...
  • Page 327: External Shift Mechanism Installation

    CRANKSHAFT/TRANSMISSION 9-47 External Shift Mechanism • Remove: Shift Shaft Assembly [A] Washer [B] • Remove: Gear Positioning Lever Bolt [A] Gear Positioning Lever [B] Collar and Spring [C] External Shift Mechanism Installation • Install the gear positioning lever [A] as shown. •...
  • Page 328: External Shift Mechanism Inspection

    9-48 CRANKSHAFT/TRANSMISSION External Shift Mechanism • Replace the circlip [A] with a new one. • Install: Circlip Special Tool - Outside Circlip Pliers: 57001-144 ○ Fit the circlip into the groove of the shift shaft securely. • Install the removed parts (see appropriate chapters). External Shift Mechanism Inspection •...
  • Page 329 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-7 Rear Wheel Installation..................... 10-8 Wheel Inspection ......................10-9 Axle Inspection........................
  • Page 330: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 331 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolts Front Axle 13.0 93.7 Rear Axle Nut 13.0 93.7 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 332: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.3 mm (0.01 in.) or less TIR 1.0 mm (0.04 in.) Radial TIR 0.5 mm (0.02 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 333: 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 334: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Bolt [A] Front Wheel Rotation Sensor [B] Front Caliper Mounting Bolts [C] (Both Sides) Front Caliper [D] (Both Sides) • Loosen: Front Axle Clamp Bolts [A] Front Axle [B] • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter).
  • Page 335: Rear Wheel Removal

    WHEELS/TIRES 10-7 Wheels (Rims) • Apply high-temperature grease to the grease seal lips. • Fit the collars [A] on the both sides of the hub. ○ The collars are identical. • Insert the front axle [B] from the right side. •...
  • Page 336: Rear Wheel Installation

    10-8 WHEELS/TIRES Wheels (Rims) • Remove the rear wheel rotation sensor from the caliper bracket (see Rear Wheel Rotation Sensor Removal in the Brakes chapter). • Remove: Cotter Pin [A] Rear Axle Nut [B] Washer [C] Rear Axle [D] (from Right Side) •...
  • Page 337: Wheel Inspection

    WHEELS/TIRES 10-9 Wheels (Rims) • Bend the cotter pin [A] over the nut. WARNING A loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper torque and install a new cotter pin. •...
  • Page 338: Axle Inspection

    10-10 WHEELS/TIRES Wheels (Rims) WARNING Damaged wheel parts may fail and cause an acci- dent resulting in serious injury or death. Never at- tempt to repair a damaged wheel part. If the wheel part is damaged, it must be replaced with a new one. Axle Inspection •...
  • Page 339: Balance Weight Removal

    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 340 10-12 WHEELS/TIRES Wheels (Rims) • Be sure to install the balance weight. ○ Check that the blade [A] and clip [B] are fully seated on the rim [C] and that the clip is hooked over the rib [D]. Left Side [E] Right Side [F]...
  • Page 341: 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 342 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 343: 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 344: 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 345: 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 347 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 348: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 349 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Sprocket Cover Bolts (L = 55) 87 in·lb Engine Sprocket Cover Bolts (L = 45) 87 in·lb Engine Sprocket Cover Damper Screws 0.31 27 in·lb Chain Guide Bolts 106 in·lb Engine Sprocket Nut 15.0...
  • Page 350: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain 30 ∼ 40 mm (1.2 ∼ 1.6 in.) Drive Chain Slack – – – Drive Chain Wear (20-link Length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 319 mm (12.6 in.) Standard Chain: Make ENUMA...
  • Page 351: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...
  • Page 352: 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 353 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 354 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 355 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 356: 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 357: Engine Sprocket Cover Disassembly

    FINAL DRIVE 11-11 Sprocket, Coupling • Install: Engine Sprocket Cover [A] • Tighten: Torque - Engine Sprocket Cover Bolts [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) Engine Sprocket Cover Disassembly • Remove: Engine Sprocket Cover (see Engine Sprocket Removal) Chain Guide Bolts [A] Chain Guide [B] •...
  • Page 358: Rear Sprocket Removal

    11-12 FINAL DRIVE Sprocket, Coupling Rear Sprocket Removal • Remove the rear wheel (see Rear Wheel Removal in the Wheels/Tires chapter). NOTICE Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.
  • Page 359: Coupling Bearing Removal

    FINAL DRIVE 11-13 Sprocket, 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 360: Coupling Damper Inspection

    11-14 FINAL DRIVE Sprocket, Coupling Coupling Damper Inspection • Remove the rear wheel coupling, and inspect the rubber dampers [A]. • Replace the damper if it appears damaged or deterio- rated. Sprocket Wear Inspection • Visually inspect the engine and rear sprocket teeth for wear and damage.
  • Page 361 BRAKES 12-1 Brakes Table of Contents Exploded View ........................12-3 Specifications ........................12-10 Special Tools .......................... 12-11 Brake Lever, Brake Pedal....................... 12-12 Brake Lever Position Adjustment..................12-12 Brake Pedal Position Inspection ..................12-12 Brake Pedal Position Adjustment ..................12-12 Brake Pedal Removal ....................... 12-12 Brake Pedal Installation ....................
  • Page 362 12-2 BRAKES Parts Location ........................12-32 KIBS Servicing Precautions ....................12-36 KIBS Troubleshooting Outline................... 12-38 Inquiries to Rider....................... 12-41 Self-diagnosis Outline ....................... 12-43 ABS and KIBS Indicator Lights (LED) Inspection ............. 12-44 KIBS Hydraulic Unit Removal ................... 12-44 KIBS Hydraulic Unit Installation ..................12-45 KIBS Hydraulic Unit Inspection ..................
  • Page 363: Exploded View

    BRAKES 12-3 Exploded View This page intentionally left blank.
  • Page 364 12-4 BRAKES Exploded View...
  • Page 365 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Reservoir Cap Stopper Screw 0.12 11 in·lb Brake Lever Pivot Bolt 0.10 8.9 in·lb Front Master Cylinder Bleed Valve 0.55 48 in·lb Front Master Cylinder Clamp Bolts 97 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb...
  • Page 366 12-6 BRAKES Exploded View...
  • Page 367 BRAKES 12-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts Rear Master Cylinder Mounting Bolts Brake Pedal Mounting Bolt Rear Caliper Pin Bolt Bleed Valve 0.80 69 in·lb Rear Brake Pad Pin Plug 2.45 0.25 22 in·lb Rear Brake Pad Pin Rear Brake Disc Mounting Bolts Rear Master Cylinder Push Rod Locknut...
  • Page 368 12-8 BRAKES Exploded View KIBS Equipped Models...
  • Page 369 BRAKES 12-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts Brake Pipe Joint Nuts Brake Pipe Banjo Bolts (L = 20.8) Brake Pipe Banjo Bolt (L = 32.3) 5. KIBS Hydraulic Unit R: Replacement Parts NOTE ○...
  • Page 370: 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 75 mm (2.95 in.) below top of –...
  • Page 371: Special Tools

    BRAKES 12-11 Special Tools Jack: Jack Attachment: 57001-1238 57001-1608 Hand Tester: 57001-1394...
  • Page 372: 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 373: 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 374 12-14 BRAKES Brake Lever, Brake Pedal • Install the front footpeg bracket. • Apply a non-permanent locking agent to the threads of the front footpeg bracket bolts, and tighten them. Torque - Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) •...
  • Page 375: 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. • Remove the caliper mounting bolts [D], and detach the caliper [E] from the disc.
  • Page 376: Caliper Installation

