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Ninja ZX-6R
Motorcycle
Service Manual

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Table of Contents

   Summary of Contents for Kawasaki Ninja ZX-6R

  • Page 1 Ninja ZX-6R 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 information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2008 Kawasaki Heavy Industries, Ltd. First Edition (1) : Oct. 31, 2008 (M)
  • Page 6: Country And Area Codes

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

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

    Be alert for problems and non-scheduled 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: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 13 Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins 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 ZX600R9F (US and CA Models) Left Side View ZX600R9F (US and CA Models) Right Side View...
  • Page 18 1-8 GENERAL INFORMATION Model Identification ZX600R9F (EUR Models) Left Side View ZX600R9F (EUR Models) Right Side View Frame Number Engine Number...
  • Page 19: General Specifications

    GENERAL INFORMATION 1-9 General Specifications Items ZX600R9F Dimensions Overall Length 2 090 mm (82.3 in.) Overall Width 710 mm (28.0 in.) Overall Height 1 115 mm (43.9 in.) Wheelbase 1 400 mm (55.1 in.) Road Clearance 120 mm (4.72 in.) Seat Height 815 mm (32.1 in.) Curb Mass:...
  • Page 20 1-10 GENERAL INFORMATION General Specifications Items ZX600R9F Lubrication System Forced lubrication (wet sump with oil cooler) Engine Oil: Type API SE, SF or SG API SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 3.6 L (3.8 US qt) Drive Train Primary Reduction System:...
  • Page 21 GENERAL INFORMATION 1-11 General Specifications Items ZX600R9F Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 8 Ah Headlight: Type Semi-sealed beam Bulb: High 12 V 55 W + 65 W (quartz-halogen) 12 V 55 W (quartz-halogen) Tail/Brake Light Alternator: Type...
  • 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 ......................... 2-13 Special Tools .......................... 2-15 Periodic Maintenance Procedures..................2-16 Fuel System (DFI)........................ 2-16 Throttle Control System Inspection................... 2-16 Engine Vacuum Synchronization Inspection..............2-16 Idle Speed Inspection .......................
  • Page 24 2-2 PERIODIC MAINTENANCE Steering Damper Oil Leak Inspection ................2-40 Electrical System ......................... 2-41 Lights and Switches Operation Inspection................ 2-41 Headlight Aiming Inspection ..................... 2-43 Sidestand Switch Operation Inspection ................2-44 Engine Stop Switch Operation Inspection................. 2-45 Others ..........................2-46 Chassis Parts Lubrication ....................
  • 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 Whichever * ODOMETER READING comes ×...
  • Page 26 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page ITEM Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Wheel bearing damage - • • • year 2-30 inspect Final Drive Drive chain lubrication condition...
  • Page 27: Periodic Maintenance

    PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page ITEM Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Engine stop switch operation - • • • year 2-45 inspect Others...
  • 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. G: Apply grease.
  • Page 29 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Radiator Bracket Mounting Bolt 87 in·lb Radiator Lower Bolt 0.70 61 in·lb Radiator Upper Bolts 87 in·lb Thermostat Housing Cover Bolts 0.60 52 in·lb Water Hose Clamp Screws 0.20 18 in·lb Water Hose Fitting Bolts...
  • Page 30 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Clutch Cover Plate Bolts 87 in·lb Clutch Hub Nut 13.8 99.6 Clutch Lever Clamp Bolts 0.80 69 in·lb Clutch Spring Bolts 0.90 78 in·lb Oil Filler Plug –...
  • Page 31 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Gear Positioning Lever Bolt 106 in·lb Idle Gear Cover Bolts 87 in·lb Oil Jet Nozzles 0.30 26 in·lb Oil Passage Nozzle 0.50 43 in·lb Oil Passage Plug Oil Passage Plugs (Taper) Race Holder Screws 0.50...
  • Page 32 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Front Master Cylinder Bleed Valve 0.55 48 in·lb Front Master Cylinder Clamp Bolts 97 in·lb Rear Brake Disc Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut Suspension Front Axle Clamp Bolts...
  • Page 33 PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Alternator Lead Holding Plate Bolt 87 in·lb Alternator Rotor Bolt 15.8 Crankshaft Sensor Bolts 0.60 52 in·lb Engine Ground Cable Terminal Bolt 87 in·lb Front Brake Light Switch Screw 0.12 11 in·lb Front Turn Signal Light Mounting Screw...
  • Page 34 2-12 PERIODIC MAINTENANCE 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 35: Specifications

    PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 1 300 ±50 r/min (rpm) – – – Throttle Body Vacuum 30.6 ±1.3 kPa (230 ±10 mmHg) at idle speed –...
  • Page 36 2-14 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive 30 ∼ 40 mm (1.2 ∼ 1.6 in.) Drive Chain Slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Drive Chain Wear (20-link 323 mm (12.7 in.) Length) Standard Chain: Make...
  • Page 37: Special Tools

    PERIODIC MAINTENANCE 2-15 Special Tools Inside Circlip Pliers: Vacuum Gauge: 57001-143 57001-1369 Steering Stem Nut Wrench: Throttle Sensor Setting Adapter: 57001-1100 57001-1538 Jack: Extension Tube: 57001-1238 57001-1578 Oil Filter Wrench: Jack Attachment: 57001-1249 57001-1608 Pilot Screw Adjuster, C: 57001-1292...
  • Page 38: Periodic Maintenance Procedures

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Throttle Control System Inspection • Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Standard: •...
  • Page 39 PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Pull off the rubber caps [A] and vacuum hose [B] from the fittings of each throttle body. • For the California, Southeast Asia and Thailand Models, pull off the vacuum hose. • Connect a vacuum gauge (special tool) and hoses [A] to the fittings on the throttle body.
  • Page 40 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Start the engine and warm it up thoroughly. • Check the idle speed, using a highly accurate tachometer [A]. Idle Speed Standard: 1 300 ±50 r/min (rpm) If the idle speed is out of the specified range, adjust it with the adjusting screw (see Idle Speed Adjustment).
  • Page 41 PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures If any one vacuum measurement is out of the standard measurement after left and right synchronization, turn in the bypass screws [A] until it seats fully but not tightly. Rear View [B] Special Tool - Pilot Screw Adjuster, C [C]: 57001-1292 CAUTION Do not over tighten them.
  • Page 42: Idle Speed Inspection

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the vacuum gauge hoses and install the rubber caps and vacuum hose on the original position. • For the California, Southeast Asia and Thailand Models, install the vacuum hose. ○ Run the vacuum hose according to Cable, Wire, and Hose Routing section in the Appendix chapter.
  • Page 43: Evaporative Emission Control System Inspection (cal, Sea And Th Models)

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • Check that the fuel hoses [A] are routed according to Cable, Wire, and Hose Routing section in the Appendix chapter. Replace the hose if it has been sharply bent or kinked. • Check that the fuel hose joints are securely connected. ○...
  • Page 44: Cooling System

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check the liquid/vapor separator as follows. ○ Remove the upper fairing assembly (see Upper Fairing Assembly Removal in the Frame chapter). ○ Disconnect the hoses from the separator, and remove the separator [A] from the motorcycle left side. ○...
  • Page 45: Radiator Hose And Pipe Inspection (coolant Leak, Damage, Installation Condition)

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition) ○ The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained.
  • Page 46: Valve Clearance Adjustment

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ Thickness gauge is horizontally inserted on the valve lifter. Appropriateness [A] Inadequacy [B] Thickness Gauge [C] Horizontally Inserts [D] Cam [E] Valve Lifter [F] Hits the Valve Lifter Ahead [G] ○ When positioning #1 piston TDC at the end of the compression stroke: Inlet Valve Clearance of #1 and #3 Cylinders Exhaust Valve Clearance of #1 and #2 Cylinders...
  • Page 47 PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Clean the shim to remove any dust or oil. • Measure the thickness of the removed shim [A]. • Select a new shim thickness calculation as follows. a + b – c = d [a] Present Shim Thickness [b] Measured Valve Clearance [c] Specified Valve Clearance (Mean Value = 0.275 mm...
  • Page 48 2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Adjustment Shims Thickness Part Number Mark 1.300 92180-0108 1.325 92180-0109 1.350 92180-0110 1.375 92180-0111 1.400 92180-0112 1.425 92180-0113 1.450 92180-0114 1.475 92180-0115 1.500 92180-0116 1.525 92180-0117 1.550 92180-0118 1.575 92180-0119 1.600 92180-0120 1.625 92180-0121 1.650 92180-0122 1.675...
  • Page 49: Air Suction System Damage Inspection

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures CAUTION Be sure to remeasure the clearance after selecting a shim. The clearance can be out of the specified range because of the shim tolerance. ○ If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance.
  • Page 50: Clutch

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Start the engine and run it at idle speed. • Plug the air switching valve hose end [A] with your finger and feel vacuum pulsing in the hose. If there is no vacuum pulsation, check the hose line for leak.
  • Page 51: Wheels/tires

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures • Push the release lever [A] toward the front of the motor- cycle until it becomes hard to turn. ○ At this time, the release lever should have the proper an- gle shown. 60° [B] If the angle is wrong, check the clutch and release parts for wear.
  • Page 52: Wheel Bearing Damage Inspection

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tread Depth Standard: Front 3.6 mm (0.14 in.) Rear 5.3 mm (0.21 in.) Service Limit: Front 1 mm (0.04 in.) (AT, CH, DE) 1.6 mm (0.06 in.) Rear 2 mm (0.08 in.) (Up to 130 km/h (80 mph)) 3 mm (0.12 in.) (Over 130 km/h (80 mph)) WARNING To ensure safe handling and stability, use only the...
  • Page 53: Final Drive

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Final Drive Drive Chain Lubrication Condition Inspection • If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. •...
  • Page 54: Drive Chain Slack Adjustment

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Slack Adjustment • Remove the cotter pin [A], and loosen the rear axle nut [B]. • Loosen the both chain adjuster locknuts [C]. If the chain is too loose, turn out the left and right chain adjusters [D] evenly.
  • Page 55: Wheel Alignment Inspection

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Wheel Alignment Inspection • Check that the notch [A] on the left alignment indicator [B] aligns with the same swingarm mark or position [C] that the right alignment indicator notch aligns with. If they do not, adjust the chain slack and align the wheel alignment (see Drive Chain Slack Adjustment).
  • Page 56: Chain Guide Wear Inspection

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Chain Guide Wear Inspection • Remove the swingarm (see Swingarm Removal in the Suspection chapter). • Visually inspect the chain guide [A]. Replace the chain guide if it shows any signs of abnormal wear or damage. Brakes Brake Fluid Leak (Brake Hose and Pipe) Inspection •...
  • Page 57: Brake Fluid Level Inspection

    PERIODIC MAINTENANCE 2-35 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 58: Brake Pad Wear Inspection

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Pad Wear Inspection • Remove the brake pads (see Front/Rear Brake Pad Re- moval in the Brakes chapter). • Check the lining thickness of the pads in each caliper. If the lining thickness of either pad is less than the service limit, replace both pads in the caliper as a set.
  • Page 59: Suspension

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures If it does not go on, inspect or replace the following parts. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Brake Light (LED) (see Tail/Brake Light (LED) Removal Installation in the Electrical System chapter) Main Fuse 30 A and Taillight Fuse 10 A (see Fuse In- spection in the Electrical System chapter) Front Brake Light Switch [A] (see Switch Inspection in...
  • Page 60: Rear Shock Absorber Oil Leak Inspection

    2-38 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. Rocker Arm Operation Inspection •...
  • Page 61: Steering Play Adjustment

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Steering Play Adjustment • Remove: Steering Stem Head with Handlebars (see Handlebar Removal in the Steering chapter). Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) • Bend the claws [A] of the claw washer [B] straighten. •...
  • Page 62: Steering Stem Bearing Lubrication

    2-40 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 63: Electrical System

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step • Set the gear position in the neutral position. • Turn the ignition switch ON. • The following lights should go on according to below table. City Lights [A] Go on Taillight (LED) [B]...
  • Page 64 2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Turn the ignition switch OFF. • The all lights should go off (for models equipped with an immobilizer system, warning indicator light (LED) will blinks. Refer to the Immobilizer System (Equipped Mod- els) section in the Electrical System chapter). If the light does not go off, replace the ignition switch.
  • Page 65: Headlight Aiming Inspection

    PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Fourth Step • Set the dimmer switch [A] to low beam position. • Start the engine. • The low beam headlight should go on. If the low beam headlight does not go on, inspect or re- place the following parts.
  • Page 66: Sidestand Switch Operation Inspection

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ ON high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper an- gle according to local regulations. NOTE ○...
  • Page 67: Engine Stop Switch Operation Inspection

    PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures If the sidestand switch operation does not work, inspect or replace the following parts. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Ignition Fuse 15 A (see Fuse Inspection in the Electrical System chapter)
  • Page 68: Others

    2-46 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 69: Bolts, Nuts And Fasteners Tightness Inspection

    PERIODIC MAINTENANCE 2-47 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 70: Replacement Parts

    Install a new element [A] so that the screen side [B] faces upward. CAUTION Use only the recommended air cleaner element (Kawasaki part number 11013-0036). Using another air cleaner element will wear the engine prema- turely or lower the engine performance. •...
  • Page 71 PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures For Primary Fuel Hose (Fuel Tank ∼ Throttle Body Assy) • Be sure to place a piece of cloth [A] around the fuel hose joint. • Insert a thin blade screwdriver [B] into the slit [C] on the joint lock [D].
  • Page 72 2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Turn [A] the driver to disconnect the joint lock [B]. • Pull the fuel hose joint [C] out of the delivery pipe. WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe.
  • Page 73: Coolant Change

    PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures • Insert [A] the fuel hose joint [B] straight onto the delivery pipe until the hose joint clicks. • Push [C] the joint lock [D]. CAUTION When inserting the fuel hose joint, do not apply strong force to the delivery pipe [E] on the nozzle assy.
  • Page 74 2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Place a container under the drain bolt [A] of the water pump cover. • Drain the coolant from the radiator by removing the drain bolt. • Remove: Coolant Reserve Tank Mounting Bolts [A] Cap [B] •...
  • Page 75 PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures • Bleed the air from the cooling system as follows. ○ Start the engine with the radiator cap removed and run it until no more air bubbles [A] can be seen in the coolant. ○...
  • Page 76: Radiator Hose And O-ring Replacement

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Thermostat Housing Cover [A] (see Thermostat Housing Removal in the Cooling System chapter) Oil Cooler [B] (see Oil Cooler Removal in the Engine Lubrication System chapter) Water Pump Cover [C] (see Water Pump Removal in the...
  • Page 77: Engine Oil Change

    PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the engine oil drain bolt [A] to drain the oil. ○ The oil in the oil filter can be drained by removing the filter (see Oil Filter Replacement).
  • Page 78: Oil Filter Replacement

    2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Oil Filter Replacement • Drain the engine oil (see Engine Oil Change). • Remove the oil filter [A] with the oil filter wrench [B]. Special Tool - Oil Filter Wrench: 57001-1249 • Replace the filter with a new one. •...
  • Page 79: Brake Hose And Pipe Replacement

    PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Brake Hose Fitting Bolt [A] Brake Hose Banjo Bolts [B] Bolt [C]...
  • Page 80 2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Level the brake fluid reservoir. • Remove: Screw [A] Stopper [B] Front Brake Reservoir Cap [C] Diaphragm Plate Diaphragm • Remove the rubber cap [A] from the bleed valve on the caliper. • Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container.
  • Page 81: Master Cylinder Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures • Install the stopper on the reservoir. • Tighten: Torque - Front Brake Reservoir Cap Stopper Screw: 1.2 N·m (0.12 kgf·m, 11 in·lb) • Tighten the bleed valve, and install the rubber cap. Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb) •...
  • Page 82: Caliper Rubber Parts Replacement

    2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Assembly • Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts.
  • Page 83 PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures WARNING To avoid serious injury, never place your fingers or palm in front of the piston. If you apply compressed air into the caliper, the piston may crush your hand or fingers. ○ Pull out the pistons by hand. •...
  • Page 84 2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the pads (see Front Brake Pad Installation in the Brakes chapter). • Wipe up any spilled brake fluid on the caliper with wet cloth. Rear Caliper Disassembly • Remove the rear caliper (see Rear Caliper Removal in the Brakes chapter).
  • Page 85: Spark Plug Replacement

    PERIODIC MAINTENANCE 2-63 Periodic Maintenance Procedures • Replace the fluid seal [A] with a new one. ○ Apply silicone grease to the fluid seal, and install it into the cylinder by hand. • Replace the dust seal [B] with a new one. ○...
  • Page 87 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........Water Temperature Sensor DFI System........3-10 Output Voltage Inspection ..3-58 DFI Parts Location......3-16 Water Temperature Sensor Specifications ........3-19 Resistance Inspection ....3-59 Special Tools and Sealant ....3-21 Atmospheric Pressure Sensor DFI Servicing Precautions ....
  • Page 88 3-2 FUEL SYSTEM (DFI) Subthrottle Sensor Input Voltage Exhaust Butterfly Valve Actuator Inspection........3-76 (Service Code 63)......3-96 Subthrottle Sensor Output Voltage Exhaust Butterfly Valve Actuator Inspection........3-77 Removal ........3-96 Subthrottle Sensor Resistance Exhaust Butterfly Valve Actuator Inspection........3-78 Installation .........
  • Page 89 FUEL SYSTEM (DFI) 3-3 Secondary Fuel Injector Nozzle Assy Disassembly.... 3-134 Removal/Installation....3-120 Nozzle Assy Assembly....3-134 Fuel Injector Audible Inspection... 3-120 Air Cleaner......... 3-136 Fuel Injector Resistance Air Cleaner Element Inspection........3-121 Removal/Installation....3-136 Fuel Injector Power Source Air Cleaner Element Inspection ... 3-136 Voltage Inspection.....
  • Page 90: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 91 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Cleaner Housing Assembly Screws 0.12 11 in·lb Air Cleaner Housing Clamp Bolts 0.20 18 in·lb Air Cleaner Housing Mounting Bolt 0.70 61 in·lb Air Inlet Duct Mounting Bolts 87 in·lb 5.
  • Page 92 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 93 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Delivery Pipe Assy Mounting Screws (Nozzle 3.43 0.35 30 in·lb Assy) Delivery Pipe Assy Mounting Screws (Throttle 3.43 0.35 30 in·lb Body Assy) Inlet Air Temperature Sensor Screw 0.80 0.081 7.1 in·lb...
  • Page 94 3-8 FUEL SYSTEM (DFI) Exploded View...
  • Page 95 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Canister Bracket Screws 0.12 11 in·lb Crankshaft Sensor Bolts 0.60 52 in·lb Exhaust Butterfly Valve Actuator Mounting Screws 0.44 38 in·lb Exhaust Butterfly Valve Actuator Pulley Bolt 0.50 43 in·lb Fuel Pump Bolts 87 in·lb...
  • Page 96: Dfi System

