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

Advertisement

ER-6n
ER-6n ABS
Motorcycle
Service Manual

Advertisement

Table of Contents

   Also See for Kawasaki ER-6n

   Summary of Contents for Kawasaki ER-6n

  • Page 1 ER-6n ER-6n 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) Kawasaki Diagnostic System ABDC after bottom dead center km/h kilometers per hour alternating current liter(s) ampere hour pound(s) ATDC after top dead center Liquid Crystal Display BBDC before bottom dead center Light Emission Diode bottom dead center...
  • Page 7: Emission Control Information

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

    Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. • venient operation. Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and • Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 11 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-12...
  • Page 12: General Information

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 13 Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.
  • Page 14 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.
  • Page 15 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 16 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.
  • Page 17: Model Identification

    GENERAL INFORMATION 1-7 Model Identification ER650EC Left Side View ER650EC Right Side View...
  • Page 18 1-8 GENERAL INFORMATION Model Identification ER650FC Left Side View ER650FC Right Side View Frame Number Engine Number...
  • Page 19: General Specifications

    GENERAL INFORMATION 1-9 General Specifications Items ER650EC/FC Dimensions Overall Length 2 110 mm (83.07 in.) Overall Width 770 mm (30.3 in.) Overall Height 1 110 mm (43.70 in.) Wheelbase 1 410 mm (55.51 in.) Road Clearance 130 mm (5.12 in.) Seat Height 805 mm (31.7 in.) Curb Mass:...
  • Page 20 1-10 GENERAL INFORMATION General Specifications Items ER650EC/FC Exhaust: Open 50° BBDC Close 30° ATDC Duration 260° Lubrication System Forced lubrication (semi-dry sump) Engine Oil: Grade API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 2.3 L (2.4 US qt) Drive Train...
  • Page 21 GENERAL INFORMATION 1-11 General Specifications Items ER650EC/FC Rear Suspension: Type Swingarm Wheel Travel 130 mm (5.12 in.) Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 10 Ah Headlight: Type Semi-sealed beam Bulb: High 12 V 55 W + 55 W (quartz-halogen) 12 V 55 W (quartz-halogen) Tail/Brake Light Alternator:...
  • Page 22: Unit Conversion Table

    1-12 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 N·m ×...
  • Page 23: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-12 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 24 2-2 PERIODIC MAINTENANCE Headlight Aiming Inspection ..................... 2-41 Sidestand Switch Operation Inspection ................2-42 Engine Stop Switch Operation Inspection................. 2-43 Others ..........................2-44 Chassis Parts Lubrication ....................2-44 Bolts, Nuts and Fasteners Tightness Inspection............... 2-45 Replacement Parts ......................2-46 Air Cleaner Element Replacement..................2-46 Fuel Hose Replacement ....................
  • Page 25: 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 * ODOMETER READING Whichever ×...
  • Page 26: Periodic Maintenance

    2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY * ODOMETER READING Whichever × 1 000 km comes first (× 1 000 mile) Page (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) ITEM Every Final Drive Drive chain lubrication condition Every 600 km (400 mile) 2-28 - inspect # Drive chain slack - inspect #...
  • Page 27 PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY * ODOMETER Whichever READING comes × 1 000 km first (× 1 000 mile) Page (0.6) (7.5) (15) (22.5) (30) ITEM Every Air cleaner element # - replace every 18 000 km (11 250 mile) 2-46 •...
  • Page 28: Torque And Locking Agent

    2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. EO: Apply engine oil.
  • Page 29 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Rear Camshaft Chain Guide Bolt Throttle Body Assy Holder Bolts 106 in·lb Cylinder Bolt (M8) 27.5 MO, S Cylinder Nut MO, S Cylinder Bolts (M6) 106 in·lb L, S Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolts...
  • Page 30 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Ground Lead Terminal Bolt 87 in·lb Crankshaft/Transmission Breather Plate Bolts 87 in·lb Race Holder Screw 0.50 43 in·lb Connecting Rod Big End Nuts see Text ← ←...
  • Page 31 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Sprocket Cover Bolts 87 in·lb Brakes Caliper Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Brake Disc Mounting Bolts...
  • Page 32 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Sidestand Switch Bolt 0.90 78 in·lb Electrical System License Plate Light Mounting Screws 0.12 11 in·lb Alternator Cover Bolts 87 in·lb Alternator Lead Holding Plate Bolt 87 in·lb Alternator Rotor Bolt 15.8 Engine Ground Lead Terminal Bolt...
  • Page 33 PERIODIC MAINTENANCE 2-11 Torque and Locking Agent The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.
  • Page 34: 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 1 300 ±50 r/min (rpm) – – – 0 ∼ 2 1/2 (for reference) Bypass Screws (Turn out) –...
  • Page 35 PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Final Drive 25 ∼ 35 mm (1.0 ∼ 1.4 in.) Drive Chain Slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Chain 20-link Length 323 mm (12.7 in.) Standard Chain: Make DAIDO –...
  • Page 36: Special Tools

    2-14 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers: Vacuum Gauge: 57001-143 57001-1369 Steering Stem Nut Wrench: Throttle Sensor Setting Adapter: 57001-1100 57001-1538 Jack: Extension Tube: 57001-1238 57001-1578 Oil Filter Wrench: Pilot Screw Adjuster, E: 57001-1249 57001-1603...
  • Page 37: 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 38 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • For SEA-B1 and TH models, remove the tubes [A] from the fittings on the throttle body. • Connect a vacuum gauge (special tool) and hoses [A] to the fittings on the throttle body. Special Tool - Vacuum Gauge: 57001-1369 •...
  • Page 39 PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures If any one vacuum is not within the specification, turn in the bypass screws until it seats fully but not tightly. Special Tool - Pilot Screw Adjuster, E [A]: 57001-1603 NOTICE Do not over tighten them. They could be damaged, requiring replacement.
  • Page 40: Idle Speed Inspection

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Disconnect: Fuel Pump Lead Connector Extension Tube • Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter), take off the vacuum gauge hoses and install the rubber caps onto the fittings on the throttle body assy.
  • Page 41: Fuel Hose Inspection (fuel Leak, Damage, Installation Condition)

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Fuel Hose Inspection (fuel leak, damage, installation condition) ○ If the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel Tank Re- moval in the Fuel System (DFI) chapter) and check the fuel hose.
  • Page 42: Evaporative Emission Control System Inspection (sea-b1 And Th Models)

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Evaporative Emission Control System Inspection (SEA-B1 and TH Models) • Inspect the canister as follows. ○ Remove: Left Frame Cover (see Frame Cover Removal in the Frame chapter) Canister Bracket Bolts [A] ○ Unhook the band [B] to remove the canister [C], and dis- connect the tubes [D] from the canister.
  • Page 43: Water Hose Damage And Installation Condition Inspection

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Water Hose Damage and Installation Condition Inspection ○ The high pressure inside the water hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. • Visually inspect the hoses for signs of deterioration.
  • Page 44: Valve Clearance Adjustment

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Using the thickness gauge [A], measure the valve clear- ance between cam and valve lifter. Valve Clearance Standard: Exhaust 0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.) 0.15 ∼ 0.21 mm (0.0059 ∼ 0.0083 in.) Intake ○...
  • Page 45 PERIODIC MAINTENANCE 2-23 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.
  • Page 46 2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm.
  • Page 47: Air Suction System Damage Inspection

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Air Suction System Damage Inspection • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) • Take the air switching valve hose end [A] outside of the frame [B].
  • Page 48: Wheels/tires

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch the engine or exhaust pipe during clutch adjustment. • Turn the adjuster [A] so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) [B] of threads are visible.
  • Page 49: Wheel/tire Damage Inspection

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Wheel/Tire Damage Inspection • Remove any imbedded stones [A] or other foreign parti- cles [B] from tread. • Visually inspect the tire for cracks and cuts, and replace the tire if necessary. Swelling or high spots indicate inter- nal damage, requiring tire replacement.
  • Page 50: Wheel Bearing Damage Inspection

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel Bearing Damage Inspection • Raise the front wheel off the ground with the jack. Special Tool - Jack: 57001-1238 • Turn the handlebar all the way to the right or left. • Inspect the roughness of the front wheel bearing by push- ing and pulling [A] the wheel.
  • Page 51: Drive Chain Slack Inspection

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures • Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the O-rings so that the O-rings will be coated with oil. •...
  • Page 52: Wheel Alignment Inspection

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. ○...
  • Page 53: Drive Chain Wear Inspection

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Drive Chain Wear Inspection • Remove the chain cover (see Swingarm Removal in the Suspension 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 54: Brake System

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake System Brake Fluid Leak (Brake Hose and Pipe) Inspection • For models equipped with an ABS, remove the right swingarm bracket (see ABS Hydraulic Unit Removal in the Brakes 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 55: Brake Fluid Level Inspection

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Brake Fluid Level Inspection • Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE ○ Hold the reservoir horizontal by turning the handlebar when checking brake fluid level.
  • Page 56: Brake Pad Wear Inspection

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Pad Wear Inspection • Check the lining thickness [A] of the pads in each caliper. Pad Lining Thickness Standard: Front [C] 4.5 mm (0.18 in.) Rear [D] 5.0 mm (0.20 in.) Service Limit: 1 mm (0.04 in.) If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set.
  • Page 57: Suspensions

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures If it does not go on, inspect or replace the following items. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Brake Light (see Tail/Brake Light (LED) Unit Removal in the Electrical System chapter) Main Fuse 30 A and Brake/Horn Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Front Brake Light Switch [A] (see Switch Inspection in...
  • Page 58: Rear Shock Absorber Oil Leak Inspection

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Shock Absorber Oil Leak Inspection • Visually inspect the shock absorber [A] for oil leakage. If the oil leakage is found on it, replace the shock absorber with a new one. Steering System Steering Play Inspection •...
  • Page 59 PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures • Loosen the upper front fork clamp bolts [A]. • Remove: Steering Stem Head Bolt Plug [B] Steering Stem Head Bolt [C] and Washer Steering Stem Head [D] • Bend the claws [A] of the claw washer straighten. •...
  • Page 60: Steering Stem Bearing Lubrication

    2-38 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 [A] in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt.
  • Page 61: Electrical System

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step • Set the gear position in the neutral position. • Turn the ignition switch to ON. • The following lights should go on according to the table below.
  • Page 62 2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Turn the ignition switch to OFF. • The all lights should go off. If any light does not go off, replace the ignition switch. Second Step • Turn the ignition switch to P (Park) position. •...
  • Page 63: Headlight Aiming Inspection

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Fourth Step • Set the dimmer switch [A] to low beam position. • Start the engine. • The low beam headlight should go on. If the low beam headlight does not go on, inspect or re- place the following item.
  • Page 64: Sidestand Switch Operation Inspection

    2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Headlight Beam Vertical Adjustment • Turn the vertical adjuster [A] on the headlight in or out to adjust the headlight vertically. NOTE ○ On high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated.
  • Page 65: Engine Stop Switch Operation Inspection

    PERIODIC MAINTENANCE 2-43 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 10 A (see Fuse Inspection in the Electrical System chapter)
  • Page 66: Others

    2-44 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 67: Bolts, Nuts And Fasteners Tightness Inspection

    PERIODIC MAINTENANCE 2-45 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 68: Replacement Parts

    2-46 PERIODIC MAINTENANCE 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 69 Install a new element so that the screen side faces up- ward. NOTICE Use only the recommended air cleaner element (Kawasaki part number 11013-0713). Using another air cleaner element will wear the engine prema- turely or lower the engine performance. •...
  • Page 70: Fuel Hose Replacement

    2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel Hose Replacement • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Be sure to place a piece of cloth [A] around the fuel hose joint. • Insert a standard tip screwdriver [B] into the slit on the joint lock [C].
  • Page 71: Coolant Change

    PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures Coolant Change WARNING Coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it cool completely. Immediately wipe any spilled coolant from tires, frame, engine or other painted parts.
  • Page 72 2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Take off the reserve tank from the frame. • Remove the reserve tank cap, and pour the coolant into a suitable container. • Hook the reserve tank to the frame again. • Tighten the drain bolt with a new gasket. Torque - Water Pump Drain Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 73: Radiator Hose And O-ring Replacement

    PERIODIC MAINTENANCE 2-51 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) Hoses [C] O-rings [D]...
  • Page 74: Oil Filter Replacement

    2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Pour in the specified type and amount of oil. Recommended Engine Oil Type: API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity: SAE 10W-40 Capacity: 1.6 L (1.7 US qt) (when filter is not removed) 1.8 L (1.9 US qt) (when filter is removed) 2.3 L (2.4 US qt) (when engine is...
  • Page 75: Brake Hose And Pipe Replacement

    PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures Brake Hose and Pipe Replacement NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Remove the brake hose banjo bolts [A]. • Remove the brake hoses [B], noting the following. ○...
  • Page 76: Brake Fluid Change

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the brake hose, noting the following. ○ Replace the washers [A] on each side of hose fitting [B] with new ones. ○ Avoid sharp bending, kinking, flattening or twisting, and route the hoses according to Cable, Wire, and Hose Rout- ing section in the Appendix chapter.
  • Page 77: Master Cylinder Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures • Change the brake fluid. ○ Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. 1. Open the bleed valve [A]. 2. Apply the brake and hold it [B]. 3.
  • Page 78: Caliper Rubber Parts Replacement

    2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Master Cylinder Disassembly NOTE ○ Do not remove the push rod clevis for master cylinder disassembly since removal requires brake position ad- justment. • Remove the rear master cylinder (see Rear Master Cylin- der Removal in the Brakes chapter).
  • Page 79 PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures • Using compressed air, remove the pistons. ○ Cover the piston area with a clean, thick cloth [A]. ○ Blow compressed air [B] into the hole for the banjo bolt to remove the piston. WARNING The piston in the brake caliper can crush hands and fingers.
  • Page 80 2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Apply brake fluid to the outside of the pistons, and push them into each cylinder by hand. • Check the friction boot [A] and the dust cover [B] replace them with new ones if they are damaged. •...
  • Page 81: Spark Plug Replacement

    PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures Rear Caliper Assembly • Clean the caliper parts except for the pads. NOTICE For cleaning of the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • Install the bleed valve and rubber cap. Torque - Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) •...
  • Page 82 2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the spark plugs with new ones. Standard Spark Plug Type: CR9EIA-9 • Insert the spark plug [A] into the plug wrench [B]. • Install the spark plug into the plug hole, and hand-tighten it first.
  • Page 83 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................3-10 DFI Parts Location........................3-15 Specifications ......................... 3-17 Special Tools and Sealant ...................... 3-19 DFI Servicing Precautions ...................... 3-21 DFI Servicing Precautions ....................3-21 Troubleshooting the DFI System .................... 3-23 Outline..........................
  • Page 84 3-2 FUEL SYSTEM (DFI) Subthrottle Sensor Input Voltage Inspection..............3-62 Subthrottle Sensor Output Voltage Inspection ..............3-63 Subthrottle Sensor Resistance Inspection ................ 3-65 Oxygen Sensor-not activated (Service Code 33) (Equipped Models) ........3-66 Oxygen Sensor Removal/Installation................3-66 Oxygen Sensor Inspection....................3-66 Stick Coils #1, #2: (Service Code 51, 52) ................
  • Page 85 FUEL SYSTEM (DFI) 3-3 Fuel Injector Resistance Inspection .................. 3-96 Fuel Injector Power Source Voltage Inspection ..............3-97 Fuel Injector Output Voltage Inspection ................3-98 Fuel Injector Fuel Line Inspection ..................3-99 Throttle Grip and Cables ......................3-101 Throttle Grip Free Play Inspection ..................3-101 Throttle Grip Free Play Adjustment...................
  • Page 86: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 87: Exploded View

    FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Cleaner Element Screw 0.12 11 in·lb Air Cleaner Housing Cover Screws 0.12 11 in·lb Intake Air Temperature Sensor Screw 0.12 11 in·lb Air Cleaner Housing Clamp Bolt 0.20 18 in·lb Timing Rotor Bolt...
  • Page 88 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 89 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Switch Housing Screws 0.36 31 in·lb Fuel Pump Bolts 87 in·lb L, S 3. Other than SEA-B1 and TH Models 4. SEA-B1 and TH Models 5. AU LAMS Model 6.
  • Page 90 3-8 FUEL SYSTEM (DFI) Exploded View SEA-B1 and TH Models...
  • Page 91 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Purge Valve Mounting Nut 0.71 62 in·lb 2. Canister 3. Purge Valve...
  • Page 92: Dfi System

    3-10 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 93 FUEL SYSTEM (DFI) 3-11 DFI System 1. ECU (Electronic Control Unit) 2. Battery 3. Fuel Tank 4. Fuel Pump 5. Pressure Regulator 6. Delivery Pipe 7. Intake Air Temperature Sensor 8. Subthrottle Valve 9. Air Cleaner Housing 10. Subthrottle Sensor 11.
  • Page 94 3-12 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 95 FUEL SYSTEM (DFI) 3-13 DFI System Part Name 1. ECU 2. Joint Connector B 3. Kawasaki Diagnostic System Connector 4. Fuel Pump 5. Frame Ground 1 6. Frame Ground 2 7. Battery 12 V 10 Ah 8. Main Fuse 30 A 9.
  • Page 96 3-14 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Subthrottle Valve Actuator: BK/O 23. Oxygen Sensor Heater (Equipped Models): 2. Subthrottle Valve Actuator: G/Y P/BK 3. Unused 24. Crankshaft Sensor (–): Y/BK 4. Oxygen Sensor (Equipped Models): BL/Y 25.
  • Page 97: Dfi Parts Location

    FUEL SYSTEM (DFI) 3-15 DFI Parts Location Ignition Switch [A] Relay Box [B] (ECU Main Relay, Radiator Fan Relay, Fuel Pump Relay) ECU [C] Intake Air Temperature Sensor [D] Vehicle-down Sensor [E] Fuse Box [F] (Oxygen Sensor Heater Fuse 10 A, Radia- tor Fan Fuse 15 A, ECU Fuse 15 A, Ignition Fuse 10 A) Intake Air Pressure Sensor [G] Subthrottle Sensor [A]...
  • Page 98 3-16 FUEL SYSTEM (DFI) DFI Parts Location Battery 12 V 10 Ah [A] Kawasaki Diagnostic System Connector [B] Crankshaft Sensor [A] Speed Sensor [A] Neutral Switch [B] Oxygen Sensor [A] (Equipped Models) Purge Valve [A] (SEA-B1 and TH Models)
  • Page 99: Specifications

