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Ninja H2

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Table of Contents

   Also See for Kawasaki Ninja H2

   Summary of Contents for Kawasaki Ninja H2

  • Page 1 Ninja H2...
  • Page 3: General Information

    Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Self-Diagnosis System...
  • Page 5 All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan.
  • Page 6 LIST OF ABBREVIATIONS ampere(s) KIBS Kawasaki intelligent antilock brake system ABDC after bottom dead center KLCM Kawasaki lunch control mode antilock brake system km/h kilometers per hour alternating current KTRC Kawasaki traction control ampere hour Kawasaki quick shift ATDC after top dead center...
  • Page 7: Emission Control Information

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

    • the vehicle. Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and • Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 11: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Technical Information - Supercharger (SC) ................1-11 Technical Information - Dog Ring Transmission ..............1-18 Unit Conversion Table ......................1-21...
  • Page 12: Before Servicing

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

    GENERAL INFORMATION 1-7 Model Identification ZX1000NF Left Side View ZX1000NF Right Side View Frame Number Engine Number...
  • Page 18: General Specifications

    1-8 GENERAL INFORMATION General Specifications Items ZX1000NF Dimensions Overall Length 2 085 mm (82.09 in.) Overall Width 770 mm (30.3 in.) Overall Height 1 125 mm (44.29 in.) Wheelbase 1 455 mm (57.28 in.) Road Clearance 130 mm (5.12 in.) Seat Height 825 mm (32.5 in.) Curb Mass:...
  • Page 19 GENERAL INFORMATION 1-9 General Specifications Items ZX1000NF Valve Timing: Intake: Open 37° BTDC Close 47° ABDC Duration 264° Exhaust: Open 50° BBDC Close 30° ATDC Duration 260° Lubrication System Forced lubrication (wet sump) Engine Oil: Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity...
  • Page 20 1-10 GENERAL INFORMATION General Specifications Items ZX1000NF Front Suspension: Type Telescopic fork (upside-down) Wheel Travel 120 mm (4.72 in.) Rear Suspension: Type Swingarm Wheel Travel 135 mm (5.31 in.) Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 8.6 Ah Headlight: High Beam...
  • Page 21: Technical Information - Supercharger (sc)

    The wide range of high-efficiency SC operation (similar to wide power band) easily translates to strong acceleration. Max pumping capacity: Over 200 L/s (atm. pressure) Max intake speed: 100 m/s Max pressure increase: 2.4× [A] Rival Image [B] Kawasaki Image [C] Pressure Ratio [D] Mass Flow Rate...
  • Page 22 1-12 GENERAL INFORMATION Technical Information - Supercharger (SC) [A] Ram Air Intake Duct [G] Drive Gear (6th Web of Crankshaft) [B] Air Cleaner Element [H] Supercharger Chain [C] Supercharger [I] Planetary Gears [D] Impeller [J] Nets (Stainless Steel) [E] Thrust Bearings (Ball Bearings) [K] Intake Chamber (Aluminum) [F] Driven Gear [L] Blow-off Valve...
  • Page 23 GENERAL INFORMATION 1-13 Technical Information - Supercharger (SC) Impeller [A] 3D machined from forged aluminum block. 6 vanes at tip, 12 vanes at base Impeller diameter: 69 mm (2.7 in.) [B] High durability, high precision Impeller Bearing Thrust bearing structure: Ceramic ball bearings Oil-film damper mechanism (floating) Reduce shaft vibration at up to 140 000 r/min (rpm) Controls both axial and radial vibrations, maintains align-...
  • Page 24 1-14 GENERAL INFORMATION Technical Information - Supercharger (SC) Oil Jet The supercharger chain is lubricated by oil jets. [A] Oil Spouts [B] Supercharger Chain Chain/sprocket contact points lubricated (2 places) Suppresses heat gain, prevents oil from running out of parts moving at high speed. The centrifugal oil jets are used at SC gear.
  • Page 25 GENERAL INFORMATION 1-15 Technical Information - Supercharger (SC) The duct is designed to prevent water (rain) ingestion into air cleaner. The water, drops are expelled via drain [A]. Other drains [B] are provided in the air cleaner housing. The material of the main duct [A] is ABS blow molding. Smooth surface reduces airflow resistance.
  • Page 26 1-16 GENERAL INFORMATION Technical Information - Supercharger (SC) Intake Chamber The intake chamber [A] is made of highly rigid aluminum to ensure airtight performance with the SC air pressure. The good surface heat radiation helps keep intake air cool. Large volume, ideal shape for high efficiency, high output The nets [A] (stainless steel) positioned over intake fun- nels.
  • Page 27 GENERAL INFORMATION 1-17 Technical Information - Supercharger (SC) [A] Intake Chamber [G] Blow-off Valve [B] #4 Throttle Bore [H] To Super Charger Air Cleaner Housing [C] #3 Throttle Bore [I] Vacuum [D] Throttle Body Assy [J] Air Flow [E] Relief Valve [K] High Pressure [F] ECU...
  • Page 28: Technical Information - Dog Ring Transmission

    1-18 GENERAL INFORMATION Technical Information - Dog Ring Transmission Overview The dog ring transmission is incorporated into the cas- sette-type transmission. [A] Dog Rings [B] Transmission Case [C] Input Shaft [D] Output Shaft [E] Shift Drum [F] Shift Forks The dog ring transmission features All gears stay in place on the transmission shafts, and the dog rings slide on the transmission shaft to engage gears.
  • Page 29 GENERAL INFORMATION 1-19 Technical Information - Dog Ring Transmission [A] Input Shaft [E] 3rd Gear [B] 6th Gear [F] 2nd Gear [C] 5th Gear [G] Low Gear [D] 4th Gear [H] Collar Output Shaft Output shaft transmission gears are free on the output shaft.
  • Page 30 [C] Needle Bearings [D] Output Shaft [E] The dog rings shifting direction Transmission oil jets (First for Kawasaki motorcycles) Jet at every gear mesh position, shift fork positions (two each): 12 jets total >> direct cooling, lubrication for trans- mission engagement points.
  • Page 31: Unit Conversion Table

    GENERAL INFORMATION 1-21 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 33 PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-14 Special Tools .......................... 2-16 Periodic Maintenance Procedures..................2-17 Fuel System (DFI)........................ 2-17 Air Cleaner Element Replacement..................2-17 Idle Speed Inspection ....................... 2-18 Idle Speed Adjustment......................
  • Page 34 2-2 PERIODIC MAINTENANCE Brake Hose and Pipe Replacement.................. 2-52 Master Cylinder Rubber Parts Replacement ..............2-54 Caliper Rubber Parts Replacement .................. 2-55 Brake Pad Wear Inspection ....................2-55 Brake Light Switch Operation Inspection ................2-56 Suspension .......................... 2-56 Suspension System Inspection..................2-56 Steering ..........................
  • Page 35: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection *A: Service at number of years shown or indicated odometer reading intervals, whichever comes first.
  • Page 36 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart Odometer Reading (*B) × 1 000 km (× 1 000 mile) year (*A) Page Items (0.6) (3.8) (7.6) (11.4) (15.2) Clutch hose/rubber parts of clutch master 2-37, : every 48 000 km cylinder and slave cylinder 2-38 (30 000 mile) Engine Lubrication System...
  • Page 37 PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Odometer Reading (*B) × 1 000 km (× 1 000 mile) year (*A) Page Items (0.6) (3.8) (7.6) (11.4) (15.2) Supercharger Supercharger oil screen 2-68 Supercharger impeller axial play 2-69 Others Chassis parts 2-70 Condition of bolts, nuts and fasteners 2-71...
  • Page 38: 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. All of the values are for use with dry solvent - cleaned threads unless otherwise indicated.
  • Page 39 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Supercharger Chain Sprocket Bolt Supercharger Outer Housing Bolts Supercharger Housing Bolts (M6, L = 30 mm) 89 in·lb Nozzle 0.31 27 in·lb Supercharger Oil Screen Bolt Supercharger Housing Stay Bolts 89 in·lb Supercharger Chain Guide Bolts 89 in·lb...
  • Page 40 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Rear Camshaft Chain Guide Bolt Camshaft Cap Bolts 106 in·lb Cylinder Head Plugs 19.6 2.00 14.5 Cylinder Head Bolts (M6) 106 in·lb Throttle Body Assy Holder Bolts 89 in·lb Muffler Body Stay Bolt Muffler Body Mounting Bolt...
  • Page 41 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Filter Pipe Oil Pressure Switch Oil Pressure Relief Valve Engine Oil Drain Bolt Oil Pan Bolts 89 in·lb Engine Removal/Installation Front Engine Mounting Bolts (Rear) L, S Front Engine Mounting Bolts (Front) L, S Swingarm Mounting Plate Nut (Upper)
  • Page 42 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Nozzles (M8) 0.51 44 in·lb Gear Positioning Lever Bolt 106 in·lb Shift Shaft Return Spring Pin Shift Lever Clamp Bolt 87 in·lb Wheels/Tires Front Axle Clamp Bolts Air Valve Nuts 0.46 40 in·lb...
  • Page 43 PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Upper Rear Shock Absorber Nut Tie-Rod Nuts Lower Rear Shock Absorber Nut Swingarm Pivot Shaft Nut 11.0 79.7 Rocker Arm Nut Steering Switch Housing Bolts 0.90 0.09 8 in·lb Throttle Case Bolts 0.36...
  • Page 44 2-12 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Head Light Unit Mounting Screws 0.12 11 in·lb Head Light Cover Screws 0.12 11 in·lb Meter Mounting Screws 0.12 11 in·lb Switch Housing Bolts 0.90 0.09 8 in·lb Tail/Brake Light Mounting Screws 0.12 11 in·lb...
  • Page 45 PERIODIC MAINTENANCE 2-13 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 46: Specifications

    2-14 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 1 100 ±100 r/min (rpm) – – – Throttle Body Vacuum 33.3 ±2.7 kPa (250 ±20 mmHg) @75°C (167°F) –...
  • Page 47 PERIODIC MAINTENANCE 2-15 Specifications Item Standard Service Limit Air Pressure (when Cold): Front Up to 105 kg (231 lb) load: – – – 250 kPa (2.50 kgf/cm², 36 psi) Rear Up to 105 kg (231 lb) load: – – – 290 kPa (2.90 kgf/cm², 42 psi) Final Drive 25 ∼...
  • Page 48: Special Tools

    2-16 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers: Vacuum Gauge: 57001-143 57001-1369 Steering Stem Nut Wrench: Extension Tube: 57001-1100 57001-1578 Oil Filter Wrench: Dial Gauge Holder Plate: 57001-1212 57001-1834...
  • Page 49: Periodic Maintenance Procedures

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Fuel System (DFI) Air Cleaner Element Replacement NOTE ○ In dusty areas, the element should be replaced more frequently than the recommended interval. WARNING If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident.
  • Page 50: Idle Speed Inspection

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Inspection • Start the engine and warm it up thoroughly. • With the engine idling, turn the handlebars to both sides [A]. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed, or damaged.
  • Page 51: Engine Vacuum Synchronization Inspection

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Engine Vacuum Synchronization Inspection WARNING The air intake chamber can become extremely hot during normal operation and cause severe burns. Do not remove the air intake chamber while it is hot. NOTE ○ These procedures are explained on the assumption that the intake and exhaust systems of the engine are in good condition.
  • Page 52 2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Connect the following parts temporarily. Fuel Pump Lead Connector Extension Tube [A] Special Tool - Extension Tube: 57001-1578 • Install the air intake chamber (see Air Intake Chamber Installation in the Fuel System (DFI) chapter). •...
  • Page 53: Fuel System Inspection

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Fuel System Inspection Fuel Hose Inspection (fuel leak, damage, installation condition) ○ If the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak [A] or the hose to burst.
  • Page 54 2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove: Fuel Pump (see Fuel Pump Removal in the Fuel System (DFI) chapter) Screws [A] Lead Terminal [B] Clip Nuts [C] • Remove: Nuts [A] and Spring Washers Lead Terminal (Blue) [B] Lead Terminal (White) [C] •...
  • Page 55: Fuel Pump Replacement

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures • Replace the fuel filter [A] with a new one. • Replace the O-ring [A] with a new one. • Install the removed parts in the reverse procedure. Fuel Pump Replacement • Remove the fuel pump (see Fuel Pump Removal in the Fuel System (DFI) chapter).
  • Page 56 2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures When removing with flat tip screwdriver • Insert the flat tip screwdriver [A] into slit on the joint lock [B]. • Turn the driver to disconnect the joint lock. When removing with fingers • Open and push up [C] the joint lock with your fingers.
  • Page 57: Evaporative Emission Control System Inspection (cal, Sea-b1 And Th Models)

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Push and pull [A] the fuel hose joint [B] back and forth more than two times and make sure it is locked and does not come off. WARNING Leaking fuel can cause a fire or explosion resulting in severe burns.
  • Page 58: Cooling System Inspection

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures ○ Remove the right inner cover to remove the reserve tank cap [A] (see Inner Cover Removal in the Frame chapter). NOTICE For refilling, add the specified mixture of coolant and soft water. Adding water alone dilutes the coolant and degrades its anticorrosion properties.
  • Page 59 PERIODIC MAINTENANCE 2-27 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 the cap [A] of the reserve tank on the right middle fairing.
  • Page 60 2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the right middle fairing (see Middle Fairing Installa- tion in the Frame chapter). • Fill the reserve tank up to the “F” (full) level line [A] with coolant and install the reserve tank cap. •...
  • Page 61: Water Hose And O-ring Replacement

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Water Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Thermostat Housing Cover [A] (see Thermostat Re- moval in the Cooling System chapter) Water Hose Fitting Cover [B] (see Thermostat Removal in the Cooling System chapter) Water Pump Housing [C] (see Water Pump Removal in...
  • Page 62: Engine Top End

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted when the engine is cold (at room temperature). • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval in the Engine Top End chapter) Crankshaft Timing Plug [A] •...
  • Page 63: Valve Clearance Adjustment

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures ○ When positioning #1 piston TDC at the end of the compression stroke: Intake Valve Clearance of #1 and #3 Cylinders Exhaust Valve Clearance of #1 and #2 Cylinders Measuring Valve [A] ○ When positioning #4 piston TDC at the end of the compression stroke: Intake Valve Clearance of #2 and #4 Cylinders Exhaust Valve Clearance of #3 and #4 Cylinders...
  • Page 64 2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTICE Be sure to remeasure the clearance after selecting a shim according to the table. If the clearance is out of the specified range, use the additional shim. ○ If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance.
  • Page 65 PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Adjustment Shims Thickness Part Number Mark 1.300 92180-0108 1.325 92180-0109 1.350 92180-0110 1.375 92180-0865 1375 1.388 92180-0866 1388 1.400 92180-0867 1400 1.413 92180-0868 1413 1.425 92180-0869 1425 1.438 92180-0870 1438 1.450 92180-0871 1450 1.463 92180-0872 1463 1.475...
  • Page 66 2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Adjustment Shims Thickness Part Number Mark 1.850 92180-0903 1850 1.863 92180-0904 1863 1.875 92180-0905 1875 1.888 92180-0906 1888 1.900 92180-0907 1900 1.913 92180-0908 1913 1.925 92180-0909 1925 1.938 92180-0910 1938 1.950 92180-0911 1950 1.963 92180-0912 1963 1.975...
  • Page 67: Air Suction System Damage Inspection

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Air Suction System Damage Inspection • Remove: Left Inner Cover (see Inner Cover Removal in the Frame chapter) Left Fuel Tank Cover (see Fuel Tank Cover Removal in the Frame chapter) • Disconnect: Air Switching Valve Hose [A] •...
  • Page 68: Clutch Operation Inspection

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Hose Damage and Installation Condition Inspec- tion • Inspect the clutch hose and fittings for deterioration, cracks, corrosion and signs of leakage. ○ The high pressure inside the clutch line can cause fluid to leak [A] or the hose to burst if the line is not properly maintained.
  • Page 69: Clutch Fluid Change

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Clutch Fluid Change • Level the clutch fluid reservoir and remove the reservoir cap. • Remove the rubber cap from the bleed valve on the clutch slave cylinder. • Attach a clear plastic hose [A] to the bleed valve and run the other end of the hose into a container.
  • Page 70: Rubber Parts Of Clutch Master Cylinder/slave Cylinder Replacement