    3-10 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 97 FUEL SYSTEM (DFI) 3-11 DFI System 1. ECU 2. Battery 12 V 8 Ah 3. Main Throttle Sensor 4. Inlet Air Temperature Sensor 5. Subthrottle Valve Actuator 6. Subthrottle Sensor 7. Fuel Injectors 8. Vehicle-down Sensor 9. Delivery Pipe Assy 10.
  • Page 98 3-12 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 99 FUEL SYSTEM (DFI) 3-13 DFI System Part Names 1. Gear Position Switch 2. ECU 3. Joint Connector C 4. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector 5. Vehicle-down Sensor 6. Fuel Pump 7. Joint Connector D 8. Exhaust Butterfly Valve Actuator 9. Fuse Box 10.
  • Page 100 3-14 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Subthrottle Valve Actuator: R/Y 2. Subthrottle Valve Actuator: R/W 3. Exhaust Battery Valve Actuator (–): GY 4. Exhaust Butterfly Valve Actuator (+): G/R 5. Exhaust Butterfly Valve Actuator Sensor: R/BK 6.
  • Page 101 54. Immobilizer Amplifier (Equipped Models): LG/W 55. Immobilizer Amplifier (Equipped Models): O/W 56. Meter Unit (Tachometer): LB 57. Unused 58. Ground for Fuel System: BK/Y 59. Ground For Ignition System: BK/Y 60. Stick Coil #4: BK/O *: KDS (Kawasaki Diagnostic System)
  • Page 102: Dfi Parts Location

    Exhaust Butterfly Valve Actuator [B] Fuse Box [C] (Ignition Fuse 15 A, ECU Fuse 10 A, Oxy- gen Sensor Heater Fuse 10 A (Equipped Models)) Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector [D] ECU [A] Relay Box [B] (Fuel Pump Relay, Radiator Fan Relay)
  • Page 103 FUEL SYSTEM (DFI) 3-17 DFI Parts Location Secondary Fuel Injectors #1, #2, #3, #4 [A] Inlet Air Temperature Sensor [B] Crankshaft Sensor [A] Speed Sensor [A] Gear Position Switch [A] Ignition Key [A] (Transponder, Immobilizer System Equipped Models) Immobilizer Antenna [B] (Equipped Models) Ignition Switch [C] Warning Indicator Light (LED) [D]...
  • Page 104 3-18 FUEL SYSTEM (DFI) DFI Parts Location Immobilizer Amplifier [A] (Equipped Models) Oxygen Sensor [A] (Equipped Models)
  • Page 105: Specifications

    FUEL SYSTEM (DFI) 3-19 Specifications Item Standard Digital Fuel Injection System Idle Speed 1 300 ±50 r/min (rpm) Throttle Body Assy: Type Four oval type Bore 38 mm (1.5 in.) Throttle Body Vacuum 30.6 ±1.3 kPa (230 ±10 mmHg) 0 ∼ 2 1/2 (for reference) Bypass Screws (Turn Out) ECU: Make...
  • Page 106 3-20 FUEL SYSTEM (DFI) Specifications Item Standard Vehicle-down Sensor: DC 4.75 ∼ 5.25 V Input Voltage With sensor tilted 60 ∼ 70° or more right or left: DC Output Voltage 0.65 ∼ 1.35 V With sensor arrow mark pointed up: DC 3.55 ∼ 4.45 V Subthrottle Sensor: DC 4.75 ∼...
  • Page 107: Special Tools And Sealant

    FUEL SYSTEM (DFI) 3-21 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: Extension Tube: 57001-1394 57001-1578 Throttle Sensor Setting Adapter #1: Fuel Pressure Gauge Adapter:...
  • Page 108 3-22 FUEL SYSTEM (DFI) Special Tools and Sealant Fuel Hose: Kawasaki Bond (Silicone Sealant): 57001-1607 56019-120 Measuring Adapter: 57001-1700...
  • Page 109: Dfi Servicing Precautions

    FUEL SYSTEM (DFI) 3-23 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 110 3-24 FUEL SYSTEM (DFI) DFI Servicing Precautions ○ If the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see Fuel Tank Removal) and check the fuel hose.
  • Page 111: Troubleshooting The Dfi System

    FUEL SYSTEM (DFI) 3-25 Troubleshooting the DFI System The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (immobilizer models) and oil pressure warning indicator. Outline When a problem occurs with DFI system, the warning in- dicator light (LED) [A] and FI warning symbol [B] blinks to alert the rider.
  • Page 112 But the service codes stored in memory of the ECU are not erased to preserve the problem history. The problem history can be referred using the KDS (Kawasaki Diagnostic System) when solving unstable problems. When the motorcycle is down, the vehicle-down sensor operates and the ECU shuts off the fuel pump relay, fuel injectors (primary and secondary) and ignition system.
  • Page 113 After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system.
  • Page 114 3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. •...
  • Page 115: Inquiries To Rider

    FUEL SYSTEM (DFI) 3-29 Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.
  • Page 116 3-30 FUEL SYSTEM (DFI) Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. □ □ □ □ □ □...
  • Page 117 FUEL SYSTEM (DFI) 3-31 Troubleshooting the DFI System □ Poor running spark plug loose (tighten it). □ or no power at spark plug dirty, broken, or gap maladjusted (remedy it). high speed □ spark plug incorrect (replace it). □ knocking (fuel poor quality or incorrect, → use high-octane gasoline). □...
  • Page 118: Dfi System Troubleshooting Guide

    3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system.
  • Page 119 FUEL SYSTEM (DFI) 3-33 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). Inlet air pressure sensor trouble Inspect (see chapter 3).
  • Page 120 3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3). Atmospheric pressure sensor trouble Inspect (see chapter 3).
  • Page 121 FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Other: Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight, and examine leads for signs of burning or fraying (see chapter 3). Poor Running or No Power at High Speed Actions Symptoms or Possible Causes...
  • Page 122 3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Inlet air temperature sensor trouble Inspect (see chapter 3). Miscellaneous: Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Speed sensor trouble Inspect (see chapter 3).
  • Page 123: Self-diagnosis

    FUEL SYSTEM (DFI) 3-37 Self-Diagnosis The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (equipped models) and oil pressure warning indicator. Self-diagnosis Outline The self-diagnosis system has two modes and can be switched to another mode by operating the meter unit. User Mode The ECU notifies the rider of troubles in DFI system, ig- nition system and immobilizer system by blinking the warn-...
  • Page 124: Self-diagnosis Procedures

    3-38 FUEL SYSTEM (DFI) Self-Diagnosis Dealer Mode The LCD (Liquid Crystal Display) display the service code(s) [A] to show the problem(s) which the DFI system, ignition system and immobilizer system has at the moment of diagnosis. Immobilizer Models [B] Self-diagnosis Procedures ○...
  • Page 125 FUEL SYSTEM (DFI) 3-39 Self-Diagnosis • Turn the ignition switch ON. • Push the MODE button [A] to display the odometer. Immobilizer Models [B] • Push the MODE button [A] for more than two seconds. • The service code [B] is displayed on the LCD by the num- ber of two digits.
  • Page 126 3-40 FUEL SYSTEM (DFI) Self-Diagnosis Self-Diagnosis Flow Chart...
  • Page 127: Service Code Reading

    FUEL SYSTEM (DFI) 3-41 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 128 3-42 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Table Problems Service Code Main throttle sensor malfunction, wiring open or short Inlet air pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Atmospheric pressure sensor malfunction, wiring open or short Crankshaft sensor malfunction, wiring open or short Speed sensor malfunction, wiring open or short...
  • Page 129: Backups

    FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI, ignition or immo- bilizer system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the output voltage is out of the usable range, Main Throttle...
  • Page 130 3-44 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the exhaust butterfly valve actuator sensor Exhaust system fails (the output voltage is out of the Butterfly Output Voltage usable range, wiring short or open), the ECU Valve 0.1 ∼...
  • Page 131 FUEL SYSTEM (DFI) 3-45 Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria Oxygen The oxygen sensor heater If the oxygen sensor heater fails (wiring short Sensor raise temperature of or open), the ECU stops the current to the Heater the sensor for its earlier heater, and it stops the feedback mode of the...
  • Page 132: Main Throttle Sensor (service Code 11)

    3-46 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Removal/Adjustment CAUTION 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 133: Main Throttle Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-47 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, note the follow- ing. ○ Disconnect the main throttle sensor connector and con- nect the harness adapter [A] between these connectors.
  • Page 134: Main Throttle Sensor Resistance Inspection

    3-48 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) If the reading is within the standard, remove the ECU and check the wiring for continuity between main harness con- nectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 135: Inlet Air Pressure Sensor (service Code 12)

    FUEL SYSTEM (DFI) 3-49 Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Removal CAUTION Never drop the inlet air pressure sensor especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) Inlet Air Pressure Sensor Connector [A] •...
  • Page 136: Inlet Air Pressure Sensor Output Voltage Inspection

    3-50 FUEL SYSTEM (DFI) Inlet 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 137 FUEL SYSTEM (DFI) 3-51 Inlet 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 138 3-52 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) then Pv = Pl – Pg For example, suppose the following data is obtained: Pg = 8 cmHg (Vacuum Gauge Reading) Pl = 70 cmHg (Barometer Reading) Vv = 3.2 V (Digital Meter Reading) then Pv = 70 –...
  • Page 139 FUEL SYSTEM (DFI) 3-53 Inlet Air Pressure Sensor (Service Code 12) ID: Idling Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle Vacuum Pressure (Absolute) ST: Standard of Sensor Output Voltage (V) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (V) Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)
  • Page 140 3-54 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Circuit 1. Inlet Air Pressure Sensor 2. ECU...
  • Page 141: Inlet Air Temperature Sensor (service Code 13)

    FUEL SYSTEM (DFI) 3-55 Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Removal/Installation CAUTION Never drop the inlet air temperature sensor espe- cially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal).
  • Page 142: Inlet Air Temperature Sensor Resistance Inspection

    3-56 FUEL SYSTEM (DFI) Inlet 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 connectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 143 FUEL SYSTEM (DFI) 3-57 Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Circuit 1. Inlet Air Temperature Sensor 2. ECU...
  • Page 144: Water Temperature Sensor (service Code 14)

    3-58 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Water Temperature Sensor Removal/Installation CAUTION Never drop the water temperature sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • Remove the throttle body assy (see Throttle Body Assy Removal).
  • Page 145: Water Temperature Sensor

    FUEL SYSTEM (DFI) 3-59 Water Temperature Sensor (Service Code 14) • Turn the ignition switch OFF. If the reading is within the standard, check the ECU for its ground and power supply (see ECU Power Supply In- spection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
  • Page 146: Atmospheric Pressure Sensor (service Code 16)

    3-60 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 16) Atmospheric Pressure Sensor Removal CAUTION Never drop the atmospheric pressure sensor espe- cially on a hard surface. Such a shock to the sensor can damage it. • Remove the air cleaner housing (see Air Cleaner Housing Removal).
  • Page 147: Atmospheric Pressure Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-61 Atmospheric Pressure Sensor (Service Code 16) 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 148 3-62 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 16) 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 149 FUEL SYSTEM (DFI) 3-63 Atmospheric Pressure Sensor (Service Code 16) Atmospheric Pressure/Altitude Relationship...
  • Page 150 3-64 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 16) Atmospheric Pressure Sensor Circuit 1. Atmospheric Pressure Sensor 2. ECU...
  • Page 151: Crankshaft Sensor (service Code 21)

    FUEL SYSTEM (DFI) 3-65 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 152 3-66 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Crankshaft Sensor Circuit 1. Crankshaft Sensor 2. ECU...
  • Page 153: Speed Sensor (service Code 24)

    FUEL SYSTEM (DFI) 3-67 Speed Sensor (Service Code 24) 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 154: Speed Sensor Output Voltage Inspection

    3-68 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) Speed Sensor Output Voltage Inspection • Raise the rear wheel off the ground with the stand. • Measure the output voltage at the speed sensor in the same way as input voltage inspection, note the following. ○...
  • Page 155 FUEL SYSTEM (DFI) 3-69 Speed Sensor (Service Code 24) Speed Sensor Circuit 1. Meter Unit 2. Speed Sensor 3. ECU 4. Frame Ground...
  • Page 156: Gear Position Switch (service Code 25)

    3-70 FUEL SYSTEM (DFI) Gear Position Switch (Service Code 25) Gear Position Switch Removal/Installation • Refer to the Gear Position Switch Removal/Installation in the Electrical System chapter. Gear Position Switch Resistance Inspection • Refer to the Gear Position Switch Inspection in the Elec- trical System chapter.
  • Page 157 FUEL SYSTEM (DFI) 3-71 Gear Position Switch (Service Code 25) Gear Position Switch Circuit 1. Meter Unit 2. Gear Position Switch 3. ECU 4. Frame Ground...
  • Page 158: Vehicle-down Sensor (service Code 31)

    3-72 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks 60 ∼ 70° or more to either side (in fact falls down), the weight turns and the signal changes.
  • Page 159: Vehicle-down Sensor Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-73 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Disconnect the vehicle-down sensor connector and con- nect the harness adapter [A] between these connectors as shown in the figure.
  • Page 160: Vehicle-down Sensor Output Voltage Inspection

    3-74 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Output Voltage Inspection • Remove the vehicle-down sensor (see Vehicle-down Sensor Removal). • Connect the harness adapter [A] to the vehicle-down sen- sor connectors as shown in the figure. Special Tool - Measuring Adapter: 57001-1700 Main Harness [B] Vehicle-down Sensor [C]...
  • Page 161 FUEL SYSTEM (DFI) 3-75 Vehicle-down Sensor (Service Code 31) If the reading is within the standard, remove the ECU and check the wiring for continuity between main harness con- nectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 162: Subthrottle Sensor (service Code 32)

    3-76 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Subthrottle Sensor Removal/Adjustment CAUTION Do not remove or adjust the subthrottle 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 163: Subthrottle Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-77 Subthrottle Sensor (Service Code 32) Subthrottle Sensor Output Voltage Inspection • Measure the output voltage at the subthrottle sensor in the same way as input voltage inspection, note the fol- lowing. ○ Disconnect the subthrottle sensor connector and connect the harness adapter [A] between these connectors.
  • Page 164: Subthrottle Sensor Resistance Inspection

    3-78 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) If the reading is within the standard, remove the ECU and check the wiring for continuity between main harness con- nectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 165: Oxygen Sensor - Not Activated (service Code 33 (equipped Models))

    FUEL SYSTEM (DFI) 3-79 Oxygen Sensor - not activated (Service Code 33 (Equipped Models)) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation (Equipped Models) in the Electrical System chapter. Oxygen Sensor Inspection • Warm up the engine thoroughly until the radiator fan starts.
  • Page 166 3-80 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33 (Equipped Models)) • Install the suitable plugs [A] on the fitting of the air suction valve covers, and shut off the secondary air. • Connect the following parts temporarily. Fuel Pump Lead Connector [A] Extension Tube [B] Air Cleaner Housing (see Air Cleaner Housing Installa-...
  • Page 167: Oxygen Sensor Inspection

    FUEL SYSTEM (DFI) 3-81 Oxygen Sensor - not activated (Service Code 33 (Equipped Models)) Oxygen Sensor Circuit 1. Ignition Switch 2. Oxygen Sensor 3. ECU 4. Fuse Box 5. Oxygen Sensor Heater Fuse 10 A 6. Battery 12 V 8 Ah 7.
  • Page 168: Exhaust Butterfly Valve Actuator Sensor (service Code 34)

    3-82 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Removal/Installation The exhaust butterfly valve actuator sensor is built in the exhaust butterfly valve actuator. So, the sensor itself can not be removed. Remove the exhaust butterfly valve actu- ator (see Exhaust Butterfly Valve Actuator Removal).
  • Page 169: Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-83 Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection NOTE ○ Before this inspection, confirm the pulley [A] is original position (see Exhaust Butterfly Valve Actuator Installa- tion). • Disconnect: 2 pins Connector [B] 3 pins Connector [C]...
  • Page 170: Exhaust Butterfly Valve Actuator Sensor Resistance Inspection

    3-84 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Resistance Inspection • Turn the ignition switch OFF. • Disconnect the exhaust butterfly valve actuator sensor connector (3 pins connector) [A]. • Connect a digital meter [B] to the exhaust butterfly valve actuator sensor connector.
  • Page 171: Immobilizer Amplifier (service Code 35 (equipped Models))

    FUEL SYSTEM (DFI) 3-85 Immobilizer Amplifier (Service Code 35 (Equipped Models)) Antenna Resistance Inspection • Turn the ignition switch OFF. • Remove the air cleaner housing (see Air Cleaner Housing Removal). • Disconnect the antenna lead connector [A]. • Measure the antenna resistance. Antenna Resistance Connections: BK lead ←→...
  • Page 172: Blank Key Detection (service Code 36 (equipped Models))

    3-86 FUEL SYSTEM (DFI) Blank Key Detection (Service Code 36 (Equipped Models)) • This code appears in the following conditions. ○ The transponder [A] in the master and/or user key is mal- function. ○ When the spare key of unregistration is used. ○...
  • Page 173 FUEL SYSTEM (DFI) 3-87 Blank Key Detection (Service Code 36 (Equipped Models)) Immobilizer System Circuit 1. Ignition Switch 2. ECU 3. Immobilizer/Kawasaki Diagnostic System Connector 4. Fuse Box 5. Ignition Fuse 15 A 6. Frame Ground 7. Battery 12 V 8 Ah 8.
  • Page 174: Ecu Communication Error (service Code 39)

    3-88 FUEL SYSTEM (DFI) ECU Communication Error (Service Code 39) ECU Communication Line Inspection ○ When the data is not sent from the ECU to the meter unit for more than about 10 seconds, the service code 39 is displayed. ○...
  • Page 175: Stick Coils #1, #2, #3, #4 (service Code 51, 52, 53, 54)

    FUEL SYSTEM (DFI) 3-89 Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) Stick Coil #1: Service Code 51 Stick Coil #2: Service Code 52 Stick Coil #3: Service Code 53 Stick Coil #4: Service Code 54 Stick Coil Removal/Installation •...
  • Page 176 3-90 FUEL SYSTEM (DFI) Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) • Turn the ignition switch OFF. If the input voltage is out of the standard, check the wiring for continuity (see wiring diagram in this section). Special Tool - Hand Tester: 57001-1394 If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).
  • Page 177: Radiator Fan Relay (service Code 56)

    FUEL SYSTEM (DFI) 3-91 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 178 3-92 FUEL SYSTEM (DFI) Radiator Fan Relay (Service Code 56) Radiator Fan Relay Circuit 1. Ignition Switch 2. Fan Motor 3. Water Temperature Sensor 4. ECU 5. Fuse Box 6. Fan Fuse 15 A 7. Frame Ground 8. Battery 12 V 8 Ah 9.
  • Page 179: Subthrottle Valve Actuator (service Code 62)

