Kawasaki Z1000SX ABS Manuals

Manuals and User Guides for Kawasaki Z1000SX ABS. We have 2 Kawasaki Z1000SX ABS manuals available for free PDF download: Service Manual, Owner's Manual

Kawasaki Z1000SX ABS Service Manual

Kawasaki Z1000SX ABS Service Manual (739 pages)

Brand: Kawasaki | Category: Motorcycle | Size: 18.48 MB
Table of contents
General Information3................................................................................................................................................................
Emission Control Information7................................................................................................................................................................
How To Use This Manual9................................................................................................................................................................
Before Servicing12................................................................................................................................................................
Model Identification17................................................................................................................................................................
General Specifications20................................................................................................................................................................
Unit Conversion Table23................................................................................................................................................................
Table Of Contents25................................................................................................................................................................
Periodic Maintenance Chart27................................................................................................................................................................
Torque And Locking Agent31................................................................................................................................................................
Specifications37................................................................................................................................................................
Special Tools39................................................................................................................................................................
Periodic Maintenance Procedures41................................................................................................................................................................
Fuel System (dfi)41................................................................................................................................................................
Throttle Control System Inspection41................................................................................................................................................................
Engine Vacuum Synchronization Inspection41................................................................................................................................................................
Idle Speed Inspection45................................................................................................................................................................
Idle Speed Adjustment46................................................................................................................................................................
Fuel Hose Inspection (fuel Leak, Damage, Installation Condition)46................................................................................................................................................................
Evaporative Emission Control System (cal And Sea-b1 Models) Inspection47................................................................................................................................................................
Cooling System48................................................................................................................................................................
Coolant Level Inspection48................................................................................................................................................................
Radiator Hose And Pipe Inspection (coolant Leak, Damage, Installation Condition)48................................................................................................................................................................
Engine Top End48................................................................................................................................................................
Valve Clearance Inspection48................................................................................................................................................................
Valve Clearance Adjustment50................................................................................................................................................................
Air Suction System Damage Inspection53................................................................................................................................................................
Clutch54................................................................................................................................................................
Clutch Operation Inspection54................................................................................................................................................................
Wheels/tires55................................................................................................................................................................
Air Pressure Inspection55................................................................................................................................................................
Wheel/tire Damage Inspection55................................................................................................................................................................
Tire Tread Wear Inspection55................................................................................................................................................................
Wheel Bearing Damage Inspection56................................................................................................................................................................
Final Drive57................................................................................................................................................................
Drive Chain Lubrication Condition Inspection57................................................................................................................................................................
Drive Chain Slack Inspection57................................................................................................................................................................
Drive Chain Slack Adjustment58................................................................................................................................................................
Wheel Alignment Inspection58................................................................................................................................................................
Wheel Alignment Adjustment58................................................................................................................................................................
Drive Chain Wear Inspection59................................................................................................................................................................
Chain Guide Wear Inspection59................................................................................................................................................................
Brakes60................................................................................................................................................................
Brake Fluid Leak (brake Hose And Pipe) Inspection60................................................................................................................................................................
Brake Hose And Pipe Damage And Installation Condition Inspection61................................................................................................................................................................
Brake Operation Inspection61................................................................................................................................................................
Brake Fluid Level Inspection61................................................................................................................................................................
Brake Pad Wear Inspection62................................................................................................................................................................
Brake Light Switch Operation Inspection63................................................................................................................................................................
Suspension64................................................................................................................................................................
Front Forks/rear Shock Absorber Operation Inspection64................................................................................................................................................................
Front Fork Oil Leak Inspection64................................................................................................................................................................
Rear Shock Absorber Oil Leak Inspection64................................................................................................................................................................
Rocker Arm Operation Inspection64................................................................................................................................................................
Tie-rod Operation Inspection65................................................................................................................................................................
Steering65................................................................................................................................................................
Steering Play Inspection65................................................................................................................................................................
Steering Play Adjustment65................................................................................................................................................................
Steering Stem Bearing Lubrication67................................................................................................................................................................
Electrical System68................................................................................................................................................................
Lights And Switches Operation Inspection68................................................................................................................................................................
Headlight Aiming Inspection70................................................................................................................................................................
Sidestand Switch Operation Inspection71................................................................................................................................................................
Engine Stop Switch Operation Inspection72................................................................................................................................................................