    FUEL SYSTEM (DFI) 3-17 Specifications Item Standard Digital Fuel Injection System Idle Speed 1 300 ±50 r/min (rpm) Throttle Body Assy: Throttle Valve Dual throttle valve Bore 38 mm (1.5 in.) 0 ∼ 2 1/2 (for reference) Bypass Screws (Turn out) ECU (Electronic Control Unit): Make DENSO...
  • Page 100 3-18 FUEL SYSTEM (DFI) Specifications Item Standard with the sensor tilted 60 ∼ 70° or more: 0.65 ∼ 1.35 V Output Voltage with the sensor arrow mark pointed up: 3.55 ∼ 4.45 V Subthrottle Sensor: Non-adjustable and non-removable DC 4.75 ∼ 5.25 V Input Voltage DC 0.6 ∼...
  • Page 101: Special Tools And Sealant

    FUEL SYSTEM (DFI) 3-19 Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Peak Voltage Adapter: 57001-125 57001-1415 Fork Oil Level Gauge: Needle Adapter Set: 57001-1290 57001-1457 Vacuum Gauge: Throttle Sensor Setting Adapter: 57001-1369 57001-1538 Hand Tester: Fuel Pressure Gauge Adapter: 57001-1394 57001-1593 Throttle Sensor Setting Adapter #1:...
  • Page 102 3-20 FUEL SYSTEM (DFI) Special Tools and Sealant Oxygen Sensor Measuring Adapter: Liquid Gasket, TB1211: 57001-1682 56019-120 Measuring Adapter: 57001-1700...
  • Page 103: Dfi Servicing Precautions

    FUEL SYSTEM (DFI) 3-21 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 104 3-22 FUEL SYSTEM (DFI) DFI Servicing Precautions ○ If the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see Fuel Tank Removal) and check the fuel hose [A].
  • Page 105: Troubleshooting The Dfi System

    FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System Outline When a problem occurs with DFI system, the yellow en- gine warning indicator light (LED) [A] goes on or blinks to alert the rider. In addition, the condition of the problem is stored in the memory of the ECU.
  • Page 106 (LED) goes off. But the service codes stored in memory of the ECU are not erased to preserve the problem history. The problem history can be referred using the KDS (Kawasaki Diagnostic System) when solv- ing unstable problems. When the motorcycle is down, the vehicle-down sensor operates and the ECU shuts off the fuel pump relay, fuel in- jectors and ignition system.
  • Page 107 FUEL SYSTEM (DFI) 3-25 Troubleshooting the DFI System ○ After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Sealant - Liquid Gasket, TB1211: 56019-120 • Always check battery condition before replacing the DFI parts.
  • Page 108 3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○ When checking a harness [A] for short circuit, open one end [B] and check the continuity between the other end [C] and ground [D]. If there is continuity, the harness has a short circuit to ground, and it must be repaired or re- placed.
  • Page 109: Inquiries To Rider

    FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System 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 110 3-28 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 111: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-29 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 112 3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Intake air pressure sensor trouble Inspect (see chapter 3).
  • Page 113 FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Water temperature sensor trouble Inspect (see chapter 3). Intake air temperature sensor trouble Inspect (see chapter 3). Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 2). Stick coil trouble Inspect (see chapter 16).
  • Page 114: Poor Running Or No Power At High Speed

    3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Poor Running or No Power at High Speed Symptoms or Possible Causes Actions Firing incorrect: Stick coil shorted or not in good contact Inspect or Reinstall (see chapter 16). Stick coil trouble Inspect (see chapter 16).
  • Page 115 FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Engine overheating - Water temperature sensor, (see Overheating of Troubleshooting Guide in crankshaft sensor or speed sensor trouble chapter 17) Air switching valve trouble Inspect and replace (see chapter 16). Air suction valve trouble Inspect and replace (see chapter 5).
  • Page 116: Self-diagnosis

    3-34 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has 2 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 and ignition system by lighting the yellow engine warning indi- cator light (LED) [A] when DFI and ignition system parts are faulty, and initiates fail-safe function.
  • Page 117 FUEL SYSTEM (DFI) 3-35 Self-Diagnosis • Turn the ignition switch to ON. • Press the left button [A] to display the odometer [B]. • Press the left button [A] for more than 2 seconds. • The service code [B] is displayed on the LCD by the num- ber of two digits.
  • Page 118 3-36 FUEL SYSTEM (DFI) Self-Diagnosis...
  • Page 119: Service Code Reading

    FUEL SYSTEM (DFI) 3-37 Self-Diagnosis Service Code Reading ○ The service code(s) is displayed on the LCD by the number of two digits. ○ When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order.
  • Page 120: Service Code Table

    3-38 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Table Service Code Problems Main throttle sensor malfunction, wiring open or short Intake air pressure sensor malfunction, wiring open or short Intake air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Crankshaft sensor malfunction, wiring open or short Speed sensor malfunction, wiring open or short First 24 is displayed and then 25, repeatedly...
  • Page 121: Backups

    FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI or the ignition 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, wiring short or open), the ECU locks ignition timing into the ignition timing at closed throttle...
  • Page 122 3-40 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria The ECU sends the data (for service code) — to the meter unit. The ECU must send If the stick coil #1 primary winding has failures signals continuously to (no signal, wiring short or open), the ECU Stick Coil #1*...
  • Page 123: Main Throttle Sensor (service Code 11)

    FUEL SYSTEM (DFI) 3-41 Main Throttle Sensor (Service Code 11) Main Throttle Sensor Removal/Adjustment NOTICE Do not remove or adjust the main throttle sensor [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 124: Main Throttle Sensor Output Voltage Inspection

    3-42 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Output Voltage Inspection • Measure the output voltage at the main throttle sensor in the same way as input voltage inspection, noting the following. ○ Disconnect the main throttle sensor connector and con- nect the harness adapter [A] between these connectors.
  • Page 125: Main Throttle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-43 Main Throttle Sensor (Service Code 11) If the output voltage is normal, check the wiring for conti- nuity. ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→ Main Throttle Sensor Connector [B] Y/R lead (ECU terminal 6) [C] BR/BK lead (ECU terminal 22) [D] If the wiring is good, check the ECU for its ground and...
  • Page 126: Intake Air Pressure Sensor (service Code 12)

    3-44 FUEL SYSTEM (DFI) Intake Air Pressure Sensor (Service Code 12) Intake Air Pressure Sensor Removal NOTICE Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. • Remove the fuel tank (see Fuel Tank Removal). •...
  • Page 127: Intake Air Pressure Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-45 Intake Air Pressure Sensor (Service Code 12) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 128 3-46 FUEL SYSTEM (DFI) Intake Air Pressure Sensor (Service Code 12) If the reading is within the usable range, remove the ECU and check the wiring for continuity between main harness connector. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 129 FUEL SYSTEM (DFI) 3-47 Intake Air Pressure Sensor (Service Code 12) Suppose: Pg: Vacuum Pressure (Gauge) to Sensor Pl: Local Atmospheric Pressure (Absolute) measured by a barometer Pv: Vacuum Pressure (Absolute) to Sensor Vv: Sensor Output Voltage (V) then Pv = Pl – Pg For example, suppose the following data is obtained: Pg = 8 cmHg (Vacuum Gauge Reading) Pl = 70 cmHg (Varometer Reading)
  • Page 130 3-48 FUEL SYSTEM (DFI) Intake Air Pressure Sensor (Service Code 12) Pv = 55 ∼ 86 cmHg 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 Output Voltage (V) (Digital Meter Reading)
  • Page 131 FUEL SYSTEM (DFI) 3-49 Intake Air Pressure Sensor (Service Code 12) Intake Air Pressure Sensor Circuit 1. ECU 2. Intake Air Pressure Sensor 3. Joint Connector C...
  • Page 132: Intake Air Temperature Sensor (service Code 13)

    3-50 FUEL SYSTEM (DFI) Intake Air Temperature Sensor (Service Code 13) Intake Air Temperature Sensor Removal/Instal- lation NOTICE Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal). •...
  • Page 133: Intake Air Temperature Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-51 Intake Air Temperature Sensor (Service Code 13) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness side connectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors.
  • Page 134 3-52 FUEL SYSTEM (DFI) Intake Air Temperature Sensor (Service Code 13) Intake Air Temperature Sensor Circuit 1. ECU 2. Intake Air Temperature Sensor 3. Joint Connector D...
  • Page 135: Water Temperature Sensor (service Code 14)

    FUEL SYSTEM (DFI) 3-53 Water Temperature Sensor (Service Code 14) Water Temperature Sensor Removal/Installation NOTICE Never drop the 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 136: Water Temperature Sensor Resistance Inspection

    3-54 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 harness connectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 137: Crankshaft Sensor (service Code 21)

    FUEL SYSTEM (DFI) 3-55 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 138: Speed Sensor (service Code 24, 25)

    3-56 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 Inspection • Refer to the Speed Sensor Inspection in the Electrical System chapter. Speed Sensor Input Voltage Inspection NOTE ○...
  • Page 139: Speed Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-57 Speed Sensor (Service Code 24, 25) Speed Sensor Output Voltage Inspection • Before this inspection, inspect the input voltage (see Speed Sensor Input Voltage Inspection). NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. •...
  • Page 140 3-58 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) Speed Sensor Circuit 1. ECU 2. Joint Connector D 3. Joint Connector C 4. Speed Sensor 5. Meter Unit...
  • Page 141: Vehicle-down Sensor (service Code 31)

    FUEL SYSTEM (DFI) 3-59 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Removal/Installation NOTICE Never drop the vehicle-down sensor especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Tank Bracket (see Air Cleaner Element Replace- ment in the Periodic Maintenance chapter) Clamp [A]...
  • Page 142 3-60 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) • Remove the vehicle-down sensor (see Vehicle-down Sensor Removal/Installation). ○ Do not disconnect the sensor connector. • Connect a digital meter [A] to the connector with needle adapter set [B]. Special Tool - Needle Adapter Set: 57001-1457 Vehicle-down Sensor Output Voltage Connections to Sensor Connector: Meter (+) →...
  • Page 143 FUEL SYSTEM (DFI) 3-61 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Circuit 1. ECU 2. Vehicle-down Sensor 3. Joint Connector C...
  • Page 144: Subthrottle Sensor (service Code 32)

    3-62 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Subthrottle Sensor Removal/Adjustment NOTICE Do not remove or adjust the subthrottle sensor since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface.
  • Page 145: Subthrottle Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-63 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. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 146 3-64 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Subthrottle Sensor Output Voltage Connections to Adapter: Digital Meter (+) → Y/W (sensor BR) lead Digital Meter (–) → BK/BL (sensor BR/BK) lead • Turn the ignition switch to ON. • Measure the output voltage when the subthrottle valve is fully opened or completely closed by hand.
  • Page 147: Subthrottle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-65 Subthrottle Sensor (Service Code 32) Subthrottle Sensor Resistance Inspection • Turn the ignition switch to OFF. • Disconnect the subthrottle sensor connector. • Connect a digital meter [A] to the subthrottle sensor con- nector [B]. • Measure the subthrottle sensor resistance.
  • Page 148: Oxygen Sensor-not Activated (service Code 33) (equipped Models)

    3-66 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 • Turn the ignition switch to OFF. • Remove the engine sprocket cover (see Engine Sprocket Removal in the Final Drive chapter).
  • Page 149 FUEL SYSTEM (DFI) 3-67 Oxygen Sensor-not activated (Service Code 33) (Equipped Models) If the reading is out of the standard (with plug: DC 0.7 V or more, without plug: DC 0.2 V or less), remove the ECU and check the wiring for continuity between main harness connectors.
  • Page 150 3-68 FUEL SYSTEM (DFI) Oxygen Sensor-not activated (Service Code 33) (Equipped Models) Oxygen Sensor Circuit 1. Ignition Switch 2. Oxygen Sensor 3. ECU 4. Frame Ground 2 5. Battery 12 V 10 Ah 6. Main Fuse 30 A 7. Relay Box 8.
  • Page 151: Stick Coils #1, #2: (service Code 51, 52)

    FUEL SYSTEM (DFI) 3-69 Stick Coils #1, #2: (Service Code 51, 52) Stick Coil #1: Service Code 51 Stick Coil #2: Service Code 52 Stick Coil Removal/Installation • Refer to the Stick Coil Removal/Installation in the Electri- cal System chapter. Stick Coil Primary Winding Resistance Inspection •...
  • Page 152 3-70 FUEL SYSTEM (DFI) Stick Coils #1, #2: (Service Code 51, 52) Stick Coil Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Stick Coils 4. ECU 5. Frame Ground 6. Battery 12 V 10 Ah 7. Main Fuse 30 A 8.
  • Page 153: Radiator Fan Relay (service Code 56)

    FUEL SYSTEM (DFI) 3-71 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 154: Subthrottle Valve Actuator (service Code 62)

    3-72 FUEL SYSTEM (DFI) 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 155: Subthrottle Valve Actuator Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-73 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. • Disconnect the subthrottle valve actuator connector and connect the harness adapter [A] between these connec- tors as shown in the figure.
  • Page 156 3-74 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Circuit 1. ECU 2. Subthrottle Valve Actuator...
  • Page 157: Air Switching Valve (service Code 64)

    FUEL SYSTEM (DFI) 3-75 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 Operation Test/Unit Test in the Electrical System chapter.
  • Page 158: Oxygen Sensor Heater (service Code 67) (equipped Models)

    3-76 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67) (Equipped Models) Oxygen Sensor Heater Removal/Installation The oxygen sensor heater is bult in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see Oxygen Sensor Removal in the Electrical System chapter).
  • Page 159: Oxygen Sensor Heater Power Source Voltage Inspection

    FUEL SYSTEM (DFI) 3-77 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 to OFF. • Disconnect the oxygen sensor lead connector and con- nect the oxygen sensor measuring adapter [A] between these connectors.
  • Page 160 3-78 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67) (Equipped Models) Oxygen Sensor Circuit 1. Ignition Switch 2. Oxygen Sensor 3. ECU 4. Frame Ground 2 5. Battery 12 V 10 Ah 6. Main Fuse 30 A 7. Relay Box 8.
  • Page 161: Oxygen Sensor-incorrect Output Voltage (service Code 94) (equipped Models)

    FUEL SYSTEM (DFI) 3-79 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 • Turn the ignition switch to OFF. • Remove the engine sprocket cover (see Engine Sprocket Removal in the Final Drive chapter).
  • Page 162 3-80 FUEL SYSTEM (DFI) Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Equipped Models) • Next, remove the plug from the fitting [A] with idling. WARNING The engine gets extremely hot during normal oper- ation and can cause serious burns. Never touch a hot engine.
  • Page 163 FUEL SYSTEM (DFI) 3-81 Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Equipped Models) Oxygen Sensor Circuit 1. Ignition Switch 2. Oxygen Sensor 3. ECU 4. Frame Ground 2 5. Battery 12 V 10 Ah 6. Main Fuse 30 A 7. Relay Box 8.
  • Page 164: Purge Valve (service Code 3a) (sea-b1 And Th Models)

    3-82 FUEL SYSTEM (DFI) Purge Valve (Service Code 3A) (SEA-B1 and TH Models) Purge Valve Removal/Installation • Remove: Left Frame Cover (see Frame Cover Removal in the Frame chapter) Purge Valve Connector [A] (Disconnect) Tubes [B] (Disconnect) Purge Valve Mounting Nut [C] Purge Valve [D] •...
  • Page 165 FUEL SYSTEM (DFI) 3-83 Purge Valve (Service Code 3A) (SEA-B1 and TH Models) • Disconnect the 12 V battery. • Blow the air to the intake air duct [A] again, and make sure that the air does not flow from the outlet air duct [B]. If the purge valve dose not operate as described, replace it with a new one.
  • Page 166: Yellow Engine Warning Indicator Light (led)

    3-84 FUEL SYSTEM (DFI) Yellow Engine Warning Indicator Light (LED) Yellow Engine Warning Indicator Light (LED) Inspection • Refer to the Electronic Combination Meter Unit Inspection in the Electrical System chapter. Yellow Engine Warning Indicator Light (LED) Circuit for DFI System 1.
  • Page 167: Ecu

    FUEL SYSTEM (DFI) 3-85 ECU Identification ○ Most countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU with each other and use only the ECU for your model. Other- wise, the motorcycle can not clear the regulation. ECU Identification Part Number [A] Specification...
  • Page 168 3-86 FUEL SYSTEM (DFI) • Turn the ignition switch to OFF. • Disconnect the ECU connectors [A]. • Set the hand tester [B] to the × 1 Ω range and check the following wiring for continuity. Special Tool - Hand Tester: 57001-1394 ECU Grounding Continuity Inspection Connections: (I) BK lead (ECU terminal...
  • Page 169 FUEL SYSTEM (DFI) 3-87 ECU Power Source Circuit 1. ECU 2. Frame Ground 1 3. Frame Ground 2 4. Battery 12 V 10 Ah 5. Main Fuse 30 A 6. Relay Box 7. ECU Main Relay 8. Fuse Box 1 9.
  • Page 170: Dfi Power Source

    3-88 FUEL SYSTEM (DFI) DFI Power Source ECU Fuse Removal • Refer to the 15 A ECU Fuse Removal in the Electrical System chapter. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 171: Fuel Line

    FUEL SYSTEM (DFI) 3-89 Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) ○ Be sure to place a piece of cloth around the fuel supply pipes of the fuel pump and the throttle body assy.
  • Page 172: Fuel Flow Rate Inspection

    3-90 FUEL SYSTEM (DFI) Fuel Line NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. • Turn the ignition switch to OFF. If the fuel pressure is much higher than specified, the fuel pressure regulator in the fuel pump have been clogged or stuck.
  • Page 173 FUEL SYSTEM (DFI) 3-91 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 supply pipe of the fuel pump.
  • Page 174: Fuel Pump

    3-92 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 175: Fuel Pump Operation Inspection

    FUEL SYSTEM (DFI) 3-93 Fuel Pump • Replace the fuel pump gasket [A] with a new one and apply grease to it. • Apply a non-permanent locking agent to the threads of the fuel pump bolts. • Tighten the fuel pump bolts to a snug fit, and tighten them alternating diagonally.
  • Page 176: Fuel Pump Operating Voltage Inspection

    3-94 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Operating Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. • Remove the left side cover (see Side Cover Removal in the Frame chapter). •...
  • Page 177: Pressure Regulator Removal