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove: Rear Intake Duct (see Intake Duct Removal in the Frame chapter) Clutch Hose Banjo Bolts [A] Clutch Hose Fitting Bolts [B] Clamp [C] • Remove the clutch hose [D] together with the clutch pipe. •...
  • Page 71: Oil Filter Replacement

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures • Remove the oil filler plug [A]. • Pour in the specified type and amount of oil. Recommended Engine Oil Type: API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity: SAE 10W-40 Capacity: 3.9 L (4.1 US qt) (When filter is not removed)
  • Page 72: Wheels/tires

    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the filter with a new one. • Apply grease to the gasket [A] before installation. • Tighten the filter with the oil filter wrench. Special Tool - Oil Filter Wrench: 57001-1212 Torque - Oil Filter: 17 N·m (1.7 kgf·m, 13 ft·lb) NOTE ○...
  • Page 73: Wheel Bearing Damage Inspection

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Tread Depth Standard: Front 3.6 mm (0.14 in.) Rear 5.0 mm (0.20 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 Some replacement tires may adversely affect han-...
  • Page 74: Final Drive

    2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Final Drive Drive Chain Lubrication Condition Inspection Lubrication is necessary after riding through rain or on wet roads, or any time that the chain appears dry. Use a lubricant for sealed chains to prevent deterioration of chain seals.
  • Page 75: Drive Chain Slack Adjustment

    PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Drive Chain Slack Adjustment • Remove: Seat (see Seat Removal in the Frame chapter) Tool Kit Bolts [A] Washer [B] Band [C] Hook Wrench [D] • Attach the adapter [A] to the hook wrench [B]. NOTE ○...
  • Page 76: Drive Chain Wear Inspection

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Tighten the bearing housing clamp bolts [A] [B] following specified tightening sequence. Tightening Sequence: [A → B → A → B → A → B → A] Torque - Bearing Housing Clamp Bolts: 33 N·m (3.4 kgf·m, 24 ft·lb) •...
  • Page 77: Chain Guide Wear Inspection

    PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures Chain Guide Wear Inspection • Remove the swingarm (see Swingarm Removal in the Suspension chapter). • Visually inspect the chain guide [A]. Replace the chain guide if it shows any signs of abnormal wear or damage.
  • Page 78: Brakes

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brakes Brake System Inspection Brake Fluid Leak (Brake Hose and Pipe) Inspection • Remove the right inner cover (see Inner Cover Removal in the Frame chapter). • Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A], pipes [B] and fittings [C].
  • Page 79: Brake Operation Inspection

    PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures Brake Hose and Pipe Damage and Installation Condi- tion Inspection • Remove the right inner cover (see Inner Cover Removal in the Frame chapter). • Inspect the brake hoses, pipes and fittings for deteriora- tion, cracks and signs of leakage.
  • Page 80: Brake Fluid Change

    2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check that the brake fluid level in the rear brake reservoir [A] is above the MIN level line [B]. If the fluid level is lower than the MIN level line, fill the reservoir to the MAX level line [C]. ○...
  • Page 81 PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures • Change the brake fluid. ○ Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. 1. Open the bleed valve [A]. 2. Apply the brake and hold it [B]. 3.
  • Page 82 2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Face the bleed valve upward. • Remove the rubber cap [A] from the bleed valve on the caliper. • Attach a wrench [B] and a clear plastic hose [C] to the bleed valve, and run the other end of the hose into a con- tainer.
  • Page 83 PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures This page intentionally left blank.
  • Page 84: Brake Hose And Pipe Replacement

    2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Replacement NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. NOTE ○ When removing the brake pipes and hoses on the hy- draulic unit, remove them with the flare nut wrench ac- cording to each assembly of the exploded view in the Brakes chapter.
  • Page 85 PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures...
  • Page 86: Master Cylinder Rubber Parts Replacement

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). • Replace the replacement parts as an assembly of the front master cylinder.
  • Page 87: Caliper Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures Caliper Rubber Parts Replacement Front Caliper • Remove: Front Caliper (see Front Caliper Removal in the Brakes chapter) Front Brake Pads (see Front Brake Pad Removal in the Brakes chapter) • Replace the replacement parts as an assembly of the front caliper.
  • Page 88: Brake Light Switch Operation Inspection

    2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Light Switch Operation Inspection • Turn the ignition switch on. • The brake light (LED) [A] should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm (0.39 in.). If it does not, adjust the brake light switch.
  • Page 89 PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures • Pump the rear seat down and up [A] 4 or 5 times, and inspect the smooth stroke. If the shock absorber does not smoothly stroke or noise is found, inspect the oil leak (see Rear Shock Absorber Oil Leak Inspection).
  • Page 90 2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Judge the front fork oil leakage as following table. Oil Leakage Judgment List Oil ring condition Ref. Oil leak or not Remark Normal oil film Observed oil film. Photo [A] (1) No oil leak No repair required Grease is...
  • Page 91 PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures (3) Oil leak • After inspecting the inner tube, replace the oil seal (see the Front Fork Disassembly in the Suspension chapter). • After replacing the oil seal, conduct the judgment of the oil leak again. NOTE ○...
  • Page 92: Steering

    2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Play Inspection • Raise the front wheel off the ground with the front stand or the webbing sling. • With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.
  • Page 93: Steering Stem Bearing Lubrication

    PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures • Install the claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of stem locknut [C]. • Hand tighten the stem locknut until it touches the claw washer.
  • Page 94: Electronic Steering Damper Oil Leak Inspection

    2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electronic Steering Damper Oil Leak Inspection • Visually inspect the steering damper [A] for oil leakage. If the oil leakage is found on it, replace the steering damper with a new one (see Electronic Steering Damper Removal/Installation in the Steering chapter).
  • Page 95: Electrical System

    PERIODIC MAINTENANCE 2-63 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 (LED) [A] Go on Taillights (LED) [B]...
  • Page 96 2-64 PERIODIC MAINTENANCE Periodic Maintenance Procedures Second Step (Other than US, CA and CAL Models) • Turn the ignition switch to hazard position. • The all lights should go off. If the light goes on, inspect or replace the following item. Ignition Switch (see Switch Inspection in the Electrical System chapter) Third Step...
  • Page 97: Headlight Aiming Inspection

    PERIODIC MAINTENANCE 2-65 Periodic Maintenance Procedures • Set the dimmer switch to high beam position. • The low beam [A] and high beam [B] headlights should go on. • The blue high beam indicator light (LED) [C] should goes If the high beam headlight and/or blue high beam indicator light (LED) does not go on, inspect or replace the following parts.
  • Page 98: Side Stand Switch Operation Inspection

    2-66 PERIODIC MAINTENANCE Periodic Maintenance Procedures Side Stand Switch Operation Inspection • Raise the rear wheel off the ground with the stand. • Inspect the side stand switch [A] operation accordance to below table. Side Stand Switch Operation Gear Clutch Engine Engine Side Stand...
  • Page 99: Engine Start/stop Switch Operation Inspection

    PERIODIC MAINTENANCE 2-67 Periodic Maintenance Procedures Engine Start/Stop Switch Operation Inspection • Turn the ignition switch on. • Set the gear position in the neutral position. • Set the engine start/stop switch to run position [A]. • Slide the start/stop switch down and start the engine. •...
  • Page 100: Supercharger

    2-68 PERIODIC MAINTENANCE Periodic Maintenance Procedures Supercharger Supercharger Oil Screen Replacement • Remove: Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Right Throttle Body Assy Holder [A] (see Throttle Body Assy Holder Removal in the Engine Top End chapter) •...
  • Page 101: Supercharger Impeller Axial Play Inspection

    PERIODIC MAINTENANCE 2-69 Periodic Maintenance Procedures Supercharger Impeller Axial Play Inspection • Remove: Air Cleaner Element (see Air Cleaner Element Replace- ment) Footpeg Bracket Bolts [A] Footpeg Bracket [B] • Install the dial gauge holder plate [A] and tighten it with the removed bolts [B] securely.
  • Page 102: Others

    2-70 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Fit the dial gauge tip [A] to the center of the impeller [B]. • Measure the supercharger impeller axial play [A] using the pliers [B]. Supercharger Impeller Axial Play Service Limit: 0.5 mm (0.02 in.) If the supercharger impeller axial play exceeds the service limit, replace the supercharger impeller housing assy.
  • Page 103: Condition Of Bolts, Nuts And Fasteners Tightness Inspection

    PERIODIC MAINTENANCE 2-71 Periodic Maintenance Procedures Cables: Lubricate with Rust Inhibitor. Throttle Cables • Lubricate the cables by seeping the oil between the cable and housing. ○ The cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant.
  • Page 104 2-72 PERIODIC MAINTENANCE Periodic Maintenance Procedures Bolt, Nut and Fastener to be checked Engine: Clutch Lever Pivot Bolt Locknut Engine Mounting Bolts and Nuts Exhaust Pipe Holder Nuts Muffler Body Clamp Bolts Muffler Body Mounting Bolt Exhaust Pipe Mounting Bolt Radiator Mounting Bolts Wheels: Front Axle Clamp Bolts...
  • Page 105 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................3-10 DFI Parts Location........................3-18 Specifications ......................... 3-22 Special Tools and Sealants ....................3-23 DFI Servicing Precautions ...................... 3-24 DFI Servicing Precautions ....................3-24 Troubleshooting the DFI System .................... 3-26 Outline ..........................
  • Page 106 3-2 FUEL SYSTEM (DFI) Air Intake Chamber Installation..................3-55 Blow-off Valve Removal ....................3-57 Blow-off Valve Installation ....................3-57 Blow-off Valve Inspection....................3-57 Purge Valve (for Supercharger) Removal/Installation............3-57 Purge Valve (for Supercharger) Inspection............... 3-57 Throttle Body Assy ......................... 3-58 Idle Speed Inspection/Adjustment ..................
  • Page 107 FUEL SYSTEM (DFI) 3-3 This page intentionally left blank.
  • Page 108: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 109: Exploded View

    FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Nozzle Assy Mounting Bolts 0.51 44 in·lb Purge Valve Nut 89 in·lb Throttle Case Bolts 0.36 31 in·lb Air Intake Chamber Pressure/Temperature 0.51 44 in·lb Sensor Bolts Air Hose Fitting 89 in·lb Air Intake Chamber Assy Bolts 0.82...
  • Page 110 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 111 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Immobilizer Amplifier Bracket Screw 0.12 11 in·lb Vehicle-down Sensor Mounting Bolts 0.60 52 in·lb Camshaft Position Sensor Bolt 89 in·lb Spark Plugs 115 in·lb Water Temperature Sensor 106 in·lb Supercharger Chain Tensioner Mounting 89 in·lb Bolts...
  • Page 112 3-8 FUEL SYSTEM (DFI) Exploded View...
  • Page 113 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Pump Bolts 89 in·lb L, S Canister Upper Bracket Bolts 0.92 80 in·lb Canister Lower Bracket Bolts 87 in·lb 4. Fuel Filter 5. Purge Valve 6. Canister 7.
  • Page 114: Dfi System

    3-10 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 115 FUEL SYSTEM (DFI) 3-11 DFI System 1. ECU 2. Battery 12 V 8.6 Ah 3. Vehicle-down Sensor 4. Air Intake Chamber Pressure/Temperature Sensor 5. Secondary Fuel Injectors 6. Primary Fuel Injectors 7. Fuel Pump 8. Pressure Regulator 9. Fuel Filter 10.
  • Page 116 3-12 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 117 FUEL SYSTEM (DFI) 3-13 DFI System Part Names 1. ECU 2. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector 3. Joint Connector F 4. Rear Wheel Rotation Sensor 5. Joint Connector H 6. Joint Connector I 7. Frame Ground 4 8. Frame Ground 3 9.
  • Page 118 3-14 FUEL SYSTEM (DFI) DFI System ○ Color Codes: BK: Black GY: Gray PU: Purple BL: Blue LB: Light Blue R: Red BR: Brown V: Violet LG: Light Green CH: Chocolate O: Orange W: White DG: Dark Green P: Pink Y: Yellow G: Green...
  • Page 119 FUEL SYSTEM (DFI) 3-15 DFI System This page intentionally left blank.
  • Page 120 3-16 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Secondary Fuel Injector #2: O/G 2. Primary Fuel Injector #3: BL/O 3. Secondary Fuel Injector #3: O/BK 4. Primary Fuel Injector #4: BL/G 5. Secondary Fuel Injector #4: O/Y 6.
  • Page 121 80. Ground for Throttle Position Sensor: BK 81. Atmospheric Pressure Sensor: R/W 82. Water Temperature Sensor: O 83. Intake Air Pressure Sensor (Air Intake Chamber): R/G 84. Oxygen Sensor: W/BK 85. Unused 86. Intake Air Pressure Sensor: R/BK *: KDS (Kawasaki Diagnostic System)
  • Page 122: Dfi Parts Location

    3-18 FUEL SYSTEM (DFI) DFI Parts Location Ignition Key [A] (Transponder, Immobilizer System Equipped Models) Immobilizer Antenna [B] (Equipped Models) Ignition Switch [C] Electronic Steering Damper [D] ECU [A] Immobilizer Amplifier [B] (Equipped Models) ETV Actuator Relay [C] Vehicle-down Sensor [A] Relay Box [B] (ECU Main Relay, Fuel Pump Relay, Ra- diator Fan Relay) Electronic Steering Damper ECU [C]...
  • Page 123 DFI Parts Location Secondary Fuel Injectors #1, #2, #3, #4 [A] Air Intake Chamber Pressure/Temperature Sensor [B] Exhaust Butterfly Valve Actuator [A] Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector [A] Battery [B] Fuse Box 2 [C] Main Fuse 30 A [A]...
  • Page 124 3-20 FUEL SYSTEM (DFI) DFI Parts Location Crankshaft Sensor [A] Oxygen Sensor [B] Front Wheel Rotation Sensor [A] Rear Wheel Rotation Sensor [A] Fuel Pump [A] Water Temperature Sensor [A]...
  • Page 125 FUEL SYSTEM (DFI) 3-21 DFI Parts Location Knock Sensor [A] Purge Valve [A] (for Evaporative Emission Control Sys- tem) (CAL, SEA-B1 and TH Models) Yellow Engine Warning Indicator Light (LED) [A]...
  • Page 126: Specifications

    3-22 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 100 ±100 r/min (rpm) Throttle Body Assy: Throttle Valve Single throttle valve Bore 50 mm (2.0 in.) Throttle Body Vacuum 33.3 ±2.7 kPa (250 ±20 mmHg) @75°C (167°F) or more (at idle speed) ECU: Make...
  • Page 127: Special Tools And Sealants

    FUEL SYSTEM (DFI) 3-23 Special Tools and Sealants Oil Pressure Gauge, 5 kgf/cm²: Measuring Adapter: 57001-125 57001-1700 Needle Adapter Set: Liquid Gasket, TB1211: 57001-1457 56019-120 Fuel Pressure Gauge Adapter: Liquid Gasket, TB1207B: 57001-1593 92104-2068 Fuel Hose: 57001-1607...
  • Page 128: Dfi Servicing Precautions

    3-24 FUEL SYSTEM (DFI) DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 129 FUEL SYSTEM (DFI) 3-25 DFI Servicing Precautions ○ If the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see Fuel Tank Removal) and check the fuel hoses [A].
  • Page 130: Troubleshooting The Dfi System

    3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System Outline When a problem occurs with DFI system, the yellow en- gine warning indicator light (LED) [A] goes on to alert the rider. For models equipped with an immobilizer system, the red immobilizer warning indicator light (LED) [A] blinks, when a problem occurs in the system.
  • Page 131 (LED) goes off. But the service codes stored in memory of the ECU are not erased to preserve the problem history. The problem history can be referred using the KDS (Kawasaki Diagnostic System) when solv- ing unstable problems. When the motorcycle is down, the vehicle-down sensor operates and the ECU shuts off the fuel pump relay, fuel injectors and ignition system.
  • Page 132 3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○ After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Sealant - Liquid Gasket, TB1211: 56019-120 • Always check battery condition before replacing the DFI parts.
  • Page 133 FUEL SYSTEM (DFI) 3-29 Troubleshooting the DFI System ○ When checking a harness [A] for short circuit, open one end [B] and check the continuity between the other end [C] and ground [D]. If there is continuity, the harness has a short circuit to ground, and it must be repaired or re- placed.
  • Page 134: Inquiries To Rider