    FUEL SYSTEM (DFI) 3-93 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy especially on a hard surface.
  • Page 180: Subthrottle Valve Actuator Input Voltage Inspection

    3-94 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Disconnect the subthrottle valve actuator connector and connect the harness adapter [A] between these connec- tors as shown in the figure.
  • Page 181 FUEL SYSTEM (DFI) 3-95 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Circuit 1. Subthrottle Valve Actuator 2. ECU...
  • Page 182: Exhaust Butterfly Valve Actuator (service Code 63)

    3-96 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator (Service Code 63) Exhaust Butterfly Valve Actuator Removal CAUTION Never drop the exhaust butterfly valve actuator es- pecially on a hard surface. Such a shock to the ac- tuator can damage it. •...
  • Page 183 FUEL SYSTEM (DFI) 3-97 Exhaust Butterfly Valve Actuator (Service Code 63) • After tightening the pulley bolt, confirm whether pulley [A] is an angle shown in the figure. 41.7° ±0.7° [B] ○ This position is original position of the pulley. NOTE ○...
  • Page 184: Exhaust Butterfly Valve Actuator Inspection

    3-98 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator (Service Code 63) Exhaust Butterfly Valve Actuator Inspection NOTE ○ Be sure the battery is fully charged. • Remove the front seat (see Front Seat Removal in the Frame chapter). • Turn the ignition switch ON. •...
  • Page 185 FUEL SYSTEM (DFI) 3-99 Exhaust Butterfly Valve Actuator (Service Code 63) Exhaust Butterfly Valve Actuator Circuit 1. Exhaust Butterfly Valve Actuator 2. ECU...
  • Page 186: Air Switching Valve (service Code 64)

    3-100 FUEL SYSTEM (DFI) Air Switching Valve (Service Code 64) Air Switching Valve Removal/Installation • Refer to the Air Switching Valve Removal/Installation in the Engine Top End chapter. Air Switching Valve Inspection • Refer to the Air Switching Valve Unit Test in the Electrical System chapter.
  • Page 187: Oxygen Sensor Heater (service Code 67 (equipped Models))

    FUEL SYSTEM (DFI) 3-101 Oxygen Sensor Heater (Service Code 67 (Equipped Models)) Oxygen Sensor Heater Removal/Installation The oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see Oxygen Sensor Removal (Equipped Mod- els) in the Electrical System chapter).
  • Page 188: Oxygen Sensor Heater Power Source Voltage Inspection

    3-102 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67 (Equipped Models)) Oxygen Sensor Heater Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Disconnect the oxygen sensor lead connector and con- nect the harness adapter [A] between these connectors as shown in the figure.
  • Page 189 FUEL SYSTEM (DFI) 3-103 Oxygen Sensor Heater (Service Code 67 (Equipped Models)) Oxygen Sensor Circuit 1. Ignition Switch 2. Oxygen Sensor 3. ECU 4. Fuse Box 5. Oxygen Sensor Heater Fuse 10 A 6. Battery 12 V 8 Ah 7. Main Fuse 30 A...
  • Page 190: Oxygen Sensor - Incorrect Output Voltage (service Code 94 (equipped Models))

    3-104 FUEL SYSTEM (DFI) Oxygen Sensor - Incorrect Output Voltage (Service Code 94 (Equipped Models)) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation (Equipped Models) in the Electrical System chapter. Oxygen Sensor Inspection • Warm up the engine thoroughly until the radiator fan starts.
  • Page 191 FUEL SYSTEM (DFI) 3-105 Oxygen Sensor - Incorrect Output Voltage (Service Code 94 (Equipped Models)) • Install the suitable plugs [A] on the fitting of the air suction valve covers, and shut off the secondary air. • Connect the following parts temporarily. Fuel Pump Lead Connector [A] Extension Tube [B] Air Cleaner Housing (see Air Cleaner Housing Installa-...
  • Page 192 3-106 FUEL SYSTEM (DFI) Oxygen Sensor - Incorrect Output Voltage (Service Code 94 (Equipped Models)) Oxygen Sensor Circuit 1. Ignition Switch 2. Oxygen Sensor 3. ECU 4. Fuse Box 5. Oxygen Sensor Heater Fuse 10 A 6. Battery 12 V 8 Ah 7.
  • Page 193: Warning Indicator Light (led)

    FUEL SYSTEM (DFI) 3-107 Warning Indicator Light (LED) Light (LED) Inspection ○ The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (equipped models) and oil pressure warning indicator. ○ In this model, the warning indicator light (LED) (FI/immo- bilizer) blinks by the data sent from the ECU.
  • Page 194: Ecu

    3-108 FUEL SYSTEM (DFI) ECU Identification ○ Most countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU with each other and use only the ECU for your model. Other- wise, the motorcycle can not clear the regulation. ECU Identification Part Number [A] Specification...
  • Page 195: Ecu Installation

    FUEL SYSTEM (DFI) 3-109 ECU Installation • Install: ECU [A] (in Rubber Protector [B]) ECU Connectors [C] • Insert the slits of the rubber protector [A] to the projections [B] of the rear fender. ECU Power Supply Inspection • Remove the front seat cover (see Seat Cover Removal in the Frame chapter).
  • Page 196 3-110 FUEL SYSTEM (DFI) If the wiring is good, check the power source voltage of the ECU. NOTE ○ Be sure the battery is fully charged. • Connect the ECU connectors. • Connect a digital meter [A] to the connector [B] with the needle adapter set.
  • Page 197 FUEL SYSTEM (DFI) 3-111 ECU Power Source Circuit 1. Ignition Switch 2. ECU 3. Joint Connector C 4. Joint Connector D 5. Fuse Box 6. ECU Fuse 10 A 7. Frame Ground 8. Battery 12 V 8 Ah 9. Main Fuse 30 A 10.
  • Page 198: Dfi Power Source

    3-112 FUEL SYSTEM (DFI) DFI Power Source ECU Fuse Removal • Refer to the 10 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 199: Fuel Line

    FUEL SYSTEM (DFI) 3-113 Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Fuel Tank Bolts [A] Primary Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) ○ Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of the throttle body assy.
  • Page 200: Fuel Flow Rate Inspection

    3-114 FUEL SYSTEM (DFI) Fuel Line NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. • Turn the ignition switch OFF. If the fuel pressure is much higher than specified, replace the fuel pump because the fuel pressure regulator in the fuel pump have been clogged or stuck.
  • Page 201 FUEL SYSTEM (DFI) 3-115 Fuel Line • Open the fuel tank cap [A] to lower the pressure in the tank. • Remove the primary fuel hose from the fuel pump (see Fuel Tank Removal). ○ Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump.
  • Page 202: Fuel Pump

    3-116 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 203: Fuel Pump Installation

    FUEL SYSTEM (DFI) 3-117 Fuel Pump Fuel Pump Installation • Remove dirt or dust from the fuel pump [A] by lightly ap- plying compressed air. • Replace the fuel pump gasket with a new one. • Check that the fuel pump terminal [A] and band [B] are in place.
  • Page 204: Fuel Pump Operating Voltage Inspection

    3-118 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Operating Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove the front seat (see Front Seat Removal in the Frame chapter). • Disconnect the fuel pump lead connector and connect the harness adapter [A] between these connectors as shown in the figure.
  • Page 205: Pressure Regulator Removal

    FUEL SYSTEM (DFI) 3-119 Fuel Pump Pressure Regulator Removal ○ The pressure regulator [A] is built into the fuel pump and can not be removed. Fuel Filter Cleaning ○ The fuel filter [A] is built into the fuel pump and can not be cleaned or checked.
  • Page 206: Fuel Injectors

    3-120 FUEL SYSTEM (DFI) Fuel Injectors Primary Fuel Injector Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Secondary Fuel Injector Removal/Installation • Refer to the Nozzle Assy Disassembly/Assembly. Fuel Injector Audible Inspection NOTE ○ Be sure the battery is fully charged. ○...
  • Page 207: Fuel Injector Resistance Inspection

    FUEL SYSTEM (DFI) 3-121 Fuel Injectors Fuel Injector Resistance Inspection For Primary Fuel Injectors • Remove the air cleaner housing (see Air Cleaner Housing Removal). • Disconnect the primary fuel injector connector [A]. • Connect a digital meter to the terminals in each primary fuel injector [A].
  • Page 208: Fuel Injector Power Source Voltage Inspection

    3-122 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. For Primary Fuel Injectors • Remove the air cleaner housing (see Air Cleaner Housing Removal).
  • Page 209 FUEL SYSTEM (DFI) 3-123 Fuel Injectors For Secondary Fuel Injectors • Remove the fuel tank (see Fuel Tank Removal). • Disconnect the injector connector and connect the har- ness adapter [A] between these connectors as shown in the figure. Main Harness [B] Secondary Fuel Injector #1 [C] Special Tool - Measuring Adapter: 57001-1700 •...
  • Page 210: Fuel Injector Output Voltage Inspection

    3-124 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Output Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove the ECU (see ECU Removal). ○ Do not disconnect the ECU connector. •...
  • Page 211 FUEL SYSTEM (DFI) 3-125 Fuel Injectors If the reading is out of the specification, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and injector connector. Wiring Continuity Inspection (Primary Fuel Injectors) ECU Connector [A] ←→...
  • Page 212: Fuel Injector Fuel Line Inspection

    3-126 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Fuel Line Inspection • Remove: Fuel Tank (see Fuel Tank Removal) Air Cleaner Housing (see Air Cleaner Housing Removal) Primary and Secondary Fuel Hoses (see Fuel Hose Re- placement in the Periodic Maintenance chapter) ○...
  • Page 213 FUEL SYSTEM (DFI) 3-127 Fuel Injectors Fuel Injector Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Primary Fuel Injector #1 4. Primary Fuel Injector #2 5. Primary Fuel Injector #3 6. Primary Fuel Injector #4 7. Secondary Fuel Injector #1 8.
  • Page 214: Throttle Grip And Cables

    3-128 FUEL SYSTEM (DFI) Throttle Grip and Cables Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Cable Installation •...
  • Page 215: Throttle Body Assy

    FUEL SYSTEM (DFI) 3-129 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 explo- sive under certain conditions.
  • Page 216: Throttle Body Assy Installation

    3-130 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the adjusting screw [A] from the clamp. • Remove the throttle body assy from the throttle body assy holders. • Remove: Bolt [A] Holder Plate [B] Throttle Cable Lower Ends • After removing the throttle body assy, stuff pieces of lint -free, clean cloth into the throttle body assy holders.
  • Page 217: Throttle Body Assy Disassembly

    FUEL SYSTEM (DFI) 3-131 Throttle Body Assy Throttle Body Assy Disassembly 1. Throttle Body Assy 2. Subthrottle Valve Actuator 3. Main Throttle Sensor 4. Subthrottle Sensor 5. Primary Fuel Injectors 6. Delivery Pipe Assy CAUTION Do not remove, disassemble or adjust the main throttle sensor, subthrottle sensor, subthrottle valve actuator, throttle link mechanism and throttle body assy, because they are adjust or set surely at...
  • Page 218: Throttle Body Assy Assembly

    3-132 FUEL SYSTEM (DFI) Throttle Body Assy • Pull out the primary fuel injectors [A] from the delivery pipe assy [B]. NOTE ○ Do not damage the insertion portions of the injectors when they are pulled out from the delivery pipe assy. CAUTION Never drop the primary fuel injector especially on a hard surface.
  • Page 219: Nozzle Assy

    FUEL SYSTEM (DFI) 3-133 Nozzle Assy Nozzle Assy Removal • Remove the fuel tank (see Fuel Tank Removal). • Disconnect the secondary fuel hose [A] from the delivery pipe of the nozzle assy [B] (see Fuel Hose Replacement in the Periodic Maintenance chapter). •...
  • Page 220: Nozzle Assy Disassembly

    3-134 FUEL SYSTEM (DFI) Nozzle Assy Nozzle Assy Disassembly • Remove the nozzle assy (see Nozzle Assy Removal). • Remove the screws [A] to pull out the secondary fuel in- jectors [B] from the stay plate [C] together with the delivery pipe assy [D].
  • Page 221 FUEL SYSTEM (DFI) 3-135 Nozzle Assy • Replace the O-rings [A] of each secondary fuel injector [B] with new ones. • Apply engine oil to the new O-rings, and insert them to the delivery pipe assy [C] and confirm whether the injectors turn smoothly or not.
  • Page 222: Air Cleaner

    3-136 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 223 FUEL SYSTEM (DFI) 3-137 Air Cleaner • Remove the caps [A]. • Loosen the air cleaner housing clamp bolts [A]. • Remove: Air Cleaner Drain Hose [A] Breather Hose [B] • Separate the air switching valve hose [A] from the air cleaner housing [B].
  • Page 224: Air Cleaner Housing Installation

    3-138 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Housing Installation • Install the air switching valve hose to the air cleaner hous- ing. • Install the air cleaner housing on the throttle body assy. ○ Install the clamp bolt heads [A] outside as shown in the figure.
  • Page 225: Air Cleaner Housing Assembly

    FUEL SYSTEM (DFI) 3-139 Air Cleaner Air Cleaner Housing Assembly • Fit the projections [A] of the duct into the slits [B] on the air cleaner housing. • Do not twist the ducts [C]. • Install: Air Cleaner Frame Gasket [A] Pads [B] Air Cleaner Element Gasket [C] Air Cleaner Element [D]...
  • Page 226: Air Line

    3-140 FUEL SYSTEM (DFI) Air Line Air Inlet Duct Removal • Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Immobilizer Amplifier [A] (Equipped Models) (see Immo- bilizer System Parts Replacement in the Electrical Sys- tem chapter) Lead [B] (Free) Air Inlet Duct Mounting Bolts [C] (Both Sides) Air Inlet Duct...
  • Page 227: Fuel Tank

    FUEL SYSTEM (DFI) 3-141 Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 228 3-142 FUEL SYSTEM (DFI) Fuel Tank • Disconnect: Battery (–) Terminal [A] Fuel Pump Lead Connector [B] • Remove: Fuel Tank Bolt [C] Fuel Tank Drain Hose [D] Fuel Tank Breather Hose [E] • For the California, Southeast Asia and Thailand models, remove the following.
  • Page 229: Fuel Tank Installation

    FUEL SYSTEM (DFI) 3-143 Fuel Tank • For the California, Southeast Asia and Thailand models, note the following. CAUTION For the California, Southeast Asia and Thailand models, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor ab- sorbing capacity is greatly reduced.
  • Page 230 3-144 FUEL SYSTEM (DFI) Fuel Tank • Install the pads [A] and trim [B] as shown in the figure. Hook [C] 8 mm (0.31 in.) [D] View A [E] View B [F] Fuel Tank Bracket [G] Weld [H] View Upper Side [I] •...
  • Page 231: Fuel Tank Inspection

    FUEL SYSTEM (DFI) 3-145 Fuel Tank • Push and pull [A] the fuel hose joint [B] back and forth more than two times, and make sure it is locked and does not come off. WARNING Make sure the hose joint is installed correctly on the delivery pipe or the fuel could leak.
  • Page 232: Evaporative Emission Control System (cal, Sea And Th Models)

    3-146 FUEL SYSTEM (DFI) Evaporative Emission Control System (CAL, SEA 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 233: Separator Operation Test

    FUEL SYSTEM (DFI) 3-147 Evaporative Emission Control System (CAL, SEA and TH Models) Separator Operation Test WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Do not smoke. Turn the ignition switch OFF. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 234 3-148 FUEL SYSTEM (DFI) Evaporative Emission Control System (CAL, SEA and TH Models) 1. Green Hose (Purge) 2. Band (for Canister) 3. Canister 4. White Hose (Vacuum) 5. Throttle Body Assy 6. Fuel Tank 7. Red Hose (Return) 8. Blue Hose (Breather) 9.
  • Page 235 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Special Tools .......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal ..................Coolant Reserve Tank Installation ..................
  • Page 236: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 237 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Coolant By-pass Fitting Bolt 0.90 78 in·lb Coolant Drain Bolt (Cylinder) 87 in·lb Coolant Drain Bolt (Water Pump) 0.90 78 in·lb Coolant Reserve Tank Mounting Bolts 0.70 61 in·lb Heat Insulation Plate Bolt 0.40 35 in·lb...
  • Page 238: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart...
  • Page 239 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 240: 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 241: Special Tools

    COOLING SYSTEM 4-7 Special Tools Bearing Driver Set: Oil Seal Driver: 57001-1129 57001-1660...
  • Page 242: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the upper fairing assembly (see Upper Fairing Assembly Removal in the Frame chapter). • Visually inspect the coolant in the reserve tank [A]. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded.
  • Page 243: 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 244: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Refer to the Oil Pump Removal in the Engine Lubrication System chapter. Water Pump Installation • Refer to the Oil Pump Installation in the Engine Lubrica- tion System chapter. Water Pump Inspection •...
  • Page 245: Water Pump Housing Assembly

    COOLING SYSTEM 4-11 Water Pump • Take the oil seal [A] out of the housing [B] with a hook [C]. Water Pump Housing Assembly CAUTION Do not reuse the mechanical seal and oil seal. • Apply high-temperature grease to the oil seal lips [A]. •...
  • Page 246: Radiator

    4-12 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal • Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Coolant Reserve Tank (see Coolant Reserve Tank Re- moval)
  • Page 247: Radiator And Radiator Fan Installation

    COOLING SYSTEM 4-13 Radiator Radiator and Radiator Fan Installation If the radiator bracket [A] was removed, install it. Torque - Radiator Bracket Mounting Bolt [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Run the radiator fan motor lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
  • Page 248: Radiator Cap Inspection

    4-14 COOLING SYSTEM Radiator CAUTION When cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage: Keep the steam gun [A] away more than 0.5 m (1.6 ft) [B] from the radiator core. Hold the steam gun perpendicular [C] (not oblique [D]) to the core surface.
  • Page 249: Thermostat

    COOLING SYSTEM 4-15 Thermostat Thermostat Removal • Remove: Oil Cooler (see Oil Cooler Removal in the Engine Lubri- cation System chapter) Thermostat Housing Cover Bolts [A] Thermostat Housing Cover [B] Thermostat Thermostat Installation • Install the thermostat [A] in the housing so that the air bleeder hole [B] is on top.
  • Page 250 4-16 COOLING SYSTEM Thermostat • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water. ○ The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [B] in the water so that the heat sen- sitive portions [C] are located in almost the same depth.
  • Page 251: Hoses And Pipes

    COOLING SYSTEM 4-17 Hoses and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). •...
  • Page 252: Water Temperature Sensor