    FUEL SYSTEM (DFI) 3-95 Fuel Pump Pressure Regulator Removal ○ The pressure regulator [A] is built into the fuel pump [B] and cannot be removed. Fuel Filter Cleaning ○ The fuel filter [A] is built into the pump and cannot be cleaned or checked.
  • Page 178: Fuel Injectors

    3-96 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Fuel Injector Audible Inspection • Start the engine, and let it to 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 179: Fuel Injector Power Source Voltage Inspection

    FUEL SYSTEM (DFI) 3-97 Fuel Injectors Fuel Injector Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. • Disconnect the injector connector and connect the har- ness adapter [A] between these connectors as shown in the figure.
  • Page 180: Fuel Injector Output Voltage Inspection

    3-98 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Output Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. • Remove the ECU (see ECU Removal). ○ Do not disconnect the ECU connector. •...
  • Page 181: Fuel Injector Fuel Line Inspection

    FUEL SYSTEM (DFI) 3-99 Fuel Injectors Fuel Injector Fuel Line Inspection • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) ○ Be sure to place a piece of cloth around the fuel supply pipes of the fuel pump and the throttle body assy.
  • Page 182 3-100 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Fuel Injectors 4. ECU 5. Frame Ground 1 6. Frame Ground 2 7. Battery 12 V 10 Ah 8. Main Fuse 30 A 9.
  • Page 183: Throttle Grip And Cables

    FUEL SYSTEM (DFI) 3-101 Throttle Grip and Cables Throttle Grip Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Throttle Grip Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter.
  • Page 184: Throttle Body Assy

    3-102 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection/Adjustment • Refer to the Idle Speed Inspection/Adjustment in the Pe- riodic Maintenance chapter. Synchronization Inspection/Adjustment • Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter. Throttle Body Assy Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the...
  • Page 185: Throttle Body Assy Installation

    FUEL SYSTEM (DFI) 3-103 Throttle Body Assy • Pull the throttle body assy [A] out of the holder. • Disconnect the subthrottle sensor connector [B]. • Loosen the locknut [A] and screw the adjuster [B] to give the throttle grip plenty of play. •...
  • Page 186: Throttle Body Assy Disassembly

    3-104 FUEL SYSTEM (DFI) Throttle Body Assy • Install the throttle body assy holder clamp bolts [A] so that their bolt heads [B] face outward. • Install the throttle body assy onto the holder securely. • Tighten: Torque - Throttle Body Assy Holder Clamp Bolts: 2.0 N·m (0.20 kgf·m, 18 in·lb) •...
  • Page 187: Throttle Body Assy Assembly

    FUEL SYSTEM (DFI) 3-105 Throttle Body Assy • Remove: Throttle Body Assy (see Throttle Body Assy Removal) Screws [A] • Pull out the fuel injectors [B] from the throttle body assy together with the delivery pipe [C]. • Pull out the fuel injectors from the delivery pipe. Throttle Body Assy Assembly •...
  • Page 188: Air Cleaner

    3-106 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 189: Air Cleaner Housing Installation

    FUEL SYSTEM (DFI) 3-107 Air Cleaner • Pull out the air cleaner housing [A] from the throttle body assy. • Disconnect the air switching valve hose [B] from the hous- ing. Air Cleaner Housing Installation • Installation is the reverse of removal. ○...
  • Page 190: Fuel Tank

    3-108 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 191 FUEL SYSTEM (DFI) 3-109 Fuel Tank • Remove the fuel tank bolts [A] and washers. • Draw the fuel out from the fuel tank with a commercially available pump [A]. ○ Use a soft plastic hose [B] as a pump intake hose in order to insert the hose smoothly.
  • Page 192: Fuel Tank Installation

    3-110 FUEL SYSTEM (DFI) Fuel Tank • Turn the driver [A] to disconnect the joint lock [B]. • Pull the fuel hose joint [C] out of the outlet pipe [D]. WARNING Fuel is flammable and explosive under certain con- ditions and can cause severe burns. Be prepared for fuel spillage;...
  • Page 193: Fuel Tank And Cap Inspection

    FUEL SYSTEM (DFI) 3-111 Fuel Tank • Push and pull [A] the hose joint [B] back and forth more than 2 times and make sure it is locked and does not come off. WARNING Leaking fuel can cause a fire or explosion resulting in serious burns.
  • Page 194: Fuel Tank Cleaning

    3-112 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 195: Evaporative Emission Control System (sea-b1 And Th Models)

    FUEL SYSTEM (DFI) 3-113 Evaporative Emission Control System (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 197 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 198: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 199 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Radiator Bolt 0.81 70 in·lb Coolant Reserve Tank Mounting Bolts 0.81 70 in·lb Water Temperature Sensor 106 in·lb Water Hose Clamp Screws 0.31 27 in·lb Thermostat Housing Bolts 87 in·lb Water Pump Cover Bolts 87 in·lb Water Pump Drain Bolt...
  • Page 200: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart...
  • Page 201 COOLING SYSTEM 4-5 Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 202: Specifications

    4-6 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type (Recommended) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point −35°C (−31°F) Total Amount...
  • Page 203: Special Tools

    COOLING SYSTEM 4-7 Special Tools Bearing Driver Set: Oil Seal Driver: 57001-1129 57001-1660...
  • Page 204: 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 205: 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 206: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Water Hose [A] Water Pump Cover Bolts [B] Water Pump Cover [C] • Shift the transmission into 1st gear. •...
  • Page 207: Water Pump Inspection

    COOLING SYSTEM 4-11 Water Pump • Be sure that the dowel pins [A] are in position. • Install the water pump cover and the bolts. [A] L = 40 mm (1.6 in.) [B] L = 30 mm (1.2 in.) • Tighten: Torque - Water Pump Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
  • Page 208: Water Pump Housing Disassembly

    4-12 COOLING SYSTEM Water Pump Water Pump Housing Disassembly NOTICE Be careful not to damage the sealing surface of the mechanical seal. • Remove the water pump housing (see Water Pump Re- moval). • Take the oil seal [A] out of the housing [B] with a hook [C]. •...
  • Page 209: Radiator

    COOLING SYSTEM 4-13 Radiator Radiator and Radiator Fan Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove the left center fairing (see Center Fairing Re- moval in the Frame chapter). • Disconnect the radiator fan lead connector [A]. •...
  • Page 210: Radiator And Radiator Fan Installation

    4-14 COOLING SYSTEM Radiator Radiator and Radiator Fan Installation • Install the radiator fan [A] and tighten the bolts. • Install the rubber dampers [B] and collar [C] to the radiator and frame. • Install the radiator so that the projections [D] on the frame fit into the holes [E] on the dampers.
  • Page 211: Radiator Inspection

    COOLING SYSTEM 4-15 Radiator Radiator Inspection • Remove the radiator (see Radiator and Radiator Fan Re- moval). • Inspect the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably de- formed fins, replace the radiator with a new one.
  • Page 212: Radiator Filler Neck Inspection

    4-16 COOLING SYSTEM Radiator Radiator Filler Neck Inspection • Remove the radiator cap (see Coolant Change in the Pe- riodic Maintenance chapter). • Inspect the radiator filler neck for signs of damage. • Inspect the condition of the top and bottom sealing seats [A] in the filler neck.
  • Page 213: Thermostat

    COOLING SYSTEM 4-17 Thermostat Thermostat Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Left Center Fairing (see Center Fairing Removal in the Frame chapter) Water Hose [A] Thermostat Housing Bolts [B] Thermostat Housing [C] •...
  • Page 214: Thermostat Inspection

    4-18 COOLING SYSTEM Thermostat Thermostat Inspection • Remove the thermostat (see Thermostat Removal), and inspect the thermostat valve [A] at room temperature. If the valve is open, replace the thermostat with a new one. • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water.
  • Page 215: Hose And Pipes

    COOLING SYSTEM 4-19 Hose and Pipes Hose Installation • Install the hoses, being careful to follow bending direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses correctly (see Cable, Wire, and Hose Rout- ing section in the Appendix chapter). •...
  • Page 216: Water Temperature Sensor

    4-20 COOLING SYSTEM Water Temperature Sensor Water Temperature Sensor Removal/Installation • Refer to the Water Temperature Sensor Removal/Instal- lation in the Fuel System (DFI) chapter. Water Temperature Sensor Inspection • Refer to the Water Temperature Sensor Inspection in the Electrical System chapter.
  • Page 217 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Cylinder Head Installation .... 5-27 Exhaust System Identification ... Cylinder Head Warp Inspection ... 5-29 Specifications ........Valves ..........5-30 Special Tools and Sealant ....Valve Clearance Inspection ..5-30 Clean Air System.......
  • Page 218: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 219 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Baffle Plate Bolts 0.60 52 in·lb Air Suction Valve Cover Bolts 87 in·lb Cylinder Head Cover Bolts 87 in·lb Camshaft Cap Bolts 106 in·lb Throttle Body Assy Holder Clamp Bolts 0.20 18 in·lb Throttle Body Assy Holder Bolts...
  • Page 220 5-4 ENGINE TOP END Exploded View...
  • Page 221 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Bolt (M8) 27.5 MO,S Cylinder Bolts (M6) 106 in·lb L, S Cylinder Nut MO, S Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolts L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil solution.
  • Page 222: Exhaust System Identification

    5-6 ENGINE TOP END Exhaust System Identification Exhaust System Muffler Mark Position [A] Honeycomb Type Catalyst Position [A] Muffler with Hole [A] for Oxygen Sensor [B]...
  • Page 223: Specifications

    ENGINE TOP END 5-7 Specifications Item Standard Service Limit Camshafts Cam Height: 35.843 ∼ 35.957 mm Exhaust 35.74 mm (1.407 in.) (1.4111 ∼ 1.4156 in.) 36.543 ∼ 36.657 mm Intake 36.44 mm (1.435 in.) (1.4387 ∼ 1.4432 in.) 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.) Camshaft Journal, Camshaft 0.16 mm (0.0063 in.) Cap Clearance...
  • Page 224 5-8 ENGINE TOP END Specifications Item Standard Service Limit Valve Spring Free Length: Exhaust 41.91 mm (1.650 in.) 40.3 mm (1.59 in.) Intake 41.91 mm (1.650 in.) 40.3 mm (1.59 in.) Cylinder, Pistons 82.994 ∼ 83.006 mm Cylinder Inside Diameter 83.09 mm (3.271 in.) (3.2675 ∼...
  • Page 225: Special Tools And Sealant

    ENGINE TOP END 5-9 Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 60° - 30: 57001-221 57001-1123 Valve Spring Compressor Assembly: Valve Seat Cutter Holder Bar: 57001-241 57001-1128 Valve Seat Cutter, 45° - 35: Valve Seat Cutter, 45° - 30: 57001-1116 57001-1187 Valve Seat Cutter, 32°...
  • Page 226 5-10 ENGINE TOP END Special Tools and Sealant Compression Gauge Adapter, M10 × 1.0: Filler Cap Driver: 57001-1317 57001-1454 Valve Seat Cutter Holder, 4.5: Piston Pin Puller: 57001-1330 57001-1568 Valve Guide Arbor, 4.5: Piston Pin Puller Adapter, 12: 57001-1331 57001-1657 Valve Guide Reamer, 4.5: Liquid Gasket, TB1216B: 57001-1333...
  • Page 227: Clean Air System

    ENGINE TOP END 5-11 Clean Air System Air Suction Valve Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Air Switching Valve (see Air Switching Valve Removal) Air Suction Valve Cover Bolts [A] Clamp [B] Air Suction Valve Cover [C]...
  • Page 228: Air Suction Valve Inspection

    5-12 ENGINE TOP END Clean Air System Air Suction Valve Inspection • Remove the air suction valve (see Air Suction Valve Re- moval). • Visually inspect the reeds [A] for cracks, folds, warps, heat damage or other damage. If there is any doubt as to the condition of the reeds, re- place the air suction valve as an assembly.
  • Page 229: Clean Air System Hose Inspection

    ENGINE TOP END 5-13 Clean Air System Clean Air System Hose Inspection • Be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the air cleaner housing, air switching valve and air suction valve cover.
  • Page 230: Cylinder Head Cover

    5-14 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal • Remove the right center fairing (see Center Fairing Re- moval in the Frame chapter). • Remove the radiator bolt [A] and lower the radiator [B] for extra clearance. •...
  • Page 231: Cylinder Head Cover Installation

    ENGINE TOP END 5-15 Cylinder Head Cover Cylinder Head Cover Installation • Replace the head cover gasket [A] with a new one. • Clean off any oil or dirt and apply liquid gasket to the areas [B] on the cylinder. Sealant - Liquid Gasket, TB1216B: 92104-1064 •...
  • Page 232 5-16 ENGINE TOP END Cylinder Head Cover • Be sure that the dampers [A] of the baffle plate are in position. • Tighten: Torque - Baffle Plate Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) • Install the other removed parts (see appropriate chap- ters).
  • Page 233: Camshaft Chain Tensioner

    ENGINE TOP END 5-17 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: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 234 5-18 ENGINE TOP END Camshaft Chain Tensioner • Install the tensioner body so that the stopper [A] faces upward. • Apply a non-permanent locking agent to the camshaft chain tensioner mounting bolts and tighten them. Torque - Camshaft Chain Tensioner Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 235: Camshaft, Camshaft Chain

    ENGINE TOP END 5-19 Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Timing Inspection Cap [A] Timing Rotor Bolt Cap [B] Special Tool - Filler Cap Driver [C]: 57001-1454 • Using a wrench on the timing rotor bolt [A], turn the crank- shaft clockwise until the 2/T mark line [B] on the timing rotor is aligned with the notch [C] in the edge of the timing inspection hole in the clutch cover.
  • Page 236 5-20 ENGINE TOP END Camshaft, Camshaft Chain • Remove the camshaft chain tensioner (see Camshaft Chain Tensioner Removal). • Loosen the camshaft cap bolts following the sequence [1 ∼ 12 ] shown in the figure, and remove them. • Remove: Camshaft Caps [A] Camshafts [B] NOTICE...
  • Page 237: Camshaft Installation

    ENGINE TOP END 5-21 Camshaft, Camshaft Chain Camshaft Installation • Replace the plug hole gaskets [A] with new ones. • Be sure to install the following parts. Dowel Pins [B] Plug Hole Gaskets • Install the camshaft sprockets so that the marked (“IN" and “EX”) side faces outward.
  • Page 238 5-22 ENGINE TOP END Camshaft, Camshaft Chain • Using a wrench on the timing rotor bolt [A], turn the crank- shaft clockwise until the 2/T mark line [B] on the timing rotor is aligned with the notch [C] in the edge of the timing inspection hole in the clutch cover.
  • Page 239 ENGINE TOP END 5-23 Camshaft, Camshaft Chain • Before installing the camshaft caps, install the camshaft chain tensioner body temporarily (see Camshaft Chain Tensioner Installation). • Install the camshaft caps as shown. NOTE ○ The exhaust cap has an “EX” mark [A] and the intake cap has an “IN”...
  • Page 240: Camshaft, Camshaft Cap Wear Inspection

    5-24 ENGINE TOP END Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear Inspection • Remove the 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 241: 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.
  • Page 242: Cylinder Head

    5-26 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Be sure the battery is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter)
  • Page 243: Cylinder Head Removal

    ENGINE TOP END 5-27 Cylinder Head Cylinder Head Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Muffler (see Muffler Removal) Cylinder Head Cover (see Cylinder Head Cover Re- moval) Camshafts (see Camshaft Removal) Throttle Body Assy (see Throttle Body Assy Removal in...
  • Page 244 5-28 ENGINE TOP END Cylinder Head • Apply molybdenum disulfide oil solution [A] to both sides of washers and the threads of bolts and nut. M10 Cylinder Head Bolts [B] M10 Cylinder Nut [C] M8 Cylinder Bolt [D] • Tighten the all bolts and nut following the tightening se- quence [1 ∼...
  • Page 245: Cylinder Head Warp Inspection

    ENGINE TOP END 5-29 Cylinder Head • Install the front camshaft chain guide [A]. ○ Insert the end [B] of front camshaft chain guide into the hollow on the lower crankcase half. • Install the other removed parts (see appropriate chap- ters).
  • Page 246: 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). •...
  • Page 247: Valve Guide Installation

    ENGINE TOP END 5-31 Valves Valve Guide Installation • Apply engine oil to the valve guide outer surface before installation. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). • Drive the valve guide in from the top of the head using the valve guide arbor.
  • Page 248: 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 249 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 250 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 251 ENGINE TOP END 5-35 Valves If the seat width is too wide, make the 60° or 55° [A] grind described 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°...
  • Page 252 5-36 ENGINE TOP END Valves...
  • Page 253: Cylinder, Pistons

    ENGINE TOP END 5-37 Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Front Engine Mounting Bolts [A] and Nuts (Left and Right) Collar [B] Cylinder [C] Cylinder Installation NOTE ○ If a new cylinder is used, use new piston ring. •...
  • Page 254: Piston Removal

    5-38 ENGINE TOP END Cylinder, Pistons Piston Removal • Remove the cylinder (see Cylinder Removal). • Place a clean cloth under the pistons. • Remove the piston pin snap ring [A] by using the pliers [B] from the outside of each piston. •...
  • Page 255: Cylinder Wear Inspection

    ENGINE TOP END 5-39 Cylinder, Pistons • Apply molybdenum disulfide oil solution to the top and second rings. • Do not mix up the top and second ring. • Install the top ring [A] so that the "R" mark [B] faces up. •...
  • Page 256: Piston Wear Inspection

    5-40 ENGINE TOP END Cylinder, Pistons Piston Wear Inspection • Measure the outside diameter [A] of each piston 18 mm (0.7087 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 257: 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: 0.87 ∼ 0.89 mm (0.0343 ∼ 0.0350 in.) Top [A] 0.97 ∼...
  • Page 258: 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 259: Muffler

    ENGINE TOP END 5-43 Muffler Muffler Removal WARNING The muffler can become extremely hot during nor- mal operation and cause severe burns. Do not re- move the muffler while it is hot. • Remove: Frame Covers (see Frame Cover Removal in the Frame chapter) Right Footpeg Stay (see Footpeg Stay Removal in the Frame chapter)
  • Page 260: Muffler Installation