Others73................................................................................................................................................................
Chassis Parts Lubrication73................................................................................................................................................................
Bolts, Nuts And Fasteners Tightness Inspection75................................................................................................................................................................
Replacement Parts76................................................................................................................................................................
Air Cleaner Element Replacement76................................................................................................................................................................
Fuel Hose Replacement76................................................................................................................................................................
Coolant Change78................................................................................................................................................................
Radiator Hose And O-ring Replacement80................................................................................................................................................................
Engine Oil Change81................................................................................................................................................................
Oil Filter Replacement81................................................................................................................................................................
Brake Hose Replacement82................................................................................................................................................................
Brake Fluid Change83................................................................................................................................................................
Master Cylinder Rubber Parts Replacement85................................................................................................................................................................
Caliper Rubber Parts Replacement86................................................................................................................................................................
Spark Plug Replacement90................................................................................................................................................................
Exploded View94................................................................................................................................................................
Dfi System100................................................................................................................................................................
Dfi Parts Location106................................................................................................................................................................
Special Tools And Sealant110................................................................................................................................................................
Dfi Servicing Precautions112................................................................................................................................................................
Troubleshooting The Dfi System114................................................................................................................................................................
Outline114................................................................................................................................................................
Inquiries To Rider118................................................................................................................................................................
Dfi System Troubleshooting Guide121................................................................................................................................................................
Self-diagnosis126................................................................................................................................................................
Self-diagnosis Outline126................................................................................................................................................................
Self-diagnosis Procedures127................................................................................................................................................................
Service Code Reading130................................................................................................................................................................
Service Code Erasing131................................................................................................................................................................
Backups132................................................................................................................................................................
Main Throttle Sensor (service Code 11)135................................................................................................................................................................
Main Throttle Sensor Removal/adjustment135................................................................................................................................................................
Main Throttle Sensor Input Voltage Inspection135................................................................................................................................................................
Main Throttle Sensor Output Voltage Inspection136................................................................................................................................................................
Main Throttle Sensor Resistance Inspection138................................................................................................................................................................
Intake Air Pressure Sensor #1 (service Code 12)139................................................................................................................................................................
Intake Air Pressure Sensor #1 Removal139................................................................................................................................................................
Intake Air Pressure Sensor #1 Installation139................................................................................................................................................................
Intake Air Pressure Sensor #1 Input Voltage Inspection140................................................................................................................................................................
Intake Air Pressure Sensor #1 Output Voltage Inspection141................................................................................................................................................................
Intake Air Temperature Sensor (service Code 13)145................................................................................................................................................................
Intake Air Temperature Sensor Removal/installation145................................................................................................................................................................
Intake Air Temperature Sensor Output Voltage Inspection145................................................................................................................................................................
Intake Air Temperature Sensor Resistance Inspection146................................................................................................................................................................
Water Temperature Sensor (service Code 14)148................................................................................................................................................................
Water Temperature Sensor Removal/installation148................................................................................................................................................................
Water Temperature Sensor Output Voltage Inspection149................................................................................................................................................................
Water Temperature Sensor Resistance Inspection150................................................................................................................................................................
Intake Air Pressure Sensor #2 (service Code 16)151................................................................................................................................................................
Intake Air Pressure Sensor #2 Removal151................................................................................................................................................................
Intake Air Pressure Sensor #2 Installation151................................................................................................................................................................
Intake Air Pressure Sensor #2 Input Voltage Inspection152................................................................................................................................................................
Intake Air Pressure Sensor #2 Output Voltage Inspection153................................................................................................................................................................
Crankshaft Sensor (service Code 21)155................................................................................................................................................................
Crankshaft Sensor Removal/installation155................................................................................................................................................................
Crankshaft Sensor Resistance Inspection155................................................................................................................................................................
Crankshaft Sensor Peak Voltage Inspection155................................................................................................................................................................
Speed Sensor (service Code 24, 25)156................................................................................................................................................................
Speed Sensor Removal/installation156................................................................................................................................................................
Speed Sensor Inspection156................................................................................................................................................................
Speed Sensor Input Voltage Inspection156................................................................................................................................................................
Speed Sensor Output Voltage Inspection157................................................................................................................................................................
Vehicle-down Sensor (service Code 31)159................................................................................................................................................................
Vehicle-down Sensor Removal159................................................................................................................................................................