    12-16 BRAKES Calipers Caliper Installation • Install the caliper and brake hose lower end. ○ For the front caliper, be sure to install the collars [A]. ○ Replace the washers on each side of hose fitting with new ones. ○ Touch the brake hoses to the stopper of the caliper.
  • Page 377: Caliper Fluid Seal Damage Inspection

    BRAKES 12-17 Calipers Caliper Fluid Seal Damage Inspection The fluid seal (piston seal) [A] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- perature of the discs or the brake fluid to increase.
  • Page 378: Caliper Piston And Cylinder Damage Inspection

    12-18 BRAKES Calipers Caliper Piston and Cylinder Damage Inspection • Visually inspect the pistons [A] and cylinder surfaces [B]. Replace the caliper if the cylinder and piston are badly scores or rusty. Rear Caliper Holder Shaft Wear Inspection The caliper body must slide smoothly on the caliper holder shafts [A].
  • Page 379: 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 380: Rear Brake Pad Removal

    12-20 BRAKES Brake Pads Rear Brake Pad Removal • Remove: Pad Pin Plug [A] Pad Pin [B] Brake Pads [C] 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. •...
  • Page 381: 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 382: 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 383: Rear Master Cylinder Installation

    BRAKES 12-23 Master Cylinder • Remove: Cotter Pin [A] Joint Pin [B] • Slide the reservoir hose lower end clamp [A]. • Remove the reservoir hose lower end [B], and drain the brake fluid into a container. Rear Master Cylinder Installation •...
  • Page 384: Front Master Cylinder Disassembly

    12-24 BRAKES Master Cylinder Front Master Cylinder Disassembly • Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter. Rear Master Cylinder Disassembly • Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter. Master Cylinder Assembly •...
  • Page 385: Brake Disc

    BRAKES 12-25 Brake Disc Brake Disc Removal • Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Remove the brake disc mounting bolts [A], and take off the disc [B]. • Remove the wheel rotation sensor rotor [C]. Brake Disc Installation •...
  • Page 386: Brake Disc Warp Inspection

    12-26 BRAKES Brake Disc Brake Disc Warp Inspection • Raise the wheel off the ground with 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 and measure disc runout, while turning [B] the wheel by hand.
  • Page 387: 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 388 12-28 BRAKES Brake Fluid • Remove: Diaphragm Plate Diaphragm • Fill the reservoir with fresh brake fluid to the upper level line in the reservoir. • Slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir.
  • Page 389 BRAKES 12-29 Brake Fluid • Bleed the brake line and the caliper. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].
  • Page 390 12-30 BRAKES Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. • Never reuse old brake fluid. • Do not use fluid from a container that has been left unsealed or that has been open for a long time. •...
  • Page 391: 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 392: Parts Location

    12-32 BRAKES KIBS (Equipped Models) Parts Location NOTE ○ The front and rear wheel rotation sensors and rotors are standard parts of this motorcycle. Front Wheel Rotation Sensor [A] Front Wheel Rotation Sensor Rotor [B] Rear Wheel Rotation Sensor [A] Rear Wheel Rotation Sensor Rotor [B] Yellow ABS Indicator Light (LED) [A] Yellow Warning Indicator Light [B]...
  • Page 393 BRAKES 12-33 KIBS (Equipped Models) KIBS Kawasaki Self-Diagnosis System Connector [A]...
  • Page 394 13. KIBS Solenoid Valve Relay Fuse 15 A 2. Front Brake Light Switch 14. KIBS Motor Relay Fuse 25 A 3. ECU 15. KIBS Kawasaki Self-diagnosis System Connector 4. Rear Wheel Rotation Sensor 16. KIBS Hydraulic Unit 5. Rear Brake Light Switch 17.
  • Page 395 2. CAN Communication Line (High): GY/BL 3. Front Wheel Rotation Sensor Signal Input: BK/W 4. Power Supply: BR/W 5. KIBS Kawasaki Self-Daignosis System Terminal: P 6. Front and Rear Brake Light Switch Signal: BL/R 7. Unused 8. Front Wheel Rotation Sensor Signal Output: G/Y 9.
  • Page 396: Kibs Servicing Precautions

    12-36 BRAKES KIBS (Equipped Models) KIBS Servicing Precautions There are a number of important precautions that should be followed servicing the KIBS. ○ This KIBS is designed to be used with a 12 V sealed bat- tery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 397 BRAKES 12-37 KIBS (Equipped Models) ○ The yellow ABS indicator light (LED) [A] and yellow warn- ing indicator light (LED)/KIBS warning symbol [B] may light if the tire pressure is incorrect, a non-recommended tire is installed, or the wheel is deformed. If the indica- tor light lights, remedy the problem and clear the service code.
  • Page 398: Kibs Troubleshooting Outline

    12-38 BRAKES KIBS (Equipped Models) KIBS Troubleshooting Outline When an abnormality in the system occurs, the yellow ABS indicator light (LED) and yellow warning 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 service code [A] is displayed on...
  • Page 399 BRAKES 12-39 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 400 12-40 BRAKES KIBS (Equipped Models) KIBS Diagnosis Flow Chart...
  • Page 401: Inquiries To Rider

    BRAKES 12-41 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 402 12-42 BRAKES KIBS (Equipped Models) Pre-Diagnosis Inspection 1...
  • Page 403: Self-diagnosis Outline

    BRAKES 12-43 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 404: Abs And Kibs Indicator Lights (led) Inspection

    12-44 BRAKES KIBS (Equipped Models) ABS and KIBS Indicator Lights (LED) Inspection ○ In this model, the yellow ABS indicator light (LED) [A] and yellow warning indicator light (LED) [B] go on or blink by the data sent from the KIBS hydraulic unit. •...
  • Page 405: Kibs Hydraulic Unit Installation

    BRAKES 12-45 KIBS (Equipped Models) • 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. Spread over a shop towel around the KIBS hy- draulic unit before removing the brake line so that brake fluid does not leak on the parts.
  • Page 406: Kibs Hydraulic Unit Inspection

    12-46 BRAKES KIBS (Equipped Models) • Install the KIBS hydraulic unit together with the bracket, and tighten the bolts. ○ Fit the bracket and KIBS hydraulic unit rubber cover (see Cable, Wire, and Hose Routing section in the Appendix chapter). •...
  • Page 407: Front Wheel Rotation Sensor Installation

    BRAKES 12-47 KIBS (Equipped Models) • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) • Slide the dust cover [A]. • Open the clamp [B]. • Disconnect the front wheel rotation sensor lead connector [C].
  • Page 408: Rear Wheel Rotation Sensor Installation

    12-48 BRAKES KIBS (Equipped Models) • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) • Slide the dust cover [A]. • Disconnect the rear wheel rotation sensor lead connector [B]. • Clear the sensor lead from the clamps [A]. •...
  • Page 409: Wheel Rotation Sensor Air Gap Inspection

    BRAKES 12-49 KIBS (Equipped Models) Wheel Rotation Sensor Air Gap Inspection • Raise the front/rear wheel off the ground (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Measure the air gap between the sensor and sensor rotor at several points by turning the wheel slowly. Thickness Gauge [A] Wheel Rotation Sensor Air Gap Standard:...
  • Page 410: Kibs Solenoid Valve Relay Fuse (15 A) Removal

