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Z1000
Z1000 ABS
Motorcycle
Service Manual

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Table of Contents

   Also See for Kawasaki Z1000

   Summary of Contents for Kawasaki Z1000

  • Page 1 Z1000 Z1000 ABS Motorcycle Service Manual...
  • Page 3: General Information

    Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 5 All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan.
  • Page 6 LIST OF ABBREVIATIONS ampere(s) 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: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................1-10 Unit Conversion Table ......................1-13...
  • Page 12: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 13 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 ZR1000DA (United States and Canada) Left Side View ZR1000DA (United States and Canada) Right Side View Frame Number Engine Number...
  • Page 18 1-8 GENERAL INFORMATION Model Identification ZR1000DA (Europe) Left Side View ZR1000DA (Europe) Right Side View...
  • Page 19 GENERAL INFORMATION 1-9 Model Identification ZR1000EA Left Side View ZR1000EA Right Side View...
  • Page 20: General Specifications

    1-10 GENERAL INFORMATION General Specifications ZR1000DA ∼ DD/EA ∼ ED Items Dimensions Overall Length 2 095 mm (82.48 in.) Overall Width 805 mm (31.7 in.) Overall Height 1 085 mm (42.72 in.) Wheelbase 1 440 mm (56.69 in.) Road Clearance 140 mm (5.51 in.) Seat Height 815 mm (32.1 in.)
  • Page 21 GENERAL INFORMATION 1-11 General Specifications ZR1000DA ∼ DD/EA ∼ ED Items Duration 276° Exhaust: Open 58° BBDC Close 18° ATDC Duration 256° Lubrication System Forced lubrication (wet sump) 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 ZR1000DA ∼ DD/EA ∼ ED Items Rear Suspension: Type Swingarm Wheel Travel 138 mm (5.43 in.) Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 8 Ah Headlight: Type Semi-sealed beam Bulb 12 V 55 W ×...
  • 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 PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-12 Special Tools .......................... 2-14 Periodic Maintenance Procedures..................2-15 Fuel System (DFI)........................ 2-15 Throttle Control System Inspection................... 2-15 Engine Vacuum Synchronization Inspection..............2-15 Idle Speed Inspection .......................
  • Page 26 2-2 PERIODIC MAINTENANCE Steering Stem Bearing Lubrication ................... 2-42 Electrical System ......................... 2-43 Lights and Switches Operation Inspection................ 2-43 Headlight Aiming Inspection ..................... 2-45 Headlight Aiming Adjustment.................... 2-45 Sidestand Switch Operation Inspection ................2-46 Engine Stop Switch Operation Inspection................. 2-47 Others ..........................
  • 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 FREQUENCY Whichever * ODOMETER READING comes ×...
  • Page 28 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page ITEM Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Final Drive Drive chain lubrication condition - Every 600 km (400 mile) 2-32 inspect # Drive chain slack - inspect #...
  • Page 29 PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart #: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping. *: For higher odometer readings, repeat at the frequency interval established here.
  • Page 30 2-6 PERIODIC MAINTENANCE Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page ITEM Every (0.6) (7.5) (15) (22.5) (30) Air cleaner element # - replace Every 18 000 km (11 250 mile) 2-51 Fuel hose - replace 5 years...
  • Page 31: Torque And Locking Agent

    PERIODIC MAINTENANCE 2-7 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 32 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Front Camshaft Chain Guide Bolt (Upper) Plugs 19.6 Rear Camshaft Chain Guide Bolt Spark Plugs 115 in·lb Throttle Body Assy Holder Bolts 106 in·lb Upper Camshaft Chain Guide Bolts 106 in·lb Exhaust Butterfly Valve Actuator Bolts 0.44...
  • Page 33 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Breather Side Plate Bolt 0.60 52 in·lb ← ← Connecting Rod Big End Nuts see the text Breather Plate Bolts 87 in·lb Shift Drum Bearing Holder Bolts 106 in·lb Oil Passage Plugs Oil Passage Plug...
  • Page 34 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Rear Brake Disc Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut Suspension Front Fork Bottom Allen Bolts Front Fork Top Plugs Lower Front Fork Clamp Bolts Piston Rod Nuts Upper Front Fork Clamp Bolts...
  • Page 35 PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Meter Unit Mounting Screws 0.12 11 in·lb Oxygen Sensor (Equipped Models) Switch Housing Screws 0.36 31 in·lb Alternator Cover Bolts (Engine No. ∼ 87 in·lb ZRT00DE013356) Alternator Cover Bolts 106 in·lb Alternator Lead Holding Plate Bolt 106 in·lb...
  • Page 36: Specifications

    2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 1 100 ±50 r/min (rpm) – – – Bypass Screws (Turn Out) 2 1/2 (for reference) –...
  • Page 37 PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Final Drive 20 ∼ 30 mm (0.8 ∼ 1.2 in.) Drive Chain Slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Drive Chain Wear (20-link 319 mm (12.56 in.) Length) Standard Chain: Make...
  • Page 38: Special Tools

    2-14 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers: Spark Plug Wrench, Hex 16: 57001-143 57001-1262 Steering Stem Nut Wrench: Vacuum Gauge: 57001-1100 57001-1369 Jack: Throttle Sensor Setting Adapter: 57001-1238 57001-1538 Oil Filter Wrench: Fuel Hose: 57001-1249 57001-1607 Attachment Jack: Jack Attachment: 57001-1252 57001-1608...
  • Page 39: Periodic Maintenance Procedures

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Fuel System (DFI) Throttle Control System Inspection • Check that the throttle grip [A] moves smoothly from full open to close, and the throttle closes quickly and com- pletely by the return spring in all steering positions. If the throttle grip does not return properly, check the throt- tle cable routing, grip free play, and cable damage.
  • Page 40 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Plug the vacuum hose end [A]. • Connect a vacuum gauge (special tool) and hoses [A] to the fittings on the throttle body. Special Tool - Vacuum Gauge: 57001-1369 • Connect a highly accurate tachometer [B] to one of the stick coil primary leads.
  • Page 41 PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Start the engine and warm it up thoroughly. • Check the idle speed, using a highly accurate tachometer [A]. Idle Speed Standard: 1 100 ±50 r/min (rpm) If the idle speed is out of the specified range, adjust it with the adjusting screw (see Idle Speed Adjustment).
  • Page 42 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures If any one vacuum measurement is out of the specified range after left (#1, #2) and right (#2, #3) synchronization, adjust the bypass screws [A]. Special Tool - Pilot Screw Adjuster, A [B]: 57001-1239 •...
  • Page 43: Idle Speed Inspection

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Back out the same number of turns counted when first turned in. This is to set the screw to its original position. NOTE ○ A throttle body has different “turns out” of the bypass screw for each individual unit.
  • Page 44: Idle Speed Adjustment

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Adjustment • Start the engine and warm it up thoroughly. • Turn the adjusting screw [A] until the idle speed is correct. ○ Open and close the throttle a few times to make sure that the idle speed is within the specified range.
  • Page 45: Evaporative Emission Control System (cal, Sea-b1 And Th Models) Inspection

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Evaporative Emission Control System (CAL, SEA-B1 and TH Models) Inspection • Inspect the canister as follows. ○ Remove the front seat (see Front Seat Removal in the Frame chapter). ○ Remove the canister [A], and disconnect the hoses from the canister.
  • Page 46: Cooling System

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cooling System Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature). • Clear the clutch cable [A] from the clamp [B]. • Check the coolant level in the reserve tank [C] with the motorcycle held perpendicular (Do not use the side- stand.).
  • Page 47: Engine Top End

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted when the engine is cold (room temperature). • Remove: Crankshaft Sensor Cover (see Crankshaft Sensor Re- moval in the Electrical System chapter) Cylinder Head Cover (see Cylinder Head Cover Re- moval in the Engine Top End chapter) •...
  • Page 48: Valve Clearance Adjustment

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures ○ 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 Measuring Valve [A] ○ 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...
  • Page 49 PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures ○ Besides the standard shims in the valve clearance adjust- ment charts, the following shims may be installed at the factory. Although they are not available as spare parts, they can be used to adjust valve clearance. Adjustment Shims Thickness 3.225 mm...
  • Page 50 2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INTAKE VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm Measured clearance is 0.45 mm...
  • Page 51 PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm.
  • Page 52: Air Suction System Damage Inspection

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTICE Be sure to remeasure the clearance after selecting a shim according to the table. If the clearance is out of the specified range, use the additional shim. ○ If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance.
  • Page 53: Clutch

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Clutch Clutch Operation Inspection • Pull the clutch lever just enough to take up the free play [A]. • Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully.
  • Page 54: Wheels/tires

    2-30 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 55: Wheel Bearing Damage Inspection

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Tread Depth Standard: Front: ZR1000D 4.0 mm (0.16 in.) ZR1000E 3.8 mm (0.15 in.) Rear: ZR1000D 5.5 mm (0.22 in.) ZR1000E 5.4 mm (0.22 in.) Service Limit: Front 1 mm (0.04 in.) (AT, CH, DE) 1.6 mm (0.06 in.) Rear 2 mm (0.08 in.) Up to 130 km/h (80 mph)
  • Page 56: Final Drive

    2-32 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 57: Drive Chain Slack Adjustment

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Drive Chain Slack Adjustment • Loosen the left and right chain adjuster clamp bolts [A]. • Using an Allen wrench, turn the adjusters [B] forward or rearward until the drive chain has the correct amount of chain slack.
  • Page 58: Drive Chain Wear Inspection

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Wear Inspection • Remove the chain cover (see Drive Chain Removal in the Final Drive chapter). • Rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain.
  • Page 59: Brakes

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Brakes Brake Fluid Leak (Brake Hose and Pipe) Inspection • For ABS equipped models, remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A], pipes (ABS equipped mod- els) [B] and fittings [C].
  • Page 60: Brake Hose And Pipe Damage And Installation Condition Inspection

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Damage and Installation Condition Inspection • For ABS equipped models, remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Inspect the brake hoses and fittings for deterioration, cracks and signs of leakage.
  • Page 61: Brake Pad Wear Inspection

    PERIODIC MAINTENANCE 2-37 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 62: Brake Light Switch Operation Inspection

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Light Switch Operation Inspection • Turn on the ignition switch. • The brake light [A] should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm (0.39 in.).
  • Page 63: Suspension

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Suspension Front Forks/Rear Shock Absorber Operation Inspection • Pump the forks down and up [A] 4 or 5 times, and inspect the smooth stroke. If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see Front Fork Oil Change in the Suspension chapter).
  • Page 64: Tie-rod Operation Inspection

    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tie-Rod Operation Inspection • Pump the seat down and up 4 or 5 times, and inspect the smooth stroke. If the tie-rod [A] does not smoothly stroke or noise is found, inspect the fasteners and tie-rod bearings (see Rocker Arm/Tie-Rod Bearing, Sleeve Inspection in the Suspension chapter).
  • Page 65 PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures • Bend the claws [A] of the claw washer back. • Remove the steering stem locknut [B] and claw washer [C]. • Adjust the steering. Special Tool - Steering Stem Nut Wrench [A]: 57001-1100 If the steering is too tight, loosen the stem nut a fraction of a turn.
  • Page 66: Steering Stem Bearing Lubrication

    2-42 PERIODIC MAINTENANCE 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 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 67: Electrical System

    PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step • Turn on the ignition switch. • The following lights should go on according to below table. City Light [A] goes on Taillight [B] goes on License Plate Light [C] goes on Meter Panel LCD [D]...
  • Page 68 2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Third Step • Turn on the turn signal switch [A] (left or right position). • The left or right turn signal lights [B] (front and rear) ac- cording to the switch position should flash. •...
  • Page 69: Headlight Aiming Inspection

    PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures • Set the dimmer switch to high beam position. • The low beam [A] and high beam [B] headlights should go on. • The high beam indicator light (LED) [C] should go on. If the high beam headlight and/or high beam indicator light (LED) does not go on, inspect or replace the following item.
  • Page 70: Sidestand Switch Operation Inspection

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures • To move the headlight beam leftward, turn the left ad- juster [A] clockwise and turn the right adjuster counter- clockwise same number as the left adjuster was turned until the beam points straight ahead. •...
  • Page 71: Engine Stop Switch Operation Inspection

    PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures If the sidestand switch operation does not work, inspect or replace the following item. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Ignition Fuse 15 A (see Fuse Inspection in the Electrical System chapter)
  • Page 72: Others

    2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Others Chassis Parts Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○...
  • Page 73 PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures • With the cable disconnected at both ends, the cable should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.
  • Page 74: Bolts, Nuts And Fasteners Tightness Inspection

    2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures Bolts, Nuts and Fasteners Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).
  • Page 75: Replacement Parts

    PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures Replacement Parts Air Cleaner Element Replacement NOTE ○ In dusty areas, the element should be replaced more frequently than the recommended interval. WARNING If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident.
  • Page 76 2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Wipe off the dirt of the surface [A] around the connection using a cloth or a soft brush. When removing with standard tip screwdriver • Insert the standard tip screwdriver [A] into slit on the joint lock [B].
  • Page 77: Coolant Change

    PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures • Run the fuel hose correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Insert the fuel hose joint [A] straight onto the delivery pipe until the hose joint clicks. •...
  • Page 78 2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the right center fairing (see Center Fairing Re- moval in the Frame chapter). • Remove the radiator cap [A] 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 79 PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures • Fill the reserve tank up to the “F” (full) level line [A] with coolant and install the cap [B]. • Start the engine, warm it up thoroughly until the radiator fan turns on and then stop the engine. •...
  • Page 80: Radiator Hose And O-ring Replacement

    2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Thermostat Housing [A] (see Thermostat Removal in the Cooling System chapter) Water Pump Cover [B] (see Water Pump Removal in the Cooling System chapter) Oil Cooler [C] (see Oil Cooler Removal in the Engine Lubrication System chapter)
  • Page 81: Engine Oil Change

    PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the engine oil drain bolt [A] to drain the oil. ○ The oil in the oil filter can be drained by removing the filter (see Oil Filter Replacement).
  • Page 82: Brake Hose Replacement

    2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose Replacement • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Brake Hose Fitting Bolt [A] NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately.
  • Page 83 PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures • For ABS equipped models; note the following. • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Battery Case (see Battery Case Removal in the Frame chapter) Brake Pipe Joint Nuts [A] Bolts [B] Clamps [C]...
  • Page 84: Brake Fluid Change

    2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Change NOTE ○ The procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is the same as for the front brake. • Level the brake fluid reservoir. •...
  • Page 85: Master Cylinder Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-61 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: Screws [A] Cap [B] Diaphragm Plate [C] Diaphragm [D] Float [E] Screw [F]...
  • Page 86: Caliper Rubber Parts Replacement

    2-62 PERIODIC MAINTENANCE 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 87 PERIODIC MAINTENANCE 2-63 Periodic Maintenance Procedures • Remove: Front Caliper Assembly Bolts [A] • Split the front caliper. • Remove: Pad Spring O-ring [A] • Using compressed air, remove the pistons. One way to remove the pistons is as follows. ○...
  • Page 88 2-64 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ If compressed air is not available, do as follows for both calipers coincidentally, with the brake hose connected to the caliper. ○ Prepare a container for brake fluid, and perform the work above it. ○...
  • Page 89 PERIODIC MAINTENANCE 2-65 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) Caliper Holder • Using a rear caliper mounting bolt [A], screw the thread hole for banjo bolt to remove the piston [B].
  • Page 90: Spark Plug Replacement

    2-66 PERIODIC MAINTENANCE Periodic Maintenance Procedures Spark Plug Replacement • Remove the stick coils (see Stick Coil Removal in the Electrical System chapter). • Remove the spark plugs [A] using the plug wrench [B] vertically. Special Tool - Spark Plug Wrench, Hex 16: 57001-1262 •...
  • Page 91 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................3-10 DFI Parts Location........................3-16 Specifications ......................... 3-18 Special Tools and Sealant ...................... 3-20 DFI Servicing Precautions ...................... 3-22 DFI Servicing Precautions ....................3-22 Troubleshooting the DFI System .................... 3-24 Outline ..........................
  • Page 92 3-2 FUEL SYSTEM (DFI) Vehicle-down Sensor Installation ..................3-68 Vehicle-down Sensor Input Voltage Inspection..............3-68 Vehicle-down Sensor Output Voltage Inspection .............. 3-69 Subthrottle Sensor (Service Code 32)..................3-72 Subthrottle Sensor Removal/Adjustment ................3-72 Subthrottle Sensor Input Voltage Inspection..............3-72 Subthrottle Sensor Output Voltage Inspection ..............3-73 Subthrottle Sensor Resistance Inspection ................
  • Page 93 FUEL SYSTEM (DFI) 3-3 DFI Power Source ........................3-108 ECU Fuse Removal ......................3-108 ECU Fuse Installation ....................... 3-108 ECU Fuse Inspection ......................3-108 ECU Main Relay Removal/Installation ................3-108 ECU Main Relay Inspection ....................3-108 Fuel Line..........................3-109 Fuel Pressure Inspection ....................3-109 Fuel Flow Rate Inspection ....................
  • Page 94: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 95 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Cleaner Duct Clamp Bolts 0.20 18 in·lb Delivery Pipe Assy Mounting Screws 0.35 30 in·lb Throttle Body Assy Holder Clamp Bolts 0.30 26 in·lb Upper Air Cleaner Housing Screws 0.11 9.7 in·lb 5.
  • Page 96 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 97 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Intake Air Temperature Sensor Screw 0.12 11 in·lb Oxygen Sensor (Equipped Models) Water Temperature Sensor Exhaust Butterfly Valve Actuator Mounting 0.12 11 in·lb Screws Exhaust Butterfly Valve Actuator Pulley Bolt 0.51 44 in·lb 6.
  • Page 98 3-8 FUEL SYSTEM (DFI) Exploded View...
  • Page 99 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Pump Bolts 87 in·lb 2. Other than CAL, SEA-B1 and TH Models 3. CAL, SEA-B1 and TH Models 4. Separator 5. Canister 6. Blue Hose 7. Green Hose 8.
  • Page 100: Dfi System