    5-44 ENGINE TOP END Muffler Muffler Installation • Installation is the reverse of removal. ○ Replace the exhaust pipe gaskets [A] with new ones. ○ Tighten: Torque - Exhaust Pipe Manifold Holder Nuts: 17 N·m (1.7 kgf·m, 13 ft·lb) Muffler Body Mounting Bolts [B]: 20 N·m (2.0 kgf·m, 15 ft·lb) ○...
  • Page 261 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tools 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 262: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 263 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Cable Clamp Bracket Bolt 87 in·lb Clutch Cable Holder Bolts 87 in·lb Clutch Cover Bolts 87 in·lb Clutch Hub Nut 13.3 Clutch Spring Bolts 87 in·lb Timing Inspection Cap 0.40 35 in·lb Timing Rotor Bolt Cap...
  • Page 264: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) Friction Plate Thickness 2.7 mm (0.106 in.) Friction Plate Warp 0.15 mm (0.059 in.) or less 0.3 mm (0.012 in.)
  • Page 265: Special Tools And Sealant

    CLUTCH 6-5 Special Tools and Sealant Clutch Holder: Liquid Gasket, TB1211F: 57001-1243 92104-0004 Filler Cap Driver: 57001-1454...
  • Page 266: 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 267: Clutch Lever Installation

    CLUTCH 6-7 Clutch Lever and Cable Clutch Lever Installation • Install the clutch lever so that the mating surface [A] of the clutch lever clamp is aligned with the punch mark [B]. • Tighten the upper clamp bolt first, and then the lower clamp bolt.
  • Page 268: Clutch Cover

    6-8 CLUTCH Clutch Cover Clutch Cover Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Right Frame Cover (see Frame Cover Removal in the Frame chapter) Lower Fairing (see Lower Fairing Removal in the Frame chapter) Clutch Cable Holder Bolts [A] Clutch Cable Lower End [B]...
  • Page 269: Release Shaft Removal

    CLUTCH 6-9 Clutch Cover Release Shaft Removal NOTICE Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary. If re- moved, the oil seal replacement may be required. • Remove the clutch cover (see Clutch Cover Removal). •...
  • Page 270: Clutch Cover Assembly

    6-10 CLUTCH Clutch Cover Clutch Cover Assembly • Replace the needle bearings [A] and oil seal [B] with new ones. NOTE ○ Install the needle bearings so that the manufacture’s mark face out. • Install the needle bearings and oil seal as shown. ○...
  • Page 271: Clutch Removal

    CLUTCH 6-11 Clutch Clutch Removal • Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts and Washers [A] Clutch Springs Clutch Spring Plate [B] (with Bearing) Pusher [C] Friction Plates Steel Plates • Hold the clutch hub [A] steady with the clutch holder [B], and remove the clutch hub nut [C] and washer [D].
  • Page 272: Clutch Installation

    6-12 CLUTCH Clutch Clutch Installation • Install the oil pump chain guide [A]. • Apply a non-permanent locking agent to the upper chain guide bolts [B]. • Tighten: Torque - Oil Pump Chain Guide Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) •...
  • Page 273 CLUTCH 6-13 Clutch • Install the washer so that the OUT SIDE mark [A] faces outward. • Replace the clutch hub nut [A] with a new one. • Hold the clutch hub [B] steady with the clutch holder [C], and tighten the clutch hub nut. Special Tool - Clutch Holder: 57001-1243 Torque - Clutch Hub Nut: 130 N·m (13.3 kgf·m, 96 ft·lb) •...
  • Page 274: 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 275: Clutch Housing Spline Inspection

    CLUTCH 6-15 Clutch Clutch Housing Spline Inspection • Visually inspect where the teeth [A] on the steel plates wear against the clutch hub splines [B]. If there are notches worn into the splines, replace the clutch hub. Also, replace the steel plates if their teeth are damaged.
  • Page 277 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealant ...................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ Oil Pan Removal .......................
  • Page 278: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 279 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Filter 17.5 EO, R Holder Mounting Bolt Oil Passage Plug (M6) 0.36 31 in·lb Oil Passage Plug Oil Pressure Switch Oil Plate Bolts 87 in·lb Oil Pressure Relief Valve Oil Pipe Plate Bolt 87 in·lb Filter Plate Bolts...
  • Page 280: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 281 ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart...
  • Page 282: Specifications

    7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity: 1.6 L (1.7 US gt) (when filter is not removed) 1.8 L (1.9 US gt) (when filter is removed) 2.3 L (2.4 US gt) (when engine is completely dry) Level Between upper and lower level lines...
  • Page 283: Special Tools And Sealant

    ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: Liquid Gasket, TB1211: 57001-164 56019-120 Oil Pressure Gauge Adapter, PT3/8: 57001-1233...
  • Page 284: Engine Oil And Oil Filter

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter according to the periodic maintenance chart.
  • Page 285: Oil Pan

    ENGINE LUBRICATION SYSTEM 7-9 Oil Pan Oil Pan Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Lower Fairing (see Lower Fairing Removal in the Frame chapter) Lower Fairing Brackets (see Lower Fairing Bracket Re- moval in the Frame chapter) Muffler (see Muffler Removal in the Engine Top End chapter)
  • Page 286: Oil Pan Installation

    7-10 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Installation If the following parts were removed, install them in the following procedure. Oil Pipes Oil Pipe Plate Dampers Oil Screen Filter Filter Plate ○ Replace the O-rings with new ones. ○ Apply grease to the O-rings on the oil pipes [A].
  • Page 287 ENGINE LUBRICATION SYSTEM 7-11 Oil Pan • Tighten the oil pan bolts following the specified tightening sequence. Torque - Oil Pan Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
  • Page 288: Oil Pressure Relief Valve

    7-12 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Pressure Relief Valve [A] Oil Pressure Relief Valve Installation • Apply a non-permanent locking agent to the threads of the oil pressure relief valve, and tighten it.
  • Page 289: Oil Pump

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump Oil Pump Removal • Remove: Clutch (see Clutch Removal in the Clutch chapter) Oil Pump Cover Bolts [A] • Temporarily install the oil pump sprocket bolt [A]. NOTE ○ The oil pump sprocket bolt has a left-hand threads. •...
  • Page 290: Oil Pump Installation

    7-14 ENGINE LUBRICATION SYSTEM Oil Pump • Remove the pin [A]. • Remove: Pin [A] Inner Rotor for Feed Pump [B] Oil Pump Shaft [C] Oil Pump Installation • Apply molybdenum disulfide oil solution to the portion [A] of the oil pump shaft as shown in the figure. •...
  • Page 291 ENGINE LUBRICATION SYSTEM 7-15 Oil Pump • Be sure that the dowel pin [A] is in position. • Fit the dowel pin into the hole [B] on the oil pump cover [C]. • Apply a non-permanent locking agent to the oil pump cover bolts and tighten them.
  • Page 292: Oil Pressure Measurement

    7-16 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement • Remove: Lower Fairing (see Lower Fairing Removal in the Frame chapter) Right Lower Fairing Bracket (see Lower Fairing Bracket Removal in the Frame chapter) Oil Passage Plug [A] NOTE ○...
  • Page 293: Oil Pressure Switch

    ENGINE LUBRICATION SYSTEM 7-17 Oil Pressure Switch Oil Pressure Switch Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Lower Fairing (see Lower Fairing Removal in the Frame chapter) Right Lower Fairing Bracket (see Lower Fairing Bracket Removal in the Frame chapter) Switch Cover [A] Switch Terminal Bolt [B]...
  • Page 295 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 296: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 297 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Engine Bracket Bolts (Left) Front Engine Bracket Bolts (Right) Front Engine Mounting Bolt (Right) Front Engine Mounting Bolt (Left) Rear Engine Mounting Bolts Rear Engine Mounting Nuts R, S Rear Engine Bracket Bolts Engine Ground Lead Terminal Bolt 87 in·lb...
  • Page 298: Engine Removal/installation

    8-4 ENGINE REMOVAL/INSTALLATION 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 299 ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation • Disconnect: Crankshaft Sensor Lead Connector [A] Starter Motor Cable Terminal [B] Engine Ground Lead Terminal [C] Water Temperature Sensor Lead Connector [D] • Disconnect the alternator lead connector [A]. • Disconnect the neutral switch lead terminal [A]. •...
  • Page 300: Engine Installation

    8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Front Engine Mounting Bolt [A] and Nut (Right) Front Engine Bracket Bolts (Right) [B] Front Engine Bracket (Right) [C] Guard [D] • Remove the rear engine mounting bolt and nut (upper) [A]. • Remove: Rear Engine Mounting Bolt and Nut (Lower) [A] Rear Engine Bracket Bolts [B]...
  • Page 301 ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Install the following temporarily: Front Engine Bracket (Right) [A] Guard [B] Front Engine Bracket Bolts (Right) [C] • Replace the front engine mounting nut (right) [D] with a new one. • Install the following temporarily: Front Engine Mounting Bolt (Right) [E] Front Engine Mounting Nut (Right) Front Engine Bracket (Left) [F]...
  • Page 302 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation ○ Tighten: Torque - Front Engine Bracket Bolts (Left) [G]: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Engine Mounting Bolt [H] (Left): 44 N·m (4.5 kgf·m, 32 ft·lb) • Run the leads, cables, and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
  • Page 303 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealants ....................Crankcase Splitting......................... 9-10 Crankcase Splitting ......................9-10 Crankcase Assembly ......................9-12 Crankshaft and Connecting Rods................... 9-19 Crankshaft Removal ......................9-19 Crankshaft Installation ...................... 9-19 Connecting Rod Removal ....................9-19 Connecting Rod Installation ....................
  • Page 304: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 305 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Connecting Rod Big End Nuts see Text ← ← Timing Rotor Bolt Oil Plate Bolts 87 in·lb Oil Pipe Bolts 87 in·lb Breather Plate Bolts 87 in·lb Shift Shaft Return Spring Pin Crankcase Bolt (M6, L = 32 mm) 19.6 Crankcase Bolts (M6, L = 38 mm)
  • Page 306 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 307 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Transmission Case Bolts Gear Positioning Lever Bolt 106 in·lb Trasnmission Case Oil Nozzle 0.30 26 in·lb Shift Drum Cam Bolt 106 in·lb Shift Drum Bearing Holder Screws 0.50 43 in·lb Shift Rod Plate Bolt 87 in·lb Neutral Switch Holder Screw...
  • Page 308: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Bend – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.2/100 mm (0.008/3.94 in.) 0.13 ∼ 0.38 mm Connecting Rod Big End Side Clearance 0.58 mm (0.0051 ∼...
  • Page 309 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankshaft Runout TIR 0.02 mm (0.0008 in.) TIR 0.05 mm or less (0.002 in.) 0.017 ∼ 0.041 mm Crankshaft Main Bearing Insert/Journal Clearance 0.07 mm (0.0007 ∼ 0.0016 in.) (0.003 in.) 37.984 ∼ 38.000 mm Crankshaft Main Journal Diameter: 37.96 mm (1.4954 ∼...
  • Page 310 9-8 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit 31.000 ∼ 31.016 mm Crankcase Bearing Bore Diameter: – – – (1.2205 ∼ 1.2211 in.) Marking: ○ 31.000 ∼ 31.008 mm – – – (1.2205 ∼ 1.2208 in.) 31.009 ∼ 31.016 mm None –...
  • Page 311: Special Tools And Sealants

    CRANKSHAFT/TRANSMISSION 9-9 Special Tools and Sealants Outside Circlip Pliers: Liquid Gasket, TB1216B: 57001-144 92104-1064 Bearing Driver Set: Liquid Gasket, TB1207B: 57001-1129 92104-2068 Liquid Gasket, TB1211F: 92104-0004...
  • Page 312: Crankcase Splitting

    9-10 CRANKSHAFT/TRANSMISSION 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 Head Cover (see Cylinder Head Cover Re- moval in the Engine Top End chapter) Cylinder Head (see Cylinder Head Removal in the En- gine Top End chapter)
  • Page 313 CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting • Remove the upper crankcase bolts [A] and the copper plated washers. • Remove: Oil Pan (see Oil Pan Removal in the Engine Lubrication System chapter) Oil Screen (see Oil Pan Removal in the Engine Lubrica- tion System chapter) Oil Pipes (see Oil Pan Removal in the Engine Lubrication System chapter)
  • Page 314: Crankcase Assembly

    9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting ○ Prepare a 5 mm rod [A], and insert it to the hole of the upper crankcase half. ○ Remove the oil pipe [B], tapping [C] the rod as shown. If the breather plate [A] is to be removed, follow the next procedure.
  • Page 315 CRANKSHAFT/TRANSMISSION 9-13 Crankcase Splitting • When the new needle bearing [A] for the shift drum is installed in the lower crankcase half [B], press and insert [C] the new needle bearing until it is bottomed. Special Tool - Bearing Driver Set: 57001-1129 •...
  • Page 316 9-14 CRANKSHAFT/TRANSMISSION 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 pipe [A]. ○ Align the white mark [B] on the pipe with the white mark [C] on the breather fitting.
  • Page 317 CRANKSHAFT/TRANSMISSION 9-15 Crankcase Splitting • Install the crankshaft and the balancer shaft on the upper crankcase half. ○ Apply molybdenum disulfide oil solution to the following items. Crankshaft Main Bearing Insert Balancer Shaft Bearing Insert ○ Align [A] the timing mark on the balancer gear [B] with the timing mark on the balancer drive gear [C] of the crank- shaft.
  • Page 318 9-16 CRANKSHAFT/TRANSMISSION Crankcase Splitting • With a high flash-point solvent, clean off the mating sur- faces of the crankcases halves and wipe dry. • Using compressed air, blow out the oil passages in the crankcase halves. • Apply liquid gasket [A] to the mating surface of the lower crankcase half.
  • Page 319 CRANKSHAFT/TRANSMISSION 9-17 Crankcase Splitting • Fit the lower crankcase half to the upper crankcase half. ○ Insert [A] the breather pipe [B] on the upper crankcase half through the hole [C] on the lower crankcase half. NOTE ○ Make the application finish within 20 minutes when the liquid gasket to the mating surface of the lower crankcase half is applied.
  • Page 320 9-18 CRANKSHAFT/TRANSMISSION Crankcase Splitting • The upper crankcase bolts [A] have copper plated wash- ers, replace them with new ones. • Tighten the upper crankcase bolts with copper plated washers. Torque - Upper Crankcase Bolts: 27.5 N·m (2.8 kgf·m, 20 ft·lb) •...
  • Page 321: Crankshaft And Connecting Rods

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove: Camshaft Chain [A] Crankshaft [B] Crankshaft Installation NOTE ○ If the crankshaft is replaced with a new one, refer to the Connecting Rod Big End Bearing/Crankshaft Main Bearing Insert Selection in the Specifications.
  • Page 322: Connecting Rod Installation

    9-20 CRANKSHAFT/TRANSMISSION 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 323 CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods ○ 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 324 9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Dent both bolt head and bolt tip with a punch as shown. • Before tightening, use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt stretch.
  • Page 325: Crankshaft/connecting Rod Cleaning

    CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Apply a small amount of molybdenum disulfide oil solution to the following. Threads [A] of Nuts and Bolts Seating Surfaces [B] of Nuts and Connecting Rods •...
  • Page 326: Connecting Rod Twist Inspection

    9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Twist Inspection • With the big-end arbor [A] still on V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being paralleled with the surface plate over a 100 mm (3.94 in.) length of the arbor to de- termine the amount of connecting rod twist.
  • Page 327 CRANKSHAFT/TRANSMISSION 9-25 Crankshaft and Connecting Rods If the clearance is within the standard, no bearing replace- ment is required. If the clearance is between 0.042 mm (0.00165 in.) and the service limit (0.08 mm, 0.003 in.), replace the bear- ing inserts [A] with inserts painted blue [B]. Check in- sert/crankpin clearance with the plastigage.
  • Page 328: Crankshaft Side Clearance Inspection

    9-26 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Select the proper bearing insert [A] in accordance with the combination of the connecting rod and crankshaft coding. Size Color [B] Bearing Insert Connecting Rod Big End Crankpin Diameter Inside Diameter Marking Marking Size Color Part Number ○...
  • Page 329: Crankshaft Main Bearing Insert/journal Wear Inspection

    CRANKSHAFT/TRANSMISSION 9-27 Crankshaft and Connecting Rods Crankshaft Main Bearing Insert/Journal Wear Inspection • Using a plastigage (press gauge) [A], measure the bear- ing insert/journal [B] clearance. NOTE ○ Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). ○ Do not turn the crankshaft during clearance measure- ment.
  • Page 330 9-28 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. ○ Crankcase Main Bearing Inside Diameter Marks: “ ” or no mark. • Tighten the crankcase bolts to the specified torque (see Crankcase Assembly).
  • Page 331: Balancer

    CRANKSHAFT/TRANSMISSION 9-29 Balancer Balancer Removal • Split the crankcase (see Crankcase Splitting). • Pull the balancer shaft [A] with the balancer gear out of the crankcase. Balancer Installation • Apply molybdenum disulfide oil solution to the inside of the balancer shaft bearing insert. •...
  • Page 332 9-30 CRANKSHAFT/TRANSMISSION Balancer NOTE ○ Do not turn the balancer shaft during clearance mea- surement. ○ Remove the lower crankcase half and measure the plas- tigage width [A] to determine the bearing insert/journal [B] clearance. Balancer Shaft Bearing Insert/Journal Clearance 0.011 ∼...
  • Page 333 CRANKSHAFT/TRANSMISSION 9-31 Balancer • Put the lower crankcase half on the upper crankcase half without bearing inserts, and tighten the case bolts to the specified torque and sequence (see Crankcase Assem- bly). • Measure the crankcase bearing bore diameter for the bal- ancer shaft, and mark the upper crankcase half in accor- dance with the bore diameter.
  • Page 334: External Shift Mechanism

    9-32 CRANKSHAFT/TRANSMISSION External Shift Mechanism Shift Pedal Removal • Remove: Shift Pedal Bolt [A] Shift Pedal [B] Shift Pedal Installation • Install the shift pedal [A] to the shift shaft. ○ Align the punch mark [B] on the shift shaft with the punch mark [C] on the shift pedal.
  • Page 335: External Shift Mechanism Installation

    CRANKSHAFT/TRANSMISSION 9-33 External Shift Mechanism • Remove: Clutch (see Clutch Removal in the Clutch chapter) Gear Positioning Lever Bolt [A] Spacer [B] Gear Positioning Lever [C] Washer and Spring External Shift Mechanism Installation • Install the gear positioning lever [A] as shown in the figure. Spring [B] Washer [C] Spacer [D]...
  • Page 336: External Shift Mechanism Inspection

    9-34 CRANKSHAFT/TRANSMISSION External Shift Mechanism • Replace the shift shaft cover gasket with a new one. • Install the shift shaft cover. • Apply a non-permanent locking agent to the shift shaft cover screw [A]. • Apply a non-permanent locking agent to the shift shaft cover bolts [B, C].
  • Page 337: Transmission