    12-50 BRAKES 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 411 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 412: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 413 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Front Fork Clamp Bolts Lower Front Fork Clamp Bolts 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 414 13-4 SUSPENSION Exploded View...
  • Page 415 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Bracket Nut Swingarm Pivot Shaft Nut 11.0 79.7 Swingarm Pivot Shaft Swingarm Pivot Adjusting Collar Locknut 10.0 Upper Rear Shock Absorber Nut Rocker Arm Bolt Lower Rear Shock Absorber Nut Tie-Rod Nuts G: Apply grease.
  • Page 416: Specifications

    13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Diameter 41 mm (1.6 in.) Air Pressure Atmospheric pressure (Non-adjustable) Rebound Damper Setting 4 1/2 turns out from the fully clockwise position (Usable Range: 0 ←→ 5 1/2 turns out) Compression Damper Setting 6 turns out from the fully clockwise position (Usable Range: 0 ←→...
  • Page 417: Special Tools

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Fork Oil Level Gauge: 57001-143 57001-1290 Oil Seal & Bearing Remover: Hook Wrench T=3.2 R37: 57001-1058 57001-1539 Bearing Driver Set: Swingarm Pivot Nut Wrench: 57001-1129 57001-1597 Jack: Jack Attachment: 57001-1238 57001-1608 Fork Oil Seal Driver, 41: Needle Bearing Driver, 17/ 18: 57001-1288 57001-1609...
  • Page 418 13-8 SUSPENSION Special Tools Needle Bearing Driver, 28: Needle Bearing Driver, 20 & Spacer, 28: 57001-1610 57001-1678 Spacer, Top Plug Wrench (45 mm): 57001-1636 57001-1741 Spacer, Rod Guide Case Wrench, 33 mm: 57001-1637 57001-1744 Hook Wrench: 57001-1641...
  • Page 419: 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 4 1/2 turns out from the fully clockwise position. ○ The damping force can be left soft for average riding. But it should be adjusted harder for high speed riding or riding with a passenger.
  • Page 420: 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 5 turns in from the fully counterclockwise position. ○ The spring preload can be left soft for average riding. But it should be adjusted harder for high speed riding or riding with a passenger.
  • Page 421: Front Fork Installation (each Fork Leg)

    SUSPENSION 13-11 Front Fork Front Fork Installation (Each Fork Leg) • Install the fork so that the top end [A] of the outer tube as shown. 7 mm (0.28 in.) [B] Steering Stem Head [C] • Tighten: Torque - Lower Front Fork Clamp Bolts: 23 N·m (2.3 kgf·m, 17 ft·lb) NOTE ○...
  • Page 422: Front Fork Oil Change

    13-12 SUSPENSION Front Fork Front Fork Oil Change Right Front Fork • Remove the front fork (see Front Fork Removal (Each Fork Leg)). • Hold the inner tube lower end in a vise. • Using the wrench [A], unscrew the top plug [B] out of the outer tube.
  • Page 423 SUSPENSION 13-13 Front Fork • Remove: Piston Rod Assy [A] Collar [B] Fork Spring [C] • Drain the fork oil into a suitable container [A]. ○ Pump the inner tube up and down at least 10 times to expel the oil from the fork. •...
  • Page 424 13-14 SUSPENSION Front Fork • Hold the inner tube bottom by a vise. • Using the rod guide case wrench [A], tighten the piston rod guide case to the inner tube. Special Tool - Rod Guide Case Wrench, 33 mm: 57001 -1744 Torque - Piston Rod Guide Case: 90 N·m (9.2 kgf·m, 66 ft·lb) NOTE...
  • Page 425 SUSPENSION 13-15 Front Fork • Replace the O-ring [A] with a new one. • Apply grease to the new O-ring. • Install the top plug [B] to the piston rod. • Holding the top plug with a wrench [C], tighten the piston rod nut against the top plug.
  • Page 426 13-16 SUSPENSION Front Fork Left Front Fork • 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 427 SUSPENSION 13-17 Front Fork • Remove: Piston Rod [A] Collar [B] Fork Spring [C] • Drain the fork oil into a suitable container [A]. ○ Pump the inner tube up and down at least 10 times to expel the oil from the fork. •...
  • Page 428 13-18 SUSPENSION Front Fork • Insert the piston rod into the inner tube. • Hold the inner tube bottom by a vise. • Using rod guide case wrench [A], tighten the piston rod guide case to the inner tube. Special Tool - Rod Guide Case Wrench, 33 mm: 57001 -1744 Torque - Piston Rod Guide Case: 90 N·m (9.2 kgf·m, 66 ft·lb) NOTE...
  • Page 429 SUSPENSION 13-19 Front Fork • Replace the O-ring [A] with a new one. • Apply grease to the new O-ring. • Install the top plug [B] to the piston rod. • Holding the top plug with the wrench [C], tighten the piston rod nut against the top plug.
  • Page 430: Front Fork Disassembly

    13-20 SUSPENSION Front Fork Front Fork Disassembly • Remove the front fork (see Front Fork Removal (Each Fork Leg)). • Drain the fork oil (see Front Fork Oil Change). • Remove the dust seal [A] from the outer tube. • Remove the circlip [B].
  • Page 431: Inner Tube Inspection

    SUSPENSION 13-21 Front Fork • Insert the inner tube to the outer tube. • After installing the washer, install the oil seal [A] by using the fork oil seal driver [B]. Special Tool - Fork Oil Seal Driver, 41: 57001-1288 •...
  • Page 432: Spring Tension Inspection

    13-22 SUSPENSION Front Fork 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. If the length of a replacement spring and that of the remaining spring vary greatly, the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability.
  • Page 433: Rear Shock Absorber

    SUSPENSION 13-23 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 1/2 turns out from the fully clockwise position. Rebound Damping Force Adjustment Adjuster Damping...
  • Page 434: Rear Shock Absorber Removal

    13-24 SUSPENSION Rear Shock Absorber • To adjust the spring preload, turn in the adjusting nut [A] to the desired position and tighten the locknut [B]. Spring Length [C] Spring Preload Setting Standard: Spring length 205 mm (8.07 in.) Usable Range: Spring length 199 ∼ 209 mm (7.83 ∼ 8.23 in.) •...
  • Page 435: Rear Shock Absorber Installation

    SUSPENSION 13-25 Rear Shock Absorber • Remove: Lower Rear Shock Absorber Nut [A] and Bolt Upper Tie-Rod Nut [B] and Bolt Upper Rear Shock Absorber Nut [C] and Bolt • Remove the rear shock absorber [D] downward. Rear Shock Absorber Installation •...
  • Page 436: Rear Shock Absorber Scrapping

    13-26 SUSPENSION Rear Shock Absorber Rear Shock Absorber Scrapping WARNING Pressurized nitrogen may explode when heated. The rear shock contains nitrogen gas. To avoid an explosion, do not incinerate the shock body without first releasing the nitrogen and removing the shraeder valve. •...
  • Page 437: Swingarm

    SUSPENSION 13-27 Swingarm Swingarm Removal • Remove: Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Chain Cover (see Drive Chain Removal in the Final Drive chapter) Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter) Mud Guard (see Mud Guard Removal in the Frame chapter) Rear Shock Absorber (see Rear Shock Absorber Re- moval)
  • Page 438: Swingarm Bearing Removal

    13-28 SUSPENSION Swingarm • Apply plenty of grease to the lip of the oil seals [A]. • Be sure to install the oil seals and sleeve [B] to the swingarm. • Fit the collar [C] on the oil seal of the left side. •...
  • Page 439: Swingarm Bearing Installation