    3-30 FUEL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.
  • Page 135 FUEL SYSTEM (DFI) 3-31 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. □ □ □ □ □ □...
  • Page 136 3-32 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ □ □ Poor running very low idle speed, very high idle speed, rough idle speed. at low speed □ battery voltage is low (charge the battery). □ spark plug loose (tighten it). □...
  • Page 137: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system.
  • Page 138 3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Intake air pressure sensor trouble Inspect (see chapter 17).
  • Page 139 FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel injector trouble Inspect (see chapter 17). Accelerator position sensor trouble Inspect (see chapter 17). Throttle position sensor trouble Inspect (see chapter 17). ETV actuator trouble Inspect (see chapter 17).
  • Page 140: Poor Running Or No Power At High Speed

    3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Intake air pressure sensor trouble Inspect (see chapter 17). Water temperature sensor trouble Inspect (see chapter 17). Air intake chamber pressure/temperature senor Inspect (see chapter 17). trouble Atmospheric pressure sensor trouble Inspect (see chapter 17).
  • Page 141 FUEL SYSTEM (DFI) 3-37 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Stick coil trouble Inspect (see chapter 16). ECU trouble Inspect (see chapter 3). Engine vacuum not synchronizing Inspect and adjust (see chapter 2). Intake air pressure sensor trouble Inspect (see chapter 17).
  • Page 142: Warning Indicator Light (led)

    3-38 FUEL SYSTEM (DFI) Warning Indicator Light (LED) Yellow Engine Warning Indicator Light (LED) Inspection Yellow Engine Warning Indicator Light (LED) [A] ○ In this model, the above mentioned warning indicator light (LED) goes on or blink by the data sent from the ECU. •...
  • Page 143: Ecu

    ECU. 2. In the reused ECU, erase the stored service code mem- ory using Kawasaki Diagnostic System (KDS Ver.3), and wait the 10 seconds after the ignition switch on at the idle speed and the coolant temperature 40°C (104°F) or...
  • Page 144: Ecu Installation

    3-40 FUEL SYSTEM (DFI) • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Bolts [A] Clamps [B] Bracket [C] NOTE ○ For EUR models, use a small chisel or other suitable tool to remove the bolts. • Remove: Bolts [A] Bracket [B]...
  • Page 145 FUEL SYSTEM (DFI) 3-41 • Turn the ignition switch off. • Disconnect the ECU connector [A] (see ECU Removal). • Set a tester [B] and check the following wiring for conti- nuity. ECU Grounding Inspection Connections: (I) BK/Y leads (ECU terminal 22 [C] or 23 ←→...
  • Page 146 3-42 FUEL SYSTEM (DFI) ECU Power Source Circuit 1. ECU 2. Frame Ground 3 3. Engine Ground 4. Battery 12 V 8.6 Ah 5. Starter Relay 6. Main Fuse 30 A 7. ECU Fuse 15 A 8. Fuse Box 1 9.
  • Page 147: Dfi Power Source

    FUEL SYSTEM (DFI) 3-43 DFI Power Source ECU Fuse Removal • Refer to the 30 A Main/15 A ECU Fuse Removal in the Electrical System chapter. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 148: Fuel Line

    3-44 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Air Intake Chamber (see Air Intake Chamber Removal) Primary Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) ○...
  • Page 149: Fuel Flow Rate Inspection

    FUEL SYSTEM (DFI) 3-45 Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure with the engine idling. Fuel Pressure (with Engine Idling) Standard: 380 kPa (3.9 kgf/cm², 55 psi) NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications.
  • Page 150 3-46 FUEL SYSTEM (DFI) 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 151: Fuel Pump

    FUEL SYSTEM (DFI) 3-47 Fuel Pump Fuel Pump Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions, creating the potential for serious burns. Make sure the area is well venti- lated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 152: Fuel Pump Installation

    3-48 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Installation WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions, creating the potential for serious burns. Make sure the area is well venti- lated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 153: Fuel Pump Operating Voltage Inspection

    FUEL SYSTEM (DFI) 3-49 Fuel Pump Fuel Pump Operating Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Remove the seat (see Seat Removal in the Frame chap- ter). • Disconnect the fuel pump lead connector and connect the measuring adapter [A] between these connectors as shown.
  • Page 154: Pressure Regulator Removal

    3-50 FUEL SYSTEM (DFI) Fuel Pump Pressure Regulator Removal ○ The pressure regulator [A] is built into the fuel pump and can not be removed. Fuel Pump Relay Removal/Installation ○ The fuel pump relay is built in the relay box [A]. •...
  • Page 155: Fuel Injectors

    FUEL SYSTEM (DFI) 3-51 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. Primary Fuel Injector Audible Inspection • Refer to the Primary Fuel Injector Audible Inspection in the Self-Diagnosis System chapter.
  • Page 156: Throttle Grip And Cables

    3-52 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 157: Air Intake Chamber

    FUEL SYSTEM (DFI) 3-53 Air Intake Chamber Air Intake Chamber Removal • Remove: Fuel Tank (see Fuel Tank Removal) • Disconnect: Secondary Fuel Hose [A] (see Fuel Hose Replacement in the Periodic Maintenance chapter) Secondary Fuel Injector Connectors [B] Air Intake Chamber Pressure/Temperature Sensor Con- nector [C] •...
  • Page 158 3-54 FUEL SYSTEM (DFI) Air Intake Chamber • Disconnect the air switching valve hose [A]. • Slide the clamp [B], and disconnect the purge valve hose [C]. • Slide the dust cover and disconnect the throttle position sensor/ETV actuator connector [A]. •...
  • Page 159: Air Intake Chamber Installation

    FUEL SYSTEM (DFI) 3-55 Air Intake Chamber Air Intake Chamber Installation • Replace the O-rings [A] with new ones. • Install the air intake chamber lower housing. • Apply a non-permanent locking agent to the air intake chamber mounting bolts. •...
  • Page 160 3-56 FUEL SYSTEM (DFI) Air Intake Chamber • Apply a non-permanent locking agent to the air intake chamber duct bolts. • Install the air intake chamber ducts [A] as shown, and tighten their bolts. Front Side [B] Torque - Air Intake Chamber Duct Bolts [C]: 6.0 N·m (0.61 kgf·m, 53 in·lb) •...
  • Page 161: Blow-off Valve Removal

    FUEL SYSTEM (DFI) 3-57 Air Intake Chamber Blow-off Valve Removal • Remove: Fuel Tank (see Fuel Tank Removal) • Loosen the clamp screw [A] and disconnect the blow-off valve hose [B]. • Slide the clamp and disconnect the purge valve hose [C]. •...
  • Page 162: Throttle Body Assy

    ECU. Erase the stored service code memory using Kawasaki Diagnostic System (KDS Ver.3), and wait the 10 seconds after the ignition switch on at the idle speed and the coolant temperature 40°C (104°F) or more to register the sensor position to the...
  • Page 163 FUEL SYSTEM (DFI) 3-59 Throttle Body Assy • Cut the bands [A]. • Disconnect the primary fuel injector connectors [A]. • Loosen the locknuts [A]. • Turn the adjusters [B] to give the more free play. • Remove: Throttle Cable Holder Clamp [A] Throttle Cable Lower Ends [B] •...
  • Page 164: Throttle Body Assy Installation

    3-60 FUEL SYSTEM (DFI) Throttle Body Assy Throttle Body Assy Installation • Replace the O-rings [A] with new ones. • Install the throttle body assy [A]. • Tighten the throttle body assy mounting bolts [B] as shown. Torque - Throttle Body Assy Mounting Bolts: 10 N·m (1.0 kgf·m, 89 in·lb) •...
  • Page 165: Throttle Body Assy Disassembly

    FUEL SYSTEM (DFI) 3-61 Throttle Body Assy Throttle Body Assy Disassembly 1. Throttle Body Assy 2. Throttle Position Sensor/ETV Actuator 3. Accelerator Position Sensor 4. Primary Fuel Injectors 5. Delivery Pipe Assy 6. Atmospheric Pressure Sensor 7. Intake Air Pressure Sensor NOTICE Do not remove, disassemble or adjust the throttle position sensor/ETV actuator, accelerator position...
  • Page 166: Throttle Body Assy Assembly

    3-62 FUEL SYSTEM (DFI) Throttle Body Assy • Remove 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. NOTICE Never drop the primary fuel injector especially on a hard surface.
  • Page 167 FUEL SYSTEM (DFI) 3-63 Throttle Body Assy • Replace the dust seals [A] with new ones. • Apply engine oil to the new dust seals. • Install the primary fuel injectors along with the delivery pipe assy to the throttle body assy. •...
  • Page 168: Nozzle Assy

    3-64 FUEL SYSTEM (DFI) Nozzle Assy Nozzle Assy Removal • Remove the fuel tank (see Fuel Tank Removal). • Disconnect the secondary fuel hose [A] from the delivery pipe assy of the nozzle assy [B] (see Fuel Hose Replace- ment in the Periodic Maintenance chapter). •...
  • Page 169: Nozzle Assy Assembly

    FUEL SYSTEM (DFI) 3-65 Nozzle Assy Nozzle Assy Assembly • Replace the O-rings [A] of the joint pipe [B] with new ones. • Apply engine oil to the new O-rings, and insert it to the delivery pipes [C]. ○ Insert the joint pipe so that the stepped side [D] faces right side.
  • Page 170: Air Cleaner

    3-66 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Element Removal/Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Element Inspection • Remove the air cleaner element (see Air Cleaner Element Replacement in the Periodic Maintenance chapter). •...
  • Page 171 FUEL SYSTEM (DFI) 3-67 Air Cleaner • Remove: Inner Plate Bolt [A] Inner Plate [B]...
  • Page 172: Air Cleaner Housing Installation

    3-68 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Housing Installation • Install the blow-off valve hose [A], and tighten its clamp screw [B] (see Cable, Wire, and Hose Routing section in the Appendix chapter). Torque - Blow-off Valve Hose Clamp Screw: 3.0 N·m (0.31 kgf·m, 27 in·lb) •...
  • Page 173: Supercharger

    FUEL SYSTEM (DFI) 3-69 Supercharger Supercharger Chain Tensioner Removal • Remove: Throttle Body Assy (see Throttle Body Assy Removal) Clutch Cover (see Clutch Cover Removal in the Clutch chapter) Supercharger Chain Tensioner Mounting Bolts [A] Supercharger Chain Tensioner [B] Supercharger Chain Tensioner Installation NOTE ○...
  • Page 174: Supercharger Housing Assy Removal

    3-70 FUEL SYSTEM (DFI) Supercharger • Push the upper chain guide [A] upward to allow the ten- sioner to expand. NOTE ○ You hear the sound from which the push rod moves out. ○ If you do not hear the sound, reassemble the camshaft chain tensioner.
  • Page 175 FUEL SYSTEM (DFI) 3-71 Supercharger • Remove: Supercharger Chain Sprocket Bolt [A] Washer [B] • Remove: Supercharger Chain Tensioner (see Supercharger Chain Tensioner Removal) Chain Guide Bolts [A] Upper Chain Guide [B] and Collar Lower Chain Guide [C] and Collars Supercharger Chain Upper Sprocket •...
  • Page 176: Supercharger Housing Assy Installation

    3-72 FUEL SYSTEM (DFI) Supercharger • Remove the supercharger housing bolt (M8) [A] while moving the supercharger housing assy [B]. • Remove the supercharger housing assy. NOTE ○ Store the supercharger housing assy so that there are not contaminants adhering to it. Supercharger Housing Assy Installation •...
  • Page 177 FUEL SYSTEM (DFI) 3-73 Supercharger • Install the supercharger chain upper sprocket [A] so that the boss side [B] faces the supercharger side. • Install the supercharger chain [A] to the sprocket. • Apply a non-permanent locking agent to the supercharger chain sprocket bolt [B], and tighten it together with the washer [C] temporarily.
  • Page 178: Supercharger Outer Housing Removal

    3-74 FUEL SYSTEM (DFI) Supercharger • Install the supercharger chain tensioner (see Super- charger Chain Tensioner Installation). • Tighten the supercharger chain sprocket bolt [A] on the upper sprocket. Torque - Supercharger Chain Sprocket Bolt: 20 N·m (2.0 kgf·m, 15 ft·lb) •...
  • Page 179 FUEL SYSTEM (DFI) 3-75 Supercharger • Install the fitting [A]. • Check that dowel pin [B] is in place on the supercharger impeller housing. • Install the supercharger outer housing [A], and tighten its bolts following specified tightening sequence [1 ∼ 4]. Torque - Supercharger Outer Housing Bolts: 23 N·m (2.3 kgf·m, 17 ft·lb)
  • Page 180: Fuel Tank

    3-76 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions, creating the potential for serious burns. Make sure the area is well venti- lated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 181 FUEL SYSTEM (DFI) 3-77 Fuel Tank • Disconnect the fuel pump lead connector [A]. • Remove the fuel tank bolts [B]. • Slide the clamps, and disconnect the hoses [A]. • Be sure to place a piece of cloth around the fuel hose joint. •...
  • Page 182: Fuel Tank Installation

    3-78 FUEL SYSTEM (DFI) Fuel Tank • Pull [A] the fuel hose joint [B] out of the outlet pipe. WARNING Fuel is flammable and explosive under certain con- ditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
  • Page 183 FUEL SYSTEM (DFI) 3-79 Fuel Tank • Remove the vinyl bag on the pipe and fuel hose joint. • Check the joint lock for deformation and wear. If the joint lock is deformed, replace the fuel hose with a new one. •...
  • Page 184: Fuel Tank And Cap Inspection

    3-80 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank and Cap Inspection • Open the tank cap. • Visually inspect the gasket [A] on the tank cap for any damage. Replace the tank cap if gasket is damaged. • Check to see if the water drain pipe [B] and fuel breather pipe [C] in the tank are not clogged.
  • Page 185: Evaporative Emission Control System (cal, Sea-b1 And Th Models)

    FUEL SYSTEM (DFI) 3-81 Evaporative Emission Control System (CAL, SEA-B1 and TH Models) The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.
  • Page 187 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 ....................4-10 Coolant Reserve Tank Removal/Installation ..............
  • Page 188: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 189 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Coolant Reserve Tank Screws 0.12 11 in·lb Water Temperature Sensor 106 in·lb Water Pipe Bolt 89 in·lb Thermostat Housing Bolts 0.61 53 in·lb Water Hose Fitting Cover Bolts 89 in·lb Upper Radiator Mounting Bolts Radiator Cover Bolts 89 in·lb...
  • Page 190: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart...
  • Page 191 COOLING SYSTEM 4-5 Coolant Flow Chart 1. Radiator 2. Radiator Cap 3. Radiator Overflow Hose 4. Reserve Tank 5. Reserve Tank Overflow Hose 6. Thermostat 7. Cylinder Head Water Jacket 8. Cylinder Water Jacket 9. Oil Cooler 10. Water Pump 11.
  • Page 192 4-6 COOLING SYSTEM Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corro- sion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 193: Specifications

    COOLING SYSTEM 4-7 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 194: Special Tools

    4-8 COOLING SYSTEM Special Tools Bearing Driver Set: Oil Seal Driver 37.5: 57001-1129 57001-1660...
  • Page 195: Coolant

    COOLING SYSTEM 4-9 Coolant Coolant Deterioration Inspection • Visually inspect the coolant in the reserve tank [A]. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.
  • Page 196: Cooling System Flushing

    4-10 COOLING SYSTEM 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 197: Water Pump

    COOLING SYSTEM 4-11 Water Pump Water Pump Removal • Situate the motorcycle so that it is perpendicular to the ground to prevent from dropping out the oil pump parts. • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) •...
  • Page 198: Water Pump Installation

    4-12 COOLING SYSTEM Water Pump Water Pump Installation • Check that the oil pump is installed correctly. • Replace the O-ring [A] with a new one. • Apply grease to the O-ring, and install it. • Install: Water Pump Housing [A] Water Pump Impeller [B] •...
  • Page 199: Water Pump Inspection