    3-10 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 101 FUEL SYSTEM (DFI) 3-11 DFI System 1. ECU 2. Battery 12 V 8 Ah 3. Air Switching Valve 4. Intake Air Pressure Sensor #1 5. Intake Air Pressure Sensor #2 6. Crankshaft Sensor 7. Subthrottle Valve Actuator 8. Subthrottle Sensor 9.
  • Page 102 3-12 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 103 25. Ignition Switch 26. Meter Unit 27. Oil Pressure/FI/Immobilizer Warning Indicator Light (LED) 28. Water-proof Joint C 29. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector 30. Engine Ground 31. Battery 12 V 8 Ah 32. Main Fuse 30 A 33. FI Fuse 15 A 34.
  • Page 104 3-14 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Subthrottle Valve Actuator: LG/R 2. Exhaust Butterfly Valve Actuator (–): GL 3. Exhaust Butterfly Valve Actuator (+): G/R 4. Fuel Pump Relay: BR/Y 5. Power Supply to Sensors: BL 6.
  • Page 105 48. Ground: P 49. Unused 50. External Communication Line (Immobilizer System, Equipped Models/*KDS): LB 51. Meter Unit (Tachometer): R/Y 52. Immobilizer Amplifier (Equipped Models): Y 53. Ground for Fuel System: BK/Y 54. Ground for Ignition System: BK/Y *: KDS (Kawasaki Diagnostic System)
  • Page 106: Dfi Parts Location

    3-16 FUEL SYSTEM (DFI) DFI Parts Location Main Throttle Sensor [A] Subthrottle Sensor [B] Crankshaft Sensor [A] Oxygen Sensor [B] (Equipped Models) Ignition Key (Transponder, Equipped Models) [A] Ignition Switch [B] Immobilizer Antenna [C] (Equipped Models) Warning Indicator Light (LED) [D] Stick Coils [A] Air Switching Valve [B] Intake Air Pressure Sensor #1 [C]...
  • Page 107 Exhaust Butterfly Valve Actuator [A] Battery 12 V 8 Ah [B] Vehicle-down Sensor [C] FI Fuse 15 A [D] Relay Box (ECU Main Relay, Radiator Fan Relay, Fuel Pump Relay) [A] ECU [B] Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector [C] Fuel Pump [A]...
  • Page 108: Specifications

    3-18 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 100 ±50 r/min (rpm) Throttle Body Assy: Throttle Valve Dual throttle valve Bore 38 mm (1.42 in.) Throttle Body Vacuum 40.7 ±1.3 kPa (305 ±10 mmHg) Bypass Screws (Turn Out) 2 1/2 (for reference) ECU:...
  • Page 109 FUEL SYSTEM (DFI) 3-19 Specifications Item Standard Subthrottle Sensor: DC 4.75 ∼ 5.25 V Input Voltage DC 1.08 ∼ 1.12 V at subthrottle valve full close Output Voltage position DC 4.2 ∼ 4.4 V at subthrottle valve full open position (for reference) 4 ∼...
  • Page 110: Special Tools And Sealant

    3-20 FUEL SYSTEM (DFI) Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Throttle Sensor Setting Adapter #1: 57001-125 57001-1400 Carburetor Drain Plug Wrench, Hex 3: Peak Voltage Adapter: 57001-1269 57001-1415 Fork Oil Level Gauge: Needle Adapter Set: 57001-1290 57001-1457 Vacuum Gauge: Throttle Sensor Setting Adapter: 57001-1369...
  • Page 111 FUEL SYSTEM (DFI) 3-21 Special Tools and Sealant Fuel Hose: Liquid Gasket, TB1211: 57001-1607 56019-120 Measuring Adapter: 57001-1700...
  • Page 112: Dfi Servicing Precautions

    3-22 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) 3-23 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

    3-24 FUEL SYSTEM (DFI) Troubleshooting the DFI System The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (equipped models) and oil pressure warning indicator. Outline When a problem occurs with DFI system, the warning in- dicator light (LED) [A] and FI warning symbol [B] blinks to alert the rider.
  • Page 115 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 solving unstable problems. When the motorcycle is down, the vehicle-down sensor operates and the ECU shuts off the fuel pump relay, fuel in- jectors and ignition system.
  • Page 116 3-26 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) 3-27 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

    3-28 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) 3-29 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 3-30 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) 3-31 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 3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Intake air pressure sensor #1 trouble Inspect (see chapter 3).
  • Page 123 FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Intake air pressure sensor #1 trouble Inspect (see chapter 3). Intake air pressure sensor #2 trouble Inspect (see chapter 3).
  • Page 124 3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Other: Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight, and examine leads for signs of burning or fraying (see chapter 3). Poor Running or No Power at High Speed Symptoms or Possible Causes Actions (chapter)
  • Page 125 FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Intake air temperature sensor trouble Inspect (see chapter 3). Miscellaneous: Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Speed sensor trouble Inspect (see chapter 3).
  • Page 126: Self-diagnosis

    3-36 FUEL SYSTEM (DFI) Self-Diagnosis The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (equipped models) and oil pressure warning indicator. Self-diagnosis Outline The self-diagnosis system has two modes and can be switched to another mode by operating the meter unit. User Mode The ECU notifies the rider of troubles in DFI system, igni- tion system and immobilizer system by blinking the warning...
  • Page 127: Self-diagnosis Procedures

    FUEL SYSTEM (DFI) 3-37 Self-Diagnosis Dealer Mode The LCD (Liquid Crystal Display) display the service code(s) [A] to show the problem(s) which the DFI system, ignition system and immobilizer system has at the moment of diagnosis. Self-diagnosis Procedures ○ When a problem occurs with the DFI system and ignition system, the warning indicator light (LED) [A] and FI warn- ing symbol [B] blink.
  • Page 128 3-38 FUEL SYSTEM (DFI) Self-Diagnosis • Turn the ignition switch ON. • Push the left button [A] to display the odometer. • Push the left button [A] for more than two seconds. • The service code [B] is displayed on the LCD by the num- ber of two digits.
  • Page 129: Service Code Reading

    FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Self-Diagnosis Flow Chart Service Code Reading ○ The service code(s) is displayed on the LCD by the num- ber of two digits. ○ When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical or- der.
  • Page 130: Service Code Erasing

    3-40 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Erasing ○ When repair has been done, FI and/or immobilizer warning symbols go off and service code is not displayed. But the service codes stored in memory of the ECU are not erased to preserve the problem history. In this model, the problem history can not be erased.
  • Page 131: Backups

    FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI, ignition or immo- bilizer system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the output voltage is out of the usable range, Main Throttle...
  • Page 132 3-42 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the exhaust butterfly valve sensor system Exhaust fails (the output voltage is out of the usable Butterfly Output Voltage range, wiring short or open), the ECU locks Valve 0.1 ∼...
  • Page 133 FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria Oxygen The oxygen sensor heater If the oxygen sensor heater fails (wiring short Sensor raise temperature of or open), the ECU stops the current to the Heater the sensor for its earlier heater, and it stops the feedback mode of the...
  • Page 134: Main Throttle Sensor (service Code 11)

    3-44 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) The main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 135: Main Throttle Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-45 Main Throttle Sensor (Service Code 11) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→...
  • Page 136 3-46 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) • Turn the ignition switch OFF. • Measure the output voltage with the engine stopped and with the connector joined. • Turn the ignition switch ON. Output Voltage DC 1.02 ∼ 1.06 V at idle throttle opening Standard: DC 4.22 ∼...
  • Page 137: Main Throttle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-47 Main Throttle Sensor (Service Code 11) Main Throttle Sensor Resistance Inspection • Turn the ignition switch OFF. • Disconnect the main throttle sensor connector. ○ Disconnect the main throttle sensor connector and con- nect the harness adapter [A] to the sensor connector only. Special Tool - Throttle Sensor Setting Adapter: 57001 -1538...
  • Page 138: Intake Air Pressure Sensor #1 (service Code 12)

    3-48 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) Intake Air Pressure Sensor #1 Removal NOTICE Never drop the intake air pressure sensor #1 espe- cially on a hard surface. Such a shock to the sensor can damage it. •...
  • Page 139: Intake Air Pressure Sensor #1 Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-49 Intake Air Pressure Sensor #1 (Service Code 12) Intake Air Pressure Sensor #1 Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove the air cleaner housing (see Air Cleaner Housing Removal).
  • Page 140: Intake Air Pressure Sensor #1 Output Voltage Inspection

    3-50 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) Intake Air Pressure Sensor #1 Output Voltage Inspection • Measure the output voltage at the intake air pressure sen- sor #1 in the same way as input voltage inspection, note the following.
  • Page 141 FUEL SYSTEM (DFI) 3-51 Intake Air Pressure Sensor #1 (Service Code 12) If the wiring is good, check the sensor for various vacuum. • Remove the intake air pressure sensor #1 [A] and discon- nect the vacuum hose from the sensor. •...
  • Page 142 3-52 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) ID: Idling Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle Vacuum Pressure (Absolute) ST: Standard of Sensor Output Voltage (V) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (V) Vv: Intake Air Pressure Sensor #1 Output Voltage (V) (Digital Meter Reading)
  • Page 143 FUEL SYSTEM (DFI) 3-53 Intake Air Pressure Sensor #1 (Service Code 12) Intake Air Pressure Sensor #1 Circuit 1. ECU 2. Intake Air Pressure Sensor #1...
  • Page 144: Intake Air Temperature Sensor (service Code 13)

    3-54 FUEL SYSTEM (DFI) Intake Air Temperature Sensor (Service Code 13) Intake Air Temperature Sensor Removal/Instal- lation NOTICE Never drop the intake air temperature sensor espe- cially on a hard surface. Such a shock to the sensor can damage it. •...
  • Page 145: Intake Air Temperature Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-55 Intake Air Temperature Sensor (Service Code 13) • Turn the ignition switch OFF. If the reading is within the standard, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
  • Page 146 3-56 FUEL SYSTEM (DFI) Intake Air Temperature Sensor (Service Code 13) Intake Air Temperature Sensor Circuit 1. ECU 2. Intake Air Temperature Sensor...
  • Page 147: Water Temperature Sensor (service Code 14)

    FUEL SYSTEM (DFI) 3-57 Water Temperature Sensor (Service Code 14) Water Temperature Sensor Removal/Installation NOTICE Never drop the water temperature sensor especially on a hard surface. Such a shock to the sensor can damage it. • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).
  • Page 148: Water Temperature Sensor Resistance Inspection

    3-58 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main and sub harness connectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→...
  • Page 149: Intake Air Pressure Sensor #2 (service Code 16)

    FUEL SYSTEM (DFI) 3-59 Intake Air Pressure Sensor #2 (Service Code 16) Intake Air Pressure Sensor #2 Removal NOTICE Never drop the intake air pressure sensor #2 espe- cially on a hard surface. Such a shock to the sensor can damage it. •...
  • Page 150: Intake Air Pressure Sensor #2 Input Voltage Inspection

    3-60 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #2 (Service Code 16) Intake Air Pressure Sensor #2 Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove the air cleaner housing (see Air Cleaner Housing Removal).
  • Page 151: Intake Air Pressure Sensor #2 Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-61 Intake Air Pressure Sensor #2 (Service Code 16) Intake Air Pressure Sensor #2 Output Voltage Inspection • Measure the output voltage at the intake air pressure sen- sor #2 in the same way as input voltage inspection, note the following.
  • Page 152 3-62 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #2 (Service Code 16) Intake Air Pressure Sensor #2 Circuit 1. ECU 2. Intake Air Pressure Sensor #2...
  • Page 153: Crankshaft Sensor (service Code 21)

    FUEL SYSTEM (DFI) 3-63 Crankshaft Sensor (Service Code 21) The crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no sig- nals. Crankshaft Sensor Removal/Installation • Refer to the Crankshaft Sensor Removal/Installation in the Electrical System chapter. Crankshaft Sensor Resistance Inspection •...
  • Page 154: Speed Sensor (service Code 24, 25)

    3-64 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) Speed Sensor Removal/Installation • Refer to the Speed Sensor Removal/Installation in the Electrical System chapter. Speed Sensor Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF.
  • Page 155: Speed Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-65 Speed Sensor (Service Code 24, 25) Speed Sensor Output Voltage Inspection • Using the stand, raise the rear wheel off the ground. • Measure the output voltage at the speed sensor in the same way as input voltage inspection, note the following. ○...
  • Page 156 3-66 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) Speed Sensor Circuit 1. ECU 2. Speed Sensor 3. Meter Unit...
  • Page 157: Vehicle-down Sensor (service Code 31)

    FUEL SYSTEM (DFI) 3-67 Vehicle-down Sensor (Service Code 31) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks 60 ∼ 70° or more to either side (in fact falls down), the weight turns and the signal changes.
  • Page 158: Vehicle-down Sensor Installation

    3-68 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Installation • Be sure to install the rubber dampers [A] and collars [B] on the battery case. • The UP mark [A] of the sensor should face upward. WARNING Incorrect installation of the vehicle-down sensor could cause sudden loss of engine power.
  • Page 159: Vehicle-down Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-69 Vehicle-down Sensor (Service Code 31) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. ○ Disconnect the ECU and sensor connections. Wiring Inspection ECU Connector [A] ←→ Vehicle-down Sensor Connector [B] BL lead (ECU terminal 5) [C] BR/BK lead (ECU terminal 33) [D]...
  • Page 160 3-70 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) • Hold the sensor vertically. • Measure the output voltage with the engine stopped and with the connector joined. • Turn the ignition switch ON. • Tilt the sensor 60 ∼ 70° or more [A] right or left, then hold the sensor almost vertical with the arrow mark pointed up [B], and measure the output voltage.
  • Page 161 FUEL SYSTEM (DFI) 3-71 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Circuit 1. ECU 2. Vehicle-down Sensor...
  • Page 162: Subthrottle Sensor (service Code 32)

    3-72 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) The subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 163: Subthrottle Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-73 Subthrottle Sensor (Service Code 32) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→ Subthrottle Sensor Connector [B] BL lead (ECU terminal 5) [C] BR/BK lead (ECU terminal 33) [D]...
  • Page 164 3-74 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) • Measure the output voltage with the engine stopped with the connector joined. • Turn the ignition switch ON. • Measure the output voltage when the subthrottle valve is completely closed by turning the lever [A] fully clockwise [B].
  • Page 165: Subthrottle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-75 Subthrottle Sensor (Service Code 32) Subthrottle Sensor Resistance Inspection • Turn the ignition switch OFF. • Disconnect the subthrottle sensor connector. ○ Disconnect the subthrottle sensor connector and connect the harness adapter [A] to the sensor connector only. Special Tool - Throttle Sensor Setting Adapter: 57001 -1538...
  • Page 166: Oxygen Sensor - Not Activated (service Code 33, Equipped Models)

    3-76 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33, Equipped Models) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection • Warm up the engine thoroughly until the radiator fan starts.
  • Page 167 FUEL SYSTEM (DFI) 3-77 Oxygen Sensor - not activated (Service Code 33, Equipped Models) • Separate the air switching valve hoses [A] from the air suction valve covers. ○ Do not disconnect the air switching valve connector [B]. • Install the suitable plugs [A] on the fitting of the air suction valve covers, and shut off the secondary air.
  • Page 168 3-78 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33, Equipped Models) If the reading is out of the standard (with plugs: DC 0.7 V or more, without plugs: DC 0.2 V or less), remove the ECU and check the wiring for continuity between main harness connectors.
  • Page 169: Exhaust Butterfly Valve Actuator Sensor (service Code 34)

    FUEL SYSTEM (DFI) 3-79 Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Removal/Installation The exhaust butterfly valve actuator sensor is built in the exhaust butterfly valve actuator. So, the sensor itself can not be removed. Remove the exhaust butterfly valve actu- ator (see Exhaust Butterfly Valve Actuator Removal).
  • Page 170: Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection

    3-80 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection NOTE ○ Before this inspection, confirm the pulley [A] is original position (see Exhaust Butterfly Valve Actuator Installa- tion). • Disconnect: 2 pins Connector [B] 3 pins Connector [C]...
  • Page 171: Exhaust Butterfly Valve Actuator Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-81 Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Resistance Inspection • Turn the ignition switch OFF. • Disconnect the exhaust butterfly valve actuator sensor connector (3 pins connector) [A]. • Connect a digital meter [B] to the exhaust butterfly valve actuator sensor connector.
  • Page 172: Immobilizer Amplifier (service Code 35, Equipped Models)

    3-82 FUEL SYSTEM (DFI) Immobilizer Amplifier (Service Code 35, Equipped Models) Antenna Resistance Inspection • Turn the ignition switch OFF. • Remove the left center fairing (see Center Fairing Re- moval in the Frame chapter). • Remove the band [A]. •...
  • Page 173: Amplifier Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-83 Immobilizer Amplifier (Service Code 35, Equipped Models) Amplifier Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove the left center fairing (see Center Fairing Re- moval in the Frame chapter).
  • Page 174: Blank Key Detection (service Code 36, Equipped Models)

    13. Main Fuse 30 A 3. Meter Ground lizer Warning Indicator 14. Battery 12 V 8 Ah 4. ECU Light (LED) 15. Immobilizer/Kawasaki Diag- 5. Ignition Switch 10. Relay Box nostic System Connector 6. Immobilizer Antenna 11. ECU Main Relay 16.
  • Page 175: Ecu Communication Error (service Code 39)

    FUEL SYSTEM (DFI) 3-85 ECU Communication Error (Service Code 39) ECU Communication Line Inspection ○ When the data is not sent from the ECU to the meter unit for more than about 10 seconds, the service code 39 is displayed. ○...
  • Page 176: Stick Coils #1, #2, #3, #4 (service Code 51, 52, 53, 54)

    3-86 FUEL SYSTEM (DFI) Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) Stick Coil #1: Service Code 51 Stick Coil #2: Service Code 52 Stick Coil #3: Service Code 53 Stick Coil #4: Service Code 54 Stick Coil Removal/Installation •...
  • Page 177 FUEL SYSTEM (DFI) 3-87 Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) • Turn the ignition switch OFF. If the input voltage is out of the standard, check the wiring for continuity (see wiring diagram in this section). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).
  • Page 178: Radiator Fan Relay (service Code 56)

    3-88 FUEL SYSTEM (DFI) Radiator Fan Relay (Service Code 56) Radiator Fan Relay Removal/Installation ○ The radiator fan relay is built in the relay box [A]. • Refer to the Relay Box Removal in the Electrical System chapter. Radiator Fan Relay Inspection •...
  • Page 179: Subthrottle Valve Actuator (service Code 62)

    FUEL SYSTEM (DFI) 3-89 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal NOTICE Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy especially on a hard surface.
  • Page 180: Subthrottle Valve Actuator Input Voltage Inspection

    3-90 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Disconnect the subthrottle valve actuator connector and connect the harness adapter [A] between these connec- tors as shown in the figure.
  • Page 181 FUEL SYSTEM (DFI) 3-91 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Circuit 1. ECU 2. Subthrottle Valve Actuator...
  • Page 182: Exhaust Butterfly Valve Actuator (service Code 63)

    3-92 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator (Service Code 63) Exhaust Butterfly Valve Actuator Removal NOTICE Never drop the exhaust butterfly valve actuator es- pecially on a hard surface. Such a shock to the ac- tuator can damage it. •...
  • Page 183 FUEL SYSTEM (DFI) 3-93 Exhaust Butterfly Valve Actuator (Service Code 63) • After tightening the pulley bolt, confirm whether pulley [A] is an angle shown in the figure. 41.7° ±7° [B] ○ This position is original position of the pulley. NOTE ○...
  • Page 184: Exhaust Butterfly Valve Actuator Inspection

    3-94 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator (Service Code 63) • Be sure to install the washers [A] on the exhaust butterfly valve actuator [B]. • Tighten: Torque - Exhaust Butterfly Valve Actuator Mounting Screws [C]: 1.2 N ·m (0.12 kgf ·m, 11 in·lb) •...
  • Page 185 FUEL SYSTEM (DFI) 3-95 Exhaust Butterfly Valve Actuator (Service Code 63) If the reading is in specification, remove the ECU and check the wiring for continuity between main harness con- nectors. ○ Disconnect the ECU and actuator connectors. Wiring Inspection ECU Connector [A] ←→...
  • Page 186: Air Switching Valve (service Code 64)

    3-96 FUEL SYSTEM (DFI) Air Switching Valve (Service Code 64) Air Switching Valve Removal/Installation • Refer to the Air Switching Valve Removal/Installation in the Engine Top End chapter. Air Switching Valve Inspection • Refer to the Air Switching Valve Unit Test in the Electrical System chapter.
  • Page 187: Oxygen Sensor Heater (service Code 67, Equipped Models)

    FUEL SYSTEM (DFI) 3-97 Oxygen Sensor Heater (Service Code 67, Equipped Models) Oxygen Sensor Heater Removal/Installation The oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see Oxygen Sensor Removal (Equipped Mod- els) in the Electrical System chapter).
  • Page 188: Oxygen Sensor Heater Power Source Voltage Inspection

    3-98 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67, Equipped Models) Oxygen Sensor Heater Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Disconnect the oxygen sensor lead connector and con- nect the harness adapter [A] between these connectors.
  • Page 189 FUEL SYSTEM (DFI) 3-99 Oxygen Sensor Heater (Service Code 67, Equipped Models) Oxygen Sensor Circuit 1. ECU 2. Frame Ground 3. Meter Ground 4. Oxygen Sensor 5. Ignition Switch 6. Relay Box 7. ECU Main Relay 8. Starter Relay 9. FI Fuse 15 A 10.
  • Page 190: Oxygen Sensor - Incorrect Output Voltage (service Code 94, Equipped Models)

    3-100 FUEL SYSTEM (DFI) Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection • Warm up the engine thoroughly until the radiator fan starts.
  • Page 191 FUEL SYSTEM (DFI) 3-101 Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models) • Separate the air switching valve hoses [A] from the air suction valve covers. ○ Do not disconnect the air switching valve connector [B]. • Install the suitable plugs [A] on the fitting of the air suction valve covers, and shut off the secondary air.
  • Page 192 3-102 FUEL SYSTEM (DFI) Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models) If the reading is out of the standard (with plugs: DC 0.7 V or more, without plugs: DC 0.2 V or less), check the following. Fuel Pressure (see Fuel Pressure Inspection) Fuel Injector (see Fuel Injectors section) If the fuel pressure and fuel injectors are good, replace...
  • Page 193: Warning Indicator Light (led)

    FUEL SYSTEM (DFI) 3-103 Warning Indicator Light (LED) Light (LED) Inspection ○ The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (immobilizer models) and oil pressure warning indicator. ○ In this model, the warning indicator light (LED) (FI/immo- bilizer) blink by the data sent from the ECU.
  • Page 194: Ecu

    3-104 FUEL SYSTEM (DFI) ECU Identification ○ Most countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU with each other and use only the ECU for your model. Other- wise, the motorcycle cannot clear the regulation. ECU Identification Model Part Number [A]...
  • Page 195: Ecu Installation

    FUEL SYSTEM (DFI) 3-105 • Remove: Relay Box (see Relay Box Removal in the Electrical Sys- tem chapter) ECU Connectors [A] ECU [B] ECU Installation • Connect the ECU connectors [A]. • Install the ECU [B] into the rubber protector [C]. •...
  • Page 196 3-106 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 and relay box connectors. • Connect a digital meter [A] to the connectors [B] with the needle adapter set.
  • Page 197 FUEL SYSTEM (DFI) 3-107 ECU Power Source Circuit 1. ECU 2. Frame Ground 3. Meter Ground 4. Ignition Switch 5. Relay Box 6. ECU Main Relay 7. Starter Relay 8. FI Fuse 15 A 9. Main Fuse 30 A 10. Battery 12 V 8 Ah 11.
  • Page 198: Dfi Power Source

    3-108 FUEL SYSTEM (DFI) DFI Power Source ECU Fuse Removal • Refer to the 15 A FI Fuse Removal in the Electrical Sys- tem 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 199: Fuel Line

    FUEL SYSTEM (DFI) 3-109 Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Tank Removal) ○ 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 200: Fuel Flow Rate Inspection

    3-110 FUEL SYSTEM (DFI) Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure with the engine idling. Fuel Pressure (with Engine Idling) Standard: 294 kPa (3.0 kgf/cm², 43 psi) NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications.
  • Page 201 FUEL SYSTEM (DFI) 3-111 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 202: Fuel Pump

    3-112 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 203: Fuel Pump Installation

    FUEL SYSTEM (DFI) 3-113 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 204: Fuel Pump Operating Voltage Inspection

    3-114 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 harness adapter [A] between these connectors as shown.
  • Page 205: Pump Screen, Fuel Filter Cleaning

    FUEL SYSTEM (DFI) 3-115 Fuel Pump Pump Screen, Fuel Filter Cleaning ○ The pump screen [A] and fuel filter [B] are built into the pump and can not be cleaned or checked. If the pump screen or fuel filter is suspected of clogging or being damaged, replace it with the fuel pump as a set.
  • Page 206 3-116 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Circuit 1. ECU 2. Frame Ground 3. Meter Ground 4. Engine Stop Switch 5. Fuel Pump/Fuel Level Sensor 6. Fuse Box 7. Ignition Fuse 15 A 8. Ignition Switch 9. Meter Unit 10.
  • Page 207: Fuel Injectors

    FUEL SYSTEM (DFI) 3-117 Fuel Injectors Fuel Injector Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Fuel Injector Audible Inspection NOTE ○ Be sure the battery is fully charged. • Start the engine, and let it idle. • Apply the tip of a screwdriver [A] to the fuel injector [B]. Put the grip end onto your ear, and listen whether the fuel injector is clicking or not.
  • Page 208: Fuel Injector Power Source Voltage Inspection

    3-118 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove the air cleaner housing (see Air Cleaner Housing Removal). • Turn the ignition switch OFF. • Disconnect the injector connector and connect the har- ness adapter [A] between these connectors as shown.
  • Page 209: Fuel Injector Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-119 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 210: Fuel Injector Fuel Line Inspection

    3-120 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Fuel Line Inspection • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Tank Removal) ○ 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 211 FUEL SYSTEM (DFI) 3-121 Fuel Injectors Fuel Injector Circuit 1. ECU 9. Meter Unit 2. Frame Ground 10. ECU Main Relay 3. Meter Ground 11. Fuel Pump Relay 4. Fuel Injectors 12. Starter Relay 5. Engine Stop Switch 13. FI Fuse 15 A 14.
  • Page 212: Throttle Grip And Cables

    3-122 FUEL SYSTEM (DFI) Throttle Grip and Cables Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Cable Installation •...
  • Page 213: Throttle Body Assy

    FUEL SYSTEM (DFI) 3-123 Throttle Body Assy Idle Speed Inspection/Adjustment • Refer to the Idle Speed Inspection/Adjustment in the Pe- riodic Maintenance chapter. Synchronization Inspection/Adjustment • Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter. Throttle Body Assy Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the...
  • Page 214 3-124 FUEL SYSTEM (DFI) Throttle Body Assy • Slide the dust covers [A]. • Loosen the locknuts [B]. • Turn the adjusters [C] to give the more free play. • Remove: Bolts [A] Throttle Pulley Cover [B] • Remove: Throttle Cable Holder Clamp [A] Throttle Cable Lower Ends [B] •...
  • Page 215: Throttle Body Assy Installation

    FUEL SYSTEM (DFI) 3-125 Throttle Body Assy • Remove the throttle body assy [A] from the throttle body assy holders. • Disconnect the injector connectors [B]. • Remove the clamps [C]. • After removing the throttle body assy, stuff pieces of lint -free, clean cloth into the throttle body assy holders.
  • Page 216: Throttle Body Assy Disassembly

    3-126 FUEL SYSTEM (DFI) Throttle Body Assy Throttle Body Assy Disassembly 1. Subthrottle Valve Actuator 2. Subthrottle Sensor 3. Main Throttle Sensor 4. Throttle Body Assy 5. Fuel Injectors 6. Delivery Pipe Assy NOTICE Do not remove, disassemble or adjust the main throttle sensor, subthrottle sensor, subthrottle valve actuator, throttle link mechanism and throttle body assy, because they are adjust or set surely at...
  • Page 217: Throttle Body Assy Assembly

    FUEL SYSTEM (DFI) 3-127 Throttle Body Assy • Pull out 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 primary fuel injector, especially on a hard surface.
  • Page 218: Air Cleaner

    3-128 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 219: Air Cleaner Housing Installation

    FUEL SYSTEM (DFI) 3-129 Air Cleaner • Loosen the both air cleaner duct clamp bolts [A]. • Lift up the air cleaner housing, and remove the air switch- ing valve hose [A]. • After removing the air cleaner housing, cover the clean cloth on the throttle body assy.
  • Page 220: Fuel Tank

    3-130 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 221 FUEL SYSTEM (DFI) 3-131 Fuel Tank • Open the fuel tank cap [A] to lower the pressure in the tank. ○ During tank removal, keep the tank cap open to release pressure in the tank. This makes fuel spillage less. •...
  • Page 222 3-132 FUEL SYSTEM (DFI) Fuel Tank • Wipe off the dirt of the surface [A] around the connection using a cloth or a soft brush. When removing with standard tip screwdriver • Insert the standard tip screwdriver [A] into slit on the joint lock [B].
  • Page 223 FUEL SYSTEM (DFI) 3-133 Fuel Tank • For the CAL, SEA-B1 and TH models, remove the follow- ing. Fuel Return Hose [A] (red) Fuel Tank Breather Hose [B] (blue) Rear Fuel Tank Bolt [C] • Remove the fuel tank, and place a it on a flat surface. ○...
  • Page 224: Fuel Tank Installation

    3-134 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Installation • Note the above WARNING (see Fuel Tank Removal). • Run the hoses correctly (see Cable, Wire, and Hose Rout- ing section in the Appendix chapter). • Check that the dampers [A], pad [B] and trims [C] are in place on the frame and the fuel tank.
  • Page 225: Fuel Tank And Cap Inspection

    FUEL SYSTEM (DFI) 3-135 Fuel Tank • Insert the fuel hose joint [A] straight onto the fuel outlet pipe until the hose joint clicks. • Push [B] the joint lock [C] until the hose joint clicks. • Push and pull [A] the hose joint [B] back and forth more than two times, and make sure it is locked and does not come off.
  • Page 226: Fuel Tank Cleaning

    3-136 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Cleaning WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the tank in a well-ventilated area, and take care that there are no sparks or flame any- where near the working area.
  • Page 227: Evaporative Emission Control System (cal, Sea-b1 And Th Models)

    FUEL SYSTEM (DFI) 3-137 Evaporative Emission Control System (CAL, SEA-B1 and TH Models) The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.
  • Page 228: Separator Operation Test

    3-138 FUEL SYSTEM (DFI) Evaporative Emission Control System (CAL, SEA-B1 and TH Models) Separator Operation Test WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 229 FUEL SYSTEM (DFI) 3-139 Evaporative Emission Control System (CAL, SEA-B1 and TH Models) 1. Fuel Tank 2. Green Hose (Purge) 3. Clamps 4. White Hose (Vacuum) 5. Blue Hose (Breather) 6. Canister 7. Blue Hose (Breather) 8. Separator 9. Damper (for Separator) 10.
  • Page 231 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Special Tools ......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal/Installation ..............Water Pump..........................
  • Page 232: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 233 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Coolant By-pass Fitting Bolt 0.90 78 in·lb Coolant Drain Bolt 97 in·lb Radiator (Water) Hose Clamp Screws 0.30 26 in·lb Thermostat Housing Bolts 0.60 52 in·lb Water Pipe Bolts 106 in·lb Water Pump Cover Bolts 97 in·lb...
  • Page 234: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart 1. Radiator Cap 9. Outlet Pipe 2. Radiator Fan 10. Water Temperature Sensor 3. Radiator 11. Thermostat Housing 4. Oil Cooler 12. Reserve Tank Overflow Hose 5. Cylinder Head Jacket 13. Reserve Tank 6. Cylinder Jacket 14.
  • Page 235 COOLING SYSTEM 4-5 Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corro- sion. 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 236: 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% −35°C (−31°F) Freezing Point Total Amount...
  • Page 237: Special Tools

    COOLING SYSTEM 4-7 Special Tools Bearing Driver Set: Oil Seal Driver: 57001-1129 57001-1660...
  • Page 238: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the right center fairing (see Center Fairing Re- moval in the Frame chapter). • Visually inspect the coolant [A] in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded.
  • Page 239: 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 240: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove the engine sprocket cover (see Engine Sprocket Cover Removal in the Final Drive chapter).
  • Page 241 COOLING SYSTEM 4-11 Water Pump • Be sure to install the dowel pins [A]. • Install: Water Pump Housing [A] Water Pump Impeller [B] • Tighten: Torque - Water Pump Impeller Bolt [C]: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Be sure to install the dowel pins [D].
  • Page 242: Water Pump Inspection