    4-18 COOLING SYSTEM Water Temperature Sensor Water Temperature Sensor Removal/Installation • Refer to the Water Temperature Sensor Removal/Instal- lation in the Fuel System (DFI) chapter. Water Temperature Sensor Inspection • Refer to the Water Temperature Sensor Inspection in the Electrical System chapter.
  • Page 253 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Cylinder Compression Exhaust System Identification ... Measurement ......5-25 Specifications ........Cylinder Head Removal ....5-26 Special Tools and Sealant ....Cylinder Head Installation .... 5-27 Clean Air System....... 5-11 Cylinder Head Warp Inspection ...
  • Page 254: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 255 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb 1 Air Suction Valve Cover Bolts 87 in·lb 2 Breather Hose Fitting 3 Camshaft Cap Bolts 106 in·lb 4 Camshaft Chain Tensioner Cap Bolt 5 Camshaft Chain Tensioner Mounting Bolts 97 in·lb 6 Camshaft Sprocket Bolts 7 Coolant Drain Bolt (Cylinder)
  • Page 256 5-4 ENGINE TOP END Exploded View...
  • Page 257 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Exhaust Butterfly Valve Cable Adjuster Locknuts 0.70 61 in·lb Exhaust Butterfly Valve Cable Locknuts 0.71 62 in·lb Exhaust Pipe Clamp Bolt Exhaust Pipe Guard Bolts 0.70 61 in·lb Exhaust Pipe Holder Nuts Muffler Body Clamp Bolt Muffler Body Cover Bolts...
  • Page 258: Exhaust System Identification

    5-6 ENGINE TOP END Exhaust System Identification Exhaust Pipe Mark Position [A] Premuffler Chamber Mark Position [A]...
  • Page 259 ENGINE TOP END 5-7 Exhaust System Identification Muffler Body Mark Position [A] Exhaust Pipe [A] with Hole [B] for Oxygen Sensor [C] Honeycomb Type Catalyst Positions [A]...
  • Page 260: Specifications

    5-8 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: 33.143 ∼ 33.257 mm (1.3048 ∼ 1.3093 in.) Exhaust 33.04 mm (1.301 in.) 34.543 ∼ 34.657 mm (1.3600 ∼ 1.3644 in.) Inlet 34.44 mm (1.356 in.) 0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.) Camshaft Journal/Camshaft 0.17 mm (0.0067 in.) Cap Clearance...
  • Page 261: Special Tools And Sealant

    ENGINE TOP END 5-9 Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter Holder Bar: 57001-221 57001-1128 Valve Spring Compressor Assembly: Valve Spring Compressor Adapter, 20: 57001-241 57001-1154 Valve Seat Cutter, 45° - 24.5: Valve Seat Cutter, 45° - 30: 57001-1113 57001-1187 Valve Seat Cutter, 32°...
  • Page 262 Valve Seat Cutter Holder, 4: Compression Gauge Adapter, M10 × 1.0: 57001-1275 57001-1601 Valve Seat Cutter, 60° - 25: L-Shape Hose: 57001-1328 57001-1606 Valve Seat Cutter, 60° - 27: Attachment C: 57001-1409 57001-1624 Valve Guide Driver: Kawasaki Bond (Silicone Sealant): 57001-1564 92104-0004...
  • Page 263: Clean Air System

    ENGINE TOP END 5-11 Clean Air System Air Suction Valve Removal • Remove: Air Switching Valve (see Air Switching Valve Removal) Air Suction Valve Cover Bolts [A] (Both Sides) Air Suction Valve Covers [B] (Both Sides) • Remove the air suction valves [A] on both sides. Air Suction Valve Installation •...
  • Page 264: 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 265: Air Switching Valve Operation Test

    ENGINE TOP END 5-13 Clean Air System Air Switching Valve Operation Test • Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter. Air Switching Valve Unit Test • Refer to the Air Switching Valve Unit Test in the Electrical System chapter.
  • Page 266: Cylinder Head Cover

    Replace the cylinder head cover gasket [A] with a new one. • Apply silicone sealant [B] to the cylinder head as shown in the figure. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Be sure to install the following parts. Dowel Pins [A] Plug Hole Gaskets [B] •...
  • Page 267 ENGINE TOP END 5-15 Cylinder Head Cover • Tighten the cover bolts following the specified tightening sequence. Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the removed parts (see appropriate chapters).
  • Page 268: Camshaft Chain Tensioner

    5-16 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below.
  • Page 269: Camshaft Chain Tensioner Installation

    ENGINE TOP END 5-17 Camshaft Chain Tensioner Camshaft Chain Tensioner Installation • Replace the O-ring [A] with a new one. • Apply grease to the new O-ring. • Release the stopper [B] and push the push rod [C] into the interior of the tensioner body [D]. •...
  • Page 270: Camshaft, Camshaft Chain

    5-18 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove the cylinder head cover (see Cylinder Head Cover Removal). • Remove the timing inspection cap [A] and starter clutch bolt cap [B] on the starter clutch cover [C]. • Using a wrench on the starter clutch bolt [A], turn the crankshaft clockwise until the line [B] (TDC mark for #1,4 pistons) on the starter clutch is aligned with the notches...
  • Page 271: Camshaft Installation

    ENGINE TOP END 5-19 Camshaft, Camshaft Chain • Remove the camshaft chain tensioner (see Camshaft Chain Tensioner Removal). • Loosen the upper camshaft chain guide bolts and camshaft cap bolts as shown sequence [1 ∼ 20] in the figure, and remove them. •...
  • Page 272 5-20 ENGINE TOP END Camshaft, Camshaft Chain • Install the camshaft sprockets as shown in the figure. #4 Cam Positions [A] Inlet Camshaft Sprocket [B] Exhaust Camshaft Sprocket [C] ○ The inlet camshaft sprocket and exhaust camshaft sprocket are identical. •...
  • Page 273 ENGINE TOP END 5-21 Camshaft, Camshaft Chain • Pull the tension side (exhaust side) [A] of the chain taut to install the chain. • Engage the camshaft chain with the sprockets so that tim- ing marks on the sprockets are positioned as shown in the figure.
  • Page 274 5-22 ENGINE TOP END Camshaft, Camshaft Chain • Install: O-rings [A] Dowel Pins [B] O-rings [C] Dowel Pins [D] • Install the camshaft caps and upper camshaft chain guide [A] as shown in the figure. “R” Mark [B] “L” Mark [C] •...
  • Page 275: Camshaft, Camshaft Cap Wear Inspection

    ENGINE TOP END 5-23 Camshaft, Camshaft Chain • Install the camshaft chain tensioner (see Camshaft Chain Tensioner Installation). • Turn the crankshaft 2 turns clockwise to allow the ten- sioner to expand and recheck the camshaft chain timing. • Replace the O-ring of the timing inspection cap and starter clutch bolt cap with new ones.
  • Page 276: Camshaft Runout Inspection

    5-24 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Runout Inspection • Remove the camshafts (see Camshaft Removal). • Set the camshaft in a camshaft alignment jig or on V blocks. • Measure the runout with a dial gauge at the specified place as shown in the figure.
  • Page 277: Cylinder Head

    ENGINE TOP END 5-25 Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove the spark plugs (see Spark Plug Replacement in the Periodic Maintenance chapter). •...
  • Page 278: Cylinder Head Removal

    5-26 ENGINE TOP END Cylinder Head Cylinder Head Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) Cylinder Head Cover (see Cylinder Head Cover Re- moval)
  • Page 279: Cylinder Head Installation

    ENGINE TOP END 5-27 Cylinder Head Cylinder Head Installation NOTE ○ The camshaft cap is machined with the cylinder head, so if a new cylinder head is installed, use the cap that is supplied with the new head. • Install the dowel pins. •...
  • Page 280: Cylinder Head Warp Inspection

    5-28 ENGINE TOP END Cylinder Head Cylinder Head Warp Inspection • Clean the cylinder head. • Lay a straightedge across the lower surface of the cylinder head at several positions. • Use a thickness gauge [A] to measure the space between the straightedge [B] and the head.
  • Page 281: Valves

    ENGINE TOP END 5-29 Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the valve lifter and shim. ○ Mark and record the valve lifter and shim locations so they can be installed in their original positions.
  • Page 282: Valve-to-guide Clearance Measurement (wobble Method)

    5-30 ENGINE TOP END Valves • Using the valve guide driver and attachment [A], press and insert the valve guide in until the attachment surface [B] touches the head surface [C]. 13.3 ∼ 13.5 mm (0.52 ∼ 0.53 in.) [D] Special Tools - Valve Guide Driver: 57001-1564 Attachment C: 57001-1624 •...
  • Page 283: Valve Seat Inspection

    ENGINE TOP END 5-31 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 284 5-32 ENGINE TOP END Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
  • Page 285 ENGINE TOP END 5-33 Valves • Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range.
  • Page 286 5-34 ENGINE TOP END Valves If the seat width is too wide, make the 60° [A] grind de- scribed below. If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 60° angle until the seat width is within the specified range.
  • Page 287 ENGINE TOP END 5-35 Valves...
  • Page 288: Throttle Body Assy Holder

    5-36 ENGINE TOP END Throttle Body Assy Holder Throttle Body Assy Holder Removal • Remove: Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Clamps [A] Throttle Body Assy Holder Bolts [B] Throttle Body Assy Holders [C] Throttle Body Assy Holder Installation •...
  • Page 289: Muffler

    ENGINE TOP END 5-37 Muffler WARNING To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. Muffler Body Removal • Remove the front seat (see Front Seat Removal in the Frame chapter).
  • Page 290: Muffler Body Installation

    5-38 ENGINE TOP END Muffler Muffler Body Installation • Replace the muffler body gasket [A] with a new one. • Install the muffler body gasket to the premuffler chamber [B] until it is bottomed so that the chamfer side [C] faces muffler body [D].
  • Page 291: Premuffler Chamber Removal

    ENGINE TOP END 5-39 Muffler • Install the muffler body cover, and tighten the bolts. Torque - Muffler Body Cover Bolts: 7.0 N·m (0.71 kgf·m, 62 in·lb) • Install the damper [A] on the muffler body cover [B]. • Install the muffler body rear cover, and tighten the bolts. Torque - Muffler Body Rear Cover Bolts: 7.0 N·m (0.71 kgf·m, 62 in·lb) •...
  • Page 292: Premuffler Chamber Installation

    5-40 ENGINE TOP END Muffler Premuffler Chamber Installation • Replace the exhaust pipe gasket [A] with a new one. • Install the exhaust pipe gasket to the exhaust pipe [B] until it is bottomed so that the chamfer side [C] faces premuffler chamber [D].
  • Page 293: Exhaust Pipe Removal

    ENGINE TOP END 5-41 Muffler • Install the muffler body (see Muffler Body Installation). • Thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts. Exhaust Pipe Removal • Remove: Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter) Oxygen Sensor (Equipped Models) (see Oxygen Sen- sor Removal (Equipped Models) in the Electrical System...
  • Page 294: Exhaust Pipe Installation

    5-42 ENGINE TOP END Muffler • Remove the exhaust pipe holder nuts [A], and pull out the exhaust pipe forward from the premuffler chamber. Exhaust Pipe Installation • Replace the exhaust pipe gaskets [A] [B] with new ones. • Install the exhaust pipe gasket [B] to the exhaust pipe [C] until it is bottomed so that the chamfer side [D] faces premuffler chamber [E].
  • Page 295: Exhaust Butterfly Valve Cable Removal

    ENGINE TOP END 5-43 Muffler • Install the removed parts (see appropriate chapters). • Thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts and nuts. Exhaust Butterfly Valve Cable Removal • Remove the front seat (see Front Seat Removal in the Frame chapter).
  • Page 296: Exhaust Butterfly Valve Cable Installation

    5-44 ENGINE TOP END Muffler • Loosen the locknuts [A], and turn the adjusters [B] to give the cable plenty of play. • Remove the clamp [A]. • Remove the upper ends [B] of the exhaust butterfly valve cables from the pulley [C]. •...
  • Page 297 ENGINE TOP END 5-45 Muffler • Run the exhaust butterfly valve cables correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Install the lower ends of the exhaust butterfly valve cables to the pulley of the muffler body as shown in the figure. Open Cable (White) [A] Close Cable (Black) [B] •...
  • Page 298 5-46 ENGINE TOP END Muffler • Install the upper ends of the exhaust butterfly valve ca- bles to the pulley of the exhaust butterfly valve actuator, following the specified installing sequence. ○ First, install the close cable (black) [A]. ○ Second, install the open cable (white) [B].
  • Page 299 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool and Sealant ......................Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Cable Removal ......................... Cable Installation ......................Cable Lubrication ......................Clutch Lever Installation....................
  • Page 300: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 301 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Cover Bolts (M6, L = 40 mm) 87 in·lb Clutch Cover Bolts (M6, L = 25 mm) 87 in·lb Clutch Cover Plate Bolts 87 in·lb Clutch Hub Nut 13.8 99.6 Clutch Lever Clamp Bolts 0.80...
  • Page 302: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch Spring Plate Free Play (Usable Range) 0.05 ∼ 0.70 mm (0.002 ∼ 0.028 in.) – – – Clutch Plate Assembly Length (Reference) 40.6 mm (1.60 in.)
  • Page 303: Special Tool And Sealant

    CLUTCH 6-5 Special Tool and Sealant Clutch Holder: Kawasaki Bond (Silicone Sealant): 57001-1243 92104-0004...
  • Page 304: Clutch Lever And Cable

    6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Cable Removal •...
  • Page 305: Clutch Cover Removal

    Clutch Cover Installation • Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Be sure that the dowel pins [B] are in position. •...
  • Page 306: Release Shaft Removal

    6-8 CLUTCH Clutch Cover Release Shaft Removal CAUTION 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 307: Clutch Cover Assembly

    CLUTCH 6-9 Clutch Cover • Remove: Bolts [A] Plate [B] Pads Needle Bearings [C] Oil Level Gauge [D] Clutch Cover Assembly • Replace the needle bearings and oil seal with new ones. NOTE ○ Install the needle bearings so that the manufacture’s mark face out.
  • Page 308 6-10 CLUTCH Clutch Cover • Install: Pads [A] Plate [B] • Apply a non-permanent locking agent to the threads of the clutch cover plate bolts [C], and tighten them. Torque - Clutch Cover Plate Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
  • Page 309: Clutch Removal

    CLUTCH 6-11 Clutch Clutch Removal • Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs (with Clutch Spring Holders) Clutch Spring Plate [B] (with Shim, Bearing, Pusher [C], Spring and Washer) • Remove: Friction Plates (8) [A] Steel Plates (7) [B] Spring [C] Spring Seat [D]...
  • Page 310: Clutch Installation

    6-12 CLUTCH Clutch • Remove: Torque Limiter Springs [A] Sub Clutch Hub [B] Clutch Hub [C] Spacer [D] ○ Remove the sub clutch hub bolts [E] as necessary. • Using the two 4 mm (0.16 in.) screws [A], pull out the sleeve [B], needle bearing [C] and clutch housing [D].
  • Page 311 CLUTCH 6-13 Clutch • Install: Needle Bearing [A] Sleeve [B] ○ Apply engine oil to the sleeve and needle bearing. • Install the spacer [C] so that the stepped side [D] faces outward. If the sub clutch hub bolts were removed, install them as follows.
  • Page 312 6-14 CLUTCH Clutch ○ Fourth Torque Limiter Spring [A] Tang [B] • Replace the clutch hub nut [A] with a new one. • Hold the sub clutch hub [B] steady with the clutch holder [C], and tighten the clutch hub nut. Special Tool - Clutch Holder: 57001-1243 Torque - Clutch Hub Nut: 135 N·m (13.8 kgf·m, 99.6 ft·lb) •...
  • Page 313: Spring Plate Free Play Measurement

    CLUTCH 6-15 Clutch • Apply molybdenum disulfide grease to the pusher end [A]. • Install the washer [B], spring [C], bearing [D] and shim [E] to the pusher. • Install the pusher to the drive shaft [F] direction as shown in the figure.
  • Page 314: Spring Plate Free Play Adjustment

    6-16 CLUTCH Clutch • Engage the clutch hub with the sub clutch hub. • To measure the free play, set a dial gauge [A] against the raised center [B] of the clutch spring plate. • Move the clutch housing gear back and forth [C]. The dif- ference between the highest and lowest gauge readings is the amount of free play.
  • Page 315: Clutch Plate, Wear, Damage Inspection

    CLUTCH 6-17 Clutch Clutch Plate Assembly Length (Reference Information) • Assemble the following parts. Clutch Hub [A] Spring Seat [B] Spring [C] Sub Clutch Hub [D] Sub Clutch Hub Bolts [E] New Friction Plates [F] Steel Plates [G] Spring Plate [H] Clutch Springs [I] Clutch Spring Holders [J] Clutch Spring Bolts [K]...
  • Page 316: Clutch Spring Free Length Measurement

    6-18 CLUTCH Clutch Clutch Spring Free Length Measurement • Measure the free length of the clutch springs [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 41.6 mm (1.64 in.) Service Limit: 40.1 mm (1.58 in.) Clutch Housing Finger Inspection •...
  • Page 317 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 318: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 319: Engine Lubrication System

    ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Bleed Bolt 87 in·lb Engine Oil Drain Bolt Impeller Bolt 87 in·lb Oil Cooler Mounting Bolts Oil Cooler/Oil Filter Case Mounting Bolts Oil Filter G, R Oil Filter Guard Bolts 0.41 35 in·lb Oil Filter Holder Bolt...
  • Page 320: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 321 ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart...
  • Page 322: Specifications

    7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SE, SF or SG API SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 2.8 L (3.0 US qt) (when filter is not removed) 3.1 L (3.3 US qt) (when filter is removed) 3.6 L (3.8 US qt) (when engine is completely dry) Between upper and lower level lines (Wait 2 ∼...
  • Page 323: Special Tools And Sealant

    ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: Outside Circlip Pliers: 57001-164 57001-144 Oil Pressure Gauge Adapter, PT3/8: Kawasaki Bond (Silicone Sealant): 57001-1233 56019-120...
  • Page 324: Engine Oil And Oil Filter

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil Level Inspection • Check that the engine oil level is between the upper [A] and lower [B] levels in the gauge.
  • Page 325: Oil Pan

    ENGINE LUBRICATION SYSTEM 7-9 Oil Pan Oil Pan Removal • Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Oil Pan Bolts [A] Clamps [B] Oil Pan [C] Oil Pan Installation •...
  • Page 326: Oil Pressure Relief Valve

    7-10 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Screen [A] • Remove the 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 [A], and tighten it.
  • Page 327: Oil Pressure Relief Valve Inspection

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pressure Relief Valve Oil Pressure Relief Valve Inspection • Remove the oil pressure relief valve (see Oil Pressure Relief Valve Removal). • Check to see if the valve [A] slides smoothly when push- ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure.
  • Page 328: Oil Pump

    7-12 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Water Pump Cover Bolts [A] Water Pump Cover [B] Water Hose Clamp Screw [C] (Loosen) Water Hose [D] •...
  • Page 329: Oil Pump Installation

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump Oil Pump Installation • Install the outer rotor [A] into the crankcase. • Install the pin [B] and inner rotor [C] to the oil (water) pump shaft [D], and install the assy. ○ Turn the pump shaft so that the slot [E] in its shaft fits onto the projection [F] of the pump drive gear shaft.
  • Page 330: Oil Pump Drive Gear Removal