    COOLING SYSTEM 4-13 Water Pump • Install the water hoses [A] and clamps [B] (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Install the removed parts (see appropriate chapters). Water Pump Inspection • Check the drainage outlet passage [A] at the bottom of the water pump housing for coolant leaks.
  • Page 200: Water Pump Housing Disassembly

    4-14 COOLING SYSTEM Water Pump Water Pump Housing Disassembly • Remove the water pump housing (see Water Pump Re- moval). • Using suitable tool [A], remove the mechanical seal [B] and oil seal from the water pump body. Water Pump Housing Assembly NOTICE Do not reuse the mechanical seal and oil seal.
  • Page 201: Radiator

    COOLING SYSTEM 4-15 Radiator Radiator and Radiator Fan Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Rear Intake Duct (see Intake Duct Removal in the Frame chapter) Air Switching Valve (see Air Switching Valve Removal in the Engine Top End chapter)
  • Page 202: Radiator And Radiator Fan Installation

    4-16 COOLING SYSTEM Radiator • Remove the lower radiator mounting bolt [A]. • Remove the upper radiator mounting bolt [A] (both sides), and remove the radiator [B]. NOTICE Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling effi- ciency.
  • Page 203 COOLING SYSTEM 4-17 Radiator • Install the rubber dampers [A], [B] and collars [C] as shown. ○ Make sure that the dampers have been fitted in the brack- ets [D]. ○ Face the large diameter side of the damper to the collar. •...
  • Page 204: Radiator Inspection

    4-18 COOLING SYSTEM Radiator Radiator Inspection • Remove the radiator (see Radiator and Radiator Fan Re- moval). • Check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably de- formed fins, replace the radiator with a new one.
  • Page 205: Radiator Filler Neck Inspection

    COOLING SYSTEM 4-19 Radiator Radiator Filler Neck Inspection • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Radiator Cap • Check the radiator filler neck for signs of damage. • Check the condition of the top and bottom sealing seats [A] in the filler neck.
  • Page 206: Thermostat

    4-20 COOLING SYSTEM Thermostat Thermostat Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Water Hose Fitting Cover Bolts [A] Water Hose Fitting Cover [B] Thermostat Housing Bolts [C] Thermostat Housing Cover [D]...
  • Page 207: Thermostat Inspection

    COOLING SYSTEM 4-21 Thermostat Thermostat Inspection • Remove the thermostat (see Thermostat Removal). • Inspect the thermostat valve [A] at room temperature. If the valve is open, replace the thermostat with a new one. • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water.
  • Page 208: Hose And Pipes

    4-22 COOLING SYSTEM Hose and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). •...
  • Page 209: Water Temperature Sensor

    COOLING SYSTEM 4-23 Water Temperature Sensor NOTICE The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it. Water Temperature Sensor Removal/Installation • Refer to the Water Temperature Sensor Removal/Instal- lation in the Self-Diagnosis System chapter.
  • Page 211 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Cylinder Head Removal ....5-26 Exhaust System Identification ... Cylinder Head Installation .... 5-26 Specifications ........Cylinder Head Warp Inspection ... 5-28 Special Tools and Sealants ....Valves ..........5-29 Clean Air System.......
  • Page 212: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 213 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb 1 Air Suction Valve Cover Bolts 89 in·lb 2 Sub Cover Bolts 89 in·lb 3 Cylinder Head Cover Bolts 89 in·lb 4 Air Switching Valve Filter Bracket Bolts 87 in·lb 5 Camshaft Sprocket Bolts 6 Upper Camshaft Chain Guide Bolts...
  • Page 214 5-4 ENGINE TOP END Exploded View...
  • Page 215 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Muffler Body Stay Bolt Muffler Body Mounting Bolt Muffler Body Nozzle Bolts 89 in·lb Muffler Body End Cover Bolts 89 in·lb Exhaust Pipe Holder Nuts Exhaust Butterfly Valve Actuator Pulley Bolt 0.51 44 in·lb Exhaust Butterfly Valve Actuator Mounting Bolt...
  • Page 216: Exhaust System Identification

    5-6 ENGINE TOP END Exhaust System Identification Exhaust Pipe Mark Position [A] Muffler Body Mark Position [A]...
  • Page 217 ENGINE TOP END 5-7 Exhaust System Identification Exhaust Pipe [A] with Hole [B] for Oxygen Sensor [C] Honeycomb Type Catalyst Position [A]...
  • Page 218: Specifications

    5-8 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: 33.943 ∼ 34.057 mm (1.3363 ∼ 1.3408 in.) 33.843 mm (1.3324 in.) Exhaust 33.743 ∼ 33.857 mm (1.3285 ∼ 1.3330 in.) 33.643 mm (1.3245 in.) Intake 0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.) Camshaft Journal/Cap 0.17 mm (0.0067 in.) Clearance...
  • Page 219: Special Tools And Sealants

    ENGINE TOP END 5-9 Special Tools and Sealants Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 60° - 30: 57001-221 57001-1123 Valve Spring Compressor Assembly: Valve Seat Cutter Holder Bar: 57001-241 57001-1128 Valve Seat Cutter, 45° - 27.5: Valve Seat Cutter, 32° - 33: 57001-1114 57001-1199 Valve Seat Cutter, 45°...
  • Page 220 5-10 ENGINE TOP END Special Tools and Sealants Valve Guide Arbor, 4.5: Valve Spring Compressor Adapter, 24: 57001-1331 57001-1586 Valve Guide Reamer, 4.5: Spacer, 9.6: 57001-1333 57001-1830 Valve Seat Cutter, 60° - 27: Liquid Gasket, TB1211F: 57001-1409 92104-0004 Valve Guide Driver: Liquid Gasket, TB1216B: 57001-1564 92104-1064...
  • Page 221: Clean Air System

    ENGINE TOP END 5-11 Clean Air System Air Suction Valve Removal • Remove: Air Switching Valve (see Air Switching Valve Removal) Air Suction Valve Cover Bolts [A] (Both Sides) Air Suction Valve Cover [B] (Both Sides) • Remove the air suction valve [A] on both sides. •...
  • Page 222: 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 223: Air Switching Valve Installation

    ENGINE TOP END 5-13 Clean Air System • Other than CAL, SEA-B1 and TH models, remove the air switching valve filter [A] from the bracket [B]. • Disconnect the connector [A]. • Disconnect the hoses [B] from the air suction valve cov- ers, and remove the air switching valve [C].
  • Page 224: Cylinder Head Cover

    5-14 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Air Suction Valves (see Air Suction Valve Removal) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Stick Coils (see Stick Coil Removal in the Electrical Sys- tem chapter)
  • Page 225: Cylinder Head Cover Installation

    ENGINE TOP END 5-15 Cylinder Head Cover Cylinder Head Cover Installation • Replace the cylinder head cover gasket [A] and plug hole gaskets [B] with new ones. • Using a high flash-point solvent, clean off any oil or dirt that may be on the mating surface. Dry them with a clean cloth.
  • Page 226 5-16 ENGINE TOP END Cylinder Head Cover • Install the cylinder head cover with the gaskets. • Install the rubber washers [A] with the metal side [B] faces upward. • Tighten the cover bolts following the specified tightening sequence [1 ∼ 6]. Torque - Cylinder Head Cover Bolts: 10 N·m (1.0 kgf·m, 89 in·lb) •...
  • Page 227: Camshaft Chain Tensioner

    ENGINE TOP END 5-17 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal NOTICE Do not turn over the crankshaft while the tensioner is removed. This could upset the camshaft chain timing, and damage the valves. • Remove: Camshaft Chain Tensioner Mounting Bolts [A] Camshaft Chain Tensioner [B] Camshaft Chain Tensioner Installation •...
  • Page 228 5-18 ENGINE TOP END Camshaft Chain Tensioner • Replace the gasket [A] with a new one. • Install the tensioner body so that the plug [B] faces up- ward. • Tighten: Torque - Camshaft Chain Tensioner Mounting Bolts: 10 N·m (1.0 kgf·m, 89 in·lb) •...
  • Page 229: Camshaft, Camshaft Chain

    ENGINE TOP END 5-19 Camshaft, Camshaft Chain Camshaft Removal • Remove the cylinder head cover (see Cylinder Head Cover Removal). • Remove the crankshaft timing plug [A] on the clutch cover. • Using a wrench on the timing rotor bolt [A], turn the crank- shaft clockwise until the line [B] (TDC mark for #1,4 pis- tons) on the timing rotor is aligned with the mating surface [C] of the crankcase.
  • Page 230: Camshaft Installation

    5-20 ENGINE TOP END Camshaft, Camshaft Chain • Remove: Camshaft Sprocket Bolts [A] Camshaft Sprockets NOTICE The crankshaft may be turned while the camshafts are removed. Always pull the chain taut while turn- ing the crankshaft. This avoids kinking the chain on the lower (crankshaft) sprocket.
  • Page 231 ENGINE TOP END 5-21 Camshaft, Camshaft Chain • Pull the tension side (exhaust side) [A] of the chain taut to install the chain. • Engage the camshaft chain with the sprockets so that tim- ing marks on the sprockets are positioned as shown. ○...
  • Page 232 5-22 ENGINE TOP END Camshaft, Camshaft Chain • Install the ten dowel pins on the marks [A]. • Install the camshaft cap, following the identification No. [B] and upper camshaft chain guide [C]. • First tighten the all camshaft cap bolts evenly to seat the camshaft in place, then tighten all bolts following the spec- ified tightening sequence [1 ∼...
  • Page 233: Camshaft, Camshaft Cap Wear Inspection

    ENGINE TOP END 5-23 Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear Inspection • Remove the camshaft caps (see Camshaft Removal). • Cut the strips of plastigage (press gauge) to journal width. Place a strip on each journal parallel to the camshaft in- stalled in the correct position.
  • Page 234: Cam Wear Inspection

    5-24 ENGINE TOP END Camshaft, Camshaft Chain Cam Wear Inspection • Remove the camshafts (see Camshaft Removal). • Measure the height [A] of each cam with a micrometer. If the cams are worn down past the service limit, replace the camshaft. Cam Height Standard: 33.943 ∼...
  • Page 235: 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 236: Cylinder Head Removal

    5-26 ENGINE TOP END Cylinder Head Cylinder Head Removal • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval)
  • Page 237 ENGINE TOP END 5-27 Cylinder Head • Replace the cylinder head bolt washers with new ones. • Apply molybdenum disulfide oil solution to both sides [A] of the cylinder head bolt washers and the threads [B] of the M10 cylinder head bolts [C]. •...
  • Page 238: Cylinder Head Warp Inspection

    5-28 ENGINE TOP END Cylinder Head • Replace the washer with a new one. • Tighten the coolant drain bolt (cylinder) [A] with washer. • Install the removed parts (see appropriate chapters). Cylinder Head Warp Inspection • Clean the cylinder head. •...
  • Page 239: Valves

    ENGINE TOP END 5-29 Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). •...
  • Page 240: Valve Guide Installation

    5-30 ENGINE TOP END Valves Valve Guide Installation • Apply engine oil to the valve guide outer surface before installation. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). NOTICE Do not heat the cylinder head with a torch. This Will warp the cylinder head.
  • Page 241: Valve Seat Inspection

    ENGINE TOP END 5-31 Valves NOTE ○ The reading is not actual valve/valve guide clearance because the measuring point is above the guide. Valve/Valve Guide Clearance (Wobble Method) Standard: 0.08 ∼ 0.16 mm (0.0031 ∼ 0.0063 in.) Exhaust 0.03 ∼ 0.10 mm (0.0012 ∼ 0.0039 in.) Intake Service Limit: Exhaust...
  • Page 242 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 243 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 244 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 245 ENGINE TOP END 5-35 Valves...
  • Page 246: 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) Clamp [A] Throttle Body Assy Holder Bolts [B] Bracket [C] Throttle Body Assy Holders [D] Throttle Body Assy Holder Installation •...
  • Page 247: Muffler

    ENGINE TOP END 5-37 Muffler WARNING The muffler can become extremely hot during nor- mal operation and cause severe burns. Do not re- move the muffler while it is hot. Muffler Body Removal • Remove the bolt [A]. • Remove the muffler body cover [B] forward. •...
  • Page 248: 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 exhaust pipe [B] until it is bottomed so that the chamfer side faces exhaust pipe. •...
  • Page 249 ENGINE TOP END 5-39 Muffler • Thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts. • Install the pads [A] to the exhaust pipe cover and muffler body cover as shown.
  • Page 250: Exhaust Pipe Removal

    5-40 ENGINE TOP END Muffler • Install the dampers [A ∼ C] as shown. Front [D] • Install: Dampers [E] Collars [F] • Insert the tab [G] of the exhaust pipe cover into the hole. • Tighten the bolts [H]. •...
  • Page 251 ENGINE TOP END 5-41 Muffler • Free the oxygen sensor lead from the clamp [A]. • Free the oxygen sensor lead [A] from the bracket [B]. • Remove the footpeg bracket bolts [A]. • Move the footpeg bracket backward. • Slide the dust covers [A].
  • Page 252 5-42 ENGINE TOP END Muffler • Remove: Exhaust Butterfly Valve Cover Bolts [A] Washers Exhaust Butterfly Valve Cover [B] • Loosen the exhaust butterfly valve cable locknuts [A]. • Disconnect the exhaust butterfly valve cable lower ends [B]. • Remove: Exhaust Pipe Mounting Nut [A] Washer [B] Exhaust Pipe Mounting Bolt and Washer...
  • Page 253: Exhaust Pipe Installation

    ENGINE TOP END 5-43 Muffler Exhaust Pipe Installation • Replace the exhaust pipe gaskets [A] and exhaust pipe mounting nut [B] with new ones. • Apply grease to the exhaust pipe gasket, and install them to engine. • Install the exhaust pipe [C]. •...
  • Page 254: Exhaust Butterfly Valve Cable Removal

    5-44 ENGINE TOP END Muffler Exhaust Butterfly Valve Cable Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Exhaust Pipe Cover and Muffler Body Cover (see Muffler Body Removal) Footpeg Bracket Bolts [A] • Move the footpeg bracket backward.
  • Page 255: Exhaust Butterfly Valve Cable Installation

    ENGINE TOP END 5-45 Muffler • Free the exhaust butterfly valve cables from the clamps [A]. • Remove the oxygen sensor connector [A] from the bracket. • Disconnect the rear wheel rotation sensor connector [B]. • Remove the exhaust butterfly valve actuator mounting screw [C].
  • Page 256 5-46 ENGINE TOP END Muffler • Install the close cable (black) [A], and then install the open cable (silver) [B] to the exhaust valve actuator pulley. • Install the clamp [C]. • Install the exhaust butterfly valve cables to the muffler body as shown.
  • Page 257 ENGINE TOP END 5-47 Muffler • After adjusting the cables, turn the ignition switch on and make sure that the pulley turns clockwise, then counter- clockwise and then returns slightly clockwise as shown. NOTE ○ The stop position [A] of the pulley is changed by the cables tension and the closed position of the exhaust butterfly valve.
  • Page 258: Exhaust Butterfly Valve Actuator Removal

    5-48 ENGINE TOP END Muffler Exhaust Butterfly Valve Actuator Removal NOTICE Never drop the exhaust butterfly valve actuator es- pecially on a hard surface. Such a shock to the ac- tuator can damage it. • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter).
  • Page 259: Exhaust Butterfly Valve Actuator Installation

    ENGINE TOP END 5-49 Muffler Exhaust Butterfly Valve Actuator Installation • When replacing the pulley, note the following. • Install the pulley [A] on the actuator so that the holes side [B] aligns with the groove [C]. • Tighten the pulley bolt [A] while holding the pulley [B] with the suitable tool [C].
  • Page 260: Exhaust Butterfly Valve Actuator Adjustment