    4-12 COOLING SYSTEM Water Pump Water Pump Inspection • Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). • Check the drainage outlet passage [A] at the bottom of the water pump body for coolant leaks. If the mechanical seal is damaged, the coolant leaks through the seal and drains through the passage.
  • Page 243: Water Pump Housing Assembly

    COOLING SYSTEM 4-13 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 244: Radiator

    4-14 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal • Remove: Center Fairings (see Center Fairing Removal in the Frame chapter) Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) • Remove: Radiator Hose Clamp [A] Radiator Cap Mounting Bolt [B] Radiator Hose [C] •...
  • Page 245 COOLING SYSTEM 4-15 Radiator • Slide the connector cover [A] to disconnect the radiator fan motor lead connector [B]. • Remove: Radiator Hose Clamp Screw [A] (Loosen) Radiator Hose [B] Radiator Lower Bolt [C] NOTICE Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling effi- ciency.
  • Page 246: Radiator And Radiator Fan Installation

    4-16 COOLING SYSTEM Radiator Radiator and Radiator Fan Installation • Installation is the reverse of removal. • Install the rubber dampers [A] and radiator bracket collars [B] as shown in the figure. [C] Larger [D] Smaller • Fit the slits [A] of the heat insulation rubber plate to the up- per mounting brackets [B] and fan bracket [C] as shown.
  • Page 247: Radiator Cap Inspection

    COOLING SYSTEM 4-17 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 248: Thermostat

    4-18 COOLING SYSTEM Thermostat Thermostat Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) Harness Holder Clamp [A] Water Hose Clamp [B] Water Hose [C] Water Pipe Bolts [D] Water Pipe [E] •...
  • Page 249: Thermostat Inspection

    COOLING SYSTEM 4-19 Thermostat • Replace the O-ring [A] with a new one. • Apply grease to the O-ring, and install it. • Install the thermostat housing cover. NOTE ○ Note that the thermostat does not move at the place when installing the thermostat housing cover.
  • Page 250: Hose And Pipes

    4-20 COOLING SYSTEM Hose and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). •...
  • Page 251: Water Temperature Sensor

    COOLING SYSTEM 4-21 Water Temperature Sensor NOTICE The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it. Water Temperature Sensor Removal/Installation • Refer to the Water Temperature Sensor Removal/Instal- lation in the Fuel System (DFI) chapter.
  • Page 253 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Valve Clearance Inspection ..5-30 Exhaust System Identification ... Valve Clearance Adjustment..5-30 Specifications ........Valve Removal ......5-30 Special Tools and Sealant ....5-11 Valve Installation ......5-30 Clean Air System.......
  • Page 254: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 255 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Suction Valve Cover Bolts 87 in·lb Camshaft Cap Bolts 106 in·lb Camshaft Chain Tensioner Cap Bolt Camshaft Chain Tensioner Mounting Bolts 97 in·lb Camshaft Sprocket Bolts Cylinder Head Bolts (M10) (First) S, MO Cylinder Head Bolts (M10) (Final) S, MO...
  • Page 256 5-4 ENGINE TOP END Exploded View...
  • Page 257 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Exhaust Butterfly Valve Actuator Bolts 0.44 38 in·lb Exhaust Butterfly Valve Actuator Pulley Bolt 0.51 44 in·lb Muffler Body Mounting Bolts Premuffler Chamber Mounting Bolt Muffler Body Clamp Bolts R: Replacement Parts...
  • Page 258: Exhaust System Identification

    5-6 ENGINE TOP END Exhaust System Identification...
  • Page 259 ENGINE TOP END 5-7 Exhaust System Identification Exhaust Pipe Mark Position [A] Left Muffler Body Mark Position [A] Right Muffler Body Mark Position [A]...
  • Page 260 5-8 ENGINE TOP END Exhaust System Identification Exhaust Pipe [A] with Hole [B] for Oxygen Sensor [C] (Equipped Models) Honeycomb Type Catalyst Positions [A]...
  • Page 261: Specifications

    ENGINE TOP END 5-9 Specifications Item Standard Service Limit Camshafts Cam Height: 33.743 ∼ 33.857 mm (1.3285 ∼ 1.3330 in.) Exhaust 33.64 mm (1.324 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 262 5-10 ENGINE TOP END Specifications Item Standard Service Limit Cylinder, Pistons 76.994 ∼ 77.006 mm (3.0313 ∼ 3.0317 in.) Cylinder Inside Diameter 77.09 mm (3.035 in.) 76.974 ∼ 76.984 mm (3.0305 ∼ 3.0309 in.) Piston Diameter 76.82 mm (3.024 in.) 0.010 ∼...
  • Page 263: Special Tools And Sealant

    ENGINE TOP END 5-11 Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 32° - 28: 57001-221 57001-1119 Valve Spring Compressor Assembly: Valve Seat Cutter, 32° - 33: 57001-241 57001-1199 Piston Pin Puller Assembly: Valve Seat Cutter Holder Bar: 57001-910 57001-1128 Valve Seat Cutter, 45°...
  • Page 264 5-12 ENGINE TOP END Special Tools and Sealant Valve Guide Reamer, 4.5: Valve Spring Compressor Adapter, 24: 57001-1333 57001-1586 Valve Seat Cutter, 60° - 33: Compression Gauge Adapter, M10 × 1.0: 57001-1334 57001-1601 Valve Seat Cutter, 60° - 27: L-Shape Hose: 57001-1409 57001-1606 Engine Mount Nut Wrench:...
  • Page 265: Clean Air System

    ENGINE TOP END 5-13 Clean Air System Air Suction Valve Removal • Remove: Left Center Fairing (see Center Fairing Removal in the Frame chapter) Air Switching Valve (see Air Switching Valve Removal) Connector [A] (from Bracket [B] at Left Side) Air Suction Valve Cover Bolts [C] and Bracket Air Suction Valve Covers [D] (Both Sides) •...
  • Page 266: Air Suction Valve Inspection

    5-14 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 267: Air Switching Valve Installation

    ENGINE TOP END 5-15 Clean Air System Air Switching Valve Installation • Install the air switching valve [A] as shown in the figure. [B] Viewed Left Side [C] About 40° Air Switching Valve Operation Test • Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter.
  • Page 268: Cylinder Head Cover

    5-16 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal • Remove: Right Center Fairing (see Center Fairing Removal in the Frame chapter) Radiator Cap Mounting Bolt [A] • Remove: Throttle Pulley Cover Bolts [A] Throttle Pulley Cover [B] •...
  • Page 269 ENGINE TOP END 5-17 Cylinder Head Cover • Using a cleaning fluid, clean off any oil or dirt on the cylin- der head [A] as shown and dry them with a clean cloth. • Apply liquid gasket to the cylinder head as shown. Sealant - Liquid Gasket, TB1216B: 92104-1064 NOTE ○...
  • Page 270: Camshaft Chain Tensioner

    5-18 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 271: Camshaft, Camshaft Chain

    ENGINE TOP END 5-19 Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Crankshaft Sensor Cover (see Crankshaft Sensor Re- moval in the Electrical System chapter) • Turn the crankshaft clockwise, align the #1, 4 mark on the timing rotor with the crankcase timing mark.
  • Page 272: Camshaft Installation

    5-20 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Installation NOTE ○ The crankshaft, camshaft chain and camshaft sprock- ets are different between the early production models ∼ (Engine Number: ZRT00DE016592), the late produc- ∼ tion models (Engine Number: ZRT00DE016593 ) and ZR1000DD/ED.
  • Page 273 ENGINE TOP END 5-21 Camshaft, Camshaft Chain • Using a wrench on the timing rotor bolt [A], turn the crank- shaft clockwise until the line [B] (TDC mark for #1,4 pis- tons) on the timing rotor is aligned with the timing mark [C] (Crankcase Halves Mating Surface).
  • Page 274 5-22 ENGINE TOP END Camshaft, Camshaft Chain ○ The timing marks must be aligned with the cylinder head upper surface [B] (Engine Number: ZRT00DE016593 ∼). EX mark [C] IN mark [D] #1 pin [E] #2 pin [F] #29 pin [G] #30 pin [H]...
  • Page 275 ENGINE TOP END 5-23 Camshaft, Camshaft Chain • Before installing the camshaft caps and upper chain guide, install the camshaft chain tensioner body tem- porarily (see Camshaft Chain Tensioner Installation). • Install the camshaft caps and upper camshaft chain guide [A] as shown in the figure.
  • Page 276: Camshaft, Camshaft Cap Wear Inspection

    5-24 ENGINE TOP END Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear Inspection • Remove: Upper Chain Guide (see Camshaft Removal) Camshaft Caps (see Camshaft Removal) • Cut strips of plastigage (press gauge) to journal width. Place a strip on each journal parallel to the camshaft in- stalled in the correct position.
  • Page 277: Camshaft Chain Removal

    ENGINE TOP END 5-25 Camshaft, Camshaft Chain Camshaft Chain Removal • Split the crankcase (see Crankcase Splitting in the Crank- shaft/Transmission chapter). • Remove the camshaft chain [A] from the crankshaft sprocket. Camshaft Chain Installation NOTE ○ The crankshaft, camshaft chain and camshaft sprock- ets are different between the early production models ∼...
  • Page 278: Cylinder Head

    5-26 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Stick Coils (see Stick Coil Removal in the Electrical Sys- tem chapter) Spark Plugs (see Spark Plug Replacement in the Peri- odic Maintenance chapter)
  • Page 279: Cylinder Head Removal

    ENGINE TOP END 5-27 Cylinder Head Cylinder Head Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Camshafts (see Camshaft Removal) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Exhaust Pipe (see Exhaust Pipe Removal) •...
  • Page 280 5-28 ENGINE TOP END Cylinder Head • Replace the cylinder head gasket [A] with a new one. • Install the dowel pins [B] and cylinder head gasket. • Replace the cylinder head bolt washers [A] with new ones. • Apply molybdenum disulfide oil solution to both sides [B] of the cylinder head bolt washers and threads [C] of the bolts.
  • Page 281: Cylinder Head Warp Inspection

    ENGINE TOP END 5-29 Cylinder Head • Install: Front Camshaft Chain Guide [A] Rear Camshaft Chain Guide [B] New O-rings [C] Collar [D] ○ Apply grease to the new O-ring. • Tighten: Torque - Front Camshaft Chain Guide Bolt (Upper) [E]: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Camshaft Chain Guide Bolt (Lower) [F]: 12 N·m (1.2 kgf·m, 106 in·lb)
  • Page 282: Valves

    5-30 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove: Cylinder Head (see Cylinder Head Removal) Valve Lifter and Shim ○...
  • Page 283: Valve Guide Installation

    ENGINE TOP END 5-31 Valves Valve Guide Installation • Apply oil to the valve guide outer surface before installa- tion. • 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 284: Valve Seat Inspection

    5-32 ENGINE TOP END Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
  • Page 285 ENGINE TOP END 5-33 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 286 5-34 ENGINE TOP END 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 287 ENGINE TOP END 5-35 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 288 5-36 ENGINE TOP END Valves...
  • Page 289: Cylinder, Pistons

    ENGINE TOP END 5-37 Cylinder, Pistons Cylinder Removal • Remove: Lower Radiator Bolt [A] Radiator Bracket Bolt [B] Radiator Bracket [C] Cylinder Head (see Cylinder Head Removal) Engine Bracket (see Engine Removal in the Engine Re- moval/Installation chapter) • Remove: Water Hose Clamp Screw (Loosen) [A] Water Hose [B] •...
  • Page 290: Piston Removal

    5-38 ENGINE TOP END Cylinder, Pistons • The piston ring openings must be positioned as shown in the figure. The openings of the oil ring steel rails must be about 30 ∼ 40° of angle from the opening of the top ring. Top Ring [A] Second Ring [B] Upper Oil Ring Steel Rail [C]...
  • Page 291: Piston Installation

    ENGINE TOP END 5-39 Cylinder, Pistons Piston Installation • 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 292: Piston Wear Inspection

    5-40 ENGINE TOP END Cylinder, Pistons Piston Wear Inspection • Measure the outside diameter [A] of each piston 11 mm (0.43 in.) [B] up from the bottom of the piston at a right angle to the direction of the piston pin. If the measurement is under service limit, replace the pis- ton.
  • Page 293: Piston Ring Thickness Inspection

    ENGINE TOP END 5-41 Cylinder, Pistons Piston Ring Thickness Inspection • Measure the piston ring thickness. ○ Use the micrometer to measure at several points around the ring. Piston Ring Thickness Standard: 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) Top [A] 0.77 ∼...
  • Page 294: Throttle Body Assy Holder

    5-42 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] Bolts [B] Throttle Body Assy Holders [C] Throttle Body Assy Holder Installation •...
  • Page 295: Muffler

    ENGINE TOP END 5-43 Muffler WARNING The exhaust pipe or muffler body can become ex- tremely hot during normal operation and cause se- vere burns. Do not remove the exhaust pipe or muf- fler body while it is hot. Muffler Body Removal Left Muffler Body •...
  • Page 296: Muffler Body Installation

    5-44 ENGINE TOP END Muffler • Remove: Clamp Bolt [A] (Loosen) Right Muffler Body Mounting Bolt [B] and Nut Right Muffler Body [C] (with the cable installed) • Remove: Bolts [A] Exhaust Butterfly Valve Pulley Cover [B] • Loosen the locknuts [A]. •...
  • Page 297 ENGINE TOP END 5-45 Muffler • Thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts and nuts. • Install the removed parts (see appropriate chapters). ○ When installing, run the cables correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
  • Page 298: Exhaust Pipe Removal

    5-46 ENGINE TOP END Muffler Exhaust Pipe Removal • Remove: Muffler Bodies (see Muffler Body Removal) Oxygen Sensor (see Oxygen Sensor Removal (Equipped Models) in the Electrical System chap- ter) • Support the premuffler chamber with the suitable stand [A]. •...
  • Page 299: Exhaust Butterfly Valve Cable Installation

    ENGINE TOP END 5-47 Muffler • Remove: Clamp [A] Exhaust Butterfly Valve Cable Upper Ends [B] Exhaust Butterfly Valve Cables [C] Exhaust Butterfly Valve Cable Installation • Confirm whether pulley [A] is an angle as shown in the figure. 41.7° ±7° [B] ○...
  • Page 300 5-48 ENGINE TOP END Muffler • Install the upper ends of the exhaust butterfly valve ca- bles to the pulley of the exhaust butterfly valve actuator, following the specified installing sequence. ○ First, install the close cable (black) [A]. ○ Second, install the open cable (white) [B].
  • Page 301 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool and Sealant ......................Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Clutch Cable Removal ...................... Clutch Cable Installation ....................Clutch Cable Lubrication....................
  • Page 302: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 303 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Lever Assembly Clamp Bolts 0.80 69 in·lb Clutch Spring Bolts 0.90 78 in·lb Clutch Cover Bolts 87 in·lb Clutch Hub Nut 13.8 99.6 Oil Filler Plug 0.20 18 in·lb CL: Apply cable lubricant.
  • Page 304: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch 51.1 ∼ 51.7 mm (2.01 ∼ 2.04 in.) Clutch Plate Assembly Length – – – 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) Friction Plate Thickness 2.4 mm (0.094 in.) Friction and Steel Plate Warp...
  • Page 305: Special Tool And Sealant

    CLUTCH 6-5 Special Tool and Sealant Clutch Holder: Liquid Gasket, TB1211F: 57001-1243 92104-0004...
  • Page 306: Clutch Lever And Cable

    6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Cable Removal •...
  • Page 307: Clutch Cover

    CLUTCH 6-7 Clutch Cover Clutch Cover Removal • Remove: Rear Lower Fairing (see Rear Lower Fairing Removal in the Frame chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Clutch Cable Lower End Clutch Cover Mounting Bolts [A] •...
  • Page 308: Clutch Cover Disassembly

    6-8 CLUTCH Clutch Cover • Fit the spring [A] as shown in the figure. Viewed from Rear [B] Release Shaft [C] Clutch Cover [D] Clutch Cover Disassembly • Remove: Clutch Cover (see Clutch Cover Removal) Release Lever and Shaft Assembly (see Release Shaft Removal) Oil Filler Plug [A] Oil Seal [B]...
  • Page 309 CLUTCH 6-9 Clutch Cover • Replace the O-ring [A] of the oil filler plug [B] with a new one. • Apply grease to the O-ring. • Tighten: Torque - Oil Filler Plug: 2.0 N·m (0.20 kgf·m, 18 in·lb)
  • Page 310: Clutch Removal