    SUSPENSION 13-29 Swingarm • Remove the ball bearing and needle bearings. Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058 Swingarm Bearing Installation • Replace the ball and needle bearings [A] with new ones. • Install the ball and needle bearings so that the manufac- turer’s marks face out.
  • Page 440: Swingarm Bearing, Sleeve Inspection

    13-30 SUSPENSION Swingarm Swingarm Bearing, Sleeve Inspection NOTICE Do not remove the bearings for inspection. Re- moval may damage them. • Inspect the needle bearings [A] and ball bearing installed in the swingarm. ○ The rollers and ball in a bearing normally wear very little, and wear is difficult to measure.
  • Page 441: Tie-rod, Rocker Arm

    SUSPENSION 13-31 Tie-Rod, Rocker Arm Tie-Rod Removal • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Premuffler Chamber (see Premuffler Chamber Removal in the Engine Top End chapter) • Squeeze the brake lever slowly and hold it with a band [A].
  • Page 442: Rocker Arm Installation

    13-32 SUSPENSION Tie-Rod, Rocker Arm • Remove: Lower Rear Shock Absorber Nut [A] and Bolt Lower Tie-Rod Nut [B] and Bolt Rocker Arm Nut [C] and Bolt Rocker Arm [D] Rocker Arm Installation • Apply grease to the inside of the oil seals [A]. •...
  • Page 443: Tie-rod And Rocker Arm Bearing Removal

    SUSPENSION 13-33 Tie-Rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Removal • Remove: Tie-Rods (see Tie-Rod Removal) Rocker Arm (see Rocker Arm Removal) Swingarm [A] (see Swingarm Removal) Sleeves [B] Oil Seals [C] • Remove the needle bearings [D], using the suitable tool. Tie-Rod and Rocker Arm Bearing Installation •...
  • Page 444 13-34 SUSPENSION Tie-Rod, Rocker Arm ○ Screw the needle bearing driver [A] into the driver holder [B]. NOTE ○ For a bearing of inside diameter 18, select the press- ing side of the needle bearing driver according to its pressing depth. ○...
  • Page 445: Rocker Arm/tie-rod Bearing, Sleeve Inspection

    SUSPENSION 13-35 Tie-Rod, Rocker Arm Needle Bearings [A] Oil Seals [B] Rear Shock Absorber [C] Tie-Rods [D] Rocker Arm [E] Swingarm [F] 7.5 mm (0.30 in.) [G] 5.0 mm (0.20 in.) [H] 5.5 mm (0.22 in.) [I] Front [J] Right Side [K] Left Side [L] Rocker Arm/Tie-Rod Bearing, Sleeve Inspection NOTICE...
  • Page 447 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Steering ..........................14-5 Steering Inspection ......................14-5 Steering Adjustment......................14-5 Steering Stem......................... 14-6 Stem, Stem Bearing Removal................... 14-6 Stem, Stem Bearing Installation..................14-7 Steering Stem Bearing Lubrication ................... 14-9 Steering Stem Warp Inspection ..................
  • Page 448: Exploded View

    14-2 STEERING Exploded View...
  • Page 449 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Handlebar Clamp Bolts Handlebar Positioning Bolts 87 in·lb Left Switch Housing Screws 0.36 31 in·lb Right Switch Housing Screws 0.36 31 in·lb Throttle Case Screws 0.36 31 in·lb Steering Stem Head Bolt Upper Front Fork Clamp Bolts Steering Stem Nut Lower Front Fork Clamp Bolts...
  • Page 450: Special Tools

    14-4 STEERING 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...
  • Page 451: Steering Inspection

    STEERING 14-5 Steering Steering Inspection • Refer to the Steering Play Inspection in the Periodic Main- tenance chapter. Steering Adjustment • Refer to the Steering Play Adjustment in the Periodic Maintenance chapter.
  • Page 452: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender (see Front Fender Removal in the Frame chapter)
  • Page 453: Stem, Stem Bearing Installation

    STEERING 14-7 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], suitable collar [D] and adapter [E]. Special Tool - Bearing Puller: 57001-135 Stem, Stem Bearing Installation •...
  • Page 454 14-8 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: Washer [D] Stem Cap [E] Steering Stem Nut [F] • Settle the bearings in place as follows. ○...
  • Page 455: Steering Stem Bearing Lubrication

    STEERING 14-9 Steering Stem • Install the claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of stem locknut [C]. • Hand tighten the stem locknut until it touches the claw washer.
  • Page 456: Stem Cap Deterioration, Damage Inspection

    14-10 STEERING Steering Stem Stem Cap Deterioration, Damage Inspection Replace the stem cap if its seal lip [A] shows damage.
  • Page 457: Handlebar

    STEERING 14-11 Handlebar Handlebar Removal • Remove: 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] Handlebar Weight [D]...
  • Page 458: Handlebar Installation

    14-12 STEERING 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 459 STEERING 14-13 Handlebar • Install the throttle cable tips [A]. • Install the throttle case. ○ Fit the projection [B] into a hole [C] in the handlebar. • Tighten: Torque - Throttle Case Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb) •...
  • Page 461 FRAME 15-1 Frame Table of Contents Exploded View........15-2 Tank Cover Installation....15-15 Seats ..........15-8 Seat Covers........15-16 Front Seat Removal ..... 15-8 Seat Cover Removal....15-16 Front Seat Installation ....15-8 Seat Cover Installation....15-16 Rear Seat Removal...... 15-8 Fenders ..........
  • Page 462: Exploded View

    15-2 FRAME Exploded View...
  • Page 463 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Frame Bolts (M10) Front Footpeg Bracket Bolts Sidestand Switch Bolt 0.90 78 in·lb Sidestand Bracket Bolts Sidestand Nut R, S Sidestand Bolt Rear Frame Bolts (M8) Rear Footpeg Bracket Bolts G: Apply grease.
  • Page 464 15-4 FRAME Exploded View...
  • Page 465 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fender Mounting Bolts 0.40 35 in·lb 2. US, CA and CAL Models L: Apply a non-permanent locking agent. R: Replacements Parts...
  • Page 466 15-6 FRAME Exploded View...
  • Page 467 FRAME 15-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Windshield Mounting Bolts 0.42 0.043 3.7 in·lb...
  • Page 468: Seats

    15-8 FRAME Seats Front Seat Removal • Remove: Side Covers (see Side Cover Removal) Bolt [A] (Both Sides) • Remove the seat [B] forward while lifting up the front part of the seat. Front Seat Installation • Slip the seat hook [A] under the rib [B] on the rear frame front.
  • Page 469: Fairings

    FRAME 15-9 Fairings Lower Fairing Removal • Remove: Quick Rivets [A] Bolts and Washers [B] • Clear the hook [C] with the standard tip screwdriver. • Pull the lower fairing [D] outward to clear the hooks [E], and remove the lower fairing. Lower Fairing Installation •...
  • Page 470 15-10 FRAME Fairings • Disconnect (Left Side): Front Turn Signal Light Lead Connector [A] Head Light Lead Connector [B] City Light Lead Connector [C] • Disconnect (Right Side): Front Turn Signal Light Lead Connector [A] Head Light Lead Connector [B] City Light Lead Connector [C] •...
  • Page 471: Upper Fairing Assembly Installation