    5-50 ENGINE TOP END Muffler Exhaust Butterfly Valve Actuator Adjustment Pulley Position Electrically Adjustment • Turn the ignition switch off. • Disconnect the exhaust butterfly valve actuator connec- tors. • Connect the exhaust butterfly valve actuator connector (2 pins) to the battery to turn the pulley as follows. Connection for counterclockwise [A] Connection for clockwise [B] •...
  • Page 261 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Clutch Lever ........................... Clutch Lever Removal/Installation ..................Clutch Lever Position Adjustment ..................Clutch Master Cylinder ......................Clutch Master Cylinder Removal ..................Clutch Master Cylinder Installation .................. Clutch Master Cylinder Disassembly/Assembly..............
  • Page 262: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 263 CLUTCH 6-3 Exploded View Fastener N·m kgf·m ft·lb Remarks 1 Clutch Reservoir Cap (for reference) 0.15 13 in·lb 2 Clutch Master Cylinder Bleed Valve 3 Clutch Reservoir Bracket Bolt 0.70 61 in·lb 4 Clutch Lever Pivot Bolt Locknut 0.61 53 in·lb 5 Clutch Master Cylinder Clamp Bolts 0.92 80 in·lb...
  • Page 264: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Clutch Lever Position Adjustable type (to suit rider) – – – Clutch Lever Free Play Non-adjustable – – – Clutch Fluid Grade DOT4 – – – Clutch Spring Plate Free Play (Usable Range) –...
  • Page 265: Special Tools And Sealant

    CLUTCH 6-5 Special Tools and Sealant Inside Circlip Pliers: Clutch Holder: 57001-143 57001-1243 Bearing Driver Set: Liquid Gasket, TB1211F: 57001-1129 92104-0004...
  • Page 266: Clutch Lever

    6-6 CLUTCH Clutch Lever Clutch Lever Removal/Installation WARNING If the starter lockout switch pin has been damaged the starter lockout system will not work properly. This allows the motorcycle to be started in gear with the clutch lever released (clutch engaged), creat- ing sudden forward movement that can result in an accident or injury.
  • Page 267 CLUTCH 6-7 Clutch Lever NOTICE Do not adjust the adjuster [A]. That has a bad affect the clutch feeling. If turn the adjuster, the clutch master cylinder assembly must be replaced. • Install: Lever Spring [A] Push Rod Assembly [B] Knocker [C] •...
  • Page 268: Clutch Lever Position Adjustment

    6-8 CLUTCH Clutch Lever Clutch Lever Position Adjustment The clutch lever position can be adjusted to suit the oper- ator’s hand. • Push the lever forward, turn the adjuster [A] and choose a suitable lever position. Adjuster Turn in ← →...
  • Page 269: Clutch Master Cylinder

    CLUTCH 6-9 Clutch Master Cylinder Clutch Master Cylinder Removal • Remove the upper fairing (see Upper Fairing Removal in the Frame chapter). • Drain the clutch fluid from the reservoir (see Clutch Fluid Change in the Periodic Maintenance chapter). • Open the clamps [A] and clear the starter lockout switch lead [B].
  • Page 270: Clutch Master Cylinder Disassembly/assembly

    6-10 CLUTCH Clutch Master Cylinder • Align the punch mark [A] on the handlebar with the mating surface [B] of the master cylinder clamp. • Tighten the upper clamp bolt first, and then the lower clamp bolt. There will be a gap at the lower part of the clamp after tightening.
  • Page 271: Clutch Slave Cylinder

    CLUTCH 6-11 Clutch Slave Cylinder Clutch Slave Cylinder Removal • Remove: Banjo Bolt [A] Clutch Slave Cylinder Bolts [B] Slave Cylinder [C] NOTICE Immediately wash away any clutch fluid that spills. It may damage painted surfaces. ○ Perform the following if the clutch slave cylinder is to be removed but not disassembled.
  • Page 272 6-12 CLUTCH Clutch Slave Cylinder • Apply a non-permanent locking agent to the threads of the slave cylinder mounting bolts. Clutch Slave Cylinder Mounting Bolts (L = 20 mm ) [A] Clutch Slave Cylinder Mounting Bolt (L = 65 mm ) [B] •...
  • Page 273: Clutch Fluid

    CLUTCH 6-13 Clutch Fluid Clutch Fluid Level Inspection • Refer to the Clutch Fluid Level Inspection in the Periodic Maintenance chapter. Clutch Fluid Change • Refer to the Clutch Fluid Change in the Periodic Mainte- nance chapter. Bleeding the Clutch Line WARNING Air in the clutch lines diminish clutch performance and can cause an accident resulting in injury or...
  • Page 274 6-14 CLUTCH Clutch Fluid • Bleed the clutch 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 clutch lever until it becomes hard, and apply the clutch lever and hold it [A].
  • Page 275: Clutch Hose Removal/installation

    CLUTCH 6-15 Clutch Fluid WARNING Mixing brands and types of hydraulic fluid lowers the fluid’s boiling point, cause rubber part to de- teriorate and can reduce the hydraulic clutch sys- tem’s effectiveness and cause an accident resulting in injury or death. Do not mix two brands of brake fluid.
  • Page 276: Clutch Cover

    6-16 CLUTCH Clutch Cover Clutch Cover Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Clutch Cover Bolts [A] Brackets [B]...
  • Page 277: Clutch Cover Assembly

    CLUTCH 6-17 Clutch Cover • Remove: Oil Filler Plug [A] Crankshaft Timing Plug [B] Clutch Outer Cover Bolts [C] Clutch Outer Cover [D] • Remove: Circlip [A] Oil Level Inspection Window [B] Special Tool - Inside Circlip Pillers: 57001-143 Clutch Cover Assembly •...
  • Page 278: Clutch Removal

    6-18 CLUTCH Clutch Clutch Removal • Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] with Spring Holders Clutch Springs Clutch Spring Plate [B] • Remove: Washer [A] Thrust Bearing [B] Pusher [C] Friction Plates and Steel Plates •...
  • Page 279: Clutch Installation

    CLUTCH 6-19 Clutch • Remove: Needle Bearing [A] Sleeve [B] Clutch Installation • Install the clutch housing [A]. ○ Fit the holes [B] to the projections [C]. ○ Engage the clutch housing gear with the crankshaft pri- mary gear [D]. •...
  • Page 280 6-20 CLUTCH Clutch • Install the four torque limiter springs [A] as shown. Tangs [B] ○ Do not over lap the tang of the springs. • Install the toothed washer [A]. • Replace the clutch hub nut [A] with a new one. •...
  • Page 281 CLUTCH 6-21 Clutch • Install the following as shown in the figure. Friction Plates [A] [B] Steel Plates [C] Spring Seat [D] Spring [E] Clutch Hub [F] NOTE ○ The lining blocks [G] of the friction plate [B] are larger than them of the friction plates [A].
  • Page 282: Spring Plate Free Play Measurement

    6-22 CLUTCH Clutch Spring Plate Free Play Measurement Insufficient clutch free play will cause the engine braking effect to be more sudden, resulting in rear wheel hop. On the other hand, if the free play is excessive, the clutch lever may feel “spongy”...
  • Page 283: Spring Plate Free Play Adjustment

    CLUTCH 6-23 Clutch Spring Plate Free Play Adjustment NOTE ○ The free play adjustment is performed by replacing the steel plate(s). • Measure the clutch spring plate free play (see Clutch Spring Plate Free Play Measurement), and then replace the steel plate(s) which brings the free play within the usable range.
  • Page 284: Clutch Plate, Wear, Damage Inspection

    6-24 CLUTCH Clutch Clutch Plate, Wear, Damage Inspection • Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. • Measure the thickness of each friction plate [A] at several points. If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones.
  • Page 285: Clutch Housing Spline Inspection

    CLUTCH 6-25 Clutch Clutch Housing Spline Inspection • Visually inspect where the teeth [A] on the steel plates wear against the sub clutch hub splines [B]. If there are notches worn into the splines, replace the sub clutch hub. Also, replace the steel plates if their teeth are damaged.
  • Page 287 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealants ....................Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ Oil Pan Removal .......................
  • Page 288: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 289 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Filler Plug 89 in·lb Oil Pump Drive Chain Guide Bolts 89 in·lb Oil Pump Driven Gear Bolt 89 in·lb L, Lh Oil Passage Plugs Oil Cooler Bolts L, S Oil Filter G, R...
  • Page 290: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 291 ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart 1. Camshaft Oil Passage 2. Camshaft Chain Tensioner 3. Crankshaft Oil Passage 4. Rear Balancer 5. Supercharger Oil Filter 6. Supercharger Chain Tensioner 7. Supercharger Impeller 8. Supercharger Chain Oil Jet 9. Piston Oil Jet 10.
  • Page 292: Specifications

    7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SG, SH, SJ, SL, or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity: 3.9 L (4.1 US qt) (When filter is not removed.) 4.4 L (4.7 US qt) (When filter is removed.) 5.0 L (5.3 US qt) (When engine is completely dry.) Between upper and lower level lines (Wait 2 ∼...
  • Page 293: Special Tools And Sealants

    ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealants Outside Circlip Pliers: Oil Pressure Gauge Adapter, PT3/8: 57001-144 57001-1233 Oil Pressure Gauge, 10 kgf/cm²: Liquid Gasket, TB1211: 57001-164 56019-120...
  • Page 294: Engine Oil And Oil Filter

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter according to the periodic maintenance chart.
  • Page 295: Oil Pan

    ENGINE LUBRICATION SYSTEM 7-9 Oil Pan Oil Pan Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Oil Pan Bolts [A] Bracket [B] Oil Pan [C] Oil Pan Gasket...
  • Page 296: Oil Screen

    7-10 ENGINE LUBRICATION SYSTEM Oil Screen Oil Screen Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Screen [A] Oil Screen Installation • Clean the oil screen (see Oil Screen Cleaning). • Replace the O-ring [A] with a new one, and install it. •...
  • Page 297: Oil Screen Cleaning

    ENGINE LUBRICATION SYSTEM 7-11 Oil Screen Oil Screen Cleaning • Remove the oil screen (see Oil Screen Removal). • Clean the oil screen with a high flash-point solvent from the inside [A] to the outside (from the clean side to the dirty side), and remove the particles stuck.
  • Page 298: Oil Pressure Relief Valve

    7-12 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Oil Screen (see Oil Screen Removal) Oil Pressure Relief Valve [A] Oil Pressure Relief Valve Cover [B] Oil Pressure Relief Valve Installation • Apply a non-permanent locking agent to the threads of the oil pressure relief valve.
  • Page 299: Oil Pump

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump Oil Pump Removal • Remove: Water Pump (see Water Pump Removal in the Cooling System chapter) Oil (Water) Pump Shaft [A] with Inner Rotor [B] and Pin Outer Rotor [C] Oil Pump Installation • Apply molybdenum disulfide oil solution to the outer rotor [A].
  • Page 300: Oil Pump Driven Gear Installation

    7-14 ENGINE LUBRICATION SYSTEM Oil Pump • Remove: Oil Pump Drive Chain Guide Bolts [A] Oil Pump Drive Chain Guide [B] Oil Pump Driven Gear Bolt [C] Oil Pump Driven Gear [D] Spacer NOTE ○ The oil pump driven gear bolt has a left-hand threads. Oil Pump Driven Gear Installation •...
  • Page 301: Oil Pump Driven Gear Shaft Installation

    ENGINE LUBRICATION SYSTEM 7-15 Oil Pump Oil Pump Driven Gear Shaft Installation • Apply molybdenum disulfide grease [A] to the oil pump driven gear shaft. • Apply molybdenum disulfide oil solution [B] to the crankcase. • Install the oil pump driven gear shaft and washer [C]. •...
  • Page 302: Oil Cooler

    7-16 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top chapter)
  • Page 303: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-17 Oil Pressure Measurement Oil Pressure Measurement • Remove: Lower Fairings (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 304: Oil Pressure Switch

    7-18 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). •...
  • Page 305 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................8-10 Swingarm Mounting Plate Removal.................. 8-12 Swingarm Mounting Plate Installation................8-12...
  • Page 306: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 307 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Engine Mounting Bolts (Rear) L, S Front Engine Mounting Bolts (Front) L, S Swingarm Mounting Plate Nut (Upper) R, S Rear Frame Front Bolts Swingarm Pivot Shaft Nut 11.0 79.7 Swingarm Mounting Plate Bolt (Lower)
  • Page 308: Engine Removal/installation

    8-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Support the front and rear of the motorcycle with the stands. WARNING Motorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to use the front and rear stands when removing the engine. NOTICE Be sure to use the front and rear stands when re- moving the engine, or the motorcycle may fall over.
  • Page 309 ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation • Remove: Knock Sensor Bolt [A] Knock Sensor [B] • Disconnect: Gear Position Sensor Lead Connector [C] Quick Shifter Sensor Lead Connector [D] • Open the clamp [A] and free the oil pressure switch lead [B] and hoses [C].
  • Page 310 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Brake Pipe Fitting Bolt [A] • Slide the clamp and disconnect the water hose [B]. • Remove the water hose fitting [A] to prevent damage to the fitting. • Disconnect: Water Temperature Sensor Connector [A]. •...
  • Page 311 ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Open the clamps [A] and free the leads. • Remove: Side Stand Bracket Bolt (Rear) [A] and Nut Side Stand Bracket Bolts (Front) [B] and Washers Side Stand Bracket [C] • Remove : Radiator Stay Bolt [A] Radiator Stay [B] •...
  • Page 312 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Loosen (Both Sides): Rear Frame Front Bolt [A] • Loosen: Swingarm Mounting Plate Nut (Upper) [A] Swingarm Pivot Shaft Nut [B] Swingarm Mounting Plate Bolt (Lower) [C] • Remove : Rear Brake Reservoir Bolt [D] •...
  • Page 313 ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation • Remove the engine [A] from the frame. • If necessary, prepare a new swingarm mounting plate [A] to hold the engine with the engine stand. Swingarm Mounting Plate (Part Number: 32036-0353)
  • Page 314: Engine Removal

    8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Installation • Support the front and rear of the motorcycle with the stands. • Install the dowel pins [A]. • Install the engine to the swingarm mounting plate [B] on the frame. ○ Hang the drive chain to the output shaft. •...
  • Page 315 ENGINE REMOVAL/INSTALLATION 8-11 Engine Removal/Installation • Run the leads, cables and hoses correctly (see Cable, Wire, and Hose Routing section in the Ap- pendix chapter). • Install the removed parts (see appropriate chapters). • Adjust: Throttle Cables (see Throttle Control System Inspection in the Periodic Maintenance chapter) Drive Chain (see Drive Chain Slack Inspection in the Periodic Maintenance chapter) •...
  • Page 316: Swingarm Mounting Plate Removal

    8-12 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Swingarm Mounting Plate Removal • Remove: Engine (see Engine Removal) Swingarm (see Swingarm Removal in the Suspension chapter) • Remove the swingarm mounting plate [A] from the frame. Swingarm Mounting Plate Installation • Install the swingarm mounting plate, and tighten its bolts and nuts temporarily.
  • Page 317 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........Rear Balancer Installation.... 9-34 Specifications ........Balancer Adjustment....9-37 Special Tools and Sealants ....Balancer Damper Inspection..9-38 Crankcase ......... 9-10 Starter Motor Clutch and Torque Crankcase Splitting ...... 9-10 Limiter ..........9-39 Crankcase Assembly ....
  • Page 318: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 319 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Breather Cover Bolts 89 in·lb Balancer Shaft Clamp Bolts 89 in·lb Balancer Shaft Clamp Lever Bolts Breather Plate Bolts 89 in·lb Oil Passage Plugs Oil Passage Plug (R1/8) Oil Nozzles (M5) 0.31 27 in·lb Transmission Oil Nozzle Pipe Bolts...
  • Page 320 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 321 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bearing Holder Screws 0.51 44 in·lb Transmission Case Bolts Shift Drum Cam Holder Bolt 106 in·lb Oil Nozzles (M8) 0.51 44 in·lb Gear Positioning Lever Bolt 106 in·lb Shift Shaft Return Spring Pin Shift Lever Clamp Bolt 87 in·lb G: Apply grease.
  • Page 322: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankcase, Crankshaft/Con- necting 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 0.6 mm (0.02 in.) Side Clearance...
  • Page 323 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankshaft Main Bearing Insert Thickness: 1.491 ∼ 1.495 mm (0.05870 ∼ 0.05886 in.) Brown – – – 1.495 ∼ 1.499 mm (0.05886 ∼ 0.05902 in.) Black – – – 1.499 ∼ 1.503 mm (0.05902 ∼ 0.05917 in.) Blue –...
  • Page 324 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 92139-0820 None None Black 92139-0819 ○ ○ ○ None Blue 92139-0818 Crankshaft Main Bearing Insert Selection Crankcase Main Crankshaft Main Bearing Insert*...
  • Page 325: Special Tools And Sealants