    7-14 ENGINE LUBRICATION SYSTEM Oil Pump • Align the line [A] of the water pump cover and the white mark [B] of the water hose [C]. • Install the water hose clamp [D] as shown in the figure. • Tighten: Torque - Water Hose Clamp Screws: 2.0 N·m (0.20 kgf·m, 18 in·lb) Oil Pump Drive Gear Removal...
  • Page 331: Oil Pump Drive Gear Shaft Installation

    ENGINE LUBRICATION SYSTEM 7-15 Oil Pump Oil Pump Drive Gear Shaft Installation • Apply molybdenum disulfide oil solution to the journal por- tions [A] on the oil pump drive gear shaft. • Install the oil pump drive gear shaft and washer [B] as shown in the figure.
  • Page 332: Oil Cooler

    7-16 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Starter Motor (see Starter Motor Removal in the Electri- cal System chapter) Water Hose Clamp Screws [A] (Loosen) Water Hoses [B]...
  • Page 333: Oil Cooler/oil Filter Case Installation

    ENGINE LUBRICATION SYSTEM 7-17 Oil Cooler • Remove the bolts [A]. • Remove: Bolts [A] Oil Cooler/Oil Filter Case [B] ○ Remove the oil filter holder bolt [C] as necessary. Oil Cooler/Oil Filter Case Installation If the crankcase was disassembled, pour the engine oil into the oil passage [A] until O-ring insert portion [B] of the upper crankcase.
  • Page 334 7-18 ENGINE LUBRICATION SYSTEM Oil Cooler • Replace the O-rings [A] with new ones. • Apply grease to the new O-rings. • Install the oil cooler/oil filter case. • Apply a non-permanent locking agent to the threads of the oil cooler/oil filter case mounting bolts, and tighten them. Torque - Oil Cooler/Oil Filter Case Mounting Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb) •...
  • Page 335: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-19 Oil Pressure Measurement Oil Pressure Measurement • Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Oil Passage Plug [A] • Attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT3/8: 57001 -1233 •...
  • Page 336: Oil Pressure Switch

    • Apply silicone sealant to the threads of the oil pressure switch, and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb) • Install the switch lead [A] as shown in the figure.
  • Page 337 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 338: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 339 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Adjusting Collar Locknuts Adjusting Collars 87 in·lb Left Front Engine Mounting Bolt Lower Engine Mounting Nut Middle Engine Mounting Nut Right Front Engine Mounting Bolt S: Follow the specified tightening sequence.
  • Page 340: Special Tool

    8-4 ENGINE REMOVAL/INSTALLATION Special Tool Engine Mount Nut Wrench: 57001-1450...
  • Page 341: Engine Removal/installation

    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal • Support the rear part of the swingarm with a stand. • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over.
  • Page 342 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove the clamp [A]. • Disconnect the sidestand switch lead connector [A]. • Remove the engine ground cable terminal bolt [A]. • Remove: Bolt [A] Heat Insulation Plate [B] ○ Clear the projections [C] from the frame [D]. •...
  • Page 343 ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Remove the left front engine mounting bolt [A]. • Remove: Right Front Engine Mounting Bolt [A] Middle Engine Mounting Nut [B] Lower Engine Mounting Nut • Using the nut wrench [A], loosen the locknuts [B]. Special Tool - Engine Mount Nut Wrench: 57001-1450 •...
  • Page 344: Engine Installation

    8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Installation • Install the adjusting collar [A] to crankcase backside until end of the threads. • Install the adjusting collar [A] to the frame until end of the threads. • Support the engine with a suitable stand. ○...
  • Page 345 ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation • Install the engine mounting bolts and nuts, following the specified installing sequence. ○ First, tighten the following bolts and nuts temporarily. Lower Engine Mounting Bolt [A] and Nut [B] Middle Engine Mounting Bolt [C] and Nut [D] Left Front Engine Mounting Bolt [E] Right Front Engine Mounting Bolt [F] ○...
  • Page 346 8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation ○ Third, tighten the adjusting collar [A] with the lower engine mounting bolt [B] counterclockwise until the adjusting col- lar touches [C] the frame [D]. Torque - Adjusting Collars: 9.8 N·m (1.0 kgf·m, 87 in·lb) ○...
  • Page 347 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........Starter Idle Gear and Starter Clutch .. 9-32 Specifications ........Starter Idle Gear Removal ... 9-32 Special Tools and Sealants ....Starter Idle Gear Installation ..9-32 Crankcase ......... 9-11 Starter Clutch Removal....9-34 Crankcase Splitting ......
  • Page 348: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 349 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bearing Holder Screws 0.50 43 in·lb Breather Hose Fitting Breather Plate Bolts 87 in·lb ← ← see the text Connecting Rod Big End Nuts Crankcase Bolt (M8, L = 90 mm) Crankcase Bolts (M8, L = 95 mm) MO, S Crankcase Bolts (M8, L = 75 mm)
  • Page 350 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 351 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Gear Position Switch Screws 0.30 26 in·lb Gear Positioning Lever Bolt 106 in·lb Idle Gear Cover Bolts 87 in·lb Shift Drum Cam Holder Bolt 106 in·lb Shift Lever Bolt 0.70 61 in·lb Shift Pedal Mounting Bolt Shift Shaft Return Spring Pin...
  • Page 352: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankcase, Crankshaft, Connecting Rods Connecting Rod Bend – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.2/100 mm (0.008/3.94 in.) 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.) Connecting Rod Big End Side 0.58 mm Clearance...
  • Page 353 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankshaft Main Bearing Insert Thickness: 1.491 ∼ 1.495 mm (0.0587 ∼ 0.0589 in.) Brown, Yellow – – – 1.495 ∼ 1.499 mm (0.0589 ∼ 0.0590 in.) – – – Black, Green 1.499 ∼ 1.503 mm (0.0590 ∼ 0.0592 in.) Blue, Purple –...
  • Page 354 9-8 CRANKSHAFT/TRANSMISSION Specifications Connecting Rod Big End Bearing Insert Selection Con-rod Big End Bearing Insert Crankpin Diameter Inside Diameter Marking Size Color Part Number Marking ○ None Brown 92139-0167 None None Black 92139-0166 ○ ○ ○ None Blue 92139-0165 Crankshaft Main Bearing Insert Selection Crankcase Main Crankshaft Main Bearing Insert*...
  • Page 355 Outside Circlip Pliers: Grip: 57001-144 57001-1591 Piston Pin Puller Assembly: Rotor Holder: 57001-910 57001-1666 Piston Ring Compressor Grip: Stopper: 57001-1095 57001-1679 Piston Ring Compressor Belt, 67 ∼ 79: Rotor Holder Attachment: 57001-1097 57001-1689 Bearing Driver Set: Kawasaki Bond (Silicone Sealant): 57001-1129 92104-0004...
  • Page 356: Special Tools And Sealants

    9-10 CRANKSHAFT/TRANSMISSION Special Tools and Sealants Kawasaki Bond (Liquid Gasket - Black): 92104-1064...
  • Page 357: Crankcase

    CRANKSHAFT/TRANSMISSION 9-11 Crankcase Crankcase Splitting • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Crankshaft Sensor (see Crankshaft Sensor Removal in the Electrical System chapter) Starter Clutch (see Starter Clutch Removal) Cylinder Head (see Cylinder Head Removal in the En-...
  • Page 358: Crankcase Assembly

    9-12 CRANKSHAFT/TRANSMISSION Crankcase Crankcase Assembly CAUTION The upper and lower crankcase halves are ma- chined at the factory in the assembled state, so the crankcase halves must be replaced as a set. • With a high-flash point solvent, clean off the mating sur- faces of the crankcase halves and wipe dry.
  • Page 359 CRANKSHAFT/TRANSMISSION 9-13 Crankcase • Press and insert the fitting [A] in the upper crankcase [B] until it is bottomed. Special Tool - Bearing Driver Set: 57001-1129 • Apply a non-permanent locking agent to the threads of the breather hose fitting [C] and tighten it. Torque - Breather Hose Fitting: 15 N·m (1.5 kgf·m, 11 ft·lb) •...
  • Page 360: Crankshaft And Connecting Rods

    9-14 CRANKSHAFT/TRANSMISSION Crankcase • Press and insert the new needle bearing [A] for the shift shaft so that its marked side faces outside [B] and its sur- face [C] is flush with the end of the hole. • Install the new oil seal [D] so that its surface [E] is flush with the end of the hole.
  • Page 361 CRANKSHAFT/TRANSMISSION 9-15 Crankcase • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond (Liquid Gasket - Black): 92104 -1064 NOTE ○ Especially, apply a sealant so that it shall be filled up on the groove [B].
  • Page 362 9-16 CRANKSHAFT/TRANSMISSION Crankcase • The M8 bolts [A] has a copper plated washer [B], replace it with a new one. • Apply molybdenum disulfide oil solution to both sides [C] of the washers and threads [D] of M8 bolts. • Tighten the lower crankcase bolts using the following steps.
  • Page 363: Crankshaft Removal

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove: Camshaft Chain (see Camshaft Chain Removal in the Engine Top End chapter) Connecting Rod Big End Caps (see Connecting Rod Re- moval) Crankshaft [A] •...
  • Page 364: Connecting Rod Removal

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods NOTE ○ The thrust washer [A] has oil grooves [B] on the one side. ○ The thrust washers are identical. • Apply molybdenum disulfide grease [C] to the oil groove side [D] of the thrust washers. •...
  • Page 365: Connecting Rod Installation

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods • Remove: Camshaft Chain (see Camshaft Chain Removal in the Engine Top End chapter) Crankshaft [A] Pistons (see Piston Removal) CAUTION Discard the connecting rod bolts and nuts. To pre- vent damage to the crankpin surfaces, do not al- low the connecting rod bolts to bump against the crankpins.
  • Page 366 9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install each connecting rod on its original crankpin. ○ The connecting rod big end is bolted using the “plastic region fastening method”. ○ This method precisely achieves the needed clamping force without exceeding it unnecessarily, allowing the use of thinner, lighter bolts further decreasing connecting rod weight.
  • Page 367 CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods • Install new bolts and nuts in reused connecting rod. If the connecting rod assy was replaced, use the bolts and nuts attached to the new connecting rod assy. • Apply a small amount of molybdenum disulfide oil solution to the following portions.
  • Page 368: Crankshaft/connecting Rod Cleaning

    9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install new bolts and nuts in reused connecting rod. If the connecting rod assy was replaced, use the bolts and nuts attached to the new connecting rod assy. • Apply a small amount of molybdenum disulfide oil solution to the following portions.
  • Page 369: Connecting Rod Twist Inspection

    CRANKSHAFT/TRANSMISSION 9-23 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 370 9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods If the clearance is within the standard, no bearing replace- ment is required. If the clearance is between 0.082 mm (0.0032 in.) and the service limit (0.11 mm, 0.0043 in.), replace the bear- ing inserts [A] with inserts painted blue [B]. Check in- sert/crankpin clearance with the plastigage.
  • Page 371: Crankshaft Side Clearance Inspection

    CRANKSHAFT/TRANSMISSION 9-25 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] Con-rod Big Bearing Insert Crankpin End Inside Diameter Diameter Size Color Part Number Marking Marking ○...
  • Page 372: Crankshaft Main Bearing Insert/journal Wear Inspection

    9-26 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Main Bearing Insert/Journal Wear Inspection • Split the crankcase (see Crankcase Splitting). • Cut strips of plastigage to journal width. Place a strip on each journal parallel to the crankshaft installed in the correct position.
  • Page 373 CRANKSHAFT/TRANSMISSION 9-27 Crankshaft and Connecting Rods • Measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. ○ [A]: Crankcase Main Bearing Inside Diameter Marks, “ ” or no mark. • Tighten the crankcase bolts to the specified torque (see Crankcase Assembly).
  • Page 374: Pistons

    9-28 CRANKSHAFT/TRANSMISSION Pistons Piston Removal • Split the crankcase (see Crankcase Splitting). • Remove the connecting rod big end nuts [A] and caps [B]. NOTE ○ Mark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions.
  • Page 375: Piston Installation

    CRANKSHAFT/TRANSMISSION 9-29 Pistons Piston Installation • Apply molybdenum disulfide oil solution to the oil ring ex- pander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] not butt together. • Apply molybdenum disulfide oil solution to the oil ring steel rails, and install the oil ring steel rails, one above the ex- pander and one below it.
  • Page 376: Cylinder (upper Crankcase) Wear Inspection

    9-30 CRANKSHAFT/TRANSMISSION Pistons • Apply molybdenum disulfide oil solution to the cylinder bore and piston skirt. • Install the piston with its marking hollow [A] facing exhaust side. • Using the piston ring compressor assembly [B] to install the piston from the cylinder head side. Special Tools - Piston Ring Compressor Grip: 57001-1095 67 ∼...
  • Page 377: Piston Ring Groove Width Inspection

    CRANKSHAFT/TRANSMISSION 9-31 Pistons Piston Ring Groove Width Inspection • Measure the piston ring groove width. ○ Use a vernier caliper at several points around the piston. Piston Ring Groove Width Standard: 0.82 ∼ 0.84 mm (0.0323 ∼ 0.0331 in.) Top [A] Second [B] 0.82 ∼...
  • Page 378: Starter Idle Gear And Starter Clutch

    9-32 CRANKSHAFT/TRANSMISSION Starter Idle Gear and Starter Clutch Starter Idle Gear Removal • Remove: Right Fairing Cover (see Fairing Cover Removal in the Frame chapter) Bolts [A] Idle Gear Cover [B] • Pull out the idle gear (starter motor side) [A] with the shaft [B].
  • Page 379 • Apply silicone sealant to the following portion. Crankshaft Sensor Lead Grommet [B] Crankcase Halves Mating Surfaces [C] Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install the dowel pins [D] and new gasket [E]. • Apply grease to the O-ring of the starter motor.
  • Page 380: Starter Clutch Removal

    9-34 CRANKSHAFT/TRANSMISSION Starter Idle Gear and Starter Clutch Starter Clutch Removal • Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Starter Clutch Cover (see Starter Idle Gear Removal) Idle Gear (Starter Clutch Side) (see Starter Idle Gear Removal) •...
  • Page 381: Starter Clutch Assembly

    CRANKSHAFT/TRANSMISSION 9-35 Starter Idle Gear and Starter Clutch Starter Clutch Assembly • Install the one-way clutch [A] so that its circlip side [B] faces in. • Install the new snap ring. • Push [A] the starter clutch gear [B] in and turn it counter- clockwise [C] and install it.
  • Page 382 9-36 CRANKSHAFT/TRANSMISSION Starter Idle Gear and Starter Clutch ○ Examine the starter clutch gear [A] as well. Replace the clutch gear if it is worn or damaged.
  • Page 383: Transmission

    CRANKSHAFT/TRANSMISSION 9-37 Transmission Transmission Assy Removal • Remove: Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter) Gear Position Switch (see Gear Position Switch Re- moval in the Electrical System chapter) Collar [A] O-ring [B] • Remove: Clutch (see Clutch Removal in the Clutch chapter) Shift Shaft Assembly (see External Shift Mechanism Re- moval) Transmission Case Bolts [A]...
  • Page 384 9-38 CRANKSHAFT/TRANSMISSION Transmission • Press and insert the ball bearing [A] in the transmission case [B] so that the stepped side faces outside until it is bottomed. • Install the bearing holder [C] as shown in the figure. • Apply a non-permanent locking agent to the threads of the bearing holder screws [D].
  • Page 385: Transmission Assy Installation

    CRANKSHAFT/TRANSMISSION 9-39 Transmission • Install the drive shaft [A] and output shaft [B] as a set in the transmission case [C]. • Install the shift forks as shown in the figure. ○ The shift fork [D] for drive shaft gears has the short ears. ○...
  • Page 386: Transmission Shaft Removal

    9-40 CRANKSHAFT/TRANSMISSION Transmission • Install the gear positioning lever (see External Shift Mech- anism Installation). • Set the gear positioning lever to the neutral position [A]. • Check that the drive and output shaft turn freely. • Apply grease to the O-ring [A] and install it to its position on the output shaft [B].
  • Page 387 CRANKSHAFT/TRANSMISSION 9-41 Transmission • Replace any circlips removed with new ones. • Install the circlip [A] on the drive shaft [B] so that the punch mark [C] faces the washer [D] and position the opening [E] as shown in the figure. •...
  • Page 388 9-42 CRANKSHAFT/TRANSMISSION 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] CAUTION Do not apply grease to the balls to hold them in place.
  • Page 389 CRANKSHAFT/TRANSMISSION 9-43 Transmission 1. 1st Gear 15. Circlip 2. 2nd Gear 16. Washer, 40 mm (1.57 in.) 3. 3rd Gear 17. Bushing 4. 4th Gear 18. Toothed Washer, 40 mm (1.57 in.) 5. 5th Gear 19. Circlip 6. 6th (Top) Gear 20.
  • Page 390: Shift Drum And Fork Removal

    9-44 CRANKSHAFT/TRANSMISSION Transmission Shift Drum and Fork Removal • Refer to the Transmission Assy Disassembly. Shift Drum and Fork Installation • Refer to the Transmission Assy Assembly. Shift Drum Disassembly • Remove the shift drum (see Transmission Assy Disas- sembly). •...
  • Page 391: Shift Fork Guide Pin/drum Groove Wear Inspection

    CRANKSHAFT/TRANSMISSION 9-45 Transmission Shift Fork Guide Pin/Drum Groove Wear Inspection • Measure the diameter of each shift fork guide pin [A], and measure the width [B] of each shift drum groove. If the guide pin on any shift fork is less than the service limit, the fork must be replaced.
  • Page 392: External Shift Mechanism

    9-46 CRANKSHAFT/TRANSMISSION External Shift Mechanism Shift Pedal Removal • Remove: Shift Lever Bolt [A] Shift Lever [B] If the tie-rod is removed from the shift pedal and shift lever, note the following. ○ The following portions have left-hand threads. Shift Lever Side of Tie-Rod (The shift lever side of the tie-rod has the grooves [C].) Locknut [D] of Shift Lever Side Ball Joint [E] of Shift Lever...
  • Page 393: External Shift Mechanism Removal

    CRANKSHAFT/TRANSMISSION 9-47 External Shift Mechanism External Shift Mechanism Removal • Remove: Shift Lever (see Shift Pedal Removal) Clutch (see Clutch Removal in the Clutch chapter) Circlip [A] Washer [B] Special Tool - Outside Circlip Pliers: 57001-144 • Remove the shift shaft assembly [A] while pulling out the shift mechanism arm.
  • Page 394: External Shift Mechanism Inspection