    FRAME 15-11 Fairings Upper Fairing Assembly Installation • Installation is the reverse of removal. • Run the hoses, leads and harness correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Insert the coolant reserve tank overflow hose [A] to the hole [B] of the middle fairing.
  • Page 472: Inner Fairing Removal

    15-12 FRAME Fairings Inner Fairing Removal • Remove: Clamps [A] Quick Rivets [B] • Remove (Both Sides): Quick Rivets [A] Inner Fairing [B] Inner Fairing Installation • Fit the hooks [A] of the inner fairings. • Insert the tab [B] into the rib [C] on the upper fairing. •...
  • Page 473: Side Covers

    FRAME 15-13 Side Covers Inner Cover Removal • Remove: Bolts [A] and Washers Inner Cover [B] Inner Cover Installation • Fit the hooks [A] on the side cover to the holes [B] on the inner cover. • Install the bolts and washers. Side Cover Removal •...
  • Page 474: Tank Cover Removal

    15-14 FRAME Side Covers • Check that the pads [A] and hook fasteners [B] are in place on the side cover. ○ Set the pad and hook fasteners to the convex [C] on the side cover. ○ Fit the pad to the rim end [D]. ○...
  • Page 475: Tank Cover Installation

    FRAME 15-15 Side Covers Tank Cover Installation • Check that the dampers [A] are in place on the side cover. • Insert the projection [B] into the hole [C]. • Tighten the bolt.
  • Page 476: Seat Covers

    15-16 FRAME Seat Covers Seat Cover Removal • Remove: Seats (see Front/Rear Seat Removal) Bolts [A] • Pull the front seat cover [B] backward to clear the hooks [C], and remove the front seat cover. • Remove: Quick Rivets [A] Bolts [B] •...
  • Page 477: Fenders

    FRAME 15-17 Fenders Front Fender Removal • Remove the front wheel (see Front Wheel Removal). • Clear the brake hoses and wheel rotation sensor lead from the clamps [A] (both sides). • Remove: Bolts [B] and Washers (Both Sides) Front Fender [C] Front Fender Installation •...
  • Page 478: Rear Fender Installation

    15-18 FRAME Fenders • Disconnect: Vehicle-down Sensor Connector [A] Tail/Brake Light Lead Connector [B] • Remove the clamps [C]. • Remove: Exhaust Butterfly Valve Actuator [A] (see Exhaust But- terfly Valve Actuator Removal in the Fuel System (DFI) chapter) ECU (with Relay Box) [B] Turn signal Relay [C] Fuse Box [D] Bolts [E]...
  • Page 479: Flap Removal

    FRAME 15-19 Fenders Flap Removal • Remove the seat cover (see Seat Cover Removal). • Disconnect: Turn Signal Relay Lead Connectors [A] License Plate Light Lead Connector [B] • Clear the lead from the clamp [C]. • Remove: Flap Mounting Bolts [A] Clamp [B] Flap Flap Installation...
  • Page 480: Rear Frame Rear Removal

    15-20 FRAME Frame Rear Frame Rear Removal • Remove: Rear Fender (see Rear Fender Removal) Rear Frame Bolts (M8) [A] (Both Sides) Rear Frame Rear [B] Rear Frame Rear Installation • Check that the pads [A] are in place on the rear frame rear.
  • Page 481: Windshield

    FRAME 15-21 Windshield Windshield Removal • Remove: Bolts with Washers [A] Windshield [B] Windshield Installation • Be sure that the wellnuts [A] are in position on the wind- shield. • Tighten: Torque - Windshield Mounting Bolts: 0.42 N·m (0.043 kgf·m, 3.7 in·lb)
  • Page 482: Guard

    15-22 FRAME Guard Mud Guard Removal • Remove: Mud Guard Mounting Bolts [A] Brake Hose Clamp [B] Mud Guard [C] Mud Guard Installation • Installation is the reverse of removal. • Apply a non-permanent locking agent to the threads of the mud guard mounting bolts, and tighten them securely.
  • Page 483: Sidestand

    FRAME 15-23 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 485 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-3 Specifications ......................... 16-10 Special Tools and Sealant ...................... 16-11 Parts Location......................... 16-13 Wiring Diagram (US, CA and CAL Models)................16-16 Wiring Diagram (Other than US, CA and CAL Models)............16-18 Wiring Diagram (KIBS Equipped Models: US, CA and CAL Models) ........
  • Page 486 16-2 ELECTRICAL SYSTEM Armature Inspection......................16-50 Brush Lead Inspection ...................... 16-50 Left-hand End Cover Assembly Inspection............... 16-51 Starter Relay Inspection....................16-51 Lighting System ........................16-53 Headlight Beam Horizontal Adjustment ................16-53 Headlight Beam Vertical Adjustment................. 16-53 Headlight Bulb Replacement .................... 16-53 City Light Bulb Replacement.....................
  • Page 487: Exploded View

    ELECTRICAL SYSTEM 16-3 Exploded View This page intentionally left blank.
  • Page 488 16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 489 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Turn Signal Light Mounting Screw 0.12 11 in·lb Meter Unit Mounting Screws 0.12 11 in·lb License Plate Light Mounting Nuts 0.36 31 in·lb License Plate Light Cover Screws 0.10 8.9 in·lb...
  • Page 490 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 491 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Left Switch Housing Screws 0.36 31 in·lb Right Switch Housing Screws 0.36 31 in·lb Front Brake Light Switch Screw 0.12 11 in·lb Crankshaft Sensor Bolts 0.60 52 in·lb Starter Clutch Cover Bolts (L = 30 mm) 87 in·lb Starter Clutch Cover Bolt (L = 20 mm) 87 in·lb...
  • Page 492 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 493 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Regulator/Rectifier Bracket Screws 0.12 11 in·lb Spark Plugs 115 in·lb Gear Position Switch Screws 0.30 26 in·lb Water Temperature Sensor 106 in·lb Starter Motor Cable Terminal Bolt 0.30 26 in·lb Fuel Pump Bolts 87 in·lb L, S...
  • Page 494: Specifications

    16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name YTX9-BS Capacity 12 V 8 Ah Voltage 12.8 V or more Gross Weight 2.9 kg (6.4 lb) Electrolyte Volume 0.40 L (24 cu in.) Charging System Type Three-phase AC Alternator Output Voltage 46.4 V or more at 4 000 r/min (rpm) 0.11 ∼...
  • Page 495 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: Stopper: 57001-1415 57001-1679 Lead Wire - Peak Voltage Adapter: Rotor Holder Attachment: 57001-1449 57001-1689 Key Registration Unit: Key Registration Adapter:...
  • Page 496: Special Tools And Sealant

    16-12 ELECTRICAL SYSTEM Special Tools and Sealant Liquid Gasket, TB1211F: 92104-0004...
  • Page 497: Parts Location

    ELECTRICAL SYSTEM 16-13 Parts Location This page intentionally left blank.
  • Page 498 16-14 ELECTRICAL SYSTEM Parts Location...
  • Page 499 ELECTRICAL SYSTEM 16-15 Parts Location 1. Immobilizer Amplifier (Equipped Models) 2. Ignition Switch (Immobilizer Equipped Models: Including Immobilizer Antenna) 3. Starter Lockout Switch 4. Starter Relay 5. Battery 12 V 8 Ah 6. ECU 7. Relay Box 8. Turn Signal Relay 9.
  • Page 500: Wiring Diagram (us, Ca And Cal Models)