    CRANKSHAFT/TRANSMISSION 9-9 Special Tools and Sealants Piston Ring Compressor Belt, 67 ∼ 79: Inside Circlip Pliers: 57001-143 57001-1097 Outside Circlip Pliers: Bearing Driver Set: 57001-144 57001-1129 Piston Pin Puller Assembly: Liquid Gasket, TB1216B: 57001-910 92104-1064 Piston Ring Compressor Grip: 57001-1095...
  • Page 326: Crankcase

    9-10 CRANKSHAFT/TRANSMISSION 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: Cylinder Head (see Cylinder Head Removal in the En- gine Top End chapter) Clutch (see Clutch Removal in the Clutch chapter) Supercharger (see Supercharger Removal in the Fuel...
  • Page 327: Crankcase Assembly

    CRANKSHAFT/TRANSMISSION 9-11 Crankcase • Remove the upper crankcase bolts, following the speci- fied sequence. ○ Firstly, loosen the M6 bolts [A]. ○ Secondly, loosen the M7 bolt [B]. ○ Lastly, loosen the M8 bolts [C]. • Remove the lower crankcase bolts, following the specified sequence.
  • Page 328 9-12 CRANKSHAFT/TRANSMISSION Crankcase • Install the clamp and breather hose [A] as shown. ○ Face the knob of the clamp to the left side [B]. • Press the new ball bearing [A] until it is bottomed. ○ Face the oil seal side of the bearing to the bottom. Special Tool - Bearing Driver Set: 57001-1129 •...
  • Page 329 CRANKSHAFT/TRANSMISSION 9-13 Crankcase Lower Crankcase Assembly • Press the new ball bearing [A] until it is bottomed. ○ Face the marked side of the bearing to the engine inside. Special Tool - Bearing Driver Set: 57001-1129 • Install the bearing holder [B] so that the tapered side faces engine inside.
  • Page 330 9-14 CRANKSHAFT/TRANSMISSION Crankcase • Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. • Apply liquid gasket [A] to the mating surface of the lower crankcase half.
  • Page 331 CRANKSHAFT/TRANSMISSION 9-15 Crankcase • Through the breather hose [A] to the hole [B] of the lower crankcase. • Fit the lower crankcase half to the upper crankcase half. • The M10 bolts [A] has a copper plated washers [B], re- place them with new ones.
  • Page 332 9-16 CRANKSHAFT/TRANSMISSION Crankcase • Tighten the upper crankcase bolts using the following steps. ○ Replace the M8 bolt washers [A] with new ones. ○ Tighten the M8 bolts with washers. Torque - Crankcase Bolts (M8): 27 N·m (2.8 kgf·m, 20 ft·lb) ○...
  • Page 333: Crankshaft And Connecting Rods

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove: Connecting Rod Big End Nuts [A] Connecting Rod Big End Caps [B] NOTE ○ Mark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions.
  • Page 334: Connecting Rod Removal

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts. 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 335: Connecting Rod Installation

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods Connecting Rod Installation NOTE ○ If the crankshaft is replaced with a new one, refer to the Connecting Rod Big End Bearing/Crankshaft Main Bearing Insert Selection in the Specifications. NOTICE To minimize vibration, the connecting rods should have the same weight mark.
  • Page 336 9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install the crankshaft (see Crankshaft Installation). • Install each connecting rod on its original crankpin. ○ The connecting rod big end is bolted using the “plastic region fastening method”. ○ This method precisely achieves the needed clamping force without exceeding it unnecessarily, allowing the use of thinner, lighter bolts further decreasing connecting rod weight.
  • Page 337 CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods • Install new bolts and nuts in reused connecting rod. If the connecting rod assembly was replaced, use the bolts and nuts attached to the new connecting rod assem- bly. • Apply a small amount of molybdenum disulfide oil solution to the following portions.
  • Page 338: 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 assembly was replaced, use the bolts and nuts attached to the new connecting rod assem- bly. • Apply a small amount of molybdenum disulfide oil solution to the following portions.
  • Page 339: 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 340 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 341: 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 342: 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 (press gauge) to journal width. • Place a strip on each journal parallel to the crankshaft installed in the correct position.
  • Page 343 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 Markings, ○ “ ” or no mark. • Tighten the crankcase bolts to the specified torque (see Crankcase Assembly).
  • Page 344: Pistons

    9-28 CRANKSHAFT/TRANSMISSION Pistons Piston Removal • Remove: Crankshaft (see Crankshaft Removal) • Remove the piston together with the connecting rod to the cylinder head side. NOTICE Discard the connecting rod bolts and nuts. To pre- vent damage to the crankpin surfaces, do not al- low the connecting rod bolts to bump against the crankpins.
  • Page 345: Piston Installation

    CRANKSHAFT/TRANSMISSION 9-29 Pistons Piston Installation NOTE ○ If a new piston is used, use new piston ring. • Apply molybdenum disulfide oil solution to the oil ring ex- pander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] not butt together. •...
  • Page 346: Cylinder (upper Crankcase) Wear Inspection

    9-30 CRANKSHAFT/TRANSMISSION Pistons • Apply molybdenum disulfide oil solution to the cylinder bore and piston skirt. • Install the piston with its dent mark [A] facing exhaust side. • Using the piston ring compressor assembly [B] to install the piston from the cylinder head side. Special Tools - Piston Ring Compressor Grip: 57001-1095 67 ∼...
  • Page 347: 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 348: Balancer

    9-32 CRANKSHAFT/TRANSMISSION Balancer Front Balancer Removal • Split the crankcase (see Crankcase Splitting). • Remove the balancer shaft clamp lever bolt [A]. • Pry off the clamp lever [A] until the oil seal [B] is removed. • Pull the balancer shaft [C] out of the crankcase. The bal- ancer weight and gear assembly [D] come off with needle bearings and washers.
  • Page 349 CRANKSHAFT/TRANSMISSION 9-33 Balancer • Apply molybdenum disulfide oil solution to the needle bearings. Install the needle bearings. • Fit the washers [A] on both ends of the weight and gear assembly. ○ The projected sides [B] face inward. • Position the crankshaft at #2, 3 position TDC. •...
  • Page 350: Rear Balancer Removal

    9-34 CRANKSHAFT/TRANSMISSION Balancer Rear Balancer Removal • Remove: Thermostat (see Thermostat Removal in the Cooling system chapter) Right Throttle Body Assy Holder [A] (see Throttle Body Assy Holder Removal in the Engine Top End chapter) • Disconnect the water temperature sensor lead connector [B].
  • Page 351 CRANKSHAFT/TRANSMISSION 9-35 Balancer • Apply molybdenum disulfide oil solution to the ribs [A] of the balancer weight. • Install the balancer weight [A] into the gear [B]. ○ Align the punch mark [C] of the balancer weight to the groove [D] of the gear. •...
  • Page 352 9-36 CRANKSHAFT/TRANSMISSION Balancer • Install the balancer shaft clamp lever [A]. • Apply a non-permanent locking agent to the threads of the balancer shaft clamp lever bolt [B]. • Tighten: Torque - Balancer Shaft Clamp Lever Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) •...
  • Page 353: Balancer Adjustment

    CRANKSHAFT/TRANSMISSION 9-37 Balancer • Replace the washer [A] with a new one. • Tighten: Torque - Breather Cover Bolts [B]: 10 N·m (1.0 kgf·m, 89 in·lb) • Install the removed parts (see appropriate chapters). Balancer Adjustment NOTE ○ First, adjust the front balancer, next the rear balancer. •...
  • Page 354: Balancer Damper Inspection

    9-38 CRANKSHAFT/TRANSMISSION Balancer • Install the removed parts (see appropriate chapters). • Start the engine and warm it up thoroughly. • Confirm the whining sound from the rear balancer. If there is the whining sound from the rear balancer, adjust the rear balancer again in the same procedure.
  • Page 355: Starter Motor Clutch And Torque Limiter

    CRANKSHAFT/TRANSMISSION 9-39 Starter Motor Clutch and Torque Limiter Starter Motor Clutch Removal • Split the crankcase (see Crankcase Splitting). • Remove: Torque Limiter (see Torque Limiter Removal) Starter Motor Clutch Assy [A] Starter Motor Clutch Installation • Apply molybdenum disulfide grease to the needle bearing [A].
  • Page 356: Starter Motor Clutch Assembly

    9-40 CRANKSHAFT/TRANSMISSION Starter Motor Clutch and Torque Limiter Starter Motor Clutch Assembly • Install the rubber dampers [A] as shown. Coupling Side [B] Drive Gear Side [C] • Apply molybdenum disulfide oil solution to the dampers. • Insert the pins [A] into the hole [B]. •...
  • Page 357: Starter Motor Clutch Damper Inspection

    CRANKSHAFT/TRANSMISSION 9-41 Starter Motor Clutch and Torque Limiter Starter Motor Clutch Damper Inspection • Remove the starter motor clutch and disassemble the coupling and gear assembly. • Visually inspect the rubber dampers [A]. If they appear damaged or deteriorated, replace them. Starter Clutch Inspection •...
  • Page 358: Transmission

    9-42 CRANKSHAFT/TRANSMISSION 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) Supercharger Chain (see Supercharger Housing Assy...
  • Page 359: Transmission Assy Disassembly

    CRANKSHAFT/TRANSMISSION 9-43 Transmission Transmission Assy Disassembly • Remove the transmission assy (see Transmission Assy Removal). • Remove the following parts from the transmission case [A]. Shift Rod [B] Shift Forks [C] Drive Shaft Assy [D] Output Shaft Assy [E] NOTE ○...
  • Page 360: Transmission Assy Assembly

    9-44 CRANKSHAFT/TRANSMISSION Transmission Transmission Assy Assembly • Press the new ball bearing [A] until it is bottomed. ○ Face the oil seal side of the bearing to the bottom. Special Tool - Bearing Driver Set: 57001-1129 • Install the bearing holders [B] so that the taper side faces outside.
  • Page 361 CRANKSHAFT/TRANSMISSION 9-45 Transmission • Install the drive shaft assy [A] and output shaft assy [B] as a set in the transmission case [C]. ○ Install the together following parts when removing the out- put shaft assy. Shifter [D] Washer [E] 1st Gear [F] Needle Bearing [G] Shim [H]...
  • Page 362: Transmission Assy Installation

    9-46 CRANKSHAFT/TRANSMISSION Transmission Transmission Assy Installation • Be sure that the dowel pins and washer [A] are in position. Engine Inside [B] Engine Outside [C] Starter Motor Clutch Shaft [D] • Install the transmission assy on the crankcase. • Tighten: Torque - Transmission Case Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb) •...
  • Page 363: Transmission Shaft Disassembly

    CRANKSHAFT/TRANSMISSION 9-47 Transmission Transmission Shaft Disassembly NOTICE Do not disassemble or adjust the transmission shafts [A], because they are adjusted or set at the manufacturer. Adjustment of these parts could result in poor performance, requiring replacement of the transmission shafts. Shift Drum and Fork Removal •...
  • Page 364: Shift Fork/shifter Groove Wear Inspection

    9-48 CRANKSHAFT/TRANSMISSION Transmission Shift Fork/Shifter Groove Wear Inspection • Measure the thickness of the shift fork ears [A], and mea- sure the width [B] of the shifters of the output shaft. If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced.
  • Page 365: External Shift Mechanism

    CRANKSHAFT/TRANSMISSION 9-49 External Shift Mechanism Shift Pedal Removal • Remove the engine sprocket cover (see Engine Sprocket Removal in the Final Drive chapter). • Remove the quick shifter sensor connector [A] from the bracket. • Disconnect the quick shifter sensor connector. •...
  • Page 366: Shift Pedal Installation

    9-50 CRANKSHAFT/TRANSMISSION External Shift Mechanism • Remove: Shift Pedal Mounting Bolt [A] Footpeg [B] Shift Pedal [C] Washers [D] Shift Pedal Installation When installing the tie-rod [A] and quick shifter sensor [B] to the shift pedal [C] and shift lever clamp [D], note the following.
  • Page 367 CRANKSHAFT/TRANSMISSION 9-51 External Shift Mechanism • After installation, confirm that the shift pedal [A] is posi- tioned as shown. About 11 mm (0.43 in.) [B] About 90° [C] If the pedal position is different, adjust it as follows. ○ To adjust the pedal position, loosen the front locknut [D] (left-hand threads) and rear locknut [E], and then turn the tie-rod [F].
  • Page 368: External Shift Mechanism Removal

    9-52 CRANKSHAFT/TRANSMISSION External Shift Mechanism External Shift Mechanism Removal • Remove: Shift Lever (see Shift Pedal Removal) Clutch Cover (see Clutch Cover Removal in the Clutch chapter) Circlip [A] Shift Shaft Assembly [B] Washers [C] Special Tool - Outside Circlip Pliers: 57001-144 •...
  • Page 369: External Shift Mechanism Inspection

    CRANKSHAFT/TRANSMISSION 9-53 External Shift Mechanism • Install: Shift Shaft Assembly [A] and Washers ○ Fit the hole [B] and return spring pin [C]. • Replace the circlip [A] with a new one. • Install: Circlip Special Tool - Outside Circlip Pliers: 57001-144 ○...
  • Page 370 9-54 CRANKSHAFT/TRANSMISSION External Shift Mechanism • Check the return spring pin [A] is not loose. If it is loose, remove it, apply a non-permanent locking agent to the threads, and tighten it. Torque - Shift Shaft Return Spring Pin: 29 N·m (3.0 kgf·m, 21 ft·lb) •...
  • Page 371 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Front Wheel Inspection ..................... 10-8 Rear Wheel Removal......................10-8 Rear Wheel Installation..................... 10-9 Rear Wheel Inspection......................
  • Page 372: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 373 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolts Air Valve Nuts 0.46 40 in·lb Front Axle Nut 13.0 93.7 Rear Wheel Nuts 11.2 81.1 G: Apply grease. HG: Apply high-temperature grease. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specified tightening sequence.
  • Page 374: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Front: 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.) Rear: Axial TIR 0.3 mm (0.01 in.) or less TIR 1.0 mm (0.04 in.) Radial...
  • Page 375: Special Tools

    WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: Bearing Remover Shaft, 13: 57001-1129 57001-1377 Bearing Remover Head, 25 × 28: Wheel Balance Adjustment Tool: 57001-1346 57001-1832...
  • Page 376: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove the front caliper mounting bolts [A] on both sides. • Remove the clamp [B] to free the brake hose. • Take the front calipers off the fork legs. • Loosen: Front Axle Clamp Bolts [A] •...
  • Page 377 WHEELS/TIRES 10-7 Wheels (Rims) • Apply a thin coat of grease [A] to the front axle [B] for rust prevention. About 10 mm (0.4 in.) [C] About 30 mm (1.2 in.) [D] NOTE ○ Do not apply grease to the threads of the axle. NOTE ○...
  • Page 378: Front Wheel Inspection

    10-8 WHEELS/TIRES Wheels (Rims) Front Wheel Inspection • Raise the front wheel off the ground with a suitable stand. • Spin the front wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the front hub bearings (see Front Hub Bearing Removal/Installation).
  • Page 379: Rear Wheel Installation

    WHEELS/TIRES 10-9 Wheels (Rims) • Remove: Rear Wheel Nuts [A] Washers [B] Rear Wheel [C] Rear Wheel Installation • Be sure to install the plate [A]. • Install: Rear Wheel [B] Washers [C] • Tighten the rear wheel nuts [D] to a snug fit following the specified sequence [1 ∼...
  • Page 380: Axle Inspection

    10-10 WHEELS/TIRES Wheels (Rims) • Remove the rear wheel with the tire, and support it using the special tool. Special Tool - Wheel Balance Adjustment Tool: 57001 -1832 ○ Install the tool [A] to the left side. ○ Install the washers of the rear wheel nuts, and tighten the wheel hub mounting bolts [B] of the special tool.
  • Page 381: Balance Inspection

    WHEELS/TIRES 10-11 Wheels (Rims) Balance Inspection Front Wheel • Remove the front wheel (see Front Wheel Removal). • Support the front wheel so that it can be spun freely. • Spin the front wheel lightly, and mark [A] the front wheel at the top when the wheel stops.
  • Page 382: Balance Weight Removal