Vehicle-down Sensor Installation160................................................................................................................................................................
Vehicle-down Sensor Input Voltage Inspection160................................................................................................................................................................
Vehicle-down Sensor Output Voltage Inspection161................................................................................................................................................................
Subthrottle Sensor (service Code 32)164................................................................................................................................................................
Subthrottle Sensor Removal/adjustment164................................................................................................................................................................
Subthrottle Sensor Input Voltage Inspection164................................................................................................................................................................
Subthrottle Sensor Output Voltage Inspection165................................................................................................................................................................
Subthrottle Sensor Resistance Inspection167................................................................................................................................................................
Oxygen Sensor - Not Activated (service Code 33, Equipped Models)168................................................................................................................................................................
Oxygen Sensor Removal/installation168................................................................................................................................................................
Oxygen Sensor Inspection168................................................................................................................................................................
Exhaust Butterfly Valve Actuator Sensor (service Code 34)171................................................................................................................................................................
Exhaust Butterfly Valve Actuator Sensor Removal/installation171................................................................................................................................................................
Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection171................................................................................................................................................................
Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection172................................................................................................................................................................
Exhaust Butterfly Valve Actuator Sensor Resistance Inspection173................................................................................................................................................................
Immobilizer Amplifier (service Code 35, Equipped Models)174................................................................................................................................................................
Antenna Resistance Inspection174................................................................................................................................................................
Amplifier Input Voltage Inspection175................................................................................................................................................................
Blank Key Detection (service Code 36, Equipped Models)176................................................................................................................................................................
Ignition Key Inspection176................................................................................................................................................................
Ecu Communication Error (service Code 39)177................................................................................................................................................................
Ecu Communication Line Inspection177................................................................................................................................................................
Stick Coils #1, #2, #3, #4 (service Code 51, 52, 53, 54)178................................................................................................................................................................
Stick Coil Removal/installation178................................................................................................................................................................
Stick Coil Primary Winding Resistance Inspection178................................................................................................................................................................
Stick Coil Input Voltage Inspection178................................................................................................................................................................
Radiator Fan Relay (service Code 56)180................................................................................................................................................................
Radiator Fan Relay Removal/installation180................................................................................................................................................................
Radiator Fan Relay Inspection180................................................................................................................................................................
Subthrottle Valve Actuator (service Code 62)181................................................................................................................................................................
Subthrottle Valve Actuator Removal181................................................................................................................................................................
Subthrottle Valve Actuator Inspection181................................................................................................................................................................
Subthrottle Valve Actuator Resistance Inspection181................................................................................................................................................................
Subthrottle Valve Actuator Input Voltage Inspection182................................................................................................................................................................
Exhaust Butterfly Valve Actuator (service Code 63)184................................................................................................................................................................
Exhaust Butterfly Valve Actuator Removal184................................................................................................................................................................
Exhaust Butterfly Valve Actuator Installation184................................................................................................................................................................
Exhaust Butterfly Valve Actuator Inspection186................................................................................................................................................................
Exhaust Butterfly Valve Actuator Resistance Inspection186................................................................................................................................................................
Air Switching Valve (service Code 64)188................................................................................................................................................................
Air Switching Valve Removal/installation188................................................................................................................................................................
Air Switching Valve Inspection188................................................................................................................................................................
Oxygen Sensor Heater (service Code 67, Equipped Models)189................................................................................................................................................................
Oxygen Sensor Heater Removal/installation189................................................................................................................................................................
Oxygen Sensor Heater Resistance Inspection189................................................................................................................................................................
Oxygen Sensor Heater Power Source Voltage Inspection190................................................................................................................................................................
Oxygen Sensor - Incorrect Output Voltage (service Code 94, Equipped Models)192................................................................................................................................................................
Warning Indicator Light (led)195................................................................................................................................................................
Light (led) Inspection195................................................................................................................................................................
Ecu196................................................................................................................................................................
Ecu Identification196................................................................................................................................................................
Ecu Removal196................................................................................................................................................................
Ecu Installation196................................................................................................................................................................
Ecu Power Supply Inspection197................................................................................................................................................................
Dfi Power Source200................................................................................................................................................................
Ecu Fuse Removal200................................................................................................................................................................
Ecu Fuse Installation200................................................................................................................................................................
Ecu Fuse Inspection200................................................................................................................................................................