    CRANKSHAFT/TRANSMISSION 9-35 Transmission Transmission Assy Removal • Remove: Shift Shaft Assembly (see External Shift Mechanism Re- moval) Neutral Switch Holder Screw [A] Neutral Switch Holder [B] and Pin Shift Drum Holder [C] and Pin • Remove the collar [A] and the O-ring [B] from the output shaft [C].
  • Page 338: Transmission Assy Disassembly

    9-36 CRANKSHAFT/TRANSMISSION Transmission • Install: Pin [A] Shift Drum Holder [B] Pin [C] Neutral Switch Holder [D] • Apply a non-permanent locking agent to the neutral switch holder screw [E] and tighten it. Torque - Neutral Switch Holder Screw: 4.9 N·m (0.50 kgf·m, 43 in·lb) •...
  • Page 339: Transmission Assy Assembly

    CRANKSHAFT/TRANSMISSION 9-37 Transmission • Remove the following from the transmission case as nec- essary. Shift Drum Bearing Holder Screws [A] Shift Drum Bearing Holder [B] • Remove the following from the transmission case as nec- essary. Drive Shaft Bearing Holder Screw [A] Drive Shaft Bearing Holder [B] Transmission Assy Assembly •...
  • Page 340 9-38 CRANKSHAFT/TRANSMISSION Transmission If the drive shaft bearing holder [A] is to be removed, fol- low the next procedure. ○ Apply a non-permanent locking agent to the threads of the drive shaft bearing holder screw [B] and tighten it. Torque - Drive Shaft Bearing Holder Screw: 4.9 N·m (0.50 kgf·m, 43 in·lb)
  • Page 341: Transmission Shaft Removal

    CRANKSHAFT/TRANSMISSION 9-39 Transmission • Apply engine oil to the shift drum groove. • Install the following on the transmission case [A]. Shift Drum [B] Pin [C] Shift Drum Cam [D] ○ Align the pin with the hole on the shift drum cam. •...
  • Page 342: Transmission Shaft Disassembly

    9-40 CRANKSHAFT/TRANSMISSION Transmission Transmission Shaft Disassembly • Remove the transmission shafts (see Transmission Assy Disassembly). • Remove the circlips, disassemble the transmission shafts. Special Tool - Outside Circlip Pliers: 57001-144 • The 5th gear [A] on the output shaft has three steel balls assembled into it for the positive neutral finder mecha- nism.
  • Page 343 CRANKSHAFT/TRANSMISSION 9-41 Transmission • Fit the steel balls into the 5th gear holes in the output shaft, aligning oil hole as shown in the figure. 5th Gear [A] Output Shaft [B] Steel Balls [C] Oil Holes [D] NOTICE Do not apply grease to the balls to hold them in place.
  • Page 344 9-42 CRANKSHAFT/TRANSMISSION Transmission 1. Drive Shaft 2. 1st Gear 3. 2nd Gear 4. 3rd Gear 5. 4th Gear 6. 5th Gear 7. 6th (Top) Gear 8. Bushing 9. Toothed Washer, 34 mm (1.34 in.) 10. Circlip 11. Bushing 12. Thrust Washer, 30 mm (1.18 in.) 13.
  • Page 345: Shift Drum And Fork Removal

    CRANKSHAFT/TRANSMISSION 9-43 Transmission Shift Drum and Fork Removal • Refer to the Transmission Assy Disassembly. Shift Drum and Fork Installation • Refer to the Transmission Assy Assembly. Shift Drum Disassembly • Refer to the Transmission Assy Disassembly. Shift Drum Assembly •...
  • Page 346: Gear Dog And Gear Dog Hole Damage Inspection

    9-44 CRANKSHAFT/TRANSMISSION Transmission Gear Dog and Gear Dog Hole Damage Inspection • Visually inspect the gear dogs [A] and gear dog holes [B]. Replace any damaged gears or gears with excessively worn dogs or dog holes.
  • Page 347: Ball Bearing, Needle Bearing, And Oil Seal

    CRANKSHAFT/TRANSMISSION 9-45 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 349 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-7 Rear Wheel Installation..................... 10-8 Wheel Inspection ......................10-10 Axle Inspection........................
  • Page 350: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 351 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle 11.0 Front Axle Clamp Bolt Rear Axle Nut 11.0 4. ER650F Model G: Apply grease. HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 352: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 1.0 mm (0.04 in.) Axle Runout/100 mm (3.94 in.) TIR 0.03 mm (0.001 in.) or less TIR 0.2 mm (0.008 in.) Wheel Balance...
  • Page 353: Special Tools

    WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: Bearing Remover Head, 20 × 22: 57001-1129 57001-1293 Jack: Bearing Remover Shaft, 13: 57001-1238 57001-1377...
  • Page 354: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Front Caliper Mounting Bolts [A] (Both Sides) Front Calipers [B] (Both Sides) • Loosen: Front Axle Clamp Bolt [A] Front Axle [B] • Remove: Lower Fairing (see Lower Fairing Removal in the Frame chapter) Lower Fairing Bracket (see Lower Fairing Bracket Re- moval in the Frame chapter)
  • Page 355: Rear Wheel Removal

    WHEELS/TIRES 10-7 Wheels (Rims) • Apply high-temperature grease to the grease seal lips. • Fit the collars [A] on the both sides of the hub. ○ The collars are identical. • Insert the front axle. • Remove the jack. • Tighten: Torque - Front Axle: 108 N·m (11.0 kgf·m, 80 ft·lb) •...
  • Page 356: Rear Wheel Installation

    10-8 WHEELS/TIRES Wheels (Rims) • Remove: Cotter Pin [A] Rear Axle Nut [B] Washer [C] Rear Axle [D] (from Right Side) • Remove the drive chain [A] from the rear sprocket toward the left. • Move the rear wheel back and remove it. NOTICE Do not lay the wheel on the ground with the disc facing down.
  • Page 357 WHEELS/TIRES 10-9 Wheels (Rims) • Bend the cotter pin [A] over the nut [B]. WARNING A loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper torque and install a new cotter pin. •...
  • Page 358: Wheel Inspection

    10-10 WHEELS/TIRES Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground. Special Tool - Jack: 57001-1238 • 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 359: Balance Inspection

    WHEELS/TIRES 10-11 Wheels (Rims) Balance Inspection • Remove the front and rear wheels (see Front/Rear Wheel Removal). • Support the wheel so that it can be spun freely. • Spin the wheel lightly, and mark [A] the wheel at the top when the wheel stops.
  • Page 360 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 361: Tires

    WHEELS/TIRES 10-13 Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove: Wheels (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...
  • Page 362 10-14 WHEELS/TIRES Tires • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull [B] the valve stem through the rim from the inside out until it snaps into place.
  • Page 363: 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 364: Hub Bearing

    10-16 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheels (see Front/Rear Wheel Removal), and take out the following. Collars Coupling (Out of rear hub) Grease Seals • Use the bearing remover to remove the hub bearings [A]. NOTICE Do not lay the wheel on the ground with the disc facing down.
  • Page 365: Hub Bearing Lubrication

    WHEELS/TIRES 10-17 Hub Bearing Hub Bearing Lubrication NOTE ○ Since the hub bearings are packed with grease and sealed, lubrication is not required.
  • Page 367 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 368: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 369 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Speed Sensor Bracket Bolts 87 in·lb Speed Sensor Bolt 0.80 69 in·lb Engine Sprocket Nut 12.7 Engine Sprocket Cover Bolts 87 in·lb Rear Sprocket Nuts Rear Axle Nut 11.0 G: Apply grease.
  • Page 370: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain 25 ∼ 35 mm (1.0 ∼ 1.4 in.) Drive Chain Slack – – – Drive Chain Wear (20-link Length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) Standard Chain: Make DAIDO...
  • Page 371: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...
  • Page 372: 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 373: Drive Chain Installation

    FINAL DRIVE 11-7 Drive Chain • Grind [A] the heads of the link pin to make it flat. • Set the cutting and riveting pin [C] in the pin holder [B] as shown in the figure. • Set the “U” holder and body, align the positioning pin [A] with the “A”...
  • Page 374 11-8 FINAL DRIVE Drive Chain • Set the “U” holder and body, align the positioning pin [A] with the “A” mark [B]. • Hold the body with a wrench [C]. • Turn the pin holder clockwise [D] with another wrench and press in the link plate on the link pin.
  • Page 375 FINAL DRIVE 11-9 Drive Chain • After riveting, check the ends of the riveted pins for cracks. • Measure the outside diameter [A] and the length [B] of the link pin. Link Pin Outside Diameter 5.5 ∼ 5.8 mm (0.22 ∼ 0.23 in.) Standard: Link Pin Length Standard:...
  • Page 376: Sprocket, Coupling

    11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove: Left Frame Cover (see Frame Cover Removal in the Frame chapter) Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] • Remove: Speed Sensor Bracket Bolts [A] Speed Sensor Bracket [B] •...
  • Page 377: Rear Sprocket Removal

    FINAL DRIVE 11-11 Sprocket, Coupling • Be sure that the dowel pins [A] are in position. • Install the speed sensor bracket and tighten the bolts. Torque - Speed Sensor Bracket Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Run the leads and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
  • Page 378: Coupling Bearing Removal

    11-12 FINAL DRIVE Sprocket, Coupling • Replace the O-ring [A] with a new one and apply grease to it. • Install: O-ring Collar [B] Coupling Coupling Bearing Removal • Remove: Coupling Grease Seal Circlip [A] Special Tool - Inside Circlip Pliers: 57001-143 •...
  • Page 379: Coupling Bearing Inspection

    FINAL DRIVE 11-13 Sprocket, Coupling Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances, the clearance can not normally be measured. NOTE ○ It is not necessary to remove the coupling bearing for inspection. If the bearing is removed, it will need to be replaced with a new one.
  • Page 380: Rear Sprocket Warp Inspection

    11-14 FINAL DRIVE Sprocket, Coupling Rear Sprocket Warp Inspection • Raise the rear wheel off the ground with a stand so that it will turn freely. • Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown in the figure, and rotate [C] the rear wheel to measure the sprocket runout (warp).
  • Page 381 BRAKES 12-1 Brakes Table of Contents Exploded View........................12-3 Specifications ......................... 12-12 Special Tools .......................... 12-13 Brake Lever, Brake Pedal....................... 12-14 Brake Lever Position Adjustment..................12-14 Brake Pedal Position Inspection ..................12-14 Brake Pedal Position Adjustment..................12-14 Brake Pedal Removal ....................... 12-15 Brake Pedal Installation ....................
  • Page 382 12-2 BRAKES ABS Servicing Precautions ....................12-35 ABS Troubleshooting Outline.................... 12-37 Inquiries to Rider....................... 12-40 Self-diagnosis Outline ....................... 12-42 Self-diagnosis Procedures ....................12-42 Service Code Clearing Procedures................... 12-43 How to Read Service Codes..................... 12-45 How to Erase Service Codes .................... 12-45 Yellow ABS Indicator Light (LED) Inspection ..............
  • Page 383: Exploded View

    BRAKES 12-3 Exploded View This page intentionally left blank.
  • Page 384 12-4 BRAKES Exploded View ER650E Model...
  • Page 385 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Reservoir Cap Screws 0.15 13 in·lb Brake Lever Pivot Bolt 0.10 9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Master Cylinder Clamp Bolts 97 in·lb Front Brake Light Switch Screw 0.12 11 in·lb...
  • Page 386 12-6 BRAKES Exploded View ER650E Model...
  • Page 387 BRAKES 12-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut Brake Pedal Bolt 0.90 78 in·lb Caliper Bleed Valve 0.80 69 in·lb Rear Caliper Mounting Bolts Brake Disc Mounting Bolts B: Apply brake fluid.
  • Page 388 12-8 BRAKES Exploded View ER650F Model...
  • Page 389 BRAKES 12-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Reservoir Cap Screws 0.15 13 in·lb Brake Lever Pivot Bolt 0.10 9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Master Cylinder Clamp Bolts 97 in·lb Front Brake Light Switch Screw 0.12 11 in·lb...
  • Page 390 12-10 BRAKES Exploded View ER650F Model...
  • Page 391 BRAKES 12-11 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut Brake Pipe Joint Nuts Caliper Bleed Valve 0.80 69 in·lb Rear Caliper Mounting Bolts Brake Disc Mounting Bolts Brake Pedal Bolt 0.90 78 in·lb...
  • Page 392: Specifications

    12-12 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Lever Position 5-way adjustable (to suit rider) – – – Lever Free Play Non-adjustable – – – Pedal Position About 50 mm (2.0 in.) below top of footpeg – – – Pedal Free Play Non-adjustable –...
  • Page 393: Special Tools

    BRAKES 12-13 Special Tools Jack: Needle Adapter Set: 57001-1238 57001-1457 Hand Tester: 57001-1394...
  • Page 394: Brake Lever, Brake Pedal

    12-14 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder.
  • Page 395: Brake Pedal Removal

    BRAKES 12-15 Brake Lever, Brake Pedal Brake Pedal Removal • Remove: Right Footpeg Stay (see Footpeg Stay Removal in the Frame chapter) Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] Brake Pedal Bolt [E] and Washer [F] Washer [G] •...
  • Page 396: Calipers

    12-16 BRAKES Calipers Front Caliper Removal • Loosen the banjo bolt [A], being careful not to spill brake fluid. • Remove the caliper mounting bolts [B]. • Remove the banjo bolt and take off the brake hoses from the caliper. NOTICE Immediately wipe up any brake fluid that spilled.
  • Page 397: Front Caliper Disassembly

    BRAKES 12-17 Calipers • Bleed the brake line (see Brake Line Bleeding). • Check the fluid level in the brake reservoirs (see Brake Fluid Level Inspection in the Periodic Maintenance chap- ter). • Check the brake for good braking power, no brake drag, and no fluid leakage.
  • Page 398: Caliper Dust Seal Damage Inspection

    12-18 BRAKES Calipers Caliper Dust Seal Damage Inspection • Check that the dust seal(s) [A] are not cracked, worn, swollen, or otherwise damaged. If they show any damage, replace the dust seals with new ones. Piston(s) [B] Fluid Seal(s) [C] Caliper Dust Boot and Friction Boot Damage Inspection •...
  • Page 399: Caliper Piston And Cylinder Damage Inspection

    BRAKES 12-19 Calipers Caliper Piston and Cylinder Damage Inspection • Visually inspect the piston(s) [A] and cylinder surface(s) [B]. Replace the caliper if the cylinder and piston are badly scores or rusty. Caliper Holder Shaft Wear Inspection The caliper body must slide smoothly on the caliper holder shaft [A].
  • Page 400: Brake Pads

    12-20 BRAKES Brake Pads Front Brake Pad Removal • Remove the front caliper with the hose installed (see Front Caliper Removal). • Draw out the holder shaft pin [A], and take off the holder shaft [B]. • Remove the pad [C] from the holder shaft [D]. •...
  • Page 401: Master Cylinder

    BRAKES 12-21 Master Cylinder Front Master Cylinder Removal • Remove the right rear view mirror (see Rear View Mirror Removal in the Frame chapter). • Disconnect the front brake light switch connectors [A]. • Loosen the banjo bolt [B], being careful not to spill brake fluid.
  • Page 402 12-22 BRAKES Master Cylinder • Install the front master cylinder. ○ Align the punch mark [A] on the handlebar with the mating surface [B] of the master cylinder clamp. • Tighten the upper clamp bolt [A] first, and then the lower clamp bolt [B].
  • Page 403: Rear Master Cylinder Removal

    BRAKES 12-23 Master Cylinder Rear Master Cylinder Removal • Loosen the banjo bolt [A], being careful not to spill brake fluid. • Remove the banjo bolt and take off the brake hose from the master cylinder [B]. NOTICE Immediately wipe up any brake fluid that spilled. •...
  • Page 404: Master Cylinder Disassembly

    12-24 BRAKES Master Cylinder • Replace the washers [A] on each side of the hose fitting [B] with new ones. • Install the brake hose lower end. • Tighten: Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) •...
  • Page 405: Master Cylinder Inspection

    BRAKES 12-25 Master Cylinder Master Cylinder Inspection • Remove the master cylinders (see Front/Rear Master Cylinder Removal). • Disassemble the front and rear master cylinders (see Master Cylinder Disassembly). • 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 406: Brake Disc

    12-26 BRAKES Brake Disc Brake Disc Removal • Remove the wheel (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Unscrew the mounting bolts [A], and take off the disc [B]. • For front brake disc, remove the gaskets. Brake Disc Installation •...
  • Page 407: Brake Fluid

    BRAKES 12-27 Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter. Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action.
  • Page 408 12-28 BRAKES Brake Fluid • Bleed the brake line and the caliper. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].
  • Page 409 BRAKES 12-29 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. 3.
  • Page 410: Brake Hose

    12-30 BRAKES Brake Hose Brake Hose Removal/Installation • Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter. Brake Hose Inspection • Refer to the Brake Hose Damage and Installation Condi- tion Inspection in the Periodic Maintenance chapter.
  • Page 411: Anti-lock Brake System (equipped Models)

    BRAKES 12-31 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] Yellow ABS Indicator Light (LED) [A] ABS Hydraulic Unit [A] ABS Solenoid Valve Relay Fuse 15 A [A] ABS Motor Relay Fuse 25 A [B]...
  • Page 412 12-32 BRAKES Anti-Lock Brake System (Equipped Models) ABS Kawasaki Diagnostic System Connector [A] ABS Self-diagnosis Terminal [B]...
  • Page 413 2. Front Wheel Rotation Sensor 3. Front Brake Light Switch 12. ABS Motor Relay Fuse 25 A 4. Rear Wheel Rotation Sensor 13. ABS Kawasaki Diagnostic System Connec- 5. Rear Brake Light Switch 6. Frame Ground 14. ABS Self-diagnosis Terminal 7.
  • Page 414 Terminal Names 1. Ground 2. Unused 3. Front Wheel Rotation Sensor Signal 4. Power Supply 5. ABS Kawasaki Diagnostic System Terminal 6. Front/Rear Brake Light Switch 7. ABS Self-diagnosis Terminal 8. Unused 9. Power Supply to ABS Solenoid Valve Relay 10.
  • Page 415: Abs Servicing Precautions

    BRAKES 12-35 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 416 12-36 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 417: Abs Troubleshooting Outline