    6-10 CLUTCH Clutch Clutch Removal • Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with Washer, Needle Bearing and Pusher [C]) • Remove: Friction Plates and Steel Plates Spring and Spring Seat NOTE ○...
  • Page 311 CLUTCH 6-11 Clutch • Install the clutch housing [A] to the drive shaft. • While holding the clutch housing, install the needle bear- ing [B] and sleeve [C]. ○ The holes [D] of the sleeve face outward. • Install the following parts to the drive shaft. Spacer ( 47 ×...
  • Page 312 6-12 CLUTCH Clutch • Install the friction plates and steel plates, starting with a friction plate and alternating them. NOTE ○ Install the both ends marked two friction plates at dis- assembled to the their original position. ○ When replace the friction plates with new ones, mark the both end two friction plates so that the two kinds of friction plates do not mix up at opening the package.
  • Page 313: Clutch Plate Assembly Inspection

    CLUTCH 6-13 Clutch Clutch Plate Assembly Inspection • Inspect the friction plate thickness (see Clutch Plate, Wear, Damage Inspection). • Measure the length [A] of the clutch plate assembly as shown in the figure. ○ Assemble: Clutch Hub [B] Spring Seat [C] Spring [D] Friction Plates [E] Steel Plates [F]...
  • Page 314: Clutch Plate, Wear, Damage Inspection

    6-14 CLUTCH Clutch Clutch Plate, Wear, Damage Inspection • Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. • Measure the thickness of each friction plate [A] at several points. If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones.
  • Page 315 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealants ....................Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ Oil Pan Removal .......................
  • Page 316: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 317: Engine Lubrication System

    ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Oil Drain Bolt Lower Fairing Bracket Bolts 106 in·lb Oil Cooler Bolts 106 in·lb Oil Filler Plug 0.20 18 in·lb Oil Filter G, R Oil Filter Pipe Oil Pan Bolts 106 in·lb Oil Passage Plug...
  • Page 318: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1. Oil Screen 9. Oil Pressure Switch 2. Oil Pump 10. Main Oil Passage 3. Output Shaft Oil Passage 11. Oil Cooler 4. Drive Shaft Oil Passage 12. Oil Filter 5. Crankshaft Oil Passage 13.
  • Page 319: Specifications

    ENGINE LUBRICATION SYSTEM 7-5 Specifications Item Standard Engine Oil Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity: 3.2 L (3.4 US gt) (when filter is not removed) 3.8 L (4.0 US gt) (when filter is removed) 4.0 L (4.2 US gt) (when engine is completely dry) Level Between upper and lower level lines (Wait several minutes after...
  • Page 320: Special Tools And Sealants

    7-6 ENGINE LUBRICATION SYSTEM Special Tools and Sealants Outside Circlip Pliers: Liquid Gasket, TB1211: 57001-144 56019-120 Oil Pressure Gauge, 10 kgf/cm²: Liquid Gasket, TB1207B: 57001-164 92104-2068 Oil Pressure Gauge Adapter, PT3/8: 57001-1233...
  • Page 321: Engine Oil And Oil Filter

    ENGINE LUBRICATION SYSTEM 7-7 Engine Oil and Oil Filter WARNING Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter according to the periodic maintenance chart.
  • Page 322: Oil Pan

    7-8 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Removal • Remove: Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Oil Filter (see Oil Filter Replacement in the Periodic Maintenance chapter) Oil Pan Bolts [A] Oil Pan [B] •...
  • Page 323 ENGINE LUBRICATION SYSTEM 7-9 Oil Pan NOTE ○ Make the application finish within 7 minutes when the liquid gasket to the mating surface of the oil pan is ap- plied. ○ Moreover fit the oil pan and tighten the bolts just after application of the liquid gasket.
  • Page 324: Oil Screen

    7-10 ENGINE LUBRICATION SYSTEM Oil Screen Oil Screen Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Screen [A] Oil Screen Installation • Clean the oil screen (see Oil Screen Cleaning). • Replace the O-ring [A] with a new one, and install it. •...
  • Page 325: Oil Pressure Relief Valve

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Oil Screen (see Oil Screen Removal) Oil Pressure Relief Valve [A] Oil Pressure Relief Valve Installation • Apply a non-parmanent locking agent to the threads of the oil pressure relief valve, and tighten it.
  • Page 326: Oil Pump

    7-12 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Remove: Water Pump (see Water Pump Removal in the Cooling System chapter) Oil Pump Cover [A] • Remove: Oil (Water) Pump Shaft [A] with Inner Rotor [B] Outer Rotor [C] Oil Pump Installation •...
  • Page 327: Oil Pump Drive Gear Removal

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump • Pack grease into the cavity [A] between the inner rotor and outer rotor for improve the oil pump initial priming. • Install the dowel pin [B]. • Install the oil pump cover [C] so that the dowel pin fit into the hole [D] of the oil pump cover.
  • Page 328: Oil Cooler

    7-14 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Water Hose Clamp Screws (Loosen) [A] Water Hoses [B] Oil Cooler Bolts [C] Oil Cooler [D] Oil Cooler Installation...
  • Page 329: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-15 Oil Pressure Measurement Oil Pressure Measurement • Remove the right lower fairing (see Lower Fairing Re- moval in the Frame chapter). • Remove the oil passage plug [A]. • Aattach 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 330: Oil Pressure Switch

    7-16 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal • Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Switch Cover [A] Switch Terminal Bolt [B] Oil Pressure Switch [C] Oil Pressure Switch Installation •...
  • Page 331: Oil Pipe

    ENGINE LUBRICATION SYSTEM 7-17 Oil Pipe Oil Pipe Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Pipe [A] Oil Pipe Installation • Replace the O-rings [A] with new ones. • Apply grease to the O-rings, and install them.
  • Page 333 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 334: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 335 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Lower Adjusting Collar Locknut Lower Adjusting Collar 87 in·lb Lower Engine Bracket Bolts Lower Engine Mounting Nut Middle Engine Bracket Bolts L, S Middle Engine Mounting Nut Upper Adjusting Collar 0.51 44 in·lb Upper Adjusting Collar Locknut...
  • Page 336: Special Tool

    8-4 ENGINE REMOVAL/INSTALLATION Special Tool Engine Mount Nut Wrench: 57001-1450...
  • Page 337: 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 338 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove the connector [A] from the bracket on the air suc- tion valve cover. • Disconnect the connector. • Disconnect: Starter Motor Cable (see Starter Motor Removal in the Electrical System chapter) Alternator Lead Connector (see Alternator Cover Re- moval in the Electrical System chapter) Crankshaft Sensor Lead Connector (see Crankshaft Sensor Removal in the Electrical System chapter)
  • Page 339 ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Support the engine with a suitable stand [A]. ○ Put a plank [B] onto the suitable stand for engine balance. • Remove: Upper Engine Mounting Bolt [A] (Both Sides) Middle Engine Mounting Nut [B] and Bolt Lower Engine Mounting Nut [C] •...
  • Page 340: Engine Installation

    8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Installation • Support the engine with a suitable stand. ○ Put a plank onto the suitable stand for engine balance. • Apply 2-stroke oil to the upper adjusting collar [A]. • Screw the upper adjusting collar and lower adjusting col- lar [B] to the frame.
  • Page 341 ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation • Install the engine mounting bolts and nuts, following the specified installing sequence. ○ First, hang the drive chain over the output shaft just before moving the engine into its final position in the frame. ○...
  • Page 342 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). Torque - Engine Ground Cable Terminal Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 343 ENGINE REMOVAL/INSTALLATION 8-11 Engine Removal/Installation • Fill the engine with engine oil (see Engine Oil Change in the Periodic Maintenance chapter). • Fill the engine with coolant (see Coolant Change in the Periodic Maintenance chapter).
  • Page 345 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........Starter Motor Clutch Disassembly 9-28 Specifications ........Starter Motor Clutch Assembly ..9-28 Special Tools and Sealants ....External Shift Mechanism....9-29 Crankcase Splitting......Shift Pedal Removal ....9-29 Crankcase Splitting ...... Shift Pedal Installation ....
  • Page 346: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 347 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Balancer Shaft Clamp Bolt 87 in·lb Balancer Shaft Clamp Lever Bolt Breather Side Plate Bolt 0.60 52 in·lb ← ← Connecting Rod Big End Nuts see the text Breather Plate Bolts 87 in·lb Shift Drum Bearing Holder Bolts 106 in·lb...
  • Page 348 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 349 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Gear Positioning Lever Bolt 106 in·lb Neutral Switch Shift Drum Cam Bolt 106 in·lb Shift Pedal Mounting Bolt Shift Shaft Return Spring Pin EO: Apply engine oil. G: Apply grease. HG: Apply high-temperature grease.
  • Page 350: 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 351 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankshaft Main Bearing Insert Thickness: 1.491 ∼ 1.495 mm (0.0587 ∼ 0.0589 in.) Brown – – – 1.495 ∼ 1.499 mm (0.0589 ∼ 0.0590 in.) Black – – – 1.499 ∼ 1.503 mm (0.0590 ∼ 0.0592 in.) Blue –...
  • Page 352: Special Tools And Sealants

    9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealants Bearing Puller: Bearing Driver Set: 57001-135 57001-1129 Outside Circlip Pliers: Flywheel Holder: 57001-144 57001-1313 Bearing Puller Adapter: Liquid Gasket, TB1216B: 57001-317 92104-1064 Bearing Driver, Liquid Gasket, TB1207B: 57001-382 92104-2068...
  • Page 353: Crankcase Splitting

    CRANKSHAFT/TRANSMISSION 9-9 Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Cylinder (see Cylinder Removal in the Engine Top End chapter) Clutch (see Clutch Removal in the Clutch chapter) External Shift Mechanism (see External Shift Mecha-...
  • Page 354: Crankcase Assembly

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Remove the lower crankcase bolts, following the specified sequence. ○ First, loosen the M7 bolts [A]. ○ Lastly, loosen the M9 bolts as shown sequence [1 ∼ 10] in the figure. • Tap lightly around the crankcase mating surface with a plastic mallet, and split the crankcase.
  • Page 355 CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting • Apply a non-permanent locking agent to the threads of the breather plate bolts [A] and tighten them. Torque - Breather Plate Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the breather side plate [A] so that the plate hole [B] fit the projection [C] of the upper crankcase.
  • Page 356 9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Apply a non-parmanent locking agent to the oil passage plugs [A], and tighten them. Torque - Oil Passage Plugs: 20 N·m (2.0 kgf·m, 15 ft·lb) • Install the oil passage plug [B] in the lower crankcase, and tighten it.
  • Page 357 CRANKSHAFT/TRANSMISSION 9-13 Crankcase Splitting • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant - Liquid Gasket, TB1216B: 92104-1064 NOTE ○ Especially, apply a sealant so that it shall be filled up on the grooves [B]. ○...
  • Page 358 9-14 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Apply molybdenum disulfide oil solution to the lower seating surface [A] on the copper plated washer [B] and threads [C] of the M9 bolts [D]. • Tighten the lower crankcase bolts using the following steps. ○...
  • Page 359 CRANKSHAFT/TRANSMISSION 9-15 Crankcase Splitting • After tightening all crankcase bolts, check the following items. ○ Wipe up the liquid gasket that seeps out around the crankcase mating surface. ○ Crankshaft and transmission shafts turn freely. ○ While spinning the output shaft, gears shift smoothly from the 1st to 6th gear, and 6th to 1st.
  • Page 360: Crankshaft And Connecting Rods

    9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove: Balancer (see Balancer Removal) Crankshaft [A] Crankshaft Installation NOTE ○ The crankshaft, camshaft chain and camshaft sprock- ets are different between the early production models ∼...
  • Page 361: Connecting Rod Installation

    CRANKSHAFT/TRANSMISSION 9-17 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 362 9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install the crankshaft (see Crankshaft Installation). • Install each connecting rod on its original crankpin. ○ The connecting rod big end is bolted using the “plastic region fastening method”. ○ This method precisely achieves the needed clamping force without exceeding it unnecessarily, allowing the use of thinner, lighter bolts further decreasing connecting rod weight.
  • Page 363 CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods • Install new bolts and nuts in reused connecting rod. If the connecting rod assy was replaced, use the bolts and nuts attached to the new connecting rod assy. • Apply a small amount of molybdenum disulfide oil solution to the following portions.
  • Page 364: Crankshaft/connecting Rod Cleaning

    9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install new bolts and nuts in reused connecting rods. If the connecting rod assy was replaced, use the bolts and nuts attached to the new connecting rod assy. • Apply a small amount of molybdenum disulfide oil solution to the following portions.
  • Page 365: Connecting Rod Twist Inspection

    CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods Connecting Rod Twist Inspection • With the big-end arbor [A] still on V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being paralleled with the surface plate over a 100 mm (3.94 in.) length of the arbor to de- termine the amount of connecting rod twist.
  • Page 366 9-22 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 (0.10 mm, 0.0039 in.), replace the bear- ing inserts [A] with inserts painted blue [B]. Check in- sert/crankpin clearance with the plastigage.
  • Page 367: Crankshaft Side Clearance Inspection

    CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rods • Measure the connecting rod big end inside diameter, and mark each connecting rod big end in accordance with the inside diameter. • Tighten the connecting rod big end nuts to the specified torque (see Connecting Rod Installation). NOTE ○...
  • Page 368: Crankshaft Runout Inspection

    9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Runout Inspection • Measure the crankshaft runout. If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: TIR 0.02 mm (0.0008 in.) or less Service Limit: TIR 0.05 mm (0.0020 in.) Crankshaft Main Bearing Insert/Journal Wear Inspection •...
  • Page 369 CRANKSHAFT/TRANSMISSION 9-25 Crankshaft and Connecting Rods • Measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. ○ Crankcase Main Bearing Inside Diameter Marks: “ ” or no mark. • Tighten the crankcase bolts to the specified torque (see Crankcase Assembly).
  • Page 370: Balancer

    9-26 CRANKSHAFT/TRANSMISSION Balancer Balancer Removal • Split the crankcase (see Crankcase Splitting). • Unscrew: Balancer Shaft Clamp Bolt [A] Balancer Shaft Lever [B] Oil Seal [C] • Remove the balancer [D] from the upper crankcase half. Balancer Installation • Check that the rubber dampers [A] are in place as shown in the figure.
  • Page 371: Balancer Adjustment

    CRANKSHAFT/TRANSMISSION 9-27 Balancer • Assemble the crankcase (see Crankcase Assembly). • Fill the oil seal lips with grease. • Install the new oil seal [A] so that its surface is flush with the surface of the crankcase. • Turn the balancer shaft so that its mark [B] faces down- ward.
  • Page 372: Starter Motor Clutch

    9-28 CRANKSHAFT/TRANSMISSION Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal/Installation in the Electrical System chapter. Starter Motor Clutch Inspection • Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Starter Idle Gear and Shaft •...
  • Page 373: External Shift Mechanism

    CRANKSHAFT/TRANSMISSION 9-29 External Shift Mechanism Shift Pedal Removal • Remove: Shift Lever Bolt [A] Shift Lever [B] Shift Pedal Mounting Bolt [C] Shift Pedal [D] with Tie-rod [E] Shift Pedal Installation • Tighten: Torque - Shift Pedal Mounting Bolt [A]: 25 N·m (2.5 kgf·m, 18 ft·lb) Shift Pedal [B] Washer [C]...
  • Page 374: External Shift Mechanism Installation

    9-30 CRANKSHAFT/TRANSMISSION External Shift Mechanism • Pull out the shift shaft assembly [A]. • Remove: Gear Positioning Lever Bolt [A] Gear Positioning Lever [B] Collar and Spring [C] • Remove: Shift Drum Cam Bolt [A] Shift Drum Cam [B] External Shift Mechanism Installation •...
  • Page 375: External Shift Mechanism Inspection

    CRANKSHAFT/TRANSMISSION 9-31 External Shift Mechanism • While prying the gear positioning lever [A], tighten the gear positioning lever bolt [B]. Torque - Gear Positioning Lever Bolt: 12 N·m (1.2 kgf·m, 106 in·lb) • Install the shift shaft [A] so that the return spring pin [A] fits between the spring [C].
  • Page 376 9-32 CRANKSHAFT/TRANSMISSION External Shift Mechanism • Check the gear positioning lever [A] and its spring for breaks or distortion. If the lever or spring are damaged in any way, replace them. • Visually inspect the shift drum cam [B]. If it is badly worn or shows any damage, replace it.
  • Page 377: Transmission

    CRANKSHAFT/TRANSMISSION 9-33 Transmission Transmission Shaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the drive shaft [A] and output shaft [B]. Transmission Shaft Installation • Check to see that the set pins [A] and set rings [B] are in place.
  • Page 378: Transmission Shaft Assembly

    9-34 CRANKSHAFT/TRANSMISSION Transmission • Remove the ball bearing [A] from each shafts. Special Tools - Bearing Puller [C]: 57001-135 Bearing Puller Adapter [D]: 57001-317 • Discard the bearing. ○ For output shaft, remove the collar [B] together with the ball bearing. Transmission Shaft Assembly •...
  • Page 379 CRANKSHAFT/TRANSMISSION 9-35 Transmission • The drive shaft gears can be recognized by size: the gear with the smallest diameter is 1st gear, and the largest one is 6th gear. Be sure that all parts are put back in the cor- rect sequence and all circlips and washers are properly in place.
  • Page 380 9-36 CRANKSHAFT/TRANSMISSION Transmission...
  • Page 381 CRANKSHAFT/TRANSMISSION 9-37 Transmission 1. Output Shaft 2. Collar 3. Bearing 4. Bushing 5. 2nd Gear (39 T) 6. Washer ( 34 × 28.1) 7. Circlips ( 33 × 25.9) 8. Top Gear (25 T) 9. Toothed Washer ( 34) 10. 4th/3rd Gear (25 T/24 T) 11.
  • Page 382: Shift Drum And Fork Removal