    30 g (1.06 oz.) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20 and 30 grams (0.35, 0.71 and 1.06 oz.) sizes. An imbalance of less than 10 grams (0.35 oz.) will not usually affect running stability.
  • Page 383 WHEELS/TIRES 10-13 Wheels (Rims) • Be sure to install the balance weight. ○ Check that the blade [A] and clip [B] are fully seated on the rim [C] and that the clip is hooked over the rib [D]. Left Side [E] Right Side [F]...
  • Page 384: Tires

    10-14 WHEELS/TIRES Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheels and Tires Inspection in the Periodic Maintenance chapter. Tire Removal • Remove: Wheels (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...
  • Page 385 WHEELS/TIRES 10-15 Tires • Install a new valve [A] in the rim. 45° [B] Front [C] Right [D] • Apply a non-permanent locking agent to the threads of air valve nut. • Tighten the valve nut. Torque - Air Valve Nuts: 4.5 N·m (0.46 kgf·m, 40 in·lb) ○...
  • Page 386: 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 387: Hub Bearing

    WHEELS/TIRES 10-17 Hub Bearing Front Hub Bearing Removal • Remove the front wheel (see Front Wheel Removal), and take out the following. Collars [A] Grease Seals [B] • Use the bearing remover to remove the hub bearings [A]. NOTICE Do not lay the wheel on the ground with the disc facing down.
  • Page 388: Front Hub Bearing Inspection

    10-18 WHEELS/TIRES Hub Bearing Front Hub Bearing Inspection Since the hub bearings are made to extremely close tol- erances, the clearance can not normally be measured. NOTE ○ Do not remove any bearings for inspection. If any bear- ings are removed, they will need to be replaced with new ones.
  • Page 389 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 Drive Chain Wear Inspection .................... 11-6 Drive Chain Lubrication..................... 11-6 Drive Chain Removal ......................
  • Page 390: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 391 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Sprocket Nut 14.8 Chain Guide Bolt (L = 14 mm) 89 in·lb Chain Guide Bolts (L = 30 mm) 89 in·lb Engine Sprocket Cover Bolt 89 in·lb Bearing Housing Clamp Bolts Rear Sprocket Nuts R, S Rear Axle Nut, First...
  • Page 392: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain 25 ∼ 35 mm (1.0 ∼ 1.4 in.) Drive Chain Slack – – – Drive Chain Wear (20-link Length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 319 mm (12.6 in.) Standard Chain: Make ENUMA...
  • Page 393: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129 Outside Circlip Pliers: 57001-144...
  • Page 394: 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. Drive Chain Wear Inspection •...
  • Page 395 FINAL DRIVE 11-7 Drive Chain • Screw the pin holder until it touches the chain pin. • Be sure that the cutting pin hits center of the chain pin. • Screw the handlebar [A] into the body. • Turn the pin holder with the wrench [B] clockwise to ex- tract the chain pin.
  • Page 396 11-8 FINAL DRIVE Drive Chain • Turn the pin holder by a wrench clockwise until two pins of link come into groove of the plate holder (A). • Take off the plate holder. • Set the plate holder (B) [A] and cutting and riveting pin [B] as shown.
  • Page 397 FINAL DRIVE 11-9 Drive Chain • After staking, check the staked area of the link pin for cracks. • Measure the outside diameter [A] of the link pin and link plates width [B]. Link Pin Outside Diameter 5.9 ∼ 6.2 mm (0.23 ∼ 0.24 in.) Standard: Link Plates Outside Width 20.75 ∼...
  • Page 398: Sprocket, Coupling

    11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Loosen the drive chain (see Drive Chain Slack Adjust- ment in the Periodic Maintenance chapter). • Remove: Engine Sprocket Cover Bolt [A] Quick Rivets [B] Engine Sprocket Cover [C] • Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter).
  • Page 399: Engine Sprocket Installation

    FINAL DRIVE 11-11 Sprocket, Coupling Engine Sprocket Installation • Replace the sprocket washer with a new one. • Engage the drive chain and engine sprocket. • Install the engine sprocket to the output shaft. • Apply molybdenum disulfide oil solution to the threads and the seating surface of the engine sprocket nut.
  • Page 400: Rear Sprocket Removal

    11-12 FINAL DRIVE Sprocket, Coupling • Install: Collar [A] Engine Sprocket Cover [B] Quick Rivets [C] • Apply a non-permanent locking agent to the threads of engine sprocket cover bolt [D]. • Tighten: Torque - Engine Sprocket Cover Bolt: 10 N·m (1.0 kgf·m, 89 in·lb) Rear Sprocket Removal •...
  • Page 401: Coupling Removal

    FINAL DRIVE 11-13 Sprocket, Coupling Coupling Removal • Loosen the drive chain (see Drive Chain Slack Adjust- ment in the Periodic Maintenance chapter). • Remove: Bolts [A] and Washers Guard [B] Collar [C] Snap Ring [D] Rear Axle Nut [E] and Washer NOTE ○...
  • Page 402: Coupling Bearing Removal

    11-14 FINAL DRIVE Sprocket, Coupling • Tighten: Torque - Rear Axle Nut [A], First: 220 N·m (22.4 kgf·m, 162 ft·lb) NOTE ○ Use the 35 mm wrench (12 pt.) while holding the right side of the rear axle with the Allen wrench. •...
  • Page 403: Coupling Bearing Inspection

    FINAL DRIVE 11-15 Sprocket, Coupling • Apply grease to the O-ring [A] and install it. • Install the coupling dampers [B] so that its projections fac- ing upward. • Install the outer coupling to the inner coupling. • Install the removed parts (see appropriate chapters). Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances, the clearance can not normally be measured.
  • Page 404: Bearing Housing Installation

    11-16 FINAL DRIVE Sprocket, Coupling • Remove: Circlip [A] Rear Caliper Holder [B] Bearing Housing [C] Special Tool - Outside Circlip Pliers: 57001-144 Bearing Housing Installation • Apply high-temperature grease to the lips of grease seals [A] and needle bearing [B]. •...
  • Page 405: Bearing Housing Bearing Installation

    FINAL DRIVE 11-17 Sprocket, Coupling Bearing Housing Bearing Installation • Replace the needle bearing, ball bearing, circlip and grease seals with new ones. • Press in the needle bearing [A]. 6.0 ±0.4 mm (0.24 ±0.02 in.) [B] Special Tool - Bearing Driver Set: 57001-1129 •...
  • Page 406: Sprocket Wear Inspection

    11-18 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 407 BRAKES 12-1 Brakes Table of Contents Exploded View........................12-3 Specifications ......................... 12-8 Brake Lever, Brake Pedal....................... 12-9 Brake Lever Removal ....................... 12-9 Brake Lever Installation ....................12-9 Brake Lever Position Adjustment..................12-9 Brake Pedal Position Inspection ..................12-9 Brake Pedal Position Adjustment..................12-9 Brake Pedal Removal .......................
  • Page 408 12-2 BRAKES Front Wheel Rotation Sensor Removal ................12-42 Front Wheel Rotation Sensor Installation ................. 12-43 Rear Wheel Rotation Sensor Removal ................12-43 Rear Wheel Rotation Sensor Installation ................12-44 Wheel Rotation Sensor Inspection..................12-45 Wheel Rotation Sensor Air Gap Inspection ..............12-45 Wheel Rotation Sensor Rotor Inspection................
  • Page 409: Exploded View

    BRAKES 12-3 Exploded View This page intentionally left blank.
  • Page 410 12-4 BRAKES Exploded View...
  • Page 411 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Fluid Reservoir Cap Screws 0.70 0.07 6.2 in·lb Front Master Cylinder Bleed Valve 0.56 49 in·lb Front Master Cylinder Clamp Bolts 0.92 80 in·lb Brake Lever Pivot Bolt Locknut 0.61 53 in·lb Front Brake Fluid Reservoir Bracket Bolt...
  • Page 412 12-6 BRAKES Exploded View...
  • Page 413 BRAKES 12-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts 24.5 2.50 18.1 Brake Pipe Joint Nuts Rear Master Cylinder Mounting Bolts Brake Pedal Bolt 0.90 78 in·lb Rear Master Cylinder Push Rod Locknut Rear Axle Nut, First 22.4 Rear Axle Nut, Final 25.5...
  • Page 414: Specifications

    12-8 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position adjustable type (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – About 68 mm (2.68 in.) below top of Pedal Position –...
  • Page 415: Brake Lever, Brake Pedal

    BRAKES 12-9 Brake Lever, Brake Pedal Brake Lever Removal • Remove the brake lever in the same way as clutch lever removal (see Clutch Lever Removal/Installation in the Clutch chapter). Brake Lever Installation • Install the brake lever in the same way as clutch lever installation (see Clutch Lever Removal/Installation in the Clutch chapter).
  • Page 416: Brake Pedal Removal

    12-10 BRAKES Brake Lever, Brake Pedal Brake Pedal Removal • Remove: Bolt [A] and Stopper Right Footpeg Bracket Bolts [B] • Remove: Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] Brake Pedal Bolt [E] and Washer [F] Brake Pedal Brake Pedal Installation •...
  • Page 417: Calipers

    BRAKES 12-11 Calipers Front Caliper Removal • Free the front wheel rotation sensor lead [A] and front brake hose [B] from the clamp [C]. • Remove the clamp [A] to free the front wheel rotation sen- sor lead [B]. • Loosen the banjo bolt [C] and tighten it loosely to prevent the fluid spillage.
  • Page 418: Rear Caliper Removal

    12-12 BRAKES Calipers • Squeeze the brake lever slowly and hold it with a band [A]. • Tighten the front caliper mounting bolt [A] [B] following specified tightening sequence. Tightening Sequence: [A → B → A] Torque - Front Caliper Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) •...
  • Page 419: Rear Caliper Installation

    BRAKES 12-13 Calipers • Loosen the banjo bolt [A] and tighten it loosely to prevent the fluid spillage. • Remove the caliper mounting bolts [B], and detach the caliper [C] from the disc. • Remove the banjo bolt and disconnect the brake hose from the caliper.
  • Page 420: Brake Pads

    12-14 BRAKES Brake Pads Front Brake Pad Removal • Remove the front caliper with the hose installed (see Front Caliper Removal). • Remove: Brake Pads [A] Front Brake Pad Installation • Check that the pad spring [A] is in place on the caliper. •...
  • Page 421: Brake Pad Wear Inspection

    BRAKES 12-15 Brake Pads • Install the brake pads [A] so that the arrow mark [B] faces the wheel rotation direction. • Install: Pad Spring [A] ○ The pad spring can install in both directions. • While pushing down the pad spring, insert the pad pin [B]. •...
  • Page 422: Master Cylinder

    12-16 BRAKES Master Cylinder Front Master Cylinder Removal • Remove: Front Brake Fluid Reservoir Bracket Bolt [A] • Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder. NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately.
  • Page 423: Front Master Cylinder Installation

    BRAKES 12-17 Master Cylinder Front Master Cylinder Installation • Run the front brake light switch lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Connect the front brake light switch connector. • Install the master cylinder clamp so that the arrow mark [A] faces upward.
  • Page 424: Rear Master Cylinder Installation

    12-18 BRAKES Master Cylinder • Remove: Cotter Pin [A] Joint Pin [B] • Drain the brake fluid from the rear brake fluid reservoir. Rear Master Cylinder Installation • Replace the cotter pin [A] with a new one. • Insert the cotter pin and bend the pin ends [B]. •...
  • Page 425: Brake Disc

    BRAKES 12-19 Brake Disc Front Brake Disc Removal • Remove: Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Bolts [A] Front Wheel Rotation Sensor Rotor [B] Front Brake Disc Mounting Bolts [C] Front Brake Disc [D] Front Brake Disc Installation •...
  • Page 426: Rear Brake Disc Installation

    12-20 BRAKES Brake Disc • Remove: Rear Brake Disc Mounting Bolts [A] Rear Wheel Rotation Sensor Rotor [B] Rear Brake Disc [C] Rear Brake Disc Installation • Install the rear brake disc [A] so that marked side [B] faces wheel side. •...
  • Page 427: Brake Disc Wear Inspection

    BRAKES 12-21 Brake Disc • Install: Washer • Tighten: Torque - Rear Axle Nut [A], First: 220 N·m (22.4 kgf·m, 162 ft·lb) NOTE ○ Use the 35 mm wrench (12 pt.) while holding the left side of the rear axle with the Allen wrench. •...
  • Page 428: Brake Fluid

    12-22 BRAKES Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter. Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action.
  • Page 429 BRAKES 12-23 Brake Fluid • Remove the rubber cap from the bleed valve on the front master cylinder. • Attach a clear plastic hose [A] to the bleed valve, and run the other end of the hose into a container. •...
  • Page 430 12-24 BRAKES Brake Fluid • Bleed the brake line and the caliper. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].
  • Page 431 BRAKES 12-25 Brake Fluid • Bleed the brake line and the caliper. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake pedal until it becomes hard, and ap- ply the brake and hold it [A].
  • Page 432 12-26 BRAKES Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. • Never reuse old brake fluid. • Do not use fluid from a container that has been left unsealed or that has been open for a long time. •...
  • Page 433: Brake Hose

    BRAKES 12-27 Brake Hose Brake Hose Removal/Installation • Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter. Brake Hose and Pipe Inspection • Refer to the Brake System Inspection in the Periodic Maintenance chapter.
  • Page 434: Kibs

    12-28 BRAKES KIBS Parts Location Front Wheel Rotation Sensor [A] Front Wheel Rotation Sensor Rotor [B] Rear Wheel Rotation Sensor [A] Rear Wheel Rotation Sensor Rotor [B] Yellow ABS Indicator Light (LED) [A] Yellow Warning Indicator Light (LED) [B] White KIBS Indicator Light (LED) [C] KIBS Hydraulic Unit [A] Fuse Box 2 [A]...
  • Page 435 BRAKES 12-29 KIBS KIBS Kawasaki Diagnosis System Connector [A]...
  • Page 436 8. Starter Relay 21. KIBS Motor Relay Fuse 25 A 9. Main Fuse 30 A 22. KIBS Solenoid Valve Relay Fuse 15 A 10. KIBS Kawasaki Diagnosis System Connec- 23. Joint Connector C 24. Joint Connector D 11. KIBS Hydraulic Unit 25.
  • Page 437 2. CAN Communication Line (High): GY/BL 3. Front Wheel Rotation Sensor Signal Input: BK/W 4. Power Supply: BR/W 5. KIBS Kawasaki Diagnosis System Terminal: P 6. Front and Rear Brake Light Switch Signal: BL 7. Unused 8. Front Wheel Rotation Sensor Signal Output: GY/Y 9.
  • Page 438: Kibs Servicing Precautions

    12-32 BRAKES KIBS KIBS Servicing Precautions There are a number of important precautions that should be followed servicing the KIBS. ○ This KIBS is designed to be used with a 12 V sealed bat- tery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 439 BRAKES 12-33 KIBS ○ The yellow ABS indicator light (LED) [A] and yellow warning indicator light (LED) [B]/white KIBS indicator light (LED) [C] may go on or blink if the tire pressure is incorrect, a non-recommended tire is installed, or the wheel is deformed.
  • Page 440: Kibs Troubleshooting Outline

    12-34 BRAKES KIBS KIBS Troubleshooting Outline When an abnormality in the system occurs, the yellow ABS indicator light (LED) goes on and/or yellow warning indicator light (LED) goes on and white KIBS indicator light (LED) blinks to alert the rider. In addition, the nature of the fault is stored in the memory of the KIBS hydraulic unit and FI ECU, and when in the self-diagnosis mode, the service code [A] is displayed on the LCD by the “B”...
  • Page 441 BRAKES 12-35 KIBS • Visually inspect the wiring for signs of burning or fraying. If any wiring is poor, replace the damaged wiring. • Pull each connector apart and inspect it for corrosion, dirt and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it.
  • Page 442 12-36 BRAKES KIBS KIBS Diagnosis Flow Chart...
  • Page 443: Inquiries To Rider

    BRAKES 12-37 KIBS Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of condition the rider is dissatisfied with. ○ Try to find out exactly what problem occurs under exactly what conditions by asking the rider; know- ing this information may help you reproduce the problem in the shop.
  • Page 444 12-38 BRAKES KIBS Pre-Diagnosis Inspection 1...
  • Page 445: Self-diagnosis Outline