    16-16 ELECTRICAL SYSTEM Wiring Diagram (US, CA and CAL Models)
  • Page 501 ELECTRICAL SYSTEM 16-17 Wiring Diagram (US, CA and CAL Models)
  • Page 502: Wiring Diagram (other Than Us, Ca And Cal Models)

    16-18 ELECTRICAL SYSTEM Wiring Diagram (Other than US, CA and CAL Models)
  • Page 503 ELECTRICAL SYSTEM 16-19 Wiring Diagram (Other than US, CA and CAL Models)
  • Page 504: Wiring Diagram (kibs Equipped Models: Us, Ca And Cal Models)

    16-20 ELECTRICAL SYSTEM Wiring Diagram (KIBS Equipped Models: US, CA and CAL Models)
  • Page 505 ELECTRICAL SYSTEM 16-21 Wiring Diagram (KIBS Equipped Models: US, CA and CAL Models)
  • Page 506: Wiring Diagram (kibs Equipped Models: Other Than Us, Ca And Cal Models)

    16-22 ELECTRICAL SYSTEM Wiring Diagram (KIBS Equipped Models: Other than US, CA and CAL Models)
  • Page 507 ELECTRICAL SYSTEM 16-23 Wiring Diagram (KIBS Equipped Models: Other than US, CA and CAL Models)
  • Page 508: 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 509: 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 510: 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 511: Battery Activation

    ELECTRICAL SYSTEM 16-27 Battery Battery Activation Electrolyte Filling • Make sure that the model name [A] of the electrolyte con- tainer matches the model name [B] of the battery. These names must be the same. Battery Model Name ZX636E/F: YTX9-BS NOTICE Each battery comes with its own specific elec- trolyte container;...
  • Page 512 16-28 ELECTRICAL SYSTEM Battery • Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery. Hold the container level, push down to break the seals of all six cells. You will see air bubbles rising into each cell as the ports fill.
  • Page 513: Precautions

    Newly activated sealed batteries require an initial charge. Standard Charge: 0.9 A × 5 ∼ 10 hours If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers: Battery Mate 150-9 OptiMate PRO 4-S/PRO S/PRO2 Yuasa MB-2040/2060...
  • Page 514: Interchange

    16-30 ELECTRICAL SYSTEM Battery DANGER Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri- ous injury and burns if ignited. Keep the battery away from sparks and open flames during charging. When using a battery charger, connect the battery to the charger before turning on the charger.
  • Page 515 ELECTRICAL SYSTEM 16-31 Battery Terminal Voltage: 11.5 ∼ less than 12.8 V Standard Charge 0.9 A × 5 ∼ 10 h (see following chart) Quick Charge 4 A × 1 h NOTICE If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on.
  • Page 516: Charging System

    16-32 ELECTRICAL SYSTEM Charging System Alternator Cover Removal • Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) • Free the lead from the clamp [A] and hook [B]. • Remove: Alternator Cover Bolts [A] Alternator Cover [B] Alternator Cover Installation •...
  • Page 517: Stator Coil Installation

    ELECTRICAL SYSTEM 16-33 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) • Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area.
  • Page 518 16-34 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 519: Charging Voltage Inspection

    ELECTRICAL SYSTEM 16-35 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 520 16-36 ELECTRICAL SYSTEM Charging System • To check the alternator output voltage, do the following procedures. ○ Turn the ignition switch off. ○ Remove the left inner cover (see Inner Cover Removal in the Frame chapter). ○ Disconnect the alternator lead connector [A]. ○...
  • Page 521: 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 522 16-38 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 2. Load 3. Frame Ground 2 4. Engine Ground 5. Battery 12 V 8 Ah 6. Starter Relay 7. Main Fuse 30 A 8. Alternator 9. Regulator/Rectifier...
  • Page 523: Ignition System

    ELECTRICAL SYSTEM 16-39 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 524: Crankshaft Sensor Inspection

    16-40 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Inspection • Disconnect the crankshaft sensor lead connector (see Crankshaft Sensor Removal). • Set the hand tester [A] to the × 10 Ω range and connect it to the crankshaft sensor lead connector [B]. Special Tool - Hand Tester: 57001-1394 Crankshaft Sensor Resistance Connections:...
  • Page 525: Stick Coil Removal

    ELECTRICAL SYSTEM 16-41 Ignition System Stick Coil Removal • Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). • Disconnect the stick coil connectors [A]. • Pull out the stick coils [B] upward. ○...
  • Page 526: Stick Coil Primary Peak Voltage Inspection

    16-42 ELECTRICAL SYSTEM 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. • Measure the primary peak voltage as follows. ○...
  • Page 527: Spark Plug Condition Inspection

    ELECTRICAL SYSTEM 16-43 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 528: Ic Igniter Inspection

    16-44 ELECTRICAL SYSTEM 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 529 ELECTRICAL SYSTEM 16-45 Ignition System...
  • Page 530 16-46 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Engine Stop Switch 17. Joint Connector C 2. Spark Plugs 18. Frame Ground 2 3. Stick Coils 19. Frame Ground 3 4. Crankshaft Sensor 20. Frame Ground 1 5. Main Throttle Sensor 21.
  • Page 531: Electric Starter System

    ELECTRICAL SYSTEM 16-47 Electric Starter System Starter Motor Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Starter Clutch Cover (see Starter Idle Gear Removal in the Crankshaft/Transmission chapter) • For KIBS equipped models, remove the KIBS hydraulic unit (see KIBS Hydraulic Unit Removal in the Brakes chapter).
  • Page 532: Starter Motor Disassembly

    16-48 ELECTRICAL SYSTEM Electric Starter System • Install the starter motor cable [A] as shown. • Tighten: Torque - Starter Motor Cable Terminal Bolt [B]: 2.9 N·m (0.30 kgf·m, 26 in·lb) • Slide back the rubber cap to the original position. •...
  • Page 533: Brush Inspection

    ELECTRICAL SYSTEM 16-49 Electric Starter System • Press the springs holding the brush leads with suitable clips [A] as shown. • Put the armature [B] among the brushes. • Install the new O-rings [A] as shown. • Align the groove [A] in the left-hand end cover and the hollow mark [B] on the yoke.
  • Page 534: Commutator Cleaning And Inspection

    16-50 ELECTRICAL SYSTEM Electric Starter System Commutator Cleaning and Inspection • Smooth the commutator surface [A] if necessary with fine emery cloth [B], and clean out the grooves. • Measure the diameter [A] of the commutator [B]. If the commutator diameter is less than the service limit, replace the starter motor with a new one .
  • Page 535: Left-hand End Cover Assembly Inspection

    ELECTRICAL SYSTEM 16-51 Electric Starter System Left-hand End Cover Assembly Inspection • Using the highest hand tester range, measure the resis- tance as shown. Terminal and Left-hand End Cover [A] Special Tool - Hand Tester: 57001-1394 If there is any reading, the left-hand end cover assembly have a short.
  • Page 536 16-52 ELECTRICAL SYSTEM 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 D 7. Joint Connector B 8. Frame Ground 3 9. Frame Ground 1 10.
  • Page 537: Lighting System

    ELECTRICAL SYSTEM 16-53 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 538: City Light Bulb Replacement

    16-54 ELECTRICAL SYSTEM Lighting System • Connect the headlight connector. • Install the dust cover [A]. • After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter). ○ Other Bulb: Repeat the above steps. City Light Bulb Replacement •...
  • Page 539: Tail/brake Light (led) Removal/installation