    9-38 CRANKSHAFT/TRANSMISSION Transmission Shift Drum and Fork Removal • Remove: Lower Crankcase Half (see Crankcase Splitting) Transmission Shafts (see Transmission Shaft Removal) Gear Positioning Lever (see External Shift Mechanism Removal) Bolts [A] Shift Drum Bearing Holder [B] • Pull out the shift rods [C], and take off the shift forks. •...
  • Page 383: Shift Fork/gear Groove Wear Inspection

    CRANKSHAFT/TRANSMISSION 9-39 Transmission Shift Fork/Gear Groove Wear Inspection • Measure the thickness of the shift fork ears [A], and mea- sure the width of the gear grooves [B]. If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced.
  • Page 384: Ball Bearing, Needle Bearing, And Oil Seal

    9-40 CRANKSHAFT/TRANSMISSION Ball Bearing, Needle Bearing, and Oil Seal Ball and Needle Bearing Replacement NOTICE Do not remove the ball or needle bearings unless it is necessary. Removal may damage them. • Using a press or puller, remove the ball bearing and/or needle bearings.
  • Page 385 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-6 Wheels (Rims) ........................10-7 Front Wheel Removal ....................... 10-7 Front Wheel Installation ....................10-7 Rear Wheel Removal......................10-8 Rear Wheel Installation..................... 10-10 Wheel Inspection ......................10-11 Axle Inspection........................
  • Page 386: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 387 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle 11.0 79.7 Front Axle Clamp Bolt Rear Axle Nut HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 388: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 1.0 mm (0.04 in.) Axle Runout/100 mm TIR 0.1 mm (0.004 in.) or less TIR 0.2 mm (0.008 in.) (3.94 in.)
  • Page 389 WHEELS/TIRES 10-5 Specifications Item Standard Service Limit Replacement Tires: Make, Type Size Front BRIDGESTONE, BATTLAX BT003F 120/70 ZR 17M/C (58W) RACING STREET BRIDGESTONE, BATTLAX BT016F 120/70 ZR 17M/C (58W) HYPERSPORT BRIDGESTONE, BATTLAX BT023F 120/70 ZR 17M/C (58W) Continental, ContiRaceAttack Street 120/70 ZR 17M/C (58W) Continental, ContiRoadAttack 2 120/70 ZR 17M/C (58W)
  • Page 390: Special Tools

    10-6 WHEELS/TIRES Special Tools Inside Circlip Pliers: Bearing Remover Head, 20 × 22: 57001-143 57001-1293 Bearing Driver Set: Bearing Remover Shaft, 13: 57001-1129 57001-1377 Jack: Jack Attachment: 57001-1238 57001-1608 Attachment Jack: 57001-1252...
  • Page 391: Wheels (rims)

    WHEELS/TIRES 10-7 Wheels (Rims) Front Wheel Removal • Remove: Front Caliper Mounting Bolts [A] (Both Sides) Front Calipers [B] (Both Sides) Rear Lower Fairing (see Rear Lower Fairing Removal in the Frame chapter) Front Fender (see Front Fender Removal in the Frame chapter) •...
  • Page 392: Rear Wheel Removal

    10-8 WHEELS/TIRES 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. • Tighten: Torque - Front Axle: 108 N·m (11.0 kgf·m, 79.7 ft·lb) •...
  • Page 393 WHEELS/TIRES 10-9 Wheels (Rims) • Remove: Rear Caliper Mounting Bolts [A] Rear Caliper [B] • For ABS equipped Models, remove the bolt [A] and rear wheel rotation sensor [B]. • Loosen the chain adjuster clamp bolts [A] (Both Sides). • Turn the chain adjuster [B] to make the chain slack.
  • Page 394: Rear Wheel Installation

    10-10 WHEELS/TIRES Wheels (Rims) Rear Wheel Installation • Apply high-temperature grease to the grease seal lips. • Fit the collars on the both sides of the hub. Left Side Collar [A] ( 40 × 35) Right Side Collar [B] ( 44 × 28) •...
  • Page 395: Wheel Inspection

    WHEELS/TIRES 10-11 Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 Attachment Jack: 57001-1252 • Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings (see Hub Bearing Removal/Installation).
  • Page 396: Balance Inspection

    10-12 WHEELS/TIRES Wheels (Rims) Balance Inspection • Remove the front and rear wheels (see Front/Rear Wheel Removal). • Support the wheel so that it can be spun freely. • Spin the wheel lightly, and mark [A] the wheel at the top when the wheel stops.
  • Page 397 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 398: Tires

    10-14 WHEELS/TIRES 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 399 WHEELS/TIRES 10-15 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 400: 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 401: Hub Bearing

    WHEELS/TIRES 10-17 Hub Bearing Hub Bearing Removal • Remove the wheels (see Front/Rear Wheel Removal), and take out the following. Collars [A] Coupling [B] (Out of rear hub) Grease Seals [C] Circlip [D] Special Tool - Inside Circlip Pliers: 57001-143 •...
  • Page 402: Hub Bearing Inspection

    10-18 WHEELS/TIRES Hub Bearing • Replace the circlip with a new one. Special Tool - Inside Circlip Pliers: 57001-143 • Replace the grease seals with new ones. • Press in the grease seals [A] so that the seal surface flush [B] with the end of the hole.
  • Page 403 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 404: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 405 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Chain Adjuster Clamp Bolts Drive Chain Guide Bolts 87 in·lb Engine Sprocket Nut 12.7 92.2 Rear Sprocket Nuts Speed Sensor Mounting Bolt 0.70 61 in·lb HG: Apply high-temperature grease. HO: Apply heavy oil.
  • Page 406: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain 25 ∼ 30 mm (1.0 ∼ 1.2 in.) Drive Chain Slack – – – Drive Chain Wear (20-link Length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 319 mm (12.56 in.) Standard Chain: Make ENUMA...
  • Page 407: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...
  • Page 408: 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 409: Drive Chain Installation

    FINAL DRIVE 11-7 Drive Chain Drive Chain Installation • Install the drive chain to the engine sprocket. • Install: Swingarm (see Swingarm Installation in the Suspension chapter) Rear Wheel (see Rear Wheel Installation in the Wheels/Tires chapter) • Insert the projection [A] on the chain cover into the swingarm hole [B].
  • Page 410 11-8 FINAL DRIVE Drive Chain • Screw the pin holder until it touches chain pin. • Be sure that the cutting pin hits center of chain pin. • Screw the handlebar [A] into body. • Turn the pin holder with wrench [B] clockwise to extract chain pin.
  • Page 411 FINAL DRIVE 11-9 Drive Chain • Turn the pin holder [A] by wrench clockwise until two pins of link come into groove of plate holders [B]. • Take off the plate holder. • Set the plate holder (B) [A] and cutting and riveting pin [B] as shown in the figure.
  • Page 412 11-10 FINAL DRIVE Drive Chain • After staking, check the staked area of the link pin for cracks. • Measure the outside diameter [A] of the link pin and link plates width [B]. Link Pin Outside Diameter 5.6 ∼ 6.0 mm (0.22 ∼ 0.24 in.) Standard: Link Plates Outside Width 20.35 ∼...
  • Page 413: Sprocket, Coupling

    FINAL DRIVE 11-11 Sprocket, Coupling Engine Sprocket Cover Removal • Remove: Engine Sprocket Inner Cover Bolts [A] Engine Sprocket Inner and Outer Cover [B] • Remove the engine sprocket outer cover screws [A] to sparate the outer and inner cover [B]. •...
  • Page 414: Engine Sprocket Removal

    11-12 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove the engine sprocket cover (see Engine Sprocket Cover Removal). • 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 415: Rear Sprocket Installation

    FINAL DRIVE 11-13 Sprocket, Coupling Rear Sprocket Installation • Install the sprocket facing the tooth number marking [A] outward. • Replace the rear sprocket nuts with new ones. • Tighten: Torque - Rear Sprocket Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb) •...
  • Page 416: Coupling Bearing Installation

    11-14 FINAL DRIVE Sprocket, Coupling Coupling Bearing Installation • Replace the bearing with a new one. • Press in the bearing [A] until it is bottomed. Special Tool - Bearing Driver Set [B]: 57001-1129 • Pack the bearing with high-temperature grease. •...
  • Page 417: Sprocket Wear Inspection

    FINAL DRIVE 11-15 Sprocket, Coupling Sprocket Wear Inspection • Visually inspect the engine and rear sprocket teeth for wear and damage. If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see Drive Chain Wear Inspection in the Periodic Maintenance chapter).
  • Page 419 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 420 12-2 BRAKES ABS Servicing Precautions ....................12-33 ABS Troubleshooting Outline.................... 12-35 Inquiries to Rider....................... 12-38 Self-diagnosis Outline ....................... 12-40 Self-diagnosis Procedures ....................12-40 Service Code Clearing Procedures................... 12-41 How to Read Service Codes..................... 12-44 How to Erase Service Codes .................... 12-44 ABS Indicator Light (LED) Inspection ................
  • Page 421: Exploded View

    BRAKES 12-3 Exploded View This page intentionally left blank.
  • Page 422 12-4 BRAKES Exploded View...
  • Page 423 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 8.8 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Brake Disc Mounting Bolts 0.12 11 in·lb Front Brake Light Switch Screw Front Brake Pad Pins...
  • Page 424 12-6 BRAKES Exploded View...
  • Page 425 BRAKES 12-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valve 69 in·lb Brake Hose Banjo Bolts Brake Pedal Bolt 0.90 78 in·lb Rear Brake Disc Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut B: Apply brake fluid.
  • Page 426 12-8 BRAKES Exploded View ABS Equipped Models...
  • Page 427 BRAKES 12-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts Brake Pipe Joint Nuts Front Brake Disc Mounting Bolts Rear Brake Disc Mounting Bolts 5. Front Wheel Rotation Sensor 6. Rear Wheel Rotation Sensor 7. ABS Hydraulic Unit 8.
  • Page 428: 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 62 mm (2.4 in.) below footpeg top –...
  • Page 429 BRAKES 12-11 Special Tools Jack: Jack Attachment: 57001-1238 57001-1608 Attachment Jack: 57001-1252...
  • Page 430: Brake Lever Position Adjustment

    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 holder.
  • Page 431: 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] Brake Pedal Bolt [E] Brake Pedal [F] Brake Pedal Installation • Apply grease to the footpeg pivot shaft [A]. •...
  • Page 432: Calipers

    12-14 BRAKES Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. NOTICE Do not loosen the caliper assembly bolts [D]. Take out only the caliper mounting bolts for caliper re- moval.
  • Page 433: Caliper Installation

    BRAKES 12-15 Calipers Caliper Installation • Install the caliper and brake hose lower end. ○ For the front caliper, install the collars [A] on the fork leg and fit the holes [B] of the front caliper to the collars. ○ Replace the washers on each side of hose fitting with new ones.
  • Page 434: Caliper Fluid Seal Damage Inspection

    12-16 BRAKES 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 435: Rear Caliper Holder Shaft Wear Inspection

    BRAKES 12-17 Calipers Rear Caliper Holder Shaft Wear Inspection The caliper body must slide smoothly on the caliper holder shafts [A]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and con- stant drag on the disc will raise brake and brake fluid tem- perature.
  • Page 436: Brake Pads

    12-18 BRAKES 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 [A] Brake Pads [B] Front Brake Pad Installation • Check that the pad spring [A] is in place on the caliper.
  • Page 437: Rear Brake Pad Removal

    BRAKES 12-19 Brake Pads Rear Brake Pad Removal • Remove the rear caliper with the hose installed (see Rear Caliper Removal). • Remove: Clip [A] Pad Pin [B] • Remove the brake pad [C] of the jaw side from the holder shaft [D], then remove the other pad [E].
  • Page 438: Master Cylinder

    12-20 BRAKES Master Cylinder Front Master Cylinder Removal • Remove the rear view mirror (see Rear View Mirror Re- moval in the Frame chapter). • Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder (see Brake Hose Removal/In- stallation).
  • Page 439: Rear Master Cylinder Installation

    BRAKES 12-21 Master Cylinder Rear Master Cylinder Installation • Replace the cotter pin [A] with a new one. • Insert the cotter pin and bend the pin ends [B]. • Replace the washers on each side of hose fitting with new ones.
  • Page 440: Master Cylinder Inspection (visual Inspection)

    12-22 BRAKES Master Cylinder Master Cylinder Inspection (Visual Inspection) • Remove the master cylinders (see Front/Rear Master Cylinder Removal). • Disassemble the front and rear master cylinders (see Master Cylinder Rubber Parts Replacement in the Peri- odic Maintenance chapter). • Check that there are no scratches, rust or pitting on the inner wall [A] of each master cylinder and on the outside of each piston [B].
  • Page 441: Brake Disc

    BRAKES 12-23 Brake Disc Brake Disc Removal • Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Unscrew the mounting bolts [A], and take off the disc [B]. • Remove the gaskets. Brake Disc Installation • Replace the gaskets with new ones. •...
  • Page 442: Brake Fluid

    12-24 BRAKES Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter. Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action.
  • Page 443 BRAKES 12-25 Brake Fluid • Bleed the brake line and the master cylinder. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].
  • Page 444 12-26 BRAKES Brake Fluid • Follow the procedure below to install the rear brake fluid reservoir cap correctly. ○ First, tighten the brake fluid reservoir cap [B] clockwise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].
  • Page 445 BRAKES 12-27 Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time.
  • Page 446: Brake Hose

    12-28 BRAKES Brake Hose Brake Hose Removal/Installation • Refer to the Brake Hose Replacement in the Periodic Maintenance chapter. Brake Hose and Pipe Inspection • Refer to the Brake Hose and Pipe Damage and Instal- lation Condition Inspection in the Periodic Maintenance chapter.
  • Page 447: Anti-lock Brake System (equipped Models)

    BRAKES 12-29 Anti-Lock Brake System (Equipped Models) Parts Location Front Wheel Rotation Sensor [A] Front Wheel Rotation Sensor Rotor [B] Rear Wheel Rotation Sensor [A] Rear Wheel Rotation Sensor Rotor [B] ABS Indicator Light [A] ABS Hydraulic Unit [A] ABS Fuse Box [A]...
  • Page 448 12-30 BRAKES Anti-Lock Brake System (Equipped Models) ABS Kawasaki Diagnostic System Connector [A] ABS Self-diagnosis Terminal [B]...
  • Page 449 7. Ignition Fuse 10 A 19. Ignition Switch 8. Front Brake Light Switch 20. ABS Hydraulic Unit 9. Meter Ground 21. ABS Kawasaki Self-diagnosis System Con- nector 10. Frame Ground 11. Water-proof Joint C 22. Front Wheel Rotation Sensor 23. Rear Wheel Rotation Sensor 12.
  • Page 450 20. Unused 21. Unused 22. Unused 23. Power Supply to Front Wheel Rotation Sensor 24. ABS Kawasaki Self-diagnosis System Terminal 25. ABS Indicator Light (LED) 26. Power Supply to Rear Wheel Rotation Sensor 27. Front Wheel Rotation Sensor Signal 28. Unused 29.
  • Page 451: Abs Servicing Precautions

    BRAKES 12-33 Anti-Lock Brake System (Equipped Models) ABS Servicing Precautions There are a number of important precautions that should be followed servicing the ABS system. ○ This ABS system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 452 12-34 BRAKES Anti-Lock Brake System (Equipped Models) WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If any of the brake line fittings, including the ABS hydraulic unit joint nuts, or the bleed valve is opened at any time, the air must be bled completely from the brake line.
  • Page 453: Abs Troubleshooting Outline

    BRAKES 12-35 Anti-Lock Brake System (Equipped Models) ○ The ABS indicator light (LED) may come on if the engine is run with the motorcycle on its stand and the transmis- sion in gear. If the indicator light comes on, just turn the ignition switch OFF, then clear service code 42, which in- dicates a “Faulty front wheel rotation sensor”.
  • Page 454 12-36 BRAKES Anti-Lock Brake System (Equipped Models) Even when the ABS is operating normally, the ABS indi- cator light (LED) may light up under the conditions listed be- low. Turn the ignition switch OFF to stop the indicator light. If the motorcycle runs without erasing the service code, the light may light up again.
  • Page 455 BRAKES 12-37 Anti-Lock Brake System (Equipped Models) ABS Diagnosis Flow Chart...
  • Page 456: Inquiries To Rider

    12-38 BRAKES Anti-Lock Brake System (Equipped Models) Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of condition the rider is dissatisfied with. ○ Try to find out exactly what problem occurs under exactly what conditions by asking the rider; know- ing this information may help you reproduce the problem in the shop.
  • Page 457 BRAKES 12-39 Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 1...
  • Page 458: Self-diagnosis Outline