    9-48 CRANKSHAFT/TRANSMISSION External Shift Mechanism External Shift Mechanism Inspection • Examine the shift shaft [A] for any damage. If the shaft is bent, replace it. If the serration [B] are damaged, replace the shaft. If the springs [C] are damaged in any way, replace them. If the shift mechanism arm [D] is damaged in any way, replace the shaft.
  • Page 395 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-7 Rear Wheel Removal......................10-8 Rear Wheel Installation..................... 10-8 Wheel Inspection ......................10-10 Axle Inspection........................
  • Page 396: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 397 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolts Front Axle Nut 13.0 93.7 Rear Axle Nut 13.0 93.7 AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 398: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 1.0 mm (0.04 in.) Axle Runout/100 mm (3.94 in.) TIR 0.03 mm (0.0012 in.) or less TIR 0.2 mm (0.008 in.) Wheel Balance 10 g (0.35 oz.) or less...
  • Page 399: Special Tools

    WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: Bearing Remover Shaft, 13: 57001-1129 57001-1377 Jack: Jack Attachment: 57001-1238 57001-1608 Bearing Remover Head, 25 × 28: 57001-1346...
  • Page 400: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Front Caliper Mounting Bolts [A] (Both Sides) Front Caliper [B] (Both Sides) • Loosen: Front Axle Clamp Bolts [A] (Right Side) Front Axle [B] • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter).
  • Page 401: Front Wheel Installation

    WHEELS/TIRES 10-7 Wheels (Rims) Front Wheel Installation NOTE ○ The direction of the wheel rotation [A] is shown by an arrow [B] on the wheel spoke. • Check the wheel rotation mark on the front wheel and install it. • Apply high-temperature grease to the grease seal lips.
  • Page 402: Rear Wheel Removal

    10-8 WHEELS/TIRES Wheels (Rims) Rear Wheel Removal • Raise the rear wheel off the ground with the stand [A]. • Remove: Rear Caliper Mounting Bolts [A] Rear Caliper [B] • Remove: Cotter Pin [A] Axle Nut [B] Washer [C] Axle [D] (from Right Side) •...
  • Page 403 WHEELS/TIRES 10-9 Wheels (Rims) • Engage the drive chain with the rear sprocket. • Install the caliper bracket [A] onto the stopper [B] of the swingarm. • Insert the axle from the right side of the wheel. • Install the washer and axle nut. •...
  • Page 404: Wheel Inspection

    10-10 WHEELS/TIRES Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 • Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings (see Hub Bearing Removal/Installation).
  • Page 405: 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 406 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 407: 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 408 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 409: 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 410: 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]. CAUTION Do not lay the wheel on the ground with the disc facing down.
  • Page 411: 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 413 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 414: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 415 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Chain Guide Bolts 87 in·lb Engine Sprocket Cover Bolts 87 in·lb Engine Sprocket Cover Plate Mounting Bolts 87 in·lb Engine Sprocket Nut 13.0 92.2 Rear Axle Nut 13.0 93.7 Rear Sprocket Nuts Speed Sensor Bolt 0.70...
  • Page 416: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain 30 ∼ 40 mm (1.2 ∼ 1.6 in.) Drive Chain Slack – – – Drive Chain Wear (20-link Length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) Standard Chain: Make ENUMA...
  • Page 417: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...
  • Page 418: 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 419 FINAL DRIVE 11-7 Drive Chain Body [A] Handlebar [B] Cutting and Riveting Pin [C] For Cutting [D] For Riveting [E] Plate Holder (A) [F] Plate Holder (B) [G] Gauge [H] • Grind [A] the pin head to make it flat. •...
  • Page 420 11-8 FINAL DRIVE Drive Chain • Set the plate holder (A) [A] and plate holder (B) [B] on the body. • Fit the plate holder (A) to the link plate. • Turn the pin holder by hand until the plate holder (B) touches the other link plate.
  • Page 421 FINAL DRIVE 11-9 Drive Chain • Turn the wrench clockwise until the tip of riveting pin hits of the link pin. • Rivet it. • Same work for the other link pin. • After staking, check the staked area of the link pin for cracks.
  • Page 422: Sprocket, Coupling

    11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove: Speed Sensor Bolt [A] Speed Sensor [B] Engine Sprocket Cover Bolts [C] Engine Sprocket Cover [D] • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer. NOTE ○...
  • Page 423: Rear Sprocket Removal

    FINAL DRIVE 11-11 Sprocket, Coupling If the chain guide and engine sprocket cover plate re- moved, install the as follows. • Install: Pad [A] Engine Sprocket Cover Plate [B] ○ Insert the groove of the pad into the rib of the engine sprocket cover.
  • Page 424: Rear Sprocket Installation

    11-12 FINAL DRIVE Sprocket, Coupling Rear Sprocket Installation • Install the sprocket facing the tooth number marking [A] outward. • Tighten: Torque - Rear Sprocket Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb) • Install the rear wheel (see Rear Wheel Installation in the Wheels/Tires chapter).
  • Page 425: Coupling Bearing Installation

    FINAL DRIVE 11-13 Sprocket, Coupling Coupling Bearing Installation • Replace the bearing with a new one. • Press in the bearing [A] until it is bottomed. Special Tool - Bearing Driver Set [B]: 57001-1129 • Pack the bearing with high-temperature grease. •...
  • Page 426: Sprocket Wear Inspection

    11-14 FINAL DRIVE Sprocket, Coupling Sprocket Wear Inspection • Visually inspect the engine and rear sprocket teeth for wear and damage. If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see Drive Chain Wear Inspection in the Periodic Maintenance chapter).
  • Page 427 BRAKES 12-1 Brakes Table of Contents Exploded View ........................12-2 Specifications ........................12-6 Special Tools .......................... 12-7 Brake Lever, Brake Pedal....................... 12-8 Brake Lever Position Adjustment..................12-8 Brake Pedal Position Inspection ..................12-8 Brake Pedal Position Adjustment ..................12-8 Brake Pedal Removal ....................... 12-8 Brake Pedal Installation ....................
  • Page 428: Exploded View

    12-2 BRAKES Exploded View...
  • Page 429 BRAKES 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 8.9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Brake Disc Mounting Bolts Front Brake Light Switch Screw 0.12 11 in·lb Front Brake Pad Pins...
  • Page 430 12-4 BRAKES Exploded View...
  • Page 431 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valve 0.80 69 in·lb Brake Hose Banjo Bolts Brake Pedal Mounting Bolt Rear Brake Disc Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut B: Apply brake fluid.
  • Page 432: Specifications

    12-6 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 6-way adjustable (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 75 mm (2.95 in.) below top of –...
  • Page 433 BRAKES 12-7 Special Tools Inside Circlip Pliers: Jack Attachment: 57001-143 57001-1608 Jack: 57001-1238...
  • Page 434: Brake Lever Position Adjustment

    12-8 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 6 positions so that the brake lever position can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder.
  • Page 435: Brake Pedal Installation

    BRAKES 12-9 Brake Lever, Brake Pedal • Remove: Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] • Remove the brake pedal mounting bolt [E] and take out the brake pedal. Brake Pedal Installation •...
  • Page 436 12-10 BRAKES Brake Lever, Brake Pedal • Install the front footpeg bracket. • Tighten: Torque - Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) • Install the rear master cylinder [A] and foot guard. NOTE ○ Depress the brake pedal [B] and then align the holes of the master cylinder.
  • Page 437: Calipers

    BRAKES 12-11 Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. CAUTION Do not loosen the caliper assembly bolts. Take out only the caliper mounting bolts for caliper removal.
  • Page 438: Caliper Installation

    12-12 BRAKES Calipers Caliper Installation • Install the caliper and brake hose lower end. ○ Replace the washers on each side of hose fitting with new ones. • Tighten: Torque - Caliper Mounting Bolts: Front: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear: 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
  • Page 439: Caliper Fluid Seal Damage Inspection

    BRAKES 12-13 Calipers Caliper Fluid Seal Damage Inspection The fluid seal (piston seal) [A] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- perature of the discs or the brake fluid to increase.
  • Page 440: Caliper Piston And Cylinder Damage Inspection

    12-14 BRAKES Calipers Caliper Piston and Cylinder Damage Inspection • Visually inspect the pistons [A] and cylinder surfaces [B]. Replace the caliper if the cylinder and piston are badly scores or rusty. Rear Caliper Holder Shaft Wear Inspection The caliper body must slide smoothly on the caliper holder shafts [A].
  • Page 441: Brake Pads

    BRAKES 12-15 Brake Pads Front Brake Pad Removal • Loosen the pad pins [A]. • Remove: Pad Pins [A] Pad Springs [B] Brake Pads [C] Front Brake Pad Installation • Push the caliper pistons in by hand as far as they will go. •...
  • Page 442: Rear Brake Pad Removal

    12-16 BRAKES Brake Pads Rear Brake Pad Removal • Remove the rear caliper with the hose installed (see Rear Caliper Removal). • Remove: Clip [A] Pad Pin [B] Brake Pads [C] Rear Brake Pad Installation • Push the caliper piston in by hand as far as it will go. •...
  • Page 443: Master Cylinder

    BRAKES 12-17 Master Cylinder Front Master Cylinder Removal • Remove the reservoir mounting bolt and nut [A]. • Unscrew the banjo bolt [A] and remove the brake hose from the master cylinder (see Brake Hose and Pipe Re- placement in the Periodic Maintenance chapter). •...
  • Page 444: Rear Master Cylinder Removal

    12-18 BRAKES Master Cylinder • Install the master cylinder clamp [A] so that the arrow mark [B] faces upward. • Set the front master cylinder to match its mating surface [A] to the punch mark [B] of the handlebar. • Tighten the upper clamp bolt first, and then the lower clamp bolt.
  • Page 445: Rear Master Cylinder Installation

    BRAKES 12-19 Master Cylinder • Remove: Cotter Pin [A] Joint Pin [B] • Slide the reservoir hose lower end clamp [A]. • Pull off the reservoir hose lower end [B], and drain the brake fluid into a container. Rear Master Cylinder Installation •...
  • Page 446: Rear Master Cylinder Disassembly

    12-20 BRAKES Master Cylinder Rear Master Cylinder Disassembly • Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter. Master Cylinder Assembly • Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter. Master Cylinder Inspection (Visual Inspection) •...
  • Page 447: Brake Disc

    BRAKES 12-21 Brake Disc Brake Disc Removal • Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Unscrew the mounting bolts [A], and take off the disc [B]. Brake Disc Installation • Replace the gaskets with new ones. •...
  • Page 448: Brake Disc Warp Inspection

    12-22 BRAKES Brake Disc Brake Disc Warp Inspection • Raise the wheel off the ground with jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 ○ For front disc inspection, turn the handlebar fully to one side. • Set up a dial gauge against the disc [A] as shown in the figure and measure disc runout, while turning [B] the wheel by hand.
  • Page 449: Brake Fluid

    BRAKES 12-23 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 450 12-24 BRAKES Brake Fluid • Release the clamps [A] and projection [B] of the cover from the rear brake reservoir. • Remove the rear brake reservoir cap [A]. • Remove: Diaphragm Plate Diaphragm • Fill the reservoir with fresh brake fluid to the upper level line in the reservoir.
  • Page 451 BRAKES 12-25 Brake Fluid • Bleed the brake line and the master cylinder. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].
  • Page 452 12-26 BRAKES Brake Fluid • Follow the procedure below to install the front/rear brake fluid reservoir cap correctly. ○ First, tighten the brake fluid reservoir cap [B] clockwise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].
  • Page 453 BRAKES 12-27 Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.
  • Page 454: Brake Hose

    12-28 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 and Pipe Damage and Instal- lation Condition Inspection in the Periodic Maintenance chapter.
  • Page 455 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-9 Rebound Damping Force Adjustment................13-9 Compression Damping Force Adjustment ................ 13-9 Spring Preload Adjustment ....................13-10 Front Fork Removal (Each Fork Leg) ................13-10 Front Fork Installation (Each Fork Leg) ................
  • Page 456: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 457 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolts Front Fork Top Plugs Lower Front Fork Clamp Bolts Piston Rod Guide Case Upper Front Fork Clamp Bolts AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.
  • Page 458 13-4 SUSPENSION Exploded View...
  • Page 459 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Lower Rear Shock Absorber Nut Rear Shock Absorber Bracket Nut Swingarm Pivot Adjusting Collar Locknut 10.0 72.3 Swingarm Pivot Shaft Swingarm Pivot Shaft Nut 11.0 79.7 Tie-Rod Nuts Uni-Trak Rocker Arm Bolt Upper Rear Shock Absorber Nut G: Apply grease.
  • Page 460: Specifications

    13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Diameter 41 mm (1.6 in.) Air Pressure Atmospheric pressure (Non-adjustable) Rebound Damper Setting 4 turns out from the fully clockwise position (Usable Range: 0 ←→ 5 1/2 turns out) Compression Damper Setting 5 1/2 turns out from the fully clockwise position (Usable Range: 0 ←→...
  • Page 461: Special Tools

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Fork Oil Level Gauge: 57001-143 57001-1290 Oil Seal & Bearing Remover: Bearing Remover Head, 20 × 22: 57001-1058 57001-1293 Bearing Driver Set: Bearing Remover Shaft, 13: 57001-1129 57001-1377 Jack: Hook Wrench T=3.2 R37: 57001-1238 57001-1539 Fork Oil Seal Driver, 41:...
  • Page 462 13-8 SUSPENSION Special Tools Jack Attachment: Hook Wrench: 57001-1608 57001-1641 Needle Bearing Driver, 17/ 18: Needle Bearing Driver, 20 & Spacer, 28: 57001-1609 57001-1678 Needle Bearing Driver, 28: Top Plug Wrench (45 mm): 57001-1610 57001-1741 Spacer, Box Wrench (27 mm): 57001-1636 57001-1742 Spacer,...
  • Page 463: Front Fork

    SUSPENSION 13-9 Front Fork Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebound damping adjuster [A] until you feel a click. ○ The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 4 turns out from the fully clockwise position.
  • Page 464: Spring Preload Adjustment

    13-10 SUSPENSION Front Fork Spring Preload Adjustment • To adjust the spring preload, turn the spring preload ad- juster [A] until you feel a click. ○ The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 4 turns in from the fully counterclockwise position.
  • Page 465: Front Fork Installation (each Fork Leg)

    SUSPENSION 13-11 Front Fork Front Fork Installation (Each Fork Leg) • Install the fork so that the top end [A] of the outer tube as shown in the figure. 5 mm (0.20 in.) [B] Steering Stem Head [C] • Tighten: Torque - Lower Front Fork Clamp Bolts: 23 N·m (2.3 kgf·m, 17 ft·lb) Front Fork Top Plugs: 35 N·m (3.6 kgf·m, 26 ft·lb)
  • Page 466 13-12 SUSPENSION Front Fork • Using the wrench [A], unscrew the piston rod guide case out of the inner tube. Special Tool - Box Wrench (27 mm): 57001-1742 • Remove: Piston Rod Assy [A] Collar [B] Fork Spring [C] Collar [D] •...
  • Page 467 SUSPENSION 13-13 Front Fork • Insert the piston rod assy into the inner tube. NOTE ○ Lifting the outer tube, and insert the piston rod assy. CAUTION When inserting, be careful not to damage the piston ring [A]. • Using the wrench [A], tighten the piston rod guide case to the inner tube.
  • Page 468: Front Fork Disassembly

    13-14 SUSPENSION Front Fork • Measure the oil level as follows. ○ Hold the inner tube vertically in a vise. ○ Wait until the oil level settles. ○ With the fork fully compressed, insert a tape measure or rod into the piston rod guide case [A], and measure the distance [B] from the top [C] of the outer tube [D] to the oil.
  • Page 469: Front Fork Assembly

    SUSPENSION 13-15 Front Fork • Remove the following parts from the inner tube. Slide Bushing [A] Guide Bushing [B] Washer [C] Oil Seal [D] Retaining Ring [E] Dust Seal [F] Front Fork Assembly • Replace the following parts with new ones. Slide Bushing Guide Bushing Oil Seal...
  • Page 470: Inner Tube Inspection

    13-16 SUSPENSION Front Fork Inner Tube Inspection • Visually inspect the inner tube [A], and repair any dam- age. • Nick or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage.
  • Page 471: Rear Shock Absorber

    SUSPENSION 13-17 Rear Shock Absorber Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebound damping adjuster [A] to the desired position, until you feel a click. ○ The standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 15th click from the first click of the fully clockwise position.
  • Page 472: Spring Preload Adjustment

    13-18 SUSPENSION Rear Shock Absorber • To adjust the low speed compression damping force, turn the inside damping adjuster with a flat-head screwdriver to the desired position. ○ The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 3 turns out from the fully clockwise position.
  • Page 473: Rear Shock Absorber Removal

    SUSPENSION 13-19 Rear Shock Absorber • Remove: Bolts [A] Quick Rivet [B] Chain Cover [C] ○ Push the central pin, and then remove the quick rivet. • To adjust the spring preload, turn in the adjusting nut to the desired position and tighten the locknut by using hook wrenches [A] with the rear shock absorber attached the frame.
  • Page 474: Rear Shock Absorber Installation

    13-20 SUSPENSION Rear Shock Absorber • Remove: Lower Rear Shock Absorber Nut and Bolt [A] Upper Tie-Rod Nut and Bolt [B] Upper Rear Shock Absorber Nut and Bolt [C] • Remove the rear shock absorber [D] downward. Rear Shock Absorber Installation •...
  • Page 475: Swingarm

    SUSPENSION 13-21 Swingarm Swingarm Removal • Remove: Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Chain Cover (see Drive Chain Removal in the Final Drive chapter) Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter) Mud Guard (see Mud Guard Removal in the Frame chapter) Rear Shock Absorber (see Rear Shock Absorber Re- moval)
  • Page 476: Swingarm Bearing Removal

    13-22 SUSPENSION Swingarm • Apply plenty of grease to the lip of the oil seals [A]. • Be sure to install the oil seals and sleeve [B] to the swingarm. • Fit the collar [C] on the oil seal of the left side. •...
  • Page 477: Swingarm Bearing Installation

    SUSPENSION 13-23 Swingarm • Remove the ball bearing and needle bearings. Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058 Swingarm Bearing Installation • Replace the ball and needle bearings [A] with new ones. • Install the ball and needle bearings so that the manufac- turer’s marks face out.
  • Page 478: Swingarm Bearing, Sleeve Inspection

    13-24 SUSPENSION Swingarm Swingarm Bearing, Sleeve Inspection CAUTION 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 479: Tie-rod, Rocker Arm

    SUSPENSION 13-25 Tie-Rod, Rocker Arm Tie-Rod Removal • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Premuffler Chamber (see Premuffler Chamber Removal in the Engine Top End chapter) • Squeeze the brake lever slowly and hold it with a band [A].
  • Page 480: Rocker Arm Installation

    13-26 SUSPENSION Tie-Rod, Rocker Arm • Remove: Lower Rear Shock Absorber Nut and Bolt [A] Lower Tie-Rod Nut and Bolt [B] Rocker Arm Nut and Bolt [C] Rocker Arm [D] Rocker Arm Installation • Apply grease to the inside of the oil seals [A]. •...
  • Page 481: Tie-rod And Rocker Arm Bearing Installation