    ELECTRICAL SYSTEM 16-55 Lighting System Tail/Brake Light (LED) Removal/Installation • Remove: Tail/Brake Light Cover (see Rear Fender Removal in the Frame chapter) • Slide the dust cover [A]. • Open the clamp [B]. • Disconnect the tail/brake light lead connector [C]. •...
  • Page 540 16-56 ELECTRICAL SYSTEM Lighting System Headlight/Tail Light Circuit 1. Ignition Switch 15. Headlight Circuit Relay 2. Frame Ground 1 16. Fuse Box 1 3. Tail/Brake Light (LED) 17. Brake Light/Horn Fuse 7.5 A 4. License Plate Light 12 V 5 W 18.
  • Page 541: Turn Signal Light Bulb Replacement

    ELECTRICAL SYSTEM 16-57 Lighting System Turn Signal Light Bulb Replacement Front Turn Signal Light • Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Front Turn Signal Light Screws [A] Front Turn Signal Light [B] • Turn the socket [A] counterclockwise and pull out the socket together with the bulb.
  • Page 542 16-58 ELECTRICAL SYSTEM Lighting System • Install: Front Turn Signal Light [A] Bracket [B] • Tighten: Torque - Front Turn Signal Light Mounting Screws [C]: 1.2 N·m (0.12 kgf·m, 11 in·lb) ○ Other Bulb: Repeat the above steps. Rear Turn Signal Light •...
  • Page 543: Turn Signal Relay Inspection

    ELECTRICAL SYSTEM 16-59 Lighting System Turn Signal Relay Inspection • Remove the front seat cover (see Seat Cover Removal in the Frame chapter). • Pull out the turn signal relay [A] backward, and remove it from the rear fender. • Disconnect the connector.
  • Page 544 16-60 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit 1. Ignition Switch 2. Rear Right Turn Signal Light 12 V 10 W 3. Rear Left Turn Signal Light 12 V 10 W 4. Joint Connector B 5. Frame Ground 3 6.
  • Page 545: Air Switching Valve

    ELECTRICAL SYSTEM 16-61 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 546 16-62 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Circuit 1. Ignition Switch 2. Air Switching Valve 3. Joint Connector D 4. ECU 5. Frame Ground 3 6. Engien Ground 7. Battery 12 V 8 Ah 8. Starter Relay 9. Main Fuse 30 A 10.
  • Page 547: Radiator Fan System

    ELECTRICAL SYSTEM 16-63 Radiator Fan System Fan Motor Inspection • Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). • Slide the dust cover [A]. • Disconnect the connector [B]. • Using an auxiliary leads, supply battery power to the fan motor.
  • Page 548: Meter, Gauge, Indicator Unit

    16-64 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Unit Removal/Installation • Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) • Disconnect: Meter Unit Connector [A] Immobilizer Amplifier Connector [B] (Equipped Models) • Remove the bolts [C]. •...
  • Page 549: Meter Operation Inspection

    ELECTRICAL SYSTEM 16-65 Meter, Gauge, Indicator Unit • Separate the meter assembly [A] and upper meter cover [B]. Meter Operation Inspection Check 1-1: Switching Inspection • Turn the ignition switch on. • Check that the following. ZX636E Model [A] ZX636F Model [B] ○...
  • Page 550 16-66 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • Indicate the ODO mode. • By pushing the RESET button each time while the MODE button pushed in, check that the display [A] changes as follows. NOTE ○ Mile/Km Display can alternate between English and metric modes (mile and km) in the digital meter.
  • Page 551 ELECTRICAL SYSTEM 16-67 Meter, Gauge, Indicator Unit • By pushing (0.3 ∼ 0.4 seconds) the power mode button [A] at the left handlebar switch housing each time, check that the power mode symbol changes to going on. If the display function does not work, check the following parts.
  • Page 552: Meter System Inspection

    16-68 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter System Inspection Check 2-1: Speedometer Inspection • Using the suitable stand, raise the rear wheel off the ground. • Rotate the rear wheel by hand or start the engine. • Check that the display changes speedometer. If the display function does not work, check the following parts.
  • Page 553: Meter Unit Inspection

    ELECTRICAL SYSTEM 16-69 Meter, Gauge, Indicator Unit Meter Unit Inspection • Remove the meter unit (see Meter Unit Removal). [1] Unused [2] Unused [3] Unused [4] Unused [5] Unused [6] Unused [7] Blue High Beam Indicator Light (LED) (+) [8] Green Neutral Indicator Light (LED) (–) [9] Green Turn Signal Indicator Light (LED) (+) for Left [10] Green Turn Signal Indicator Light (LED) (+) for Right [11] Unused...
  • Page 554 16-70 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • Check that the following. ZX636E Model [A] ZX636F Model [B] ○ The following Indicator lights (LED) go on for 1 second. Yellow Shift Up Indicator Light (LED) [C] Yellow Engine Warning Indicator Light (LED) [D] ○...
  • Page 555 ELECTRICAL SYSTEM 16-71 Meter, Gauge, Indicator Unit • Check that the green turn signal indicator light (LED) [A] goes on. If the indicator light does not go on, replace the meter unit. Check 3-5: Red Warning Indicator Light (LED) (Oil Pres- sure Warning) Inspection •...
  • Page 556 16-72 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Unit Circuit (ZX636E Model) 1. Ignition Switch 13. Battery 12 V 8 Ah 2. Oil Pressure Switch 14. Starter Relay 3. Crankshaft Sensor 15. Main Fuse 30 A 4. Water-proof Joint 2 16.
  • Page 557 ELECTRICAL SYSTEM 16-73 Meter, Gauge, Indicator Unit Meter Unit Circuit (ZX636F Model) 1. Ignition Switch 14. Fuel Reserve Switch 2. Oil Pressure Switch 15. KIBS Hydraulic Unit 3. Crankshaft Sensor 16. Frame Ground 2 4. Water-proof Joint 2 17. Mode Switch 5.
  • Page 558: Immobilizer System (equipped Models)