    BRAKES 12-37 Anti-Lock Brake System (Equipped Models) ○ The yellow ABS indicator light (LED) may go on if the engine is run with the motorcycle on its stand and the transmission in gear. If the warning indicator light goes on, just turn the ignition switch to OFF, then clear service code 42, which indicates a “Faulty front wheel rotation sensor”.
  • Page 418 12-38 BRAKES Anti-Lock Brake System (Equipped Models) Even when the ABS is operating normally, the yellow ABS indicator light (LED) may go on under the conditions listed below. Turn the ignition switch to OFF to stop the yel- low ABS indicator light (LED). If the motorcycle runs with- out erasing the service code, the yellow ABS indicator light (LED) may go on again.
  • Page 419 BRAKES 12-39 Anti-Lock Brake System (Equipped Models) ABS Diagnosis Flow Chart...
  • Page 420 12-40 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 421 BRAKES 12-41 Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 1...
  • Page 422: Self-diagnosis Outline

    12-42 BRAKES Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 2 Self-diagnosis Outline When the yellow ABS indicator light (LED) has blinked or goes on, the ABS hydraulic unit memorizes and stores the service code (15 codes including “Normal Code”) for the service person to troubleshoot easily.
  • Page 423: Service Code Clearing Procedures

    BRAKES 12-43 Anti-Lock Brake System (Equipped Models) • Remove the front seat (see Front Seat Removal in the Frame chapter). • Ground the self-diagnosis terminal [A] (Gray) to the bat- tery (–) terminal or battery (–) cable connector, using a lead.
  • Page 424 12-44 BRAKES Anti-Lock Brake System (Equipped Models) Self-diagnosis Flow Chart...
  • Page 425: How To Read Service Codes

    BRAKES 12-45 Anti-Lock Brake System (Equipped Models) How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the yellow ABS indicator light (LED) as shown below. ○ Read 10th digit and unit digit as the yellow ABS indicator light (LED) blinks. ○...
  • Page 426 12-46 BRAKES Anti-Lock Brake System (Equipped Models) Service Code Table Service Yellow ABS Indicator Problems Light State Code Light (LED) After starts, Start code (not fault) turn off Rear intake solenoid valve trouble (open, temperature abnormal) Rear outlet solenoid valve trouble (open, temperature abnormal) Front intake solenoid valve trouble (open, temperature abnormal)
  • Page 427: Yellow Abs Indicator Light (led) Inspection

    BRAKES 12-47 Anti-Lock Brake System (Equipped Models) Yellow ABS Indicator Light (LED) Inspection • Turn the ignition switch to ON. If the yellow ABS indicator light (LED) [A] goes on, it is normal. If the yellow ABS indicator light (LED) does not go on, go to step “Yellow ABS Indicator Light (LED) does not go on (When the Ignition Switch turned to ON)”.
  • Page 428: Yellow Abs Indicator Light (led) Goes On (when The Motorcycle Is Running, - No Service Code)

    12-48 BRAKES Anti-Lock Brake System (Equipped Models) • Do the 3rd step test as follows. ○ Disconnect the ABS hydraulic unit connector (see ABS Hydraulic Unit Removal). ○ Check for continuity between the black/white lead termi- nal of the main harness side connector (meter unit) [A] and black/white lead terminal of the main harness side connector (ABS hydraulic unit) [B].
  • Page 429 BRAKES 12-49 Anti-Lock Brake System (Equipped Models) • Do the 2nd step test as follows. ○ Disconnect the ABS hydraulic unit connector [A] (see ABS Hydraulic Unit Removal). ○ Check for continuity between the red/black and black lead terminals of the ABS hydraulic unit connector. If there is the continuity in the lead, replace the ABS hy- draulic unit.
  • Page 430: Front, Rear Wheel Rotation Difference Abnormal (service Code 25)

    12-50 BRAKES Anti-Lock Brake System (Equipped Models) Front, Rear Wheel Rotation Difference Abnormal (Service Code 25) • Do the 1st step test as follows. ○ Check the following and correct the faulty part. Incorrect the tire pressure. Tires not recommended for the motorcycle were installed (incorrect tire size).
  • Page 431: Front Wheel Rotation Sensor Signal Abnormal (service Code 42)

    BRAKES 12-51 Anti-Lock Brake System (Equipped Models) • Do the 4th step test as follows. ○ Check the battery terminal voltage between the red/white lead terminal of the fuse box [A] and ground. Special Tool - Hand Tester: 57001-1394 Battery Terminal Voltage Battery Voltage Standard: If the battery terminal voltage is not within the specifica-...
  • Page 432: Front Wheel Rotation Sensor Wiring Inspection (service Code 43)

    12-52 BRAKES Anti-Lock Brake System (Equipped Models) • Do the 2nd step test as follows. ○ 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. ○...
  • Page 433: Rear Wheel Rotation Sensor Signal Abnormal (service Code 44)

    BRAKES 12-53 Anti-Lock Brake System (Equipped Models) • Do the 3rd step test as follows. ○ Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the yellow ABS indicator light (LED) [A] goes on, faulty ECU in the ABS hydraulic unit.
  • Page 434: Rear Wheel Rotation Sensor Wiring Inspection (service Code 45)

    (Service Code 52) • Do the 1st step test as follows. ○ Disconnect: ABS Kawasaki Diagnostic System Connector ABS Hydraulic Unit Connector (see ABS Hydraulic Unit Removal) ○ Check for continuity between the red/white lead terminal of the main harness side connector [A] and brown/white lead terminal of the main harness side connector (ABS hydraulic unit ) [B].
  • Page 435: Power Supply Voltage Abnormal (over-voltage) (service Code 53)

    Connect the ABS Kawasaki diagnostic system connector and ABS hydraulic unit connector. ○ Check the battery terminal voltage, connect the hand tester to the brown/white terminal of ABS Kawasaki diagnostic system connector [A] and ground. Special Tool - Hand Tester: 57001-1394 ○...
  • Page 436: Ecu Inspection (service Code 55)

    Connect the ABS Kawasaki diagnostic system connector and ABS hydraulic unit connector. ○ Check the battery terminal voltage, connect the hand tester to the brown/white terminal of ABS Kawasaki diagnostic system connector [A] and ground. Special Tool - Hand Tester: 57001-1394 ○...
  • Page 437: Abs Hydraulic Unit Removal

    BRAKES 12-57 Anti-Lock Brake System (Equipped Models) ABS Hydraulic Unit Removal NOTICE The ABS hydraulic unit has been adjusted and set with precision at the factory. Therefore, it should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface. Be careful not to get water or mud on the ABS hy- draulic unit.
  • Page 438 12-58 BRAKES Anti-Lock Brake System (Equipped Models) • Remove the brake pipe joint nuts [A] with the flare nut wrench. NOTE ○ Remove the brake hoses and pipes according to each assembly of the exploded view. • Tape the brake line opening to prevent brake fluid leakage or contamination by foreign matter.
  • Page 439: Abs Hydraulic Unit Installation

    BRAKES 12-59 Anti-Lock Brake System (Equipped Models) ABS Hydraulic Unit Installation • Install the bracket to the ABS hydraulic unit. NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Install the ABS hydraulic unit to the frame. •...
  • Page 440: Front Wheel Rotation Sensor Installation

    12-60 BRAKES Anti-Lock Brake System (Equipped Models) • Remove the headlight unit (see Headlight Unit Removal in the Electrical System chapter). • Disconnect the front wheel rotation sensor connector [A]. • Free the front wheel rotation sensor lead [A] from the clamps [B].
  • Page 441: Rear Wheel Rotation Sensor Installation

    BRAKES 12-61 Anti-Lock Brake System (Equipped Models) • Remove: Right Frame Cover (see Frame Cover Removal in the Frame chapter) • Disconnect the connector [A]. • Remove: Rear Wheel Rotation Sensor Bolt [A] Rear Wheel Rotation Sensor [B] • Free the sensor lead from the clamps. Rear Wheel Rotation Sensor Installation •...
  • Page 442: Wheel Rotation Sensor Air Gap Inspection

    12-62 BRAKES Anti-Lock Brake System (Equipped Models) Wheel Rotation Sensor Air Gap Inspection • Raise the front/rear wheel off the ground (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Measure the air gap between the sensor and sensor rotor at several points by turning the wheel slowly.
  • Page 443: Abs Motor Relay Fuse 25 A Removal

    BRAKES 12-63 Anti-Lock Brake System (Equipped Models) ABS Motor Relay Fuse 25 A Removal • Remove the left frame cover (see Frame Cover Removal in the Frame chapter). • Unlock the hook, and open the lid [A]. • Pull out the relay fuse [B] from the fuse box with needle nose pliers.
  • Page 445 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-8 Front Fork Removal ......................13-8 Front Fork Installation ....................... 13-8 Front Fork Oil Change ...................... 13-9 Front Fork Disassembly ....................13-10 Front Fork Assembly......................
  • Page 446: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 447 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Top Plugs 22.5 Front Fork Clamp Bolts (Upper) Front Fork Clamp Bolts (Lower) 20.5 Front Axle Clamp Bolt Front Fork Bottom Allen Bolts AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.
  • Page 448 13-4 SUSPENSION Exploded View...
  • Page 449 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Mounting Bolts Swingarm Bracket Bolts Swingarm Bracket Bolt (Lower Left) Swingarm Pivot Shaft Nut 11.0 G: Apply grease. R: Replacement Parts...
  • Page 450: Specifications

    13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Outside Diameter 41 mm (1.6 in.) Air Pressure Atmospheric pressure (Non-adjustable) Fork Spring Setting Non-adjustable Damper Setting Non-adjustable Fork Oil: Recommended Oil KAYABA KHL34-G10 or equivalent Amount approx.
  • Page 451: Special Tools

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Jack: 57001-143 57001-1238 Fork Cylinder Holder Handle: Front Fork Oil Seal Driver: 57001-183 57001-1219 Fork Cylinder Holder Adapter: Fork Oil Level Gauge: 57001-1057 57001-1290 Oil Seal & Bearing Remover: Needle Bearing Driver, 28: 57001-1058 57001-1610 Bearing Driver Set:...
  • Page 452: Front Fork

    13-8 SUSPENSION Front Fork Front Fork Removal • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Front Fender (see Front Fender Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Wheel Rotation Sensor Lower End (ABS equipped models, see Front Wheel Rotation Sensor Removal in the Brakes chapter) •...
  • Page 453: Front Fork Oil Change

    SUSPENSION 13-9 Front Fork Front Fork Oil Change • Remove: Front Fork (see Front Fork Removal) Top Plug [A] with O-ring Spacer [B] Fork Spring Seat [C] Fork Spring [D] • Compress [A] the fork [B] upside down to draw out the oil into the suitable container [C].
  • Page 454: Front Fork Disassembly

    13-10 SUSPENSION Front Fork • Hold the outer tube vertically in a vise and compress the fork completely. • Wait until the oil level stabilizes. • Use the fork oil level gauge [A] to measure the distance from the top of the inner tube to the oil level. Special Tool - Fork Oil Level Gauge: 57001-1290 ○...
  • Page 455 SUSPENSION 13-11 Front Fork • Remove the cylinder unit [A], washer [B], and the spring [C] from the inner tube. • Remove the following from the top of the outer tube. Dust Seal [A] Retaining Ring [B] • Separate the inner tube [A] from the outer tube [B]. NOTE ○...
  • Page 456: Front Fork Assembly

    13-12 SUSPENSION Front Fork Front Fork Assembly • Replace the following parts with new ones. Top Plug O-ring Retaining Ring [A] Dust Seal [B] Oil Seal [C] Inner Guide Bushing [D] Outer Guide Bushing [E] Fork Bottom Allen Bolt Gasket [F] •...
  • Page 457: Inner Tube, Outer Tube Inspection

    SUSPENSION 13-13 Front Fork • Apply non-permanent locking agent to the threads of the bottom Allen bolt [A]. • Hold the front fork horizontally in a vise [B]. • Hold the cylinder unit [C] with the special tools and tighten the bottom Allen bolt to secure the cylinder in place.
  • Page 458: Spring Tension Inspection

    13-14 SUSPENSION Front Fork Spring Tension Inspection • Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, replace it with a new one. If the length of a replace- ment spring and that of the remaining spring vary greatly, the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability.
  • Page 459: Rear Shock Absorber

    SUSPENSION 13-15 Rear Shock Absorber Spring Preload Adjustment • Using the hook wrench [A], turn the adjusting nut [B] to adjust the spring preload. ○ The standard adjuster setting is 4th position. Spring Preload Setting Standard Position: 4th position Adjustable Range: 1st to 7th position •...
  • Page 460: Rear Shock Absorber Installation

    13-16 SUSPENSION Rear Shock Absorber • Remove: Right Stay Cover [A] • Remove: Rear Shock Absorber Mounting Bolt (Upper) [A], Washer and O-ring Rear Shock Absorber Mounting Bolt (Lower) [B], Nut, Collar and Washer • Remove the rear shock absorber [C] backward. Rear Shock Absorber Installation •...
  • Page 461: Swingarm

    SUSPENSION 13-17 Swingarm Swingarm Removal • Remove: Chain Cover Bolts [A] Chain Cover [B] • Remove: Frame Covers (see Frame Cover Removal in the Frame chapter) Engine Sprocket Cover (see Engine Sprocket Cover Re- moval in the Final Drive chapter) Footpeg Stays (see Footpeg Stay Removal in the Frame chapter) Muffler (see Muffler Removal in the Engine Top End...
  • Page 462: Swingarm Installation

    13-18 SUSPENSION Swingarm • Support the frame using the jack. Special Tool - Jack: 57001-1238 • Remove the following parts, and remove the swingarm. Rear Shock Absorber Mounting Bolt (Lower), Nut, Collar and Washer Swingarm Pivot Shaft Nut Swingarm Pivot Shaft Swingarm Installation •...
  • Page 463: Swingarm Bearing Installation

    SUSPENSION 13-19 Swingarm • Remove the ball bearing and needle bearings with oil seal & bearing remover [A]. Special Tool - Oil Seal & Bearing Remover: 57001-1058 Swingarm Bearing Installation • Replace the ball and needle bearings [A] with new ones. •...
  • Page 464: Swingarm Bearing, Sleeve Inspection

    13-20 SUSPENSION Swingarm Swingarm Bearing, Sleeve Inspection NOTICE Do not remove the bearings for inspection. Re- moval may damage them. • Inspect the needle bearings [A] and ball bearing installed in the swingarm. ○ The rollers and ball in a bearing normally wear very little, and wear is difficult to measure.
  • Page 465 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 466: Exploded View

    14-2 STEERING Exploded View...
  • Page 467 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Switch Housing Screws 0.36 31 in·lb Handlebar Holder Bolts Steering Stem Head Bolt 11.0 Front Fork Clamp Bolts (Upper) Handlebar Holder Mounting Nuts Steering Stem Nut Front Fork Clamp Bolts (Lower) 20.5 AD: Apply adhesive.
  • Page 468: Special Tools

    14-4 STEERING Special Tools Head Pipe Outer Race Press Shaft: Steering Stem Bearing Driver, 42.5: 57001-1075 57001-1344 Steering Stem Nut Wrench: Steering Stem Bearing Driver Adapter, 41.5: 57001-1100 57001-1345 Bearing Driver Set: Head Pipe Outer Race Driver, 55: 57001-1129 57001-1446...
  • Page 469: 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 470: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Meter Unit (see Meter Unit Removal in the Electrical Sys- tem chapter) Handlebar (see Handlebar Removal) Headlight Unit (see Headlight Unit Removal in the Elec- trical System chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Forks (see Front Fork Removal in the Suspension chapter)
  • Page 471: 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 472 14-8 STEERING Steering Stem • Install the lower ball bearing [A] onto the stem. • Apply grease to the following. Inner and Outer Races Lower Ball Bearing • Install the steering stem [A] through the head pipe, and install the upper ball bearing [B] and upper ball bearing inner race [C] on it.
  • Page 473: Steering Stem Bearing Lubrication

    STEERING 14-9 Steering Stem NOTE ○ Tighten the upper front fork clamp bolts first, next the stem head bolt, last the lower front fork clamp bolts. ○ Tighten the two lower front fork clamp bolts alternately two times to ensure even tightening torque. Torque - Front Fork Clamp Bolts (Upper): 20 N·m (2.0 kgf·m, 15 ft·lb) Steering Stem Head Bolt: 108 N·m (11.0 kgf·m, 80...
  • Page 474: Handlebar

    14-10 STEERING Handlebar Handlebar Removal • Remove: Meter Unit (see Meter Unit Removal in the Electrical Sys- tem chapter) Clutch Lever Clamp Bolts [A] and Washers 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] Handlebar Weight [C]...
  • Page 475 STEERING 14-11 Handlebar • Set the handlebar onto the lower handlebar holders. ○ Align the punch mark [A] on the handlebar with the corner edge [B] of the lower handlebar holder. • Install the upper handlebar holder [A]. • Tighten the front handlebar holder bolts [B] first, and then the rear handlebar holder bolts [C].
  • Page 476 14-12 STEERING Handlebar • Install: Throttle Grip Throttle Cable Tips [A] Right Switch Housing ○ Fit the projection [B] into a hole [C] on the handlebar. ○ The lower switch housing screw is longer than the upper one. • Tighten: Torque - Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb) •...
  • Page 477 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Seats ............................15-8 Rear Seat Removal......................15-8 Rear Seat Installation......................15-8 Front Seat Removal ......................15-8 Front Seat Installation ....................... 15-8 Fairings........................... 15-9 Lower Fairing Removal ..................... 15-9 Lower Fairing Installation ....................15-9 Lower Fairing Bracket Removal..................
  • Page 478: Exploded View

    15-2 FRAME Exploded View...
  • Page 479 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Footpeg Stay Bolts Sidestand Bolt Sidestand Switch Bolt 0.90 78 in·lb 4. CA and AU Models 5. AU Model G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specified tightening sequence.
  • Page 480 15-4 FRAME Exploded View...
  • Page 481 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Turn Signal Light Mounting Bolts 0.43 37 in·lb 2. AU Model 3. CA Model...
  • Page 482 15-6 FRAME Exploded View...
  • Page 483 FRAME 15-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Grab Rail Mounting Bolts Lower Fairing Bracket Bolts 106 in·lb Lower Fairing Mounting Bolts 0.90 78 in·lb Seat Lock Mounting Screws 0.04 4 in·lb L: Apply a non-permanent locking agent.
  • Page 484: Seats