    SUSPENSION 13-27 Tie-Rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Installation • Replace the needle bearings and oil seals with new ones. • Install the needle bearings and oil seals position as shown in the figure. ○ Screw the needle bearing driver [A] into the driver holder [B].
  • Page 482: Tie-rod/rocker Arm Bearing, Sleeve Inspection

    13-28 SUSPENSION Tie-Rod, Rocker Arm Needle Bearings [A] Oil Seals [B] Front [C] Right Side [D] Left Side [E] Rear Shock Absorber [F] Tie-Rods [G] Rocker Arm [H] 7.5 mm (0.30 in.) [I] 5.0 mm (0.20 in.) [J] 5.5 mm (0.22 in.) [K] 5.5 mm (0.22 in.) [L] Tie-Rod/Rocker Arm Bearing, Sleeve Inspection CAUTION...
  • Page 483 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Specifications ......................... 14-4 Special Tools .......................... 14-5 Steering ..........................14-6 Steering Inspection ......................14-6 Steering Adjustment......................14-6 Steering Damper ........................14-7 Damping Force Adjustment ....................14-7 Steering Damper Removal....................14-7 Steering Damper Installation..................... 14-7 Steering Damper Oil Leak Inspection ................
  • Page 484: Exploded View

    14-2 STEERING Exploded View...
  • Page 485 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Handlebar Clamp Bolts Handlebar Positioning Bolts 87 in·lb Left Switch Housing Screws 0.36 31 in·lb Lower Front Fork Clamp Bolts Right Switch Housing Screws 0.36 31 in·lb Steering Damper Mounting Bolts 97 in·lb Steering Stem Head Nut Steering Stem Nut...
  • Page 486: Specifications

    14-4 STEERING Specifications Item Standard Steering Damper Damper Setting 18th click from the first click of the fully clockwise position (Usable Range: 0 ←→ 18 Clicks)
  • Page 487: Special Tools

    STEERING 14-5 Special Tools Bearing Puller: Steering Stem Bearing Driver, 42.5: 57001-135 57001-1344 Head Pipe Outer Race Press Shaft: Steering Stem Bearing Driver Adapter, 41.5: 57001-1075 57001-1345 Steering Stem Nut Wrench: Head Pipe Outer Race Driver, 55: 57001-1100 57001-1446 Bearing Driver Set: 57001-1129...
  • Page 488: Steering Inspection

    14-6 STEERING Steering Steering Inspection • Refer to the Steering Play Inspection in the Periodic Main- tenance chapter. Steering Adjustment • Refer to the Steering Play Adjustment in the Periodic Maintenance chapter.
  • Page 489: Steering Damper

    STEERING 14-7 Steering Damper Damping Force Adjustment • To adjust the damping force, turn the damping adjuster [A] until you feel a click. ○ The standard adjuster setting is the 18th click from the 1st of the fully clockwise position. If the damping feels too soft or too stiff, adjust it in accordance with the following table.
  • Page 490: Steering Stem

    14-8 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Steering Damper (see Steering Damper Removal) Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Front Fender (see Front Fender Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the...
  • Page 491: Stem, Stem Bearing Installation

    STEERING 14-9 Steering Stem • Remove the lower ball bearing [A] from the steering stem. • Remove the lower bearing inner race (with its grease seal) [A] which is pressed onto the steering stem [B] with the bearing puller [C] and adapter [D]. Special Tool - Bearing Puller: 57001-135 Stem, Stem Bearing Installation •...
  • Page 492 14-10 STEERING Steering Stem • Install the steering stem [A] through the head pipe and install the upper bearing [B] and inner race [C] on it. • Install: Stem Cap [D] Steering Stem Nut [E] • Settle the bearings in place as follows. ○...
  • Page 493: Steering Stem Bearing Lubrication

    STEERING 14-11 Steering Stem Steering Stem Bearing Lubrication • Refer to the Steering Stem Bearing Lubrication in the Pe- riodic Maintenance chapter. Steering Stem Warp Inspection • Whenever the steering stem is removed, or if the steering can not be adjusted for smooth action, check the steering stem for straightness.
  • Page 494: Handlebar

    14-12 STEERING Handlebar Handlebar Removal • Remove: Steering Damper (see Steering Damper Removal) Clutch Lever Clamp Bolts [A] Clutch Lever Assembly [B] Left Switch Housing [C] Handlebar Weight [D] Left Handlebar Grip [E] • Remove: Front Master Cylinder [A] (see Front Master Cylinder Re- moval in the Brakes chapter) Right Switch Housing [B] Throttle Case [C]...
  • Page 495: Handlebar Installation

    STEERING 14-13 Handlebar Handlebar Installation • Apply a non-permanent locking agent to the threads of the handlebar positioning bolts and tighten them. Torque - Handlebar Positioning Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the steering stem head with handlebars. •...
  • Page 496 14-14 STEERING Handlebar • Install: Clutch Lever Assembly (see Clutch Lever Installation in the Clutch chapter) Front Master Cylinder (see Front Master Cylinder Instal- lation in the Brakes chapter) Steering Damper (see Steering Damper Installation)
  • Page 497 15-8 Seat Cover Installation....15-18 Rear Seat Removal...... 15-8 Upper Seat Cover Removal (Only Rear Seat Installation....15-8 on Ninja ZX-6R MONSTER Fairings..........15-9 ENERGY® Model) ....15-19 Lower Fairing Removal ....15-9 Upper Seat Cover Installation Lower Fairing Installation .....
  • Page 498: Exploded View

    15-2 FRAME Exploded View...
  • Page 499 Rear Footpeg Bracket Bolts Rear Frame Bolts (M10) Rear Frame Bolts (M8) Sidestand Bolt Sidestand Bracket Bolts Sidestand Switch Bolt 0.90 78 in·lb 8. Only on Ninja ZX-6R MONSTER ENERGY® Model G: Apply grease. L: Apply a non-permanent locking agent.
  • Page 500 15-4 FRAME Exploded View...
  • Page 501 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fender Mounting Bolts 0.40 35 in·lb 2. US, CA, CAL and SEA Models L: Apply a non-permanent locking agent.
  • Page 502 15-6 FRAME Exploded View...
  • Page 503 FRAME 15-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Windshield Mounting Bolts 0.42 0.043 3.7 in·lb 2. Other than CAL, SEA and TH Models...
  • Page 504: Seats

    15-8 FRAME Seats Front Seat Removal • Remove: Side Covers (see Side Cover Removal) Bolts [A] (Both Sides) • Remove the seat [B] forward while lifting up the front part of the seat. Front Seat Installation • Installation is the reverse of removal, note the following. ○...
  • Page 505: Fairings

    FRAME 15-9 Fairings Lower Fairing Removal • Remove: Lower Inner Fairing (see Lower Inner Fairing Removal) Quick Rivet [A] Bolts [B] ○ Pull up the core by the flat-head screwdriver, and then remove the quick rivet. • Clear the hook portions [C] from the slots and remove the lower fairing [D].
  • Page 506: Lower Inner Fairing Installation

    15-10 FRAME Fairings Lower Inner Fairing Installation • Installation is the reverse of removal, note the following. ○ Insert the projection [A] into the hole [B]. Upper Fairing Assembly Removal • Remove: Lower Fairings (see Lower Fairing Removal) Upper Inner Fairings (see Upper Inner Fairing Removal) Windshield (see Windshield Removal) Quick Rivet [A] •...
  • Page 507: Upper Fairing Assembly Removal

    FRAME 15-11 Fairings • Remove: Bolts [A] Rear View Mirror [B] Bolt [C] • Remove the bolts [A]. • Clear the projections [B] from the holes and remove the upper fairing assembly [C]. Upper Fairing Assembly Installation • Installation is the reverse of removal, note the following. ○...
  • Page 508: Center Fairing Installation

    15-12 FRAME Fairings Center Fairing Installation • Installation is the reverse of removal, note the following. ○ Check that the pads [A] are in place on the center fairing. Left Center Fairing [B] Right Center Fairing [C] ○ Insert the hook portions [A] into the slots [B]. Upper Fairing Removal •...
  • Page 509: Upper Inner Fairing Removal

    FRAME 15-13 Fairings Upper Center Fairing Installation • Installation is the reverse of removal, note the following. ○ Check that the pads [A] are in place on the upper center fairing [B]. ○ Insert the slots [A] onto the hook portions. ○...
  • Page 510: Center Inner Fairing Removal

    15-14 FRAME Fairings Center Inner Fairing Removal • Remove the bolt [A]. • Clear the slots [B] from the hook portions and remove the center inner fairing. Center Inner Fairing Installation • Installation is the reverse of removal, note the following. ○...
  • Page 511: Fairing Cover Removal

    FRAME 15-15 Fairings Fairing Cover Removal • Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal) Bolts [A] Left Fairing Cover [B] Right Fairing Cover [C] Fairing Cover Installation • Installation is the reverse of removal.
  • Page 512: Side Covers

    15-16 FRAME Side Covers Side Cover Removal • Remove the bolt [A]. • Pull the side cover [B] evenly outward to clear the projec- tion [C] and hook fasteners [D], and remove it. Side Cover Installation • Installation is the reverse of removal, note the following. ○...
  • Page 513: Side Cover Removal

    FRAME 15-17 Seat Covers Seat Cover Removal • Remove: Seats (see Front/Rear Seat Removal) Bolts [A] • Pull the front seat cover [B] backward to clear the hook portions [C], and remove it upward. • Remove the quick rivets [A]. ○...
  • Page 514: Seat Cover Installation

    15-18 FRAME Seat Covers • Remove the bolt [A]. • Clear the hook portion [B] from the slot. • Remove the lower end [A] of the seat lock cable [B]. • Remove: Connector [A] Bolt [B] Rear Seat Cover [C] Tail/Brake Light (LED) (see Tail/Brake Light (LED) Re- moval/Installation in the Electrical System chapter) Seat Cover Installation...
  • Page 515: Monster Energy® Model)

    Check that the pad [A] is in place on the front seat cover [B]. ○ Insert the hook portions [A] into the slots [B]. Upper Seat Cover Removal (Only on Ninja ZX-6R MONSTER ENERGY® Model) • Insert the ignition switch key [A] into the seat lock.
  • Page 516: Fenders

    15-20 FRAME Fenders Front Fender Removal • Remove: Clamps [A] (Both Sides) Bolts [B] with Washers (Both Sides) Reflectors [C] (Both Sides, US, CA, CAL and SEA Mod- els) Front Fender [D] Front Fender Installation • Tighten: Torque - Front Fender Mounting Bolts: 3.9 N·m (0.40 kgf·m, 35 in·lb) Flap and Rear Fender Removal •...
  • Page 517 FRAME 15-21 Fenders Flap and Rear Fender Installation • Installation is the reverse of removal, note the following. ○ Check that the pad [A] is in place on the rear fender [B]. 5 mm (0.20 in.) [C] ○ Run the harness, cables and leads correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
  • Page 518: Rear Frame Rear Removal

    15-22 FRAME Frame Rear Frame Rear Removal • Remove: Rear Seat Cover (see Seat Cover Removal) Tool Kit Case (see Flap and Rear Fender Removal) Bolts [A] (Both Sides) Rear Frame Rear [B] Rear Frame Rear Installation • Apply a non-permanent locking agent to the threads of the rear frame bolts (M8) and tighten them.
  • Page 519: Windshield

    FRAME 15-23 Windshield Windshield Removal • Remove: Bolts with Washers [A] Windshield [B] Windshield Installation • Be sure that the wellnuts [A] are in position as shown in the figure. • Tighten: Torque - Windshield Mounting Bolts: 0.42 N·m (0.043 kgf·m, 3.7 in·lb)
  • Page 520: Guard

    15-24 FRAME Guard Mud Guard Removal • Remove: Bolts [A] and Brake Hose Clamp [B] Mud Guard [C] Mud Guard Installation • Installation is the reverse of removal, note the following. ○ Apply a non-permanent locking agent to the threads of the mud guard mounting bolts, and tighten them securely.
  • Page 521: Sidestand

    FRAME 15-25 Sidestand Sidestand Removal • Raise the rear wheel off the ground with the stand [A]. • Remove: Sidestand Switch Bolt [A] Sidestand Switch [B] • Remove: Spring [A] Sidestand Nut [B] Sidestand Bolt [C] Sidestand [D] Sidestand Installation •...
  • Page 523 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-4 Specifications ......................... 16-10 Special Tools and Sealant ...................... 16-11 Parts Location......................... 16-12 Wiring Diagram (US, CAL and CA Models)................16-14 Wiring Diagram (Other than US, CAL and CA Models)............16-16 Precautions..........................
  • Page 524 16-2 ELECTRICAL SYSTEM Right-hand End Cover Assembly Inspection ..............16-45 Starter Relay Inspection....................16-45 Lighting System ........................16-47 Headlight Beam Horizontal Adjustment ................16-47 Headlight Beam Vertical Adjustment................. 16-47 Headlight Bulb Replacement .................... 16-47 City Light Bulb Replacement..................... 16-48 Headlight Removal/Installation ..................16-48 Tail/Brake Light (LED) Removal/Installation..............
  • Page 525 ELECTRICAL SYSTEM 16-3 Dummy Page...
  • Page 526: Exploded View

    16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 527: Electrical System

    ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Turn Signal Light Mounting Screw 0.12 11 in·lb License Plate Light Cover Screws 0.10 8.9 in·lb License Plate Light Mounting Nuts 0.36 31 in·lb Meter Unit Mounting Screws 0.12 11 in·lb Rear Turn Signal Light Lens Screws...
  • Page 528 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 529 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Alternator Cover Bolts 87 in·lb Alternator Lead Holding Plate Bolt 87 in·lb Alternator Rotor Bolt 15.8 Crankshaft Sensor Bolts 0.60 52 in·lb Front Brake Light Switch Screw 0.12 11 in·lb Left Switch Housing Screws 0.36 31 in·lb...
  • Page 530 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 531 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Ground Cable Terminal Bolt 87 in·lb Fuel Pump Bolts 87 in·lb L, S Gear Position Switch Screws 0.30 26 in·lb Oxygen Sensor (Equipped Models) Regulator/Rectifier Bracket Screws 0.12 11 in·lb Sidestand Switch Bolt 0.90...
  • Page 532: Specifications

    16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name YTX9-BS Capacity 12 V 8 Ah Voltage 12.8 V or more Charging System Type Three-phase AC Alternator Output Voltage 54 V or more at 4 000 r/min (rpm) 0.11 ∼...
  • Page 533: Special Tools And Sealant

    57001-1394 57001-1591 Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: Rotor Holder: 57001-1405 57001-1666 Peak Voltage Adapter: Stopper: 57001-1415 57001-1679 Lead Wire - Peak Voltage Adapter: Rotor Holder Attachment: 57001-1449 57001-1689 Key Registration Unit: Kawasaki Bond (Silicone Sealant): 57001-1582 92104-0004...
  • Page 534: Parts Location

    16-12 ELECTRICAL SYSTEM Parts Location...
  • Page 535 2. Ignition Switch 3. Immobilizer Antenna (Equipped Models) 4. Starter Lockout Switch 5. Starter Relay 6. Battery 12 V 8 Ah 7. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector 8. Relay Box 9. ECU 10. Turn Signal Relay 11. Fuse Box 12.
  • Page 536: Wiring Diagram (us, Cal And Ca Models)

    16-14 ELECTRICAL SYSTEM Wiring Diagram (US, CAL and CA Models)
  • Page 537 ELECTRICAL SYSTEM 16-15 Wiring Diagram (US, CAL and CA Models)
  • Page 538: Wiring Diagram (other Than Us, Cal And Ca Models)

    16-16 ELECTRICAL SYSTEM Wiring Diagram (Other than US, CAL and CA Models)
  • Page 539 ELECTRICAL SYSTEM 16-17 Wiring Diagram (Other than US, CAL and CA Models)
  • Page 540: Precautions

    16-18 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 541: Electrical Wiring

    ELECTRICAL SYSTEM 16-19 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 542: Battery

    16-20 ELECTRICAL SYSTEM Battery Battery Removal • Turn off the ignition switch. • Remove the front seat (see Front Seat Removal in the Frame chapter). • Slide the red cap [A]. • Disconnect the negative (–) cable [B] and then positive (+) cable [C].
  • Page 543 ELECTRICAL SYSTEM 16-21 Battery CAUTION Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. • Place the battery on a level surface. •...
  • Page 544 Newly activated sealed batteries require an initial charge. Standard Charge: 0.9 A × 5 ∼ 10 hours If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers: Optimate III Yuasa 1.5 Amp Automatic Charger Battery Mate 150-9 If the above chargers are not available, use equivalent one.
  • Page 545 ELECTRICAL SYSTEM 16-23 Battery NOTE ○ To ensure maximum battery life and customer satisfac- tion, it is recommended the battery be load tested at three times its amp-hour rating for 15 seconds. Re-check voltage and if less than 12.8 V repeat the charging cycle and load test.
  • Page 546: Precautions

    16-24 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 547: Refreshing Charge

    ELECTRICAL SYSTEM 16-25 Battery If the reading is 12.8 V or more, no refresh charge is re- quired, however, if the read is below the specified, refresh charge is required. Battery Terminal Voltage Standard: 12.8 V or more Terminal Voltage (V) [A] Battery Charge Rate (%) [B] Good [C] Refresh charge is required [D]...
  • Page 548: Charging System

    Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface [A] on the front and rear sides of the cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Check that dowel pins [B] are in place on the crankcase.
  • Page 549: Stator Coil Installation

    Apply silicone sealant to the circumference of the alterna- tor lead grommet [A], and fit the grommet into the notch of the cover securely. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Secure the alternator lead with a holding plate [B], and apply a non-permanent locking agent to the threads of the plate bolt [C] and tighten it.
  • Page 550 16-28 ELECTRICAL SYSTEM Charging System • Using a cleaning fluid, clean off any oil or dirt on the washer [A] and dry it with a clean cloth. • Install the washer. NOTE ○ Confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque.
  • Page 551: Charging Voltage Inspection

    ELECTRICAL SYSTEM 16-29 Charging System Charging Voltage Inspection • Check the battery condition (see Charging Condition In- spection). • Warm up the engine to obtain actual alternator operating conditions. • Remove the front seat (see Front Seat Removal in the Frame chapter).
  • Page 552 16-30 ELECTRICAL SYSTEM Charging System • To check the alternator output voltage, do the following procedures. ○ Turn the ignition switch OFF. ○ Remove the right upper inner fairing (see Upper Inner Fairing Removal in the Frame chapter). ○ Disconnect the alternator lead connector [A]. ○...
  • Page 553: Regulator/rectifier Inspection

    CAUTION Use only Kawasaki Hand Tester 57001-1394 for this test. A tester other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large capacity battery is used, the regulator/rectifier will be damaged.
  • Page 554 16-32 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 2. Load 3. Regulator/Rectifier 4. Alternator 5. Frame Ground 6. Battery 12 V 8 Ah 7. Starter Relay 8. Main Fuse 30 A...
  • Page 555: Ignition System