    12-40 BRAKES Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 2 Self-diagnosis Outline When the indicator light has blinked or come on, the ABS hydraulic unit memorizes and stores the service code (17 codes including “Normal Code”) for the service person to troubleshoot easily. The service code memory is powered directly by the battery and cannot be canceled by the ignition switch.
  • Page 459: Service Code Clearing Procedures

    BRAKES 12-41 Anti-Lock Brake System (Equipped Models) • Remove the rear seat (see Rear Seat Removal in the Frame chapter). • Turn on the ignition switch. • Ground the self-diagnosis terminal [A] (Gray) to the bat- tery (–) terminal, using a suitable lead. ○...
  • Page 460 12-42 BRAKES Anti-Lock Brake System (Equipped Models)
  • Page 461 BRAKES 12-43 Anti-Lock Brake System (Equipped Models) Self-diagnosis Flow Chart...
  • Page 462: How To Read Service Codes

    12-44 BRAKES Anti-Lock Brake System (Equipped Models) How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the ABS indicator light (LED) as shown below. ○ Read 10th digit and unit digit as the ABS indicator light (LED) blinks. ○...
  • Page 463 BRAKES 12-45 Anti-Lock Brake System (Equipped Models) Service Code Table Service Light ABS Indicator Light (LED) Problems Code State Rise in heat of solenoid coil by ABS continuousness operation After Start code (not fault) starts, turn off Rear inlet solenoid valve trouble (shorted or open, stuck valve) Rear outlet solenoid valve trouble (shorted or open, stuck valve)
  • Page 464: Abs Indicator Light (led) Inspection

    12-46 BRAKES Anti-Lock Brake System (Equipped Models) ABS Indicator Light (LED) Inspection ○ In this model, the ABS indicator light (LED) [A] goes on or blinks by the control of the ABS hydraulic unit. • Turn the ignition switch ON. If the ABS indicator light (LED) lights, it is normal.
  • Page 465: Abs Solenoid Valve Relay Inspection (service Code 19)

    BRAKES 12-47 Anti-Lock Brake System (Equipped Models) ABS Solenoid Valve Relay Inspection (Service Code 19) • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) • Check the ABS solenoid valve relay fuse (20 A) [A] (see Fuse Inspection in the Electrical System chapter).
  • Page 466: Abs Motor Relay Inspection (service Code 35)

    12-48 BRAKES Anti-Lock Brake System (Equipped Models) If the ABS indicator light (LED) [A] lights, the ABS hy- draulic unit has trouble. Replace the ABS hydraulic unit. If the ABS indicator light (LED) does not light, ABS system is normal (service code is not stored; temporary failure.). ABS Motor Relay Inspection (Service Code 35) •...
  • Page 467: Front Wheel Rotation Sensor Wiring Inspection (service Code 43)

    BRAKES 12-49 Anti-Lock Brake System (Equipped Models) • Check that there is iron or other magnetic deposits be- tween the sensor [A] and sensor rotor [B], and the sensor rotor slots for obstructions. • Check the installation condition of the sensor for loose- ness.
  • Page 468: Rear Wheel Rotation Sensor Signal Abnormal (service Code 44)

    12-50 BRAKES Anti-Lock Brake System (Equipped Models) Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44) • Measure the air gap between the rear wheel rotation sen- sor and sensor rotor (see Wheel Rotation Sensor Air Gap Inspection). • Check the rear wheel rotation sensor (see Rear Wheel Rotation Sensor Inspection).
  • Page 469: Power Supply Voltage Abnormal (low-voltage) (service Code 52)

    BRAKES 12-51 Anti-Lock Brake System (Equipped Models) • Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the ABS indicator light (LED) [A] lights, replace the rear wheel rotation sensor (see Rear Wheel Rotation Sensor Removal).
  • Page 470: Ecu Inspection (service Code 55)

    12-52 BRAKES Anti-Lock Brake System (Equipped Models) ECU Inspection (Service Code 55) • Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the ABS indicator light (LED) [A] lights, the ABS hy- draulic unit has trouble.
  • Page 471 BRAKES 12-53 Anti-Lock Brake System (Equipped Models) • Remove: Battery Case (see Battery Case Removal in the Frame chapter) Brake Hose (see Brake Hose Replacement in the Peri- odic maintenance chapter) • Clean the ABS hydraulic unit. NOTICE Clean all fittings on the ABS hydraulic unit and the rear master cylinder because dirt around the banjo bolts could contaminate the brake fluid in the line during removal/installation.
  • Page 472: Abs Hydraulic Unit Installation

    12-54 BRAKES Anti-Lock Brake System (Equipped Models) • Remove: Bolts [A] ABS Hydraulic Unit [B] NOTICE The ABS hydraulic unit [A] has been adjusted and set with precision at the factory. Do not try to dis- assemble and repair the ABS hydraulic unit. ABS Hydraulic Unit Installation •...
  • Page 473: Front Wheel Rotation Sensor Removal

    BRAKES 12-55 Anti-Lock Brake System (Equipped Models) • Visually inspect the connector terminals [A]. Replace the ABS hydraulic unit or main harness if either of the terminals are cracked, bent, or otherwise damaged. If the ABS hydraulic unit connector is clogged with mud or dust, blow it off with compressed air.
  • Page 474: Rear Wheel Rotation Sensor Removal

    12-56 BRAKES Anti-Lock Brake System (Equipped Models) Rear Wheel Rotation Sensor Removal NOTICE The wheel rotation sensor should be handled care- fully, never struck sharply, as with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made.
  • Page 475: Wheel Rotation Sensor Inspection

    BRAKES 12-57 Anti-Lock Brake System (Equipped Models) Wheel Rotation Sensor Inspection • Remove the front wheel rotation sensor [A] from the front fork. • Remove the rear wheel rotation sensor [B] from the caliper bracket. • Visually inspect the wheel rotation sensors. Replace the wheel rotation sensor if it is cracked, bent, or otherwise damaged.
  • Page 476: Wheel Rotation Sensor Rotor Inspection

    12-58 BRAKES Anti-Lock Brake System (Equipped Models) Wheel Rotation Sensor Rotor Inspection • Remove: Wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter) Brake Disc Mounting Bolts [A] Sensor Rotor [B] Front Wheel [C] Rear Wheel [D] • Visually inspect the wheel rotation sensor rotor. If the rotor is deformed or damaged (chipped teeth [A]), replace the sensor rotor with a new one.
  • Page 477: Fuse Installation

    BRAKES 12-59 Anti-Lock Brake System (Equipped Models) Fuse Installation • If a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage (see Fuse Installation in the Electrical System chapter).
  • Page 479 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 Spring Preload Adjustment ....................13-9 Compression Damping Force Adjustment ................ 13-10 Front Fork Removal (Each Fork Leg) ................13-10 Front Fork Installation .......................
  • Page 480: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 481 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Bottom Allen Bolts Front Fork Top Plugs Lower Front Fork Clamp Bolts Piston Rod Nuts Upper Front Fork Clamp Bolts AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. R: Replacement Parts...
  • Page 482 13-4 SUSPENSION Exploded View...
  • Page 483 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Nut (Lower) Rear Shock Absorber Bolt (Upper) Swingarm Pivot Shaft Swingarm Pivot Adjusting Collar Locknut Swingarm Pivot Shaft Nut 11.0 79.7 Tie-rod Nuts Torque Link Nuts Rocker Arm Nut 2T: Apply 2-stroke oil.
  • Page 484: 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) 2 turns out from the fully clockwise position Rebound Damper Setting (Usable range: 0 ←→ 3 1/2 turns out) 1 3/4 turns out from the fully clockwise position Compression Damper Setting (Usable range: 0 ←→...
  • Page 485: Special Tools

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Fork Oil Level Gauge: 57001-143 57001-1290 Oil Seal & Bearing Remover: Bearing Remover Head, 15 × 17: 57001-1058 57001-1267 Bearing Driver Set: Fork Piston Rod Puller, M10 × 1.0: 57001-1129 57001-1298 Jack: Fork Spring Stopper: 57001-1238 57001-1374 Fork Oil Seal Driver, 41:...
  • Page 486 13-8 SUSPENSION Special Tools Hook Wrench T=3.2 R37: Needle Bearing Driver, 17/ 18: 57001-1539 57001-1609 Fork Spring Compressor: Needle Bearing Driver, 28: 57001-1587 57001-1610 Swingarm Pivot Nut Wrench: Clamp: 57001-1597 57001-1693 Jack Attachment: Bar: 57001-1608 57001-1751...
  • Page 487: Front Fork

    SUSPENSION 13-9 Front Fork Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebound damping adjuster [A] until you feel a click. ○ The standard adjuster setting is the 2 turns out from the fully clockwise position. WARNING If both adjusters are not adjusted equally, handling may be impaired and a hazardous condition may...
  • Page 488: Compression Damping Force Adjustment

    13-10 SUSPENSION Front Fork Compression Damping Force Adjustment • To adjust the compression damping force, turn the com- pression damping adjuster [A] until you feel a click. ○ The standard adjuster setting is the 1 3/4 turns out from the fully clockwise position. WARNING If both adjusters are not adjusted equally, handling may be impaired and a hazardous condition may...
  • Page 489: Front Fork Installation

    SUSPENSION 13-11 Front Fork ○ If fork leg is to be disassembled, loosen the upper and lower front fork clamp bolts to lower the fork leg [A] as shown. And retighten the lower front fork clamp bolts. Then, loosen the top plug beforhand. NOTE ○...
  • Page 490 13-12 SUSPENSION Front Fork • Holding the top plug [A] with a wrench [B], tighten the spring preload adjuster [C]. NOTE ○ After tightening, lift the top plug to make the space. • Side down the damper [D]. • Install the clamps [A] as shown in the figure. NOTE ○...
  • Page 491 SUSPENSION 13-13 Front Fork • Screw the adjust nut [A] onto the compression shaft as shown in the figure. • Screw the locknut [B]. About 20 mm (0.79 in.) [C] • Set the other side compression shaft same process. • Set the holder bar [A] and compression shafts [B].
  • Page 492 13-14 SUSPENSION Front Fork • Remove: Top Plug with the Rebound Damping Adjuster Rod Damper [A] Slider [B] Collar [C] Fork Spring [D] • Drain the fork oil into a suitable container. ○ Pump the piston rod [A] up and down at least ten times to expel the oil from the fork.
  • Page 493 SUSPENSION 13-15 Front Fork Oil Level (fully compressed, without spring) Standard: 100 ±2 mm (3.94 ±0.08 in.) (from the top of the outer tube) NOTE ○ Fork oil level may also be measured using the fork oil level gauge. Special Tool - Fork Oil Level Gauge [A]: 57001-1290 ○...
  • Page 494 13-16 SUSPENSION Front Fork • Check the distance between the upper end [A] of the spring preload adjuster [B] and rebound damping adjuster [C] with a pair of vernier caliper. 1.5 mm (0.059 in.) [D] • Set the fork spring compressor on the slider [A] using the outer tube as a guide.
  • Page 495: Front Fork Disassembly

    SUSPENSION 13-17 Front Fork Front Fork Disassembly • Remove the front fork (see Front Fork Removal). • Drain the fork oil (see Fork Oil Change). • Install the suitable pipe ( 26 ∼ 32) [A] into the cylinder unit. • Set the fork leg inverted.
  • Page 496: Front Fork Assembly

    13-18 SUSPENSION Front Fork Front Fork Assembly • Replace the following parts with new one. Oil Seal [A] Outer Tube Guide Bushing [B] Inner Tube Guide Bushing [C] Dust Seal [D] Retaining [E] Bottom Allen Bolt Gasket • Install the following parts onto the inner tube. Dust Seal Retaining Ring Oil Seal...
  • Page 497: Inner Tube, Outer Tube Inspection

    SUSPENSION 13-19 Front Fork Inner Tube, Outer Tube Inspection • Visually inspect the inner tube [A]. If there is any damage, replace the inner tube. Since damage to the inner tube damages the oil seal and dust seal, replace the oil seal and dust seal whenever the inner tube is replaced.
  • Page 498: Rear Shock Absorber

    13-20 SUSPENSION Rear Shock Absorber Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the lower damping adjuster [A] to the desired position, until you feel a click. ZR1000DA/EA ○ The standard adjuster setting is the 1 3/4 turns out from the fully clockwise position.
  • Page 499: Rear Shock Absorber Removal

    SUSPENSION 13-21 Rear Shock Absorber • Remove the bolts [A] and footpeg bracket (both side) [B] for turning the hook wrench easily. • To adjust the spring preload, turn in the adjusting nut to the desired position and tighten the locknut by using hook wrenches [A] with the rear shock absorber attached the frame.
  • Page 500: Rear Shock Absorber Installation

    13-22 SUSPENSION Rear Shock Absorber • Raise the rear wheel off the ground with the jack. Special Tools - Jack [A]: 57001-1238 Jack Attachment [B]: 57001-1608 WARNING Be sure to hold the front brake when removing the shock absorber, or the motorcycle may fall over. It could cause an accident and injury.
  • Page 501: Rear Shock Absorber Bearing Removal

    SUSPENSION 13-23 Rear Shock Absorber Rear Shock Absorber Bearing Removal • Remove: Rear Shock Absorber (see Rear Shock Absorber Re- moval) Sleeve [A] Grease Seals [B] • Remove the needle bearing [A], using the bearing re- mover head [B] and bearing remover shaft [C]. Special Tools - Bearing Remover Head, 15 ×...
  • Page 502: Swingarm

    13-24 SUSPENSION Swingarm Swingarm Removal • Remove: Rear Brake Hose Lower End (see Rear Caliper Removal in the Brakes chapter) Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Mud Guard (see Mad Guard Removal in the Frame chapter) Rocker Arm (see Rocker Arm Removal) •...
  • Page 503: Swingarm Installation

    SUSPENSION 13-25 Swingarm • Turn the swingarm pivot shaft [A] counterclockwise to free the adjusting collar from the swingarm. ○ Make the gap between the adjusting collar and swingarm. • Pull out the pivot shaft to the right side and remove the swingarm.
  • Page 504: Swingarm Bearing Removal

    13-26 SUSPENSION Swingarm • Tighten the swingarm pivot shaft nut. Torque - Swingarm Pivot Shaft Nut: 108 N·m (11.0 kgf·m, 79.7 ft·lb) • Move the swingarm up and down to check for abnormal friction. • Install the removed parts (see appropriate chapters). Swingarm Bearing Removal •...
  • Page 505: Swingarm Bearing, Sleeve Inspection

    SUSPENSION 13-27 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 [B] in- stalled in the swingarm. ○ The rollers and ball in a bearing normally wear very little, and wear is difficult to measure.
  • Page 506: Tie-rod, Rocker Arm

    13-28 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal • Remove: Mud Guard (see Mud Guard Removal in the Frame chapter) • Squeeze the brake lever slowly and hold it with a band [A]. • Raise the rear wheel off the ground with the jack (see Rear Shock Absorber Removal).
  • Page 507: Tie-rod And Rocker Arm Bearing Removal

    SUSPENSION 13-29 Tie-Rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Removal • Remove: Tie-Rods (see Tie-Rod Removal) Rocker Arm (see Rocker Arm Removal) Sleeves [A] Oil Seals [B] Swingarm [C] (see Swingarm Removal) • Remove the needle bearings [D], using the bearing re- mover head and bearing remover shaft.
  • Page 508: Rocker Arm/tie-rod Bearing, Sleeve Inspection

    13-30 SUSPENSION Tie-Rod, Rocker Arm NOTE ○ Install the needle bearings so that the marked side faces in. Rocker Arm/Tie-Rod Bearing, Sleeve Inspection NOTICE Do not remove the bearings for inspection. Re- moval may damage them. • Visually inspect the rocker arm, or tie-rod sleeves [A] and needle bearings [B].
  • Page 509 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 510: Exploded View

    14-2 STEERING Exploded View...
  • Page 511 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Handlebar Holder Bolts Handlebar Holder Nuts Left Switch Housing Screws 0.36 31 in·lb Right Switch Housing Screws 0.36 31 in·lb Steering Stem Head Bolt 11.0 79.7 Steering Stem Nut AD: Apply adhesive. G: Apply grease.
  • Page 512: Special Tools

    14-4 STEERING Special Tools Head Pipe Outer Race Press Shaft: Steering Stem Bearing Driver, 42.5: 57001-1075 57001-1344 Head Pipe Outer Race Driver, 54.5: Steering Stem Bearing Driver Adapter, 41.5: 57001-1077 57001-1345 Steering Stem Nut Wrench: Head Pipe Outer Race Driver, 55: 57001-1100 57001-1446...
  • Page 513: 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 514: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Upper Fairing Bracket (see Upper Fairing Bracket Re- moval in the Frame chapter) Meter Unit (see Meter Unit Removal in the Electrical Sys- tem chapter) Handlebar (see Handlebar Removal) Front Forks (see Front Fork Removal in the Suspension...
  • Page 515: Stem, Stem Bearing Installation