    15-8 FRAME Seats Rear Seat Removal • Insert the ignition switch key [A] into the seat lock. • Turn the key clockwise, and pull up the front part of the seat [B]. • Remove the seat forward. Rear Seat Installation •...
  • Page 485: Fairings

    FRAME 15-9 Fairings Lower Fairing Removal • Remove the mounting bolts [A] on both sides, and take off the lower fairing [B]. Lower Fairing Installation • Install the lower fairing. • Apply a non-permanent locking agent to the threads of the lower fairing mounting bolts and tighten them.
  • Page 486: Center Fairing Removal

    15-10 FRAME Fairings Center Fairing Removal • Remove: Bolt [A] and Washer Bolt [B] • Pull out the center fairing [C] outward to clear the stop- pers. Center Fairing Installation • Installation is the reverse of removal. ○ Install the center fairing so that the projections [A] fit into the grommets [B].
  • Page 487: Seat Covers

    FRAME 15-11 Seat Covers Front Seat Cover Removal • Remove: Front Seat (see Front Seat Removal) Screws [A] Front Seat Covers [B] Front Seat Cover Installation • Installation is the reverse of removal. Rear Seat Cover Removal • Remove: Front Seat (see Front Seat Removal) Bolts [A] and Washers (Left and Right) Grab Rails [B] (Left and Right) •...
  • Page 488: Rear Seat Cover Installation

    15-12 FRAME Seat Covers Rear Seat Cover Installation • Installation is the reverse of removal. ○ Install the rear seat cover [A] so that the ribs [B] fit inside the rear fender [C]. ○ Install the center seat cover [A] so that the projections [B] fit into the slots [C].
  • Page 489: Fenders

    FRAME 15-13 Fenders Front Fender Removal • Remove: Bolts [A] and Washers (Left and Right) Bolts [B] (Left and Right) Front Fender [C] Front Fender Installation • Install the front fender [A] together with the brake hose clamps [B] on both sides. Flap Removal •...
  • Page 490: Rear Fender Removal

    15-14 FRAME Fenders Rear Fender Removal • Remove: Flap (with Reinforce installed, see Flap Removal) Bolts [A] and Washers (Left and Right) Rear Brake Fluid Reservoir Mounting Bolt [B] and Washer • Clear the hook [A] from the frame to remove the rear fender [B].
  • Page 491: Frame

    FRAME 15-15 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 492: Battery Case

    15-16 FRAME Battery Case Battery Case Removal • Remove: Battery (see Battery Removal in the Electrical System chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Screw [A] and Connector Holder [B] (ABS Equipped Models) Starter Relay [C] Dust Cover [D] •...
  • Page 493: Footpeg Stay

    FRAME 15-17 Footpeg Stay Footpeg Stay Removal • Remove: Frame Cover (see Frame Cover Removal) Footpeg Stay Mounting Bolts [A] Footpeg Stay [B] Rear Master Cylinder (Right Side, see Rear Master Cylinder Removal in the Brakes chapter) Brake Pedal (Right Side, see Brake Pedal Removal in the Brakes chapter) Rear Brake Light Switch Lead Connector (Right Side) Footpeg Stay Installation...
  • Page 494: Sidestand

    15-18 FRAME Sidestand Sidestand Removal • Raise the rear wheel off the ground using a stand [A]. • Remove: Sidestand Switch Bolt [A] Clamp [B] Sidestand Switch [C] • Remove: Spring [A] Sidestand Nut [B] Sidestand Bolt [C] Sidestand [D] Sidestand Installation •...
  • Page 495: Frame Cover

    FRAME 15-19 Frame Cover Frame Cover Removal • Remove the bolt [A] and collar. • Pull the frame cover [B] outward to clear the stoppers. Frame Cover Installation • Installation is the reverse of removal. ○ Fit the rib [A] to the inside of the footpeg stay. ○...
  • Page 496: Rear View Mirrors

    15-20 FRAME Rear View Mirrors Rear View Mirror Removal • Slide out the dust cover [A]. • Loosen the lower hexagonal area [B], and remove the rear view mirror [C] from the holder. ○ The upper hexagonal area has left-hand threads. Rear View Mirror Installation •...
  • Page 497 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-4 Specifications ......................... 16-10 Special Tools and Sealants ....................16-11 Parts Location......................... 16-13 Wiring Diagram (ER650E Model) ................... 16-16 Wiring Diagram (ER650F Model) ................... 16-18 Precautions..........................16-20 Electrical Wiring........................16-21 Wiring Inspection ......................
  • Page 498 16-2 ELECTRICAL SYSTEM Starter Motor Installation....................16-47 Starter Motor Disassembly....................16-48 Starter Motor Assembly ....................16-48 Brush Inspection ....................... 16-50 Commutator Cleaning and Inspection................16-51 Armature Inspection......................16-51 Brush Lead Inspection ...................... 16-51 Right-hand End Cover Inspection ..................16-52 Starter Relay Inspection....................16-52 Lighting System ........................
  • Page 499 ELECTRICAL SYSTEM 16-3 This page intentionally left blank.
  • Page 500: Exploded View

    16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 501 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Turn Signal Light Mounting Bolts 0.43 37 in·lb License Plate Light Mounting Screws 0.12 10 in·lb...
  • Page 502 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 503 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Switch Housing Screws 0.36 31 in·lb Front Brake Light Switch Screw 0.12 11 in·lb Engine Ground Lead Terminal Bolt 87 in·lb Starter Relay Terminal Bolts 0.36 31 in·lb Starter Motor Cable Terminal Nut 0.61 53 in·lb Starter Motor Terminal Locknut...
  • Page 504 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 505 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Regulator/Rectifier Bolts 87 in·lb Fuel Pump Bolts 87 in·lb L, S Sidestand Switch Bolt 0.90 78 in·lb Spark Plugs Water Temperature Sensor 106 in·lb Alternator Cover Bolts 87 in·lb Stator Coil Bolts 106 in·lb Alternator Lead Holding Plate Bolt...
  • Page 506: Specifications

    16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name YT12A-BS Capacity 12 V 10 Ah Voltage 12.8 V or more Charging System Type Three-phase AC Alternator Output Voltage 42 V or more at 4 000 r/min (rpm) 0.18 ∼...
  • Page 507: Special Tools And Sealants

    ELECTRICAL SYSTEM 16-11 Special Tools and Sealants Hand Tester: Grip: 57001-1394 57001-1591 Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: Rotor Holder: 57001-1405 57001-1567 Peak Voltage Adapter: Extension Tube: 57001-1415 57001-1578 Lead Wire - Peak Voltage Adapter: Rotor Holder: 57001-1449 57001-1658 Needle Adapter Set: Stopper:...
  • Page 508 16-12 ELECTRICAL SYSTEM Special Tools and Sealants Liquid Gasket, TB1211: Liquid Gasket, TB1211F: 56019-120 92104-0004...
  • Page 509: Parts Location

    ELECTRICAL SYSTEM 16-13 Parts Location This page intentionally left blank.
  • Page 510 16-14 ELECTRICAL SYSTEM Parts Location...
  • Page 511 ELECTRICAL SYSTEM 16-15 Parts Location 1. Regulator/Rectifier 2. Water Temperature Sensor 3. Starter Relay with Main Fuse 4. Battery 12 V 10 Ah 5. Speed Sensor 6. Sidestand Switch 7. Neutral Switch 8. Oxygen Sensor (Equipped Models) 9. Alternator 10. Turn Signal Relay 11.
  • Page 512: Wiring Diagram (er650e Model)

    16-16 ELECTRICAL SYSTEM Wiring Diagram (ER650E Model)
  • Page 513 ELECTRICAL SYSTEM 16-17 Wiring Diagram (ER650E Model)
  • Page 514: Wiring Diagram (er650f Model)

    16-18 ELECTRICAL SYSTEM Wiring Diagram (ER650F Model)
  • Page 515 ELECTRICAL SYSTEM 16-19 Wiring Diagram (ER650F Model)
  • Page 516: Precautions

    16-20 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 517: Electrical Wiring

    ELECTRICAL SYSTEM 16-21 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 518: Battery

    16-22 ELECTRICAL SYSTEM Battery Battery Removal • Turn the ignition switch to OFF. • Remove the front seat (see Front Seat Removal in the Frame chapter) • Remove: Front Seat Bracket Bolts [A] Front Seat Bracket [B] • Disconnect the negative (–) cable [A]. NOTICE Be sure to disconnect the negative (–) cable first.
  • Page 519: Battery Activation

    ELECTRICAL SYSTEM 16-23 Battery Battery Activation Electrolyte Filling • Make sure that the model name [A] of the electrolyte con- tainer matches the model name [B] of the battery. These names must be the same. Battery Model Name ER650E/F: YT12A-BS NOTICE Each battery comes with its own specific elec- trolyte container;...
  • Page 520 16-24 ELECTRICAL SYSTEM Battery • Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery. Hold the container level, push down to break the seals of all six cells. You will see air bubbles rising into each cell as the ports fill.
  • Page 521 Newly activated sealed batteries require an initial charge. Standard Charge: 1.2 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 522: Precautions

    16-26 ELECTRICAL SYSTEM Battery Precautions 1) No need of topping-up No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that. 2) Refreshing charge If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been discharged.
  • Page 523: Charging Condition Inspection

    ELECTRICAL SYSTEM 16-27 Battery Charging Condition Inspection Battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter [A]. • Remove the battery (see Battery Removal). NOTICE Be sure to disconnect the negative (−) lead first. •...
  • Page 524 16-28 ELECTRICAL SYSTEM Battery NOTE ○ Increase the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially. Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current. If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case.
  • Page 525: Charging System

    ELECTRICAL SYSTEM 16-29 Charging System Alternator Cover Removal • Remove: Lower Fairing (see Lower Fairing Removal in the Frame chapter) Frame Cover (see Frame Cover Removal in the Frame chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter)
  • Page 526: Stator Coil Removal

    16-30 ELECTRICAL SYSTEM Charging System Stator Coil Removal • Remove: Alternator Cover (see Alternator Cover Removal) Alternator Lead Holding Plate Bolt [A] and Holding Plate Alternator Lead Grommet [C] Stator Coil Bolts [D] • Take off the stator coil [E] from the alternator cover. Stator Coil Installation •...
  • Page 527: Alternator Rotor Installation

    ELECTRICAL SYSTEM 16-31 Charging System • Using the flywheel puller assembly [A], remove the alter- nator rotor from the crankshaft. Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: 57001-1405 NOTICE Do not strike the alternator rotor. Striking the rotor can cause the magnets to lose their magnetism.
  • Page 528: Alternator Inspection

    16-32 ELECTRICAL SYSTEM Charging System • Install the washer [A]. NOTE ○ Confirm that the alternator rotor fits onto the crankshaft before tightening it with specified torque. • Apply molybdenum disulfide oil solution to the threads and seating surface of the rotor bolt. •...
  • Page 529 ELECTRICAL SYSTEM 16-33 Charging System • To check the alternator output voltage, do the following procedures. ○ Turn the ignition switch to OFF. ○ Remove the left frame cover (see Frame Cover Removal in the Frame chapter). ○ Pull out the alternator lead connector [A] from the bracket and disconnect it.
  • Page 530: Regulator/rectifier Inspection

    16-34 ELECTRICAL SYSTEM Charging System Regulator/Rectifier Inspection • Remove: Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter) Baffle Plate Bolts [A] Baffle Plate [B] • Remove the regulator/rectifier bolts [A]. • Disconnect the connector [A]. • Remove the regulator/rectifier [B].
  • Page 531 ELECTRICAL SYSTEM 16-35 Charging System Regulator Circuit Check To test the regulator out of circuit, use three 12 V batteries and a test light (12 V 3 ∼ 6 W bulb in a socket with leads). NOTICE The test light works as an indicator and also a cur- rent limiter to protect the regulator/rectifier from ex- cessive current.
  • Page 532: Charging Voltage Inspection

    16-36 ELECTRICAL SYSTEM Charging System • Installation is the reverse of removal. ○ Tighten: Torque - Regulator/Rectifier Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Baffle Plate Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) Charging Voltage Inspection • Check the battery condition (see Charging Condition In- spection).
  • Page 533 ELECTRICAL SYSTEM 16-37 Charging System Charging System Circuit 1. Ignition Switch 2. Load 3. Alternator 4. Regulator/Rectifier 5. Frame Ground 6. Battery 12 V 10 Ah 7. Main Fuse 30 A...
  • Page 534: Starter Motor Clutch

    16-38 ELECTRICAL SYSTEM Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal/Installation. Starter Motor Clutch Inspection • Remove: Alternator Cover (see Alternator Cover Removal) Starter Idle Gear and Shaft (see Alternator Rotor Re- moval) Torque Limiter and Shaft (see Alternator Rotor Removal) •...
  • Page 535: Ignition System

    ELECTRICAL SYSTEM 16-39 Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. NOTICE Do not disconnect the battery cables or any other electrical connections when the ignition switch is...
  • Page 536: Crankshaft Sensor Inspection

    16-40 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Inspection • Remove the right frame cover (see Frame Cover Removal in the Frame chapter). • Disconnect the crankshaft sensor lead connector [A]. • Set the hand tester to the × 10 Ω range and connect (+) lead to the yellow lead and (–) lead to the black lead in the connector.
  • Page 537: Timing Rotor Removal

    ELECTRICAL SYSTEM 16-41 Ignition System Timing Rotor Removal • Remove: Clutch Cover (see Clutch Cover Removal in the Clutch chapter) Crankshaft Sensor (see Crankshaft Sensor Removal) • Hold the timing rotor [A] steady with the flywheel & pulley holder [B]. Special Tool - Flywheel &...
  • Page 538: Stick Coil Inspection

    16-42 ELECTRICAL SYSTEM Ignition System Stick Coil Inspection • Remove the stick coils (see Stick Coil Removal). • Measure the primary winding resistance [A] as follows. ○ Connect the hand tester between the coil terminals. ○ Set the tester to the × 1 Ω range, and read the tester. •...
  • Page 539: Spark Plug Removal

    ELECTRICAL SYSTEM 16-43 Ignition System WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • Turn the ignition switch to ON and the engine stop switch to run position. • Pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measure the primary peak voltage.
  • Page 540: Interlock Operation Inspection

    16-44 ELECTRICAL SYSTEM Ignition System Interlock Operation Inspection • Raise the rear wheel off the ground with a stand. 1st Check • Start the engine in the following conditions. Condition Transmission Gear → 1st Position Clutch Lever → Release Sidestand → Down or Up ○...
  • Page 541 ELECTRICAL SYSTEM 16-45 Ignition System...
  • Page 542 16-46 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Ignition Switch 10. Water Temperature Sensor 18. Battery 12 V 10 Ah 2. Engine Stop Switch 11. Neutral Switch 19. Main Fuse 30 A 3. Spark Plugs 12. Crankshaft Sensor 20. Relay Box 4.
  • Page 543: Electric Starter System

    ELECTRICAL SYSTEM 16-47 Electric Starter System Starter Motor Removal NOTICE Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter)
  • Page 544: Starter Motor Disassembly

    16-48 ELECTRICAL SYSTEM Electric Starter System Starter Motor Disassembly • Remove the starter motor (see Starter Motor Removal). • Take off the starter motor through bolts [A] and remove the both end covers [B]. • Pull out the armature [A] out of the yoke [B]. NOTE ○...
  • Page 545 ELECTRICAL SYSTEM 16-49 Electric Starter System • Align the stoppers [A] on the negative brush assembly [B] with the grooves [C] on the brush holder [D]. • Tighten the screw securely. • Align the stoppers [A] on the positive brush assembly [B] with the grooves [C] on the brush holder [D].
  • Page 546: Brush Inspection

    16-50 ELECTRICAL SYSTEM Electric Starter System • Apply thin coat of grease to the oil seal [A]. • Replace the O-rings [A] with new ones. • Insert the armature [B] so that commutator side [C] faces hollow side [D] of the yoke [E]. •...
  • Page 547: Commutator Cleaning And Inspection

    ELECTRICAL SYSTEM 16-51 Electric Starter System Commutator Cleaning and Inspection • Clean the metallic debris off the between commutator segments [A]. NOTE ○ Do not use emery or sand paper on the commutator. • Check the commutator for damage or abnormal wear. Replace the starter motor with a new one if there is any damage or wear.
  • Page 548: Right-hand End Cover Inspection

    16-52 ELECTRICAL SYSTEM Electric Starter System Right-hand End Cover Inspection • Using the highest tester range, measure the resistance as shown. Terminal Bolt and Right-hand End Cover [A] Terminal Bolt and Negative Brushes [B] Special Tool - Hand Tester: 57001-1394 If there is any reading, the brush assy and/or terminal bolt assy have a short.
  • Page 549 ELECTRICAL SYSTEM 16-53 Electric Starter System Electric Starter Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Neutral Switch 5. Sidestand Switch 6. Frame Ground 7. Battery 12 V 10 Ah 8. Main Fuse 30 A 9. Starter Relay 10.
  • Page 550: Lighting System

    16-54 ELECTRICAL SYSTEM Lighting System This motorcycle adopt the daylight system and have a headlight circuit relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off.
  • Page 551: City Light Bulb Replacement

    ELECTRICAL SYSTEM 16-55 Lighting System • Fit the dust cover [A] onto the bulb [B] firmly as shown. Good [C] Bad [D] • Install the headlight unit (see Headlight Unit Installation). • After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter).
  • Page 552: Tail/brake Light (led) Unit Removal

    16-56 ELECTRICAL SYSTEM Lighting System Tail/Brake Light (LED) Unit Removal • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Rear Seat Covers (see Rear Seat Cover Removal in the Frame chapter) • Remove the tool bag. •...
  • Page 553 ELECTRICAL SYSTEM 16-57 Lighting System Headlight/Tail Light Circuit 1. Ignition Switch 11. Fuse Box 12. Headlight Fuse 15 A 2. Alternator 3. License Plate Light 12 V 5 W 13. Passing Button 4. Tail/Brake Light (LED) 13.5 V 0.3/3.4 W 14.
  • Page 554: Turn Signal Light Bulb Replacement

    16-58 ELECTRICAL SYSTEM Lighting System Turn Signal Light Bulb Replacement • Unscrew the screw [A] and remove the lens [B]. • Remove the bulb [A]. ○ Push and turn the bulb counterclockwise. • Replace the bulb [A] with a new one. •...
  • Page 555 ELECTRICAL SYSTEM 16-59 Lighting System • Connect one 12 V battery and turn signal lights as indi- cated in the figure, and count how may times the lights blink for one minute. Turn Signal Relay [A] Turn Signal Lights [B] 12 V Battery [C] Testing Turn Signal Relay Load...
  • Page 556 16-60 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit 1. Ignition Switch 2. Meter Unit 3. Joint Connector A 4. Front Right Turn Signal Light 12 V 10 W 5. Front Left Turn Signal Light 12 V 10 W 6. Joint Connector B 7.
  • Page 557: Air Switching Valve