    BRAKES 12-39 KIBS Pre-Diagnosis Inspection 2 Self-diagnosis Outline Refer to the Self-Diagnosis System chapter for the self-diagnosis or service code.
  • Page 446: Abs And Kibs Indicator Lights (led) Inspection

    12-40 BRAKES KIBS ABS and KIBS Indicator Lights (LED) Inspection ○ In this model, the yellow ABS indicator light (LED) [A], yellow warning indicator light (LED) [B] and white KIBS indicator light (LED) [C] go on or blink by the data sent from the KIBS hydraulic unit.
  • Page 447: Kibs Hydraulic Unit Installation

    BRAKES 12-41 KIBS • Clean the KIBS hydraulic unit. NOTICE Clean all fittings on the KIBS hydraulic unit and the rear master cylinder because dirt around the banjo bolts could contaminate the brake fluid in the line during removal/installation. Spread over a shop towel around the KIBS hy- draulic unit before removing the brake line so that brake fluid does not leak on the parts.
  • Page 448: Kibs Hydraulic Unit Inspection

    12-42 BRAKES KIBS • Install the KIBS hydraulic unit together with the bracket, and tighten the bolts. • Pull the lever [A] to connect the KIBS hydraulic unit con- nector [B]. • Replace the washers that are on each side of pipe fitting with new ones.
  • Page 449: Front Wheel Rotation Sensor Installation

    BRAKES 12-43 KIBS • Clear the sensor lead from the clamps [A]. • Remove: Bolt [B] Front Wheel Rotation Sensor [C] Front Wheel Rotation Sensor Installation • Installation is the reverse of removal. • Run the lead correctly (see Cable, Wire, and Hose Rout- ing section in the Appendix chapter).
  • Page 450: Rear Wheel Rotation Sensor Installation

    12-44 BRAKES KIBS • Remove: Mud Guard (see Mud Guard Removal in the Frame chapter) Rear Fender (see Rear Fender Removal in the Frame chapter) Bolts [A] • Clear the sensor lead from the clamps [B]. • Remove: Bolt [A] Rear Wheel Rotation Sensor [B] Spacer Rear Wheel Rotation Sensor Installation...
  • Page 451: Wheel Rotation Sensor Inspection

    BRAKES 12-45 KIBS Wheel Rotation Sensor Inspection • Remove the front wheel rotation sensor [A] from the front fork. • Remove the rear wheel rotation sensor [B] from the rear caliper holder. • Visually inspect the wheel rotation sensors. Replace the wheel rotation sensor if it is cracked, bent, or otherwise damaged.
  • Page 452: Wheel Rotation Sensor Rotor Inspection

    12-46 BRAKES KIBS Wheel Rotation Sensor Rotor Inspection Front Wheel Rotation Sensor • Remove: Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Bolts [A] Front Wheel Rotation Sensor Rotor [B] Rear Wheel Rotation Sensor • Remove: Rear Brake Disc Assembly (see Rear Brake Disc Re- moval) Rear Brake Disc Mounting Bolts [A] Rear Wheel Rotation Sensor Rotor [B]...
  • Page 453: Kibs Motor Relay Fuse (25 A) Removal

    BRAKES 12-47 KIBS KIBS Motor Relay Fuse (25 A) Removal • Refer to the Fuse Box Fuse Removal in the Electrical Sys- tem chapter. Fuse Installation • If a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage (see Fuse Installation in the Electrical System chapter).
  • Page 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) ................13-11 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 Upper Front Fork Clamp Bolts Lower Front Fork Clamp Bolts Front Fork Top Plugs 22.5 2.29 16.6 Piston Rod Nuts Cylinder Unit 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 Rear Shock Absorber Bracket Nuts Upper Rear Shock Absorber Nut Tie-Rod Nuts Lower Rear Shock Absorber Nut Swingarm Pivot Shaft Nut 11.0 79.7 Rocker Arm Nut G: Apply grease. R: Replacement Parts...
  • Page 460: Specifications

    Fork Spring Preload Setting 8 turns in from the fully counterclockwise position (Usable Range: 0 ←→ 15 turns in) Suspension Oil Kawasaki KHL15-10 or equivalent Amount: 370 ±4 mL (12.5 ±0.135 US oz.) (after disassembly and completely dry) Approx. 315 mL (10.7 US oz.) (when changing oil) Oil Level 128 ±2 mm (5.0 ±0.08 in.) (fully compressed, without spring,...
  • Page 461: Special Tools

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Fork Spring Stopper: 57001-143 57001-1374 Oil Seal & Bearing Remover: Fork Oil Seal Driver, 43: 57001-1058 57001-1530 Bearing Driver Set: Needle Bearing Driver, 28: 57001-1129 57001-1610 Fork Oil Level Gauge: Needle Bearing Driver, 20 & Spacer, 28: 57001-1290 57001-1678 Fork Piston Rod Puller, M10 ×...
  • Page 462 13-8 SUSPENSION Special Tools Fork Oil Seal Driver Weight, 26 ∼ 46: Fork Cylinder Wrench: 57001-1795 57001-1831 Fork Oil Seal Driver Attachment, 36 ∼ 46: Top Plug Wrench, 37 mm: 57001-1798 57001-1835...
  • Page 463: Front Fork

    SUSPENSION 13-9 Front Fork Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebound damping force adjuster [A]. ○ The standard adjuster setting is the 13 clicks from the fully clockwise position. WARNING If both adjusters are not adjusted equally, handling may be impaired and a hazardous condition may result.
  • Page 464: Spring Preload Adjustment

    13-10 SUSPENSION Front Fork ○ The damping force can be left soft for average riding. But it should be adjusted harder for high speed riding or riding with a passenger. If the damping feels too soft or too stiff, adjust it in accordance with the following table. Compression Damping Force Adjustment Adjuster Damping...
  • Page 465: Front Fork Removal (each Fork Leg)

    SUSPENSION 13-11 Front Fork Front Fork Removal (Each Fork Leg) • Adjust the damping force and spring preload to weakest point. Loosen the front fork top plug [A] beforehand if the fork leg is to be disassembled. Special Tool - Top Plug Wrench, 37 mm: 57001-1835 NOTE ○...
  • Page 466: Front Fork Installation (each Fork Leg)

    13-12 SUSPENSION Front Fork • Loosen: Lower Front Fork Clamp Bolts [A] • With a twisting motion, work the fork leg [B] down and out. Front Fork Installation (Each Fork Leg) • Install the front fork so that the top end [A] of the outer tube protrudes from the steering stem head [B].
  • Page 467: Front Fork Oil Change

    SUSPENSION 13-13 Front Fork • Install the removed parts (see appropriate chapters). • Adjust: Spring Preload (see Spring Preload Adjustment) Rebound Damping Force (see Rebound Damping Force Adjustment) Compression Damping Force (see Compression Damp- ing Force Adjustment) Front Fork Oil Change •...
  • Page 468 13-14 SUSPENSION Front Fork • Remove: Rebound Damping Adjuster Rod (Inside) [A] Compression Damping Adjuster Rod (Outside) [B] Piston Rod Nut [C] • Remove: Special Tools Guide [A] Spacer [B] Fork Spring [C] • Drain the fork oil into a suitable container. ○...
  • Page 469 SUSPENSION 13-15 Front Fork • Using the piston rod puller [A], move the piston rod [B] up and down more than ten times in order to expel all the air from the fork oil. Special Tool - Fork Piston Rod Puller, M10 × 1.0: 57001 -1298 •...
  • Page 470: Front Fork Disassembly

    13-16 SUSPENSION Front Fork • Install the fork spring [A] with the smaller end [B] facing upward. • Install: Spacer [C] Guide [D] • Holding the spacer [A] with the fork spring compressor [B], compress the fork spring. Special Tool - Fork Spring Compressor: 57001-1685 •...
  • Page 471: Front Fork Assembly

    SUSPENSION 13-17 Front Fork • Remove the cylinder unit [A] from the inner tube. ○ Do not disassemble the cylinder unit. • Remove the dust seal [A] from the outer tube. • Remove the circlip [B]. • Separate the outer tube from the inner tube. •...
  • Page 472: Inner Tube Inspection

    13-18 SUSPENSION Front Fork • Insert the inner tube to the outer tube. • After installing the washer, install the oil seal [A] by using the fork oil seal driver [B]. Special Tools - Fork Oil Seal Driver, 43: 57001-1530 26 ∼...
  • Page 473: Dust Seal Inspection

    SUSPENSION 13-19 Front Fork Dust Seal Inspection • Inspect the dust seals [A] for any signs of deterioration or damage. Replace it if necessary. Spring Tension Inspection • Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced.
  • Page 474: Rear Shock Absorber

    13-20 SUSPENSION Rear Shock Absorber Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebound damping force adjuster [A] to the desired position. ○ The standard adjuster setting is the 1 1/4 turns out from the fully clockwise position. Rebound Damping Force Adjustment Adjuster Damping...
  • Page 475: Spring Preload Adjustment

    SUSPENSION 13-21 Rear Shock Absorber • To adjust the low speed compression damping force, turn the inside damping adjuster with a flat tip screwdriver to the desired position. ○ The standard adjuster setting is the 6 clicks from the fully clockwise position.
  • Page 476: Rear Shock Absorber Installation

    13-22 SUSPENSION Rear Shock Absorber NOTICE Do not loosen the reservoir tank bolt [A]. The shock absorber could be damaged. Rear Shock Absorber Installation • Replace the rear shock absorber nuts with new ones. • Install the rear shock absorber, bolts and nuts temporarily. ○...
  • Page 477: Swingarm

    SUSPENSION 13-23 Swingarm Swingarm Removal • Loosen: Swingarm Mounting Plate Nut (Upper) [A] Swingarm Mounting Plate Bolt (Lower) [B] Swingarm Pivot Shaft Nut [C] • Remove: Footpeg Bracket Bolts [D] • Remove: Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter) Coupling (see Coupling Removal in the Final Drive chap- ter)
  • Page 478: Swingarm Bearing Removal

    13-24 SUSPENSION Swingarm • Visually inspect the caliper holder guide [A]. Replace the caliper holder guide and O-ring [B] if the guide shows any signs of abnormal wear or damage. • Apply grease to the O-ring. • Insert the caliper holder guide until it clicks. •...
  • Page 479: Swingarm Bearing Installation

    SUSPENSION 13-25 Swingarm • Remove the ball bearing and needle bearings. Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058 Swingarm Bearing Installation • Replace the needle bearings, ball bearing, grease seals and circlip with new ones. NOTE ○ Install the needle and ball bearings so that their marked sides face outward.
  • Page 480: Swingarm Bearing, Sleeve Inspection

    13-26 SUSPENSION Swingarm Swingarm Bearing, Sleeve Inspection NOTICE Do not remove the bearings for inspection. Re- moval may damage them. • Inspect the needle bearings [A] and ball bearing [B] that are installed in the swingarm. ○ The rollers and balls in a bearing normally wear very little, and wear is difficult to measure.
  • Page 481: Tie-rod, Rocker Arm

    SUSPENSION 13-27 Tie-Rod, Rocker Arm Tie-Rod Removal • Support the front of the motorcycle with the stand. WARNING When raising the rear wheel off the ground and re- moving part(s) from the motorcycle, be sure to sup- port the front of the motorcycle, or the motorcycle may fall over.
  • Page 482: Rocker Arm Removal

    13-28 SUSPENSION Tie-Rod, Rocker Arm Rocker Arm Removal • Support the front of the motorcycle with the stand. WARNING When raising the rear wheel off the ground and re- moving part(s) from the motorcycle, be sure to sup- port the front of the motorcycle, or the motorcycle may fall over.
  • Page 483: Rocker Arm Installation

    SUSPENSION 13-29 Tie-Rod, Rocker Arm Rocker Arm Installation NOTE ○ Since the rocker arm bearings are packed with grease, cleaning is not required. The bearing that was cleaned should be replacing. • Apply grease to the grease seal lips [A]. •...
  • Page 484: Tie-rod And Rocker Arm Bearing Removal

    13-30 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Removal • Remove: Swingarm Mounting Plate [A] (see Engine Removal in the Engine Removal/Installation chapter) Rocker Arm [B] (see Rocker Arm Removal) Sleeves [C] Grease Seals [D] • Remove the needle bearings [E] using a suitable tool. Tie-Rod and Rocker Arm Bearing Installation •...
  • Page 485: Rocker Arm/tie-rod Bearing, Sleeve Inspection

    SUSPENSION 13-31 Tie-Rod, Rocker Arm Viewed from Bottom [A] Tie-Rods [F] Swingarm Mounting Bracket [B] Rear Shock Absorber [G] Grease Seals [C] Rocker Arm [H] 5.5 ±0.4 mm (0.22 ±0.02 in.) [D] 6.0 ±0.4 mm (0.24 ±0.02 in.) [I] Needle Bearings [E] Swingarm [J] Rocker Arm/Tie-Rod Bearing, Sleeve Inspection NOTICE...
  • Page 486: Rocker Arm/tie-rod Bearing Lubrication

    13-32 SUSPENSION Tie-Rod, Rocker Arm Rocker Arm/Tie-Rod Bearing Lubrication NOTE ○ Since the bearings are packed with grease, lubrication is not required.
  • Page 487 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Steering ..........................14-5 Steering Inspection ......................14-5 Steering Adjustment......................14-5 Electronic Steering Damper (ESD)..................14-6 Electronic Steering Damper Removal................14-6 Electronic Steering Damper Installation................14-6 Electronic Steering Damper Oil Leak Inspection .............. 14-6 Electronic Steering Damper Inspection................
  • Page 488: Exploded View

    14-2 STEERING Exploded View...
  • Page 489 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Switch Housing Bolts 0.90 0.09 8 in·lb Throttle Case Bolts 0.36 31 in·lb Handlebar Clamp Bolts Handlebar Positioning Bolts 87 in·lb Handlebar Weights Steering Stem Head Nut Upper Front Fork Clamp Bolts Steering Damper Mounting Bolts 97 in·lb Steering Stem Nut...
  • Page 490: Special Tools

    14-4 STEERING Special Tools Head Pipe Outer Race Press Shaft: Bearing Driver Set: 57001-1075 57001-1129 Head Pipe Outer Race Driver, 54.5: Steering Stem Bearing Driver, 42.5: 57001-1077 57001-1344 Steering Stem Nut Wrench: Steering Stem Bearing Driver Adapter, 41.5: 57001-1100 57001-1345...
  • Page 491: Steering Inspection

    STEERING 14-5 Steering Steering Inspection • Refer to the Steering Play Inspection in the Periodic Main- tenance chapter. Steering Adjustment • Refer to the Steering Play Adjustment in the Periodic Maintenance chapter.
  • Page 492: Electronic Steering Damper (esd)

    14-6 STEERING Electronic Steering Damper (ESD) Electronic Steering Damper Removal • Disconnect the connector [A]. • Remove: Clamp [B] Steering Damper Mounting Bolts [C] Metal Washer [D] Plastic Washer and Flanged Collar [E] Electronic Steering Damper [F] Electronic Steering Damper Installation •...
  • Page 493: Esd Ecu Removal

    STEERING 14-7 Electronic Steering Damper (ESD) ESD ECU Removal NOTICE Never drop the ECU especially on a hard surface. Such a shock to the ECU can damage it. • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) •...
  • Page 494: Steering Stem

    14-8 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Electronic Steering Damper (see Electronic Steering Damper Removal) • Loosen the steering stem head nut [A]. NOTE ○ Use the 28 mm wrench (12 pt.). • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter)
  • Page 495: Stem, Stem Bearing Installation

    STEERING 14-9 Steering Stem • While pushing up the stem base [A], remove the steering stem nut [B] and stem cap [C]. Special Tool - Steering Stem Nut Wrench [D]: 57001-1100 • Remove: Steering Stem Upper Ball Bearing Inner Race Upper Ball Bearing •...
  • Page 496 14-10 STEERING Steering Stem • Replace the bearing inner races and grease seals with new ones. • Apply grease to the grease seal lips. • Install the lower grease seal [A] on the steering stem, and press the lower ball bearing inner race [B] applied the grease onto the stem.
  • Page 497 STEERING 14-11 Steering Stem • Install the claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of stem locknut [C]. • Hand tighten the stem locknut until it touches the claw washer.
  • Page 498: Steering Stem Bearing Lubrication