    STEERING 14-7 Steering Stem • To remove the ball bearing outer races [A] pressed into the head pipe [B], insert a bar [C] into the recesses of head pipe, and applying it to both recess alternately ham- mer it to drive the race out. NOTE ○...
  • Page 516 14-8 STEERING Steering Stem • Install the stem [A] through the head pipe and install the ball bearing [B] and inner race [C] on it. • Install: Stem Cap [D] Steering Stem Nut [E] • Settle the bearings in place as follows. ○...
  • Page 517: Steering Stem Bearing Lubrication

    STEERING 14-9 Steering Stem Steering Stem Bearing Lubrication • Refer to the Steering Stem Bearing Lubrication in the Pe- riodic Maintenance chapter. Steering Stem Warp Inspection • Whenever the steering stem is removed, or if the steering can not be adjusted for smooth action, check the steering stem for straightness.
  • Page 518: Handlebar

    14-10 STEERING Handlebar Handlebar Removal • Remove: Rear View Mirrors (see Rear View Mirrors Removal in the Frame chapter) Clutch Lever Clamp Bolts [A] Clutch Lever Assembly [B] Left Switch Housing [C] Handlebar Weight [D] • Remove: Front Master Cylinder [A] (see Front Master Cylinder Re- moval in the Brakes chapter) Right Switch Housing [B] Throttle Case [C]...
  • Page 519: Handlebar Installation

    STEERING 14-11 Handlebar • Side the dust cover [A] to disconnect the meter unit con- nector. • Remove: Meter Unit Mounting Screws [A] Meter Unit [B] Handlebar Installation • Assemble the meter unit bracket [A] and handlebar holder [B] as shown. ○...
  • Page 520 14-12 STEERING Handlebar • For other than US and CA models, align the punch mark [A] on the handlebar and the corner edge [B] on the upper holder. • Tighten: Torque - Handlebar Holder Bolts [A]: 25 N·m (2.5 kgf·m, 18 ft·lb) •...
  • Page 521 FRAME 15-1 Frame Table of Contents Exploded View........15-2 Fenders ..........15-17 Seats ..........15-9 Front Fender Removal ....15-17 Rear Seat Removal...... 15-9 Front Fender Installation ....15-17 Rear Seat Installation....15-9 Flap and Rear Fender Removal... 15-18 Front Seat Removal ..... 15-9 Flap and Rear Fender Installation 15-19...
  • Page 522: Exploded View

    15-2 FRAME Exploded View ZR1000DA/EA...
  • Page 523 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Center Fairing Assembly Screws 0.12 11 in·lb Front Fender Assembly Screws 0.12 11 in·lb Front Fender Mounting Bolts 0.40 35 in·lb 4. Reflectors (US, CA, and CAL Models) 5. ZR1000DA/EA Early Model...
  • Page 524 15-4 FRAME Exploded View ZR1000DB ∼/EB ∼...
  • Page 525 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Center Fairing Assembly Screws 0.12 11 in·lb Front Fender Assembly Screws 0.12 11 in·lb Front Fender Mounting Bolts 0.40 35 in·lb Rear View Mirror (Lower Hexagonal Area) Rear View Mirror (Upper Hexagonal Area) 6.
  • Page 526 15-6 FRAME Exploded View...
  • Page 527 FRAME 15-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Footpeg Bracket Bolts Rear Footpeg Bracket Bolts Rear Frame Bolts Rear Frame Bracket Bolts Sidestand Bolt Sidestand Locknut R, S Sidestand Bracket Bolts Sidestand Switch Bolt 0.90 78 in·lb 9.
  • Page 528 15-8 FRAME Exploded View 1. Reflectors (US, CA, and CAL Models) 2. ZR1000DC/EC Late Models ∼ R: Replacement Parts...
  • Page 529: Seats

    FRAME 15-9 Seats Rear Seat Removal • Insert the ignition switch key [A] into the seat lock, turning the key clockwise, pulling the front part of the seat [B] up, and pull the seat forward. Rear Seat Installation • Insert the rear seat hook [A] under the rear frame [B]. •...
  • Page 530: Fairings

    15-10 FRAME Fairings Lower Fairing Removal • Remove: Quick Rivets [A] Bolts [B] • Pull out the lower fairing [C]. Lower Fairing Installation • Be sure to install the dampers [A]. • For left lower fairing installation, insert the stopper [A] into the damper [B] on the oil pan bracket.
  • Page 531: Rear Lower Fairing Installation

    FRAME 15-11 Fairings Rear Lower Fairing Installation • Insert the projection [A] into the damper [B] on the right lower fairing. • Insert the projection [C] into the damper [D]. Center Fairing Removal • Remove: Bolt [A] • Clear the clutch cable from the holder [A]. •...
  • Page 532: Windshield Removal

    15-12 FRAME Fairings Windshield Removal • Remove: Bolts [A] with Washers Windshield [B] Windshield Installation • Installation is the reverse of removal. Upper Fairing Removal • Remove: Windshield (see Windshield Removal) Quick Rivets [A] (Both Sides) • Remove: Bolts [A] •...
  • Page 533: Upper Fairing Disassembly

    FRAME 15-13 Fairings Upper Fairing Disassembly • Remove: Upper Fairing (see Upper Fairing Removal) Bolts [A] Quick Rivets [B] Headlight [C] • Remove: Bolts [A] • Separate the upper fairing. Upper Fairing Assembly • Fit the projection [A] into the slit [B]. Upper Fairing Installation •...
  • Page 534: Upper Fairing Bracket Installation

    15-14 FRAME Fairings • Remove: Upper Fairing (see Upper Fairing Removal) Throttle Cables [A] Meter Unit Lead [B] Right Switch Housing Lead [C] Left Switch Housing Lead [D] Bolts [E] Upper Fairing Bracket [F] Upper Fairing Bracket Installation • Installation is the reverse of removal. ○...
  • Page 535: Side Covers

    FRAME 15-15 Side Covers Side Cover Removal • Remove: Seat (see Seat Removal) Bolts [A] • Pull the side cover [B] outward to clear the stopper [C]. Side Cover Installation • Be sure to install the pads [A]. • Hang the hooks [A] to the frame. •...
  • Page 536: Seat Covers

    15-16 FRAME Seat Covers Seat Cover Removal • Remove: Seats (see Rear/Front Seat Removal) Bolts [A] and Washers Seat Cover [B] ○ Pull out the seat cover rearward to clear the craws. Seat Cover Installation • Fit the craws [A] into the slits [B] on the rear fender.
  • Page 537: Fenders

    FRAME 15-17 Fenders Front Fender Removal • Remove: Brake Hose Clamps [A] (Both Sides) Front Fender Mounting Bolts [B] with Washers (Both Sides) Front Fender Assy [C] • Remove the front fender assembly screws [A]. • Separate the front fender side covers [B] and front fender. Front Fender Installation •...
  • Page 538: Flap And Rear Fender Removal

    15-18 FRAME Fenders • Install the brake hose clamps to the front fender holes. • For ZR1000DC ∼/EC ∼, face the lock [A] of the brake hose clamp backward. Flap and Rear Fender Removal • Remove: Seat Covers (see Seat Cover Removal) Owner’s Tool [A] and Pad •...
  • Page 539: Flap And Rear Fender Installation

    FRAME 15-19 Fenders • Remove: Bolts [A] Screw [B] • Push the rear fender [A] downward. • Remove: Relay Box [B] ECU [C] Turn Signal Relay [D] • Remove the rear fender rearward. Flap and Rear Fender Installation • Installation is the reverse of removal. •...
  • Page 540: Frame Inspection

    15-20 FRAME Frame Frame Inspection • Visually inspect the frame for cracks, dents, bending, or warp. ○ If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident resulting in injury or death. If the frame is bent, dented, cracked, or warped, replace it.
  • Page 541: Battery Case

    FRAME 15-21 Battery Case Battery Case Removal • Remove: Battery (see Battery Removal in the Electrical System chapter) Exhaust Butterfly Valve Actuator [A] (see Exhaust But- terfly Valve Actuator Removal in the Fuel System (DFI) chapter) Seat Bracket • Disconnect: Vehicle-down Sensor Connector [B] Starter Relay Connector [C] •...
  • Page 542: Guard

    15-22 FRAME Guard Mud Guard Removal • Remove: Rear Lower Fairing (see Rear Lower Fairing Removal) Right Front Footpeg Bracket Bolts [A] • Remove: Bolts [A] • Remove: Quick Rivets [A] Mud Guard [B] Mud Guard Installation • Installation is the reverse of removal. note the following. Torque - Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
  • Page 543: Sidestand

    FRAME 15-23 Sidestand Sidestand Removal • Raise the rear wheel off the ground with the stand. • Remove: Sidestand Switch Bolt [A] and Nut [B] Sidestand Switch [C] • Remove: Spring [A] Sidestand Nut [B] Sidestand Bolt [C] Sidestand [D] Sidestand Installation •...
  • Page 544: Rear View Mirrors

    15-24 FRAME Rear View Mirrors Rear View Mirrors Removal (ZR1000DA/EA) • Slide the cover [A] upward. • Loosen the lower hexagonal area [B] to remove the rear view mirror from the holder. NOTICE Do not force to tighten and/or loosen the upper hexagonal area (adapter) [C] with a pair of span- ners.
  • Page 545: Rear View Mirrors Installation (zr1000db /eb )

    FRAME 15-25 Rear View Mirrors ∼ ∼ Rear View Mirrors Installation (ZR1000DB • Tighten: Torque - Lower Hexagonal Area [B]: 30 N·m (3.1 kgf·m, 22 ft·lb) Upper Hexagonal Area [A]: 18 N·m (1.8 kgf·m, 13 ft·lb) ○ The lock nut and rear view mirror are left-hand thread. ○...
  • Page 547 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-4 Specifications ......................... 16-10 Special Tools and Sealant ...................... 16-11 Parts Location......................... 16-13 Wiring Diagram (US and CA Models)..................16-16 Wiring Diagram (Other than US and CA Models)..............16-18 Wiring Diagram (ABS Equipped Models) ................16-20 Precautions..........................
  • Page 548 16-2 ELECTRICAL SYSTEM Commutator Cleaning and Inspection................16-52 Armature Inspection......................16-53 Brush Lead Inspection ...................... 16-53 Right-hand End Cover Inspection ..................16-53 Starter Relay Inspection....................16-53 Lighting System ........................16-56 Headlight Beam Horizontal Adjustment ................16-56 Headlight Beam Vertical Adjustment................. 16-56 Headlight Bulb Replacement ....................
  • Page 549 ELECTRICAL SYSTEM 16-3 Fuse Installation........................ 16-127 Fuse Inspection......................... 16-128...
  • Page 550: Exploded View

    16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 551: Electrical System

    ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Light Switch Screw 0.12 11 in·lb Front Turn Signal Light Mounting Screws 0.12 11 in·lb Licence Plate Light Mounting Screws 0.12 11 in·lb Meter Unit Mounting Screws 0.12 11 in·lb Oxygen Sensor (Equipped Models)
  • Page 552 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 553 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Alternator Cover Bolts (Engine No. ∼ 87 in·lb ZRT00DE013356) 106 in·ib Alternator Cover Bolts Alternator Lead Holding Plate Bolt 106 in·ib Alternator Rotor Bolt 15.8 Brush Holder Screw 0.39 34 in·ib Crankshaft Sensor Bolts 0.60...
  • Page 554 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 555 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Ground Cable Terminal Bolt 87 in·lb Neutral Switch Sidestand Switch Bolt 0.90 78 in·lb Speed Sensor Mounting Bolt 0.70 61 in·lb 5. Air Switching Valve 6. Fuel Box 7.
  • Page 556: 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 43 V or more at 4 000 rpm Alternator Output Voltage 0.18 ∼...
  • Page 557: Special Tools And Sealant

    ELECTRICAL SYSTEM 16-11 Special Tools and Sealant Hand Tester: Grip: 57001-1394 57001-1591 Peak Voltage Adapter: Flywheel & Pulley Holder: 57001-1415 57001-1605 Lead Wire - Peak Voltage Adapter: Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: 57001-1449 57001-1615 Needle Adapter Set: Stopper: 57001-1457 57001-1679...
  • Page 558 16-12 ELECTRICAL SYSTEM Special Tools and Sealant Key Registration Adapter: Liquid Gasket, TB1211F: 57001-1746 92104-0004...
  • Page 559: Parts Location

    ELECTRICAL SYSTEM 16-13 Parts Location 1. Timing Rotor 2. Crankshaft Sensor 3. Horn 4. Oxygen Sensor (Equipped Models) 5. Relay Box 6. ECU 7. Turn Signal Relay 8. Rear Brake Light Switch 9. Regulator/Rectifier 10. Water Temperature Sensor 11. Speed Sensor 12.
  • Page 560 16-14 ELECTRICAL SYSTEM Parts Location 15. Neutral Switch 16. Oil Pressure Switch 17. Sidestand Switch 18. Fuse Box 19. Battery 12 V 8 Ah 20. Starter Relay 21. Air Switching Valve 22. Stick Coils 23. Spark Plugs 24. Immobilizer Amplifier (Immobilizer Mod- els) 25.
  • Page 561 ELECTRICAL SYSTEM 16-15 Parts Location This page intentionally left blank.
  • Page 562: Wiring Diagram (us And Ca Models)

    16-16 ELECTRICAL SYSTEM Wiring Diagram (US and CA Models)
  • Page 563 ELECTRICAL SYSTEM 16-17 Wiring Diagram (US and CA Models)
  • Page 564: Wiring Diagram (other Than Us And Ca Models)

    16-18 ELECTRICAL SYSTEM Wiring Diagram (Other than US and CA Models)
  • Page 565 ELECTRICAL SYSTEM 16-19 Wiring Diagram (Other than US and CA Models)
  • Page 566: Wiring Diagram (abs Equipped Models)

    16-20 ELECTRICAL SYSTEM Wiring Diagram (ABS Equipped Models)
  • Page 567 ELECTRICAL SYSTEM 16-21 Wiring Diagram (ABS Equipped Models)
  • Page 568: Precautions

    16-22 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 569: Electrical Wiring

    ELECTRICAL SYSTEM 16-23 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 570: Battery

    16-24 ELECTRICAL SYSTEM Battery Battery Removal • Turn off the ignition switch. • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) • Disconnect the negative (–) cable [A]. NOTICE Be sure to disconnect the negative (–) cable first. •...
  • Page 571 ELECTRICAL SYSTEM 16-25 Battery NOTICE Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. DANGER Sulfuric acid in battery electrolyte can cause severe burns.
  • Page 572 16-26 ELECTRICAL SYSTEM Battery • Check the electrolyte flow. If no air bubbles [A] are coming up from the filler ports, or if the container cells have not emptied completely, tap the container [B] a few times. NOTE ○ Be careful not to have the battery fall down. •...
  • Page 573: 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 574: Interchange

    16-28 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 575 ELECTRICAL SYSTEM 16-29 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 576: Charging System

    16-30 ELECTRICAL SYSTEM Charging System Alternator Cover Removal • Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) • Support the fuel tank with a suitable bar (see Fuel Tank Removal in the Fuel System (DFI) chapter). •...
  • Page 577: Stator Coil Removal

    ELECTRICAL SYSTEM 16-31 Charging System Stator Coil Removal • Remove: Alternator Cover (see Alternator Cover Removal) Holding Plate Bolt [A] and Plate Alternator Lead Grommet [B] Stator Coil Bolts [C] • Remove the stator coil [D] from the alternator cover. Stator Coil Installation •...
  • Page 578: Alternator Rotor Installation

    16-32 ELECTRICAL SYSTEM Charging System • Using the flywheel puller [A], remove the alternator rotor [B] from the crankshaft. Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: 57001-1615 NOTICE Do not attempt to strike the alternator rotor itself. Striking the rotor can cause the magnets to lose their magnetism.
  • Page 579: Alternator Inspection

    ELECTRICAL SYSTEM 16-33 Charging System • Remove the rotor bolt and washer. • Check the tightening torque with flywheel puller [A]. Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: 57001-1615 If the rotor is not pulled out with 20 N·m (2.0 kgf·m, 15 ft·lb) of drawing torque, it is installed correctly.
  • Page 580 16-34 ELECTRICAL SYSTEM Charging System • To check the alternator output voltage, do the following procedures. ○ Turn off the ignition switch. ○ Support the fuel tank with a suitable bar [A] (see Fuel Tank Removal in the Fuel System (DFI) chapter). ○...
  • Page 581: Regulator/rectifier Inspection

    ELECTRICAL SYSTEM 16-35 Charging System Regulator/Rectifier Inspection ABS Non-equipment Models • Remove: Bolts [A] and Nuts [B] Connector [C] (Disconnect) Regulator/Rectifier [D] ABS Equipment Models • Remove: ABS Hydraulic Unit (see ABS Hydraulic Unit Removal in the Brakes chapter) Bolts [A] and Nuts [B] Regulator/Rectifier [C] Rectifier Circuit Check •...
  • Page 582 16-36 ELECTRICAL SYSTEM Charging Syst