    ELECTRICAL SYSTEM 16-61 Air Switching Valve Air Switching Valve Operation Test • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) • Take the air switching valve hose end [A] outside of the frame [B].
  • Page 558: Air Switching Valve Unit Test

    16-62 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Unit Test • Remove the air switching valve (see Air Switching Valve Removal in the Engine Top End chapter). • Set the hand tester [A] to the × Ω range and connect it to the air switching valve terminals as shown.
  • Page 559 ELECTRICAL SYSTEM 16-63 Air Switching Valve Air Switching Valve Circuit 1. Ignition Switch 2. Air Switching Valve 3. ECU 4. Frame Ground 2 5. Battery 12 V 10 Ah 6. Main Fuse 30 A 7. Relay Box 8. ECU Main Relay 9.
  • Page 560: Radiator Fan System

    16-64 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Inspection • Remove the left center fairing (see Center Fairing Re- moval in the Frame chapter). • Disconnect the connector [A]. • Using an auxiliary leads, supply the battery power to the fan motor.
  • Page 561: Meter, Gauge, Indicator Unit

    ELECTRICAL SYSTEM 16-65 Meter, Gauge, Indicator Unit Meter Unit Removal • Remove: Bolts [A] and Washers Upper Meter Cover [B] • Remove: Wellnuts [A] Lower Meter Cover [B] • Slide out the dust cover [A], and disconnect the connector [B]. •...
  • Page 562: Electronic Combination Meter Unit Inspection

    16-66 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • Separate the meter assembly [A] and upper meter case [B]. Electronic Combination Meter Unit Inspection • Remove the meter unit (see Meter Unit Removal). [1] Green Left Turn Signal Indicator Light (LED) [2] Green Neutral Indicator Light (LED) (–) [3] Unused [4] Unused...
  • Page 563 ELECTRICAL SYSTEM 16-67 Meter, Gauge, Indicator Unit ○ Then the tachometer needle [A] sweeps to the maximum reading [B], then sweeps back to the minimum reading [C]. • Connect the terminal [15] to the terminal [16]. ○ Then the tachometer needle [A] sweeps to the maximum reading, then sweeps back to the minimum reading.
  • Page 564 16-68 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Left and Right Button Operation Check • Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • Check that the multifunction meter displays shift as shown when the left button [A] is pressed.
  • Page 565 ELECTRICAL SYSTEM 16-69 Meter, Gauge, Indicator Unit • In the HOUR setting mode, press the right button to effect the MINUTE setting mode. ○ The minute display blinks on the display. • Press the left button to set the minute. •...
  • Page 566 16-70 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Speedometer Check • Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • The speed equivalent to the input frequency is indicated in the oscillator [A], if the square wave (illustrated as shown) would be input into the terminal [10].
  • Page 567 ELECTRICAL SYSTEM 16-71 Meter, Gauge, Indicator Unit Tachometer Check • Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • The revolutions per minute (rpm) equivalent to the input frequency is indicated in the oscillator [A] if the square wave (illustrated as shown) would be input into the termi- nal [9].
  • Page 568 16-72 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Fuel Level Warning Check • Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • Connect the variable rheostat [A] to the terminal [5]. •...
  • Page 569 ELECTRICAL SYSTEM 16-73 Meter, Gauge, Indicator Unit Yellow Engine Warning Indicator Light (LED) Battery Negative (–) Terminal to Terminal [11] Green Left and Right Turn Signal Indicator Light (LED) For Green Left Turn Signal Indicator Light (LED) Battery Positive (+) Terminal to Terminal [1] For Green Right Turn Signal Indicator Light (LED) Battery Positive (+) Terminal to Terminal [7] Green Neutral Indicator Light (LED)
  • Page 570 16-74 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Circuit 1. Ignition Switch 10. Frame Ground 2. Speed Sensor 11. Battery 12 V 10 Ah 3. Joint Connector C 12. Main Fuse 30 A 4. Joint Connector D 13. ABS Hydraulic Unit (ABS Equipped Models) 5.
  • Page 571: Switches And Sensors

    ELECTRICAL SYSTEM 16-75 Switches and Sensors Brake Light Timing Inspection • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Brake Light Timing Adjustment • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Switch Inspection •...
  • Page 572: Water Temperature Sensor Inspection

    16-76 ELECTRICAL SYSTEM Switches and Sensors Water Temperature Sensor Inspection • Remove the water temperature sensor (see Water Tem- perature Sensor Removal/Installation in the Fuel System (DFI) chapter). • Suspend the sensor [A] in a container of coolant so that the temperature-sensing projection [C] is submerged.
  • Page 573: Speed Sensor Inspection

    ELECTRICAL SYSTEM 16-77 Switches and Sensors Speed Sensor Inspection • Remove the speed sensor (see Speed Sensor Removal). • Connect the speed sensor connector [A] with the battery [B], 10 kΩ resistor [C] and hand tester [D] as shown. • Set the tester to the DC 25 V range.
  • Page 574: Oxygen Sensor Removal (equipped Models)

    16-78 ELECTRICAL SYSTEM Switches and Sensors Oxygen Sensor Removal (Equipped Models) NOTICE Never drop the sensor especially on a hard surface. Such a shock to the sensor can damage it. NOTICE Do not pull strongly, twist, or bend the oxygen sen- sor lead.
  • Page 575: Relay Box

    ELECTRICAL SYSTEM 16-79 Relay Box NOTE ○ The relay box [A] has relays and diodes. The relays and diodes can not be removed. Relay Box Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Element (see Air Cleaner Element Replace- ment in the Periodic Maintenance chapter) •...
  • Page 576: Diode Circuit Inspection

    16-80 ELECTRICAL SYSTEM Relay Box Relay Circuit Inspection (with the battery connected) Battery Tester Tester Connection Connection Reading (Ω) (–) 2-11 ECU Main Relay Fuel Pump Relay 9-10 Fan Relay 18-19 17-20 Battery Tester Connection Tester Connection DC 25 V Range Reading (V) (–) Starter...
  • Page 577 ELECTRICAL SYSTEM 16-81 Relay Box Relay Box Internal Circuit A: Headlight Circuit Relay B: ECU Main Relay C: Fuel Pump Relay D: Starter Circuit Relay E: Radiator Fan Relay...
  • Page 578: Fuse

    16-82 ELECTRICAL SYSTEM Fuse 30 A Main Fuse Removal • Remove the starter relay (see Starter Relay Inspection). • Slide out the cap [A]. • Open the cover [B], and pull out the main fuse [C] straight out of the fuse box with needle nose pliers. Fuse Box Fuse Removal •...
  • Page 579 APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-46...
  • Page 580 17-2 APPENDIX Cable, Wire, and Hose Routing...
  • Page 581 APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Run the main harness inside the ribs on the air cleaner housing cover. 2. Clamp (Hold the main harness.) 3. Fix the clamp to the bracket. 4. Run the rear (smaller) ECU connecter lead above the other one. 5.
  • Page 582 17-4 APPENDIX Cable, Wire, and Hose Routing...
  • Page 583 APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Guide (Hold the intake air pressure sensor lead.) 2. Vehicle-down Sensor Lead 3. Fix the ignition switch lead connector (upper) and the left switch housing lead connector (lower) to the bracket. 4. Bracket 5.
  • Page 584 17-6 APPENDIX Cable, Wire, and Hose Routing...
  • Page 585 APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Fix the clamp to the frame gusset. 2. Run the frame ground lead on the left side of the air cleaner housing. 3. Run the frame ground lead terminal to the outside from between the frame gussets, and fix the lead terminal on the gusset.
  • Page 586 17-8 APPENDIX Cable, Wire, and Hose Routing...
  • Page 587 APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Run the rear brake light switch lead through the hole on frame. 2. Hook (Hold the main harness.) 3. Fix the starter relay to the ribs on the battery case. 4. Run the tail/brake light lead into the groove on the battery case. 5.
  • Page 588 17-10 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models...
  • Page 589 2. From rear to front, run the following under the hook on the battery case; starter relay lead, battery positive (+) cable connector lead, battery negative (–) cable. 3. Locate the ABS Kawasaki diagnostic system connector and ABS self-diagnosis terminal inside the dust cover.
  • Page 590 17-12 APPENDIX Cable, Wire, and Hose Routing...
  • Page 591 APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Do not loosen the leads in this area. 2. Run the leads above the hook on the reinforce. 3. Fix the clamp to the reinforce. 4. Run the leads under the hook on the reinforce. 5.
  • Page 592 17-14 APPENDIX Cable, Wire, and Hose Routing...
  • Page 593 APPENDIX 17-15 Cable, Wire, and Hose Routing 1. From upper to lower, run the following on the left side of the head pipe; clutch cable, left switch housing lead, main harness. 2. Guide 3. Run the main harness as follows; through the guide, on the left side of the head pipe, inside the clamp on the bracket.
  • Page 594 17-16 APPENDIX Cable, Wire, and Hose Routing...
  • Page 595 APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Meter Unit Lead 2. Fix the clamp to the bracket. 3. Bracket 4. Run the left city light lead through the clamp and locate its connector in front of the main harness. 5.
  • Page 596 17-18 APPENDIX Cable, Wire, and Hose Routing...
  • Page 597 APPENDIX 17-19 Cable, Wire, and Hose Routing 1. Turn Signal Relay 2. Run the horn lead inside the water hose. 3. Run the radiator fan lead inside the frame. 4. Fix the clamps to the frame bracket. 5. Fix the clamp to the engine mounting bracket. 6.
  • Page 598 17-20 APPENDIX Cable, Wire, and Hose Routing...
  • Page 599 APPENDIX 17-21 Cable, Wire, and Hose Routing 1. Fix the fuel pump lead connector (upper) and the alternator lead connector (lower) to the bracket. 2. Canister* 3. Purge Valve* 4. Run the harness in front of the tube (purge valve ~ canister)* 5.
  • Page 600 17-22 APPENDIX Cable, Wire, and Hose Routing...
  • Page 601 APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Guide 2. Run the brake hose (front master cylinder ~ front right caliper) through the guide. 3. Fix the clamp to the bracket. 4. Bracket 5. Run the brake hose inside the front fork. 6.
  • Page 602 17-24 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models...
  • Page 603 APPENDIX 17-25 Cable, Wire, and Hose Routing 1. Guide 2. Fix the front wheel rotation sensor lead connector to the bracket. 3. Bracket 4. Fix the clamp to the bracket. 5. Brake Hose (ABS Hydraulic Unit ~ Front Caliper) 6. Run the brake hose (front master cylinder ~ ABS hydraulic unit) through the guide. 7.
  • Page 604 17-26 APPENDIX Cable, Wire, and Hose Routing...
  • Page 605 APPENDIX 17-27 Cable, Wire, and Hose Routing 1. Fix the rear brake reservoir tank to the battery case. 2. Clamps 3. Run the brake hose (rear master cylinder ~ rear caliper) through the swingarm. 4. Fix the brake hose (rear brake reservoir tank ~ rear master cylinder) to the frame with the clamps. 5.
  • Page 606 17-28 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models...
  • Page 607 APPENDIX 17-29 Cable, Wire, and Hose Routing 1. Fix the rear brake reservoir tank to the battery case. 2. Clamps 3. Run the brake hose (ABS hydraulic unit ~ rear caliper) through the swingarm. 4. Fix the brake hose (rear brake reservoir tank ~ rear master cylinder) to the frame with the clamps. 5.
  • Page 608 17-30 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models...
  • Page 609 APPENDIX 17-31 Cable, Wire, and Hose Routing ABS Equipped Models 1. Collar and Damper (Hold the brake pipes.) 2. Run the brake pipe (front master cylinder ~ ABS hydraulic unit) inside the brake pipe (ABS hydraulic unit ~ front caliper). 3.
  • Page 610 17-32 APPENDIX Cable, Wire, and Hose Routing...
  • Page 611 APPENDIX 17-33 Cable, Wire, and Hose Routing 1. Guide (Run the front brake hose through the guide.) 2. Clamps (Hold the front brake hose.) 3. Clamps (Hold the rear brake hose.) 4. Clamp with Damper (Hold the rear brake hose.)
  • Page 612 17-34 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models...
  • Page 613 APPENDIX 17-35 Cable, Wire, and Hose Routing ABS Equipped Models 1. Guide (Run the front brake hose through the guide.) 2. Clamps (Hold the front brake hose.) 3. Clamp (Hold the front wheel rotation sensor lead.) 4. Clamps (Hold the brake pipe.) 5.
  • Page 614 17-36 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models...
  • Page 615 APPENDIX 17-37 Cable, Wire, and Hose Routing 1. Front 2. Brake Hose (to Front Master Cylinder) 3. About 50° 4. Brake Hose (to Front Caliper) 5. About 65° 6. ABS Hydraulic Unit 7. Brake Pipe (to Rear Caliper) 8. About 29.9° 9.
  • Page 616 17-38 APPENDIX Cable, Wire, and Hose Routing...
  • Page 617 APPENDIX 17-39 Cable, Wire, and Hose Routing 1. Reserve Tank Overflow Hose 2. Reserve Tank Hose 3. Fit the reserve tank hose into the groove on the reserve tank. 4. Brake Pipe (ER650F Model) 5. White Paint Mark 6. Throttle Cables 7.
  • Page 618 17-40 APPENDIX Cable, Wire, and Hose Routing...
  • Page 619 APPENDIX 17-41 Cable, Wire, and Hose Routing 1. Reserve Tank Overflow Hose 2. Run the reserve tank overflow hose between the air suction valve cover and the stick coil. 3. Run the reserve tank overflow hose under the stick coil lead. 4.
  • Page 620 17-42 APPENDIX Cable, Wire, and Hose Routing...
  • Page 621 APPENDIX 17-43 Cable, Wire, and Hose Routing 1. Air Cleaner Housing 2. Air Switching Valve 3. Air Switching Valve Hoses 4. ECU 5. Breather Hose 6. Clamp 7. Drain Hose 8. Throttle Body Assy 9. Vacuum Hose 10. To the Intake Air Pressure Sensor 11.
  • Page 622 17-44 APPENDIX Cable, Wire, and Hose Routing SEA-B1 and TH Models...
  • Page 623 APPENDIX 17-45 Cable, Wire, and Hose Routing 1. Blue Label 2. Tube (Fuel Tank ~ Canister) 3. Purge Valve 4. Canister 5. Green Paint Marks 6. Tube (Canister ~ Purge Valve) 7. Tube (Purge Valve ~ Throttle Body Assy)
  • Page 624: Troubleshooting Guide

    17-46 APPENDIX Troubleshooting Guide NOTE Spark plug dirty, broken, or gap malad- ○ Refer to the Fuel System (DFI) chapter for justed most of DFI trouble shooting guide. Stick coil shorted or not in good contact ○ This is not an exhaustive list, giving every Stick coil trouble possible cause for each problem listed.
  • Page 625 APPENDIX 17-47 Troubleshooting Guide Compression low: Cylinder head gasket damaged Spark plug loose Cylinder head warped Cylinder head not sufficiently tightened Valve spring broken or weak down Valve not seating properly (valve bent, No valve clearance worn, or carbon accumulation on the Cylinder, piston worn seating surface) Piston ring bad (worn, weak, broken, or...
  • Page 626: Gear Shifting Faulty

    17-48 APPENDIX Troubleshooting Guide Gear Shifting Faulty: Engine oil viscosity too high Drive train trouble Doesn’t go into gear; shift pedal doesn’t Brake dragging return: Lubrication inadequate: Clutch not disengaging Engine oil level too low Shift fork bent or seized Engine oil poor quality or incorrect Gear stuck on the shaft Gauge incorrect:...
  • Page 627: Exhaust Smokes Excessively

    APPENDIX 17-49 Troubleshooting Guide Engine mount loose O-ring at the oil passage in the crankcase Crankshaft bearing worn damaged Primary gear worn or chipped Exhaust Smokes Excessively: Camshaft chain tensioner trouble Camshaft chain, sprocket, guide worn White smoke: Air suction valve damaged Piston oil ring worn Air switching valve damaged Cylinder worn...
  • Page 628: Battery Trouble

    17-50 APPENDIX Troubleshooting Guide Battery Trouble: Rear shock adjustment too soft Front fork, rear shock absorber spring weak Battery discharged: Rear shock absorber oil leaking Charge insufficient Battery faulty (too low terminal voltage) Brake Doesn’t Hold: Battery cable making poor contact Load excessive (e.g., bulb of excessive Air in the brake line wattage)
  • Page 629 MODEL APPLICATION Year Model Beginning Frame No. □ JKAEREE1 CDA00001 2012 ER650EC JKAER650EEDA00001 □ JKAEREF1 CDA00001 2012 ER650FC JKAER650EFDA00001 □ :This digit in the frame number changes from one machine to another. Part No.99924-1453-01 Printed in Japan...

This manual is also suitable for:

Er-6n abs

Comments to this Manuals

Symbols: 0
Latest comments:
  • Hanne Obel May 07, 2018 04:22:
    Hi

    I’ve a ER6N 2006, which has run 30.000 km.
    Any one who can tell me interval to exchange the oil, check/adju​st ventils - and/or if regular service is required?

    Thanks a lot for your help/infor​mation/adv​ise.

    Best regards
    Ha​nne
  • Zahra Waqar Nov 16, 2017 07:35:
    please quote for the following items:
    lin​e 30 qty 7
    SEAL,BU​LK NOUN:
    PARE​NT EQUIPMENT/​FUNCTION:
    ​MECHANICAL​,COMPONENT​,BALANCED,​O-RING SEC SEAL;
    SIZE​:35.5 MM HSNG BORE,37 MM SHFT/SLV DIA;
    MATER​IAL:CARBON ROT FACE,STL STA FACE,
    RUBB​ER GAS KET,STL HARDWARE,S​TL SPRING;
    AD​DITIONAL DATA:
    FOR KAWASAKI ELECTRO HYDRAULIC POLISHING PUMP
    DWG NO: Y307179-1
    TYPE 45-4LXA059​93,.

    KAWA​SAKI HEAVY INDUSTRIES LTD.:
    DWG#​510/SEAL