    Apply silicone sealant to the circumference of the crank- shaft sensor lead grommet [B], and fit the grommet into the notch of the crankcase securely. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Run the crankshaft sensor lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
  • Page 556: Crankshaft Sensor Inspection

    16-34 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Inspection • Disconnect the crankshaft sensor lead connector (see Crankshaft Sensor Removal). • Set the hand tester [A] to the × 10 Ω range and connect it to the crankshaft sensor lead connector [B]. Special Tool - Hand Tester: 57001-1394 Crankshaft Sensor Resistance Connections:...
  • Page 557: Stick Coil Removal

    ELECTRICAL SYSTEM 16-35 Ignition System Stick Coil Removal • Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). • Disconnect the stick coil connectors [A]. • Pull out the stick coils [B] upward. ○...
  • Page 558: Stick Coil Primary Peak Voltage Inspection

    16-36 ELECTRICAL SYSTEM Ignition System Stick Coil Primary Peak Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove the stick coils (see Stick Coil Removal). ○ Do not remove the spark plugs. • Measure the primary peak voltage as follows. ○...
  • Page 559: Spark Plug Condition Inspection

    ELECTRICAL SYSTEM 16-37 Ignition System Spark Plug Condition Inspection • Remove the spark plugs (see Spark Plug Replacement in the Periodic Maintenance chapter). • Visually inspect the spark plugs. If the spark plug center electrode [A] and/or side elec- trode [B] are corroded or damaged, or if the insulator [C] is cracked, replace the plug.
  • Page 560: Interlock Operation Inspection

    16-38 ELECTRICAL SYSTEM Ignition System 3rd Check • Inspect the engine for its secure stop after the following operations are completed. • Run the engine to the following conditions. Condition: Transmission Gear → 1st Position Clutch Lever → Release Sidestand → Up •...
  • Page 561 ELECTRICAL SYSTEM 16-39 Ignition System...
  • Page 562 16-40 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Stick Coils 4. Spark Plugs 5. Primary Fuel Injector 6. Secondary Fuel Injector 7. Crankshaft Sensor 8. Gear Position Switch 9. Sidestand Switch 10. ECU 11.
  • Page 563: Electric Starter System

    ELECTRICAL SYSTEM 16-41 Electric Starter System Starter Motor Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Starter Clutch Cover (see Starter Idle Gear Removal in the Crankshaft/Transmission chapter) Clamp Screw [A] (Loosen) Water Hose [B]...
  • Page 564: Starter Motor Disassembly

    16-42 ELECTRICAL SYSTEM Electric Starter System • Install the starter motor cable [A] as shown in the figure. • Tighten: Torque - Starter Motor Cable Terminal Bolt [B]: 2.9 N·m (0.30 kgf·m, 26 in·lb) • Slide back the rubber cap to the original position. Starter Motor Disassembly •...
  • Page 565: Brush Inspection

    ELECTRICAL SYSTEM 16-43 Electric Starter System • Press the springs holding the brush leads with suitable clips [A] as shown in the figure. • Put the armature [B] among the brushes. • Install the new O-rings [A] as shown in the figure. •...
  • Page 566: Commutator Cleaning And Inspection

    16-44 ELECTRICAL SYSTEM Electric Starter System Commutator Cleaning and Inspection • Smooth the commutator surface [A] if necessary with fine emery cloth [B], and clean out the grooves. • Measure the diameter [A] of the commutator [B]. If the commutator diameter is less than the service limit, replace the starter motor with a new one .
  • Page 567: Right-hand End Cover Assembly Inspection

    ELECTRICAL SYSTEM 16-45 Electric Starter System Right-hand End Cover Assembly Inspection • Using the highest hand tester range, measure the resis- tance as shown in the figure. Terminal and Right-hand End Cover [A] Special Tool - Hand Tester: 57001-1394 If there is any reading, the right-hand end cover assembly have a short.
  • Page 568 16-46 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Gear Position Switch 5. Sidestand Switch 6. ECU 7. Fuse Box 8. Ignition Fuse 15 A 9. Frame Ground 10. Battery 12 V 8 Ah 11.
  • Page 569: Lighting System

    ELECTRICAL SYSTEM 16-47 Lighting System This motorcycle adopt the daylight system and have a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off.
  • Page 570: City Light Bulb Replacement

    16-48 ELECTRICAL SYSTEM Lighting System • Turn the headlight bulb [A] clockwise. • Connect the headlight connector. • After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter). ○ Other Bulb: Repeat the above steps. City Light Bulb Replacement •...
  • Page 571: Tail/brake Light (led) Removal/installation

    ELECTRICAL SYSTEM 16-49 Lighting System Tail/Brake Light (LED) Removal/Installation • Remove: Rear Seat Cover (see Seat Cover Removal in the Frame chapter) Bolts [A] Tail/Brake Light (LED) [B] • Installation is the reverse of removal, note the following. ○ Fit the projections [A] of the rear seat cover into the slots [B] of the tail/brake light (LED).
  • Page 572 16-50 ELECTRICAL SYSTEM Lighting System Headlight/Tail Light Circuit 1. Ignition Switch 13. Main Fuse 30 A 2. Regulator/Rectifier 14. Relay Box 3. Alternator 15. Headlight Circuit Relay 16. Dimmer Switch 4. License Plate Light 12 V 5 W 5. Tail/Brake Light (LED) 13.5 V 0.5/4.1 W 17.
  • Page 573: Turn Signal Light Bulb Replacement

    ELECTRICAL SYSTEM 16-51 Lighting System Turn Signal Light Bulb Replacement Front Turn Signal Light • Remove the upper fairing assembly (see Upper Fairing Assembly Removal in the Frame chapter). • Turn the socket [A] counterclockwise and pull out the socket together with the bulb. •...
  • Page 574: Turn Signal Relay Inspection

    16-52 ELECTRICAL SYSTEM Lighting System • Push and turn the rear turn signal light bulb [A] counter- clockwise and remove it. • Insert the new bulb [A] by aligning its left and right pins [B] with the left and right grooves [C] in the socket, and turn the bulb clockwise.
  • Page 575 ELECTRICAL SYSTEM 16-53 Lighting System • Connect one 12 V battery and turn signal lights as indi- cated in the figure, and count how may times the lights flash for one minute. Turn Signal Relay [A] Turn Signal Light 21 W [B] Turn Signal Light 10 W [C] 12 V Battery [D] If the lights do not flash as specified, replace the turn sig-...
  • Page 576 16-54 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit 1. Turn Signal Indicator Light (LED) 2. Ignition Switch 3. Rear Right Turn Signal Light 12 V 10 W 4. Rear Left Turn Signal Light 12 V 10 W 5. Joint Connector C 6.
  • Page 577: Air Switching Valve

    ELECTRICAL SYSTEM 16-55 Air Switching Valve Air Switching Valve Operation Test • Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter. Air Switching Valve Unit Test • Remove the air switching valve (see Air Switching Valve Removal in the Engine Top End chapter).
  • Page 578 16-56 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Air Switching Valve 4. ECU 5. Fuel Pump 6. Fuse Box 7. Ignition Fuse 15 A 8. Frame Ground 9. Battery 12 V 8 Ah 10.
  • Page 579: Radiator Fan System

    ELECTRICAL SYSTEM 16-57 Radiator Fan System Fan Motor Inspection • Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). • Slide the dust cover [A]. • Disconnect the connector [B]. • Using an auxiliary leads, supply battery power to the fan motor.
  • Page 580: Meter, Gauge, Indicator Unit

    16-58 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Unit Removal/Installation • Remove the upper fairing assembly (see Upper Fairing Assembly Removal in the Frame chapter). • Slide back the dust cover and disconnect the meter unit connector [A]. • Remove: Screws [B] Meter Unit [C] CAUTION...
  • Page 581: Electronic Unit (combination Meter) Inspection

    ELECTRICAL SYSTEM 16-59 Meter, Gauge, Indicator Unit Electronic Unit (Combination Meter) Inspection • Remove the meter unit [A] (see Meter Unit Removal/In- stallation). [1] Left Turn Signal Indicator Light (LED) (+) [2] Unused [3] Unused [4] Unused [5] Stop Watch (+) [6] Lap Time (+) [7] Water Temperature Sensor [8] High Beam Indicator Light (LED) (+)
  • Page 582 16-60 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit ○ When the terminals are connected, all the LCD segments [A] blinks 2 times, then appear for 1 seconds. ○ The fuel level warning indicator light (LED) [B] goes on for 3 seconds. If the LCD segments do not appear, replace the meter unit.
  • Page 583 ELECTRICAL SYSTEM 16-61 Meter, Gauge, Indicator Unit MODE and RESET 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 display [B] change to the ODO, TRIP, and STOP WATCH displays each time the MODE button [A] is pressed.
  • Page 584 16-62 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • In the MINUTE setting mode, press the RESET button to return to the HOUR/MINUTE setting mode. • Press the MODE button to complete the time setting process. • Indicate the ODO mode. •...
  • Page 585 ELECTRICAL SYSTEM 16-63 Meter, Gauge, Indicator Unit Odometer Check • Check the odometer with the speedometer check in the same way. If value indicated in the odometer is not added, replace the meter unit. NOTE ○ The data is maintained even if the battery is discon- nected.
  • Page 586 16-64 ELECTRICAL SYSTEM 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”. ○ When the terminals are connected, the tachometer nee- dle momentary points to the last reading, and then return to the 0 position.
  • Page 587 ELECTRICAL SYSTEM 16-65 Meter, Gauge, Indicator Unit Stop Watch Check • Connect the 12 V battery and terminal in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • Press the MODE button each time to set the stop watch mode.
  • Page 588 16-66 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Lights (LED) Inspection Shift Up Indicator Light (LED) [A] Illumination Light (LED) [B] Fuel Level Warning Indicator Light (LED) [C] High Beam Indicator Light (LED) [D] Neutral Indicator Light (LED) [E] Turn Signal Indicator Light (LED) [F] Warning Indicator Light (LED) [G] Illumination Light (LED) Inspection •...
  • Page 589 ELECTRICAL SYSTEM 16-67 Meter, Gauge, Indicator Unit Left and Right Turn Signal Indicator Light (LED) • Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments check”. • Using the insulated auxiliary leads, 12 V battery to the meter unit connector as follows.
  • Page 590 16-68 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit ○ When the terminals are connected, the fuel level warning indicator light (LED) [A] should go on and the FUEL seg- ments [B] appears in the display. ○ The FUEL segments is flashing. If the fuel level warning indicator light (LED) does not go on and/or the FUEL segments does not appear, replace the meter unit.
  • Page 591 ELECTRICAL SYSTEM 16-69 Meter, Gauge, Indicator Unit Meter Unit Circuit 1. Ignition Switch 2. Stop Watch Button 3. Speed Sensor 4. Water Temperature Sensor 5. Oil Pressure Switch 6. Gear Position Switch 7. ECU 8. Fuel Reserve Switch 9. Fuse Box 10.
  • Page 592: Immobilizer System (equipped Models)

    Cut the key in accordance with the shape of the current user key. • Remove the front seat (see Front Seat Removal in the Frame chapter). • Disconnect the immobilizer/Kawasaki diagnostic system connector [A]. • Connect the key registration unit [A]. Special Tool - Key Registration Unit: 57001-1582...
  • Page 593 ELECTRICAL SYSTEM 16-71 Immobilizer System (Equipped Models) • Insert the master key to the ignition switch and turn it ON. Verified ○ The warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the registration mode (go to the next step).
  • Page 594 16-72 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) ○ If there is any problem in the registration, the warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the collation error. Immobilizer Amplifier Failure When Registered User Key is Inserted. User Key Collation Error •...
  • Page 595 ELECTRICAL SYSTEM 16-73 Immobilizer System (Equipped Models) ○ If there is any problem in the registration, the warning indicator light and immobilizer warning symbol [A] blinks to display the collation error. Immobilizer Amplifier Failure When Registered User Key is Inserted. User Key Collation Error •...
  • Page 596 Immobilizer System (Equipped Models) • The warning indicator light (LED) goes off [A]. • Remove the key registration unit and connect the immo- bilizer/Kawasaki diagnostic system connector. NOTE ○ Turn the ignition switch ON with the registered user key. ○...
  • Page 597 ELECTRICAL SYSTEM 16-75 Immobilizer System (Equipped Models) Spare User Key Registration Flow Chart...
  • Page 598 Ignition Switch and Immobilizer Antenna (see Immobi- lizer System Parts Replacement) Front Seat (see Front Seat Removal in the Frame chap- ter) • Disconnect the immobilizer/Kawasaki diagnostic system connector [A]. • Connect the key registration unit [A]. Special Tool - Key Registration Unit: 57001-1582 •...
  • Page 599 ELECTRICAL SYSTEM 16-77 Immobilizer System (Equipped Models) Verified ○ The warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the ECU is in the registration mode (go to the next step). Not Verified ○ The warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the collation error.
  • Page 600 16-78 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) ○ If there is any problem in the registration, the warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the collation error. Immobilizer Amplifier Failure When Registered User Key is Inserted. User Key Collation Error •...
  • Page 601 ELECTRICAL SYSTEM 16-79 Immobilizer System (Equipped Models) ○ If there is any problem in the registration, the warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the collation error. Immobilizer Amplifier Failure When Registered User Key is Inserted. User Key Collation Error •...
  • Page 602 16-80 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) • Remove the key registration unit and connect the immo- bilizer/Kawasaki diagnostic system connector. NOTE ○ Turn the ignition switch ON with the registered user key. ○ Check that the engine can be started using all regis- tered user keys.
  • Page 603 ELECTRICAL SYSTEM 16-81 Immobilizer System (Equipped Models) Master Key Collation Error • The master key is registered in the ECU. ○ The warning indicator light (LED) and immobilizer warning symbol [A] blinks 1 time and stops for 1 second and the repeats this cycle to indicate successful registration of the master key.
  • Page 604 16-82 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) When Registered User Key is Inserted. User Key Collation Error • The user key 1 is registered in the ECU. ○ The warning indicator light (LED) and immobilizer warn- ing symbol [A] blinks 2 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key.
  • Page 605 ELECTRICAL SYSTEM 16-83 Immobilizer System (Equipped Models) ○ If there is any problem in the registration, the warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the collation error code. Immobilizer Amplifier Failure When Registered User Key is Inserted. User Key Collation Error •...
  • Page 606 16-84 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) Case 4: When master key is faulty or lost. The master key replacement is considered very rare case. However if it is required, the following is necessary. NOTE ○ The ECU must be replaced with a new one because the master key code that is registered in the current ECU can not be rewritten.
  • Page 607 ELECTRICAL SYSTEM 16-85 Immobilizer System (Equipped Models) All Keys Initial Registration Flow Chart...
  • Page 608: Immobilizer System Parts Replacement

    16-86 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) Immobilizer System Parts Replacement Immobilizer Antenna • Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) •...
  • Page 609: Immobilizer System Inspection

    ELECTRICAL SYSTEM 16-87 Immobilizer System (Equipped Models) Immobilizer Amplifier Replacement • Remove the upper fairing assembly (see Upper Fairing Assembly Removal in the Frame chapter). • Disconnect the connector [A]. • Pull out the immobilizer amplifier [B] together with the rub- ber protector [C] from the air inlet duct [D].
  • Page 610 16-88 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) Immobilizer System Circuit 1. Ignition Switch 2. ECU 3. Immobilizer/Kawasaki Diagnostic System Connector 4. Fuse Box 5. Ignition Fuse 15 A 6. Frame Ground 7. Battery 12 V 8 Ah 8. Main Fuse 30 A 9.
  • Page 611: Switches And Sensors

    ELECTRICAL SYSTEM 16-89 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 612: Water Temperature Sensor Inspection

    16-90 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 threaded portion is submerged.
  • Page 613: Speed Sensor Installation

    ELECTRICAL SYSTEM 16-91 Switches and Sensors • Remove: Bolt [A] Lead [B] (Free) Speed Sensor [C] Speed Sensor Installation • Run the lead [A] as shown in the figure. • Apply a non-permanent locking agent to the threads of the speed sensor bolt, and tighten it. Torque - Speed Sensor Bolt: 6.9 N·m (0.70 kgf·m, 61 in·lb) •...
  • Page 614: Oxygen Sensor Removal (equipped Models)

    16-92 ELECTRICAL SYSTEM Switches and Sensors • Connect the test light [A] (12 V 3.4 W bulb in a socket with leads) and the 12 V battery [B] to the fuel pump lead connector [C]. Connections: Battery (+) → 12 V 3.4 W Bulb (One Side) 12 V 3.4 W Bulb (Other Side) →...
  • Page 615: Oxygen Sensor Installation (equipped Models)

    ELECTRICAL SYSTEM 16-93 Switches and Sensors Oxygen Sensor Installation (Equipped Models) CAUTION Never drop the oxygen sensor [A] especially on a hard surface. Such a shock to the unit can damage it. Do not touch the sensing part [B] to prevent oil contact.
  • Page 616: Gear Position Switch Installation

    16-94 ELECTRICAL SYSTEM Switches and Sensors Gear Position Switch Installation • Securely place the springs [A] and pins [B] into the holes [C] of the shift drum. • Apply grease to the new O-ring [D]. • Install the gear position switch [E] and holding plate [F]. •...
  • Page 617 ELECTRICAL SYSTEM 16-95 Switches and Sensors • Set the hand tester [A] to the × 1 kΩ or × 100 Ω range and connect it to the terminals in the connector [B] and ground. ○ When changing the gear position from lower gear to higher gear, raise the rear wheel off the ground with the stand and rotate the rear wheel by hand.
  • Page 618: Relay Box

    16-96 ELECTRICAL SYSTEM Relay Box Relay Box Removal • Remove the front seat cover (see Seat Cover Removal in the Frame chapter). • Disconnect the connectors [A]. • Pull out the relay box [B] from the rubber protector [C]. NOTE ○...
  • Page 619: Diode Circuit Inspection

    ELECTRICAL SYSTEM 16-97 Relay Box Diode Circuit Inspection • Remove the relay box (see Relay Box Removal). • Check conductivity of the following pairs of terminals (see Relay Box Internal Circuit in this section). Diode Circuit Inspection 1-11, 2-11, 12-13, 12-15, 12-16, 13-14, Tester Connection 13-15 The resistance should be low in one direction and more...
  • Page 620: Fuse

    16-98 ELECTRICAL SYSTEM Fuse 30 A Main Fuse Removal • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Disconnect the connector [A]. • Pull out the main fuse [A] from the starter relay with needle nose pliers.
  • Page 621: Fuse Installation

    ELECTRICAL SYSTEM 16-99 Fuse • Pull the ECU fuse [A] straight out of the fuse box with needle nose pliers. Fuse Installation If a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 623 APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-48...
  • Page 624 17-2 APPENDIX Cable, Wire, and Hose Routing...