    • Remove the rear seat (see Rear Seat Removal in the Frame chapter). • Remove the immobilizer/Kawasaki diagnostic system connector cap [A]. • Connect the key registration unit [A] and key registration adapter [B] as shown. Special Tools - Key Registration Unit: 57001-1582...
  • Page 559 ELECTRICAL SYSTEM 16-75 Immobilizer System (Equipped Models) • Insert the registered ignition key to the ignition switch and turn it to “ON.” Verified ○ The red warning indicator light (LED) and immobilizer warning symbol [A] blink to display the registration mode (go to the next step).
  • Page 560 16-76 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) ○ If there is any problem in the registration, the red warning indicator light (LED) and immobilizer warning symbol [A] blink to display the collation error. Immobilizer Amplifier Failure When Registered Ignition Key is Inserted. Ignition Key Collation Error •...
  • Page 561 ELECTRICAL SYSTEM 16-77 Immobilizer System (Equipped Models) • Turn the ignition key 1 to “OFF” and remove the ignition key 1. ○ The red warning indicator light (LED) and immobilizer warning symbol [A] blink to display the registration mode. NOTE ○...
  • Page 562 The registration mode automatically ends. • The red warning indicator light (LED) goes off [A]. • Remove the key registration unit, key registration adapter and install the immobilizer/Kawasaki diagnostic system connector cap. NOTE ○ Turn the ignition switch to “ON” with the registered igni- tion key.
  • Page 563 ELECTRICAL SYSTEM 16-79 Immobilizer System (Equipped Models) Spare Ignition Key Registration Flow Chart...
  • Page 564 Ignition Switch and Immobilizer Antenna (see Immobi- lizer System Parts Replacement) Rear Seat (see Rear Seat Removal in the Frame chap- ter) • Remove the immobilizer/Kawasaki diagnostic system connector cap [A]. • Connect the key registration unit [A] and key registration adapter [B] as shown.
  • Page 565 ELECTRICAL SYSTEM 16-81 Immobilizer System (Equipped Models) ○ The red warning indicator light (LED) and immobilizer warning symbol [A] blink 1 time and stops for 1 second and repeats this cycle. Not Verified ○ The red warning indicator light (LED) and immobilizer warning symbol [A] blink to display the collation error.
  • Page 566 16-82 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) • Disconnect the immobilizer antenna connector, then con- nect the antenna connector of the new ignition switch. • Insert the ignition key 1 [A] again into the new ignition switch and turn it to “ON.” NOTE ○...
  • Page 567 ELECTRICAL SYSTEM 16-83 Immobilizer System (Equipped Models) • The ignition key 1 is successfully registered in the ECU. ○ The red warning indicator light (LED) and immobilizer warning symbol [A] blink 2 times and stops for 1 second and then repeats this cycle to indicate successful regis- tering of ignition key 1.
  • Page 568 The registration mode automatically ends. • The red warning indicator light (LED) goes off [A]. • Remove the key registration unit, key registration adapter and install the immobilizer/Kawasaki diagnostic system connector cap. NOTE ○ Turn the ignition switch to “ON” with the registered igni- tion key.
  • Page 569 ELECTRICAL SYSTEM 16-85 Immobilizer System (Equipped Models) • Replace the ECU [A] (see ECU Removal/Installation in the Fuel System (DFI) chapter). • Insert the current registered ignition key into the ignition switch and turn it to “ON.” ○ If there is any problem in the registration, the red warning indicator light (LED) and immobilizer warning symbol [A] blink to display the collation error.
  • Page 570 16-86 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) • Turn to “OFF” the registered ignition key and remove it. ○ The red warning indicator light (LED) and immobilizer warning symbol [A] blink to display the registration mode. NOTE ○ Insert next key and turn it to “ON” within 15 seconds af- ter previous key is turned to “OFF”...
  • Page 571 ELECTRICAL SYSTEM 16-87 Immobilizer System (Equipped Models) • The other remaining ignition key is registered in the ECU. ○ The red warning indicator light (LED) and immobilizer warning symbol [A] blink 2 times and stops for 1 second and then repeats this cycle to indicate successful regis- tration of ignition key.
  • Page 572 16-88 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) ○ If there is any problem in the registration, the red warning indicator light (LED) and immobilizer warning symbol [A] blink to display the collation error. Immobilizer Amplifier Failure Ignition Key Collation Error •...
  • Page 573 ELECTRICAL SYSTEM 16-89 Immobilizer System (Equipped Models) ○ If there is any problem in the registration, the red warning indicator light (LED) and immobilizer warning symbol [A] blink to display the collation error. Immobilizer Amplifier Failure When Registered Ignition Key is Inserted Ignition Key Collation Error •...
  • Page 574 16-90 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) NOTE ○ Turn the ignition switch to “ON” with the registered igni- tion key. ○ Check that the engine can be started using all regis- tered ignition keys.
  • Page 575 ELECTRICAL SYSTEM 16-91 Immobilizer System (Equipped Models) All Keys Initial Registration Flow Chart...
  • Page 576: Immobilizer System Parts Replacement

    16-92 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) Immobilizer System Parts Replacement Ignition Switch Replacement • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) • Open the clamp [A]. • Disconnect the lead connectors [B]. •...
  • Page 577: Immobilizer System Inspection

    ELECTRICAL SYSTEM 16-93 Immobilizer System (Equipped Models) Immobilizer Relational Parts Replacement Chart Failed or Lost Part Ignition Ignition Amplifier Switch Ignition • ○ Ignition • Switch • Amplifier ○ • Replacement Part • Main Replacement Part ○ Additional Replacement Part Immobilizer System Inspection •...
  • Page 578 Immobilizer System (Equipped Models) Immobilizer System Circuit 1. Ignition Switch 2. Joint Connector D 3. ECU 4. Immobilizer/Kawasaki Diagnostic System Connector 5. Frame Ground 1 6. Engine Ground 7. Battery 12 V 8 Ah 8. Starter Relay 9. Main Fuse 30 A 10.
  • Page 579: Switches And Sensors

    ELECTRICAL SYSTEM 16-95 Switches and Sensors Brake Light Timing Inspection • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Brake Light Timing Adjustment • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Switch Inspection •...
  • Page 580: Water Temperature Sensor Inspection

    16-96 ELECTRICAL SYSTEM Switches and Sensors Water Temperature Sensor Inspection • Remove the water temperature sensor (see Wa- ter Temperature Sensor Removal/Installation in the Self-Diagnosis System chapter). • Suspend the sensor [A] in a container of coolant so that the temperature-sensing projection [C] is submerged. •...
  • Page 581: Oxygen Sensor Removal (equipped Models)

    ELECTRICAL SYSTEM 16-97 Switches and Sensors • Draw the fuel out from the fuel tank with a commercially available pump (see Fuel Tank Removal in the Fuel Sys- tem (DFI) chapter). • Connect the test light (12 V 3.4 W bulb in a socket with leads) and the 12 V battery to the fuel pump lead connec- tor in the same way again.
  • Page 582: Oxygen Sensor Heater Inspection (equipped Models)

    16-98 ELECTRICAL SYSTEM Switches and Sensors Oxygen Sensor Heater Inspection (Equipped Models) • Refer to the Oxygen Sensor Heater Resistance Inspec- tion in the Self-Diagnosis System chapter. Gear Position Switch Removal • Remove: Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) Left Lower Fairing (see Lower Fairing Removal in the Frame chapter)
  • Page 583: Gear Position Switch Installation

    ELECTRICAL SYSTEM 16-99 Switches and Sensors Gear Position Switch Installation • Securely place the springs [A] and pins [B] into the holes [C] of the shift drum. • Apply grease to the new O-ring [D]. • Install the gear position switch [E] and holding plate [F]. •...
  • Page 584 16-100 ELECTRICAL SYSTEM Switches and Sensors • Set the hand tester [A] to the × 1 kΩ or × 100 Ω range and connect it to the terminals in the connector [B] and ground. ○ When changing the gear position from lower gear to higher gear, raise the rear wheel off the ground with the stand and rotate the rear wheel by hand.
  • Page 585: Relay Box

    ELECTRICAL SYSTEM 16-101 Relay Box Relay Box Removal • Remove the front seat cover (see Seat Cover Removal in the Frame chapter). • Disconnect the connectors [A]. • Pull out the relay box [B] from the rubber protector [C]. NOTE ○...
  • Page 586: Diode Circuit Inspection

    16-102 ELECTRICAL SYSTEM Relay Box Diode Circuit Inspection • Remove the relay box (see Relay Box Removal). • Check conductivity of the following pairs of terminals (see Relay Box Internal Circuit in this section). Diode Circuit Inspection 1-11, 2-11, 12-13, 12-15, 12-16, 13-14, Tester Connection 13-15 The resistance should be low in one direction and more...
  • Page 587: Fuse

    ELECTRICAL SYSTEM 16-103 Fuse 30 A Main/15 A ECU Fuse Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Starter Relay Cover [A] • Pull out the fuses [A] from the starter relay with needle nose pliers.