Ecu Main Relay Removal/installation200................................................................................................................................................................
Ecu Main Relay Inspection200................................................................................................................................................................
Fuel Line201................................................................................................................................................................
Fuel Pressure Inspection201................................................................................................................................................................
Fuel Flow Rate Inspection202................................................................................................................................................................
Fuel Pump204................................................................................................................................................................
Fuel Pump Removal204................................................................................................................................................................
Fuel Pump Installation205................................................................................................................................................................
Fuel Pump Operation Inspection205................................................................................................................................................................
Fuel Pump Operating Voltage Inspection206................................................................................................................................................................
Pressure Regulator Removal206................................................................................................................................................................
Pump Screen, Fuel Filter Cleaning207................................................................................................................................................................
Fuel Pump Relay Removal/installation207................................................................................................................................................................
Fuel Pump Relay Inspection207................................................................................................................................................................
Fuel Injectors209................................................................................................................................................................
Fuel Injector Removal/installation209................................................................................................................................................................
Fuel Injector Audible Inspection209................................................................................................................................................................
Fuel Injector Resistance Inspection209................................................................................................................................................................
Fuel Injector Power Source Voltage Inspection210................................................................................................................................................................
Fuel Injector Output Voltage Inspection211................................................................................................................................................................
Fuel Injector Fuel Line Inspection212................................................................................................................................................................
Throttle Grip And Cables214................................................................................................................................................................
Free Play Inspection214................................................................................................................................................................
Free Play Adjustment214................................................................................................................................................................
Cable Installation214................................................................................................................................................................
Cable Lubrication214................................................................................................................................................................
Throttle Body Assy215................................................................................................................................................................
Idle Speed Inspection/adjustment215................................................................................................................................................................
Synchronization Inspection/adjustment215................................................................................................................................................................
Throttle Body Assy Removal215................................................................................................................................................................
Throttle Body Assy Installation217................................................................................................................................................................
Throttle Body Assy Disassembly218................................................................................................................................................................
Throttle Body Assy Assembly219................................................................................................................................................................
Air Cleaner220................................................................................................................................................................
Air Cleaner Element Removal/installation220................................................................................................................................................................
Air Cleaner Element Inspection220................................................................................................................................................................
Air Cleaner Oil Draining220................................................................................................................................................................
Air Cleaner Housing Removal220................................................................................................................................................................
Air Cleaner Housing Installation221................................................................................................................................................................
Fuel Tank222................................................................................................................................................................
Fuel Tank Removal222................................................................................................................................................................
Fuel Tank Installation225................................................................................................................................................................
Fuel Tank And Cap Inspection227................................................................................................................................................................
Fuel Tank Cleaning227................................................................................................................................................................
Evaporative Emission Control System (cal And Sea-b1 Models)228................................................................................................................................................................
Parts Removal/installation228................................................................................................................................................................
Hose Inspection228................................................................................................................................................................
Separator Inspection228................................................................................................................................................................
Separator Operation Test229................................................................................................................................................................
Canister Inspection229................................................................................................................................................................
Coolant Flow Chart234................................................................................................................................................................
Coolant238................................................................................................................................................................
Coolant Deterioration Inspection238................................................................................................................................................................
Coolant Draining238................................................................................................................................................................
Coolant Filling238................................................................................................................................................................
Pressure Testing238................................................................................................................................................................
Cooling System Flushing239................................................................................................................................................................
Coolant Reserve Tank Removal/installation239................................................................................................................................................................
Water Pump240................................................................................................................................................................
Water Pump Removal240................................................................................................................................................................
Water Pump Installation240................................................................................................................................................................
Water Pump Inspection242................................................................................................................................................................
Water Pump Impeller Disassembly/assembly242................................................................................................................................................................
Water Pump Impeller Inspection242................................................................................................................................................................
Water Pump Housing Disassembly242................................................................................................................................................................
Water Pump Housing Assembly243................................................................................................................................................................
Mechanical Seal Inspection243................................................................................................................................................................
Radiator244................................................................................................................................................................
Radiator And Radiator Fan Removal244................................................................................................................................................................
Radiator And Radiator Fan Installation246................................................................................................................................................................
Radiator Inspection247................................................................................................................................................................
Radiator Cap Inspection247................................................................................................................................................................
Radiator Filler Neck Inspection248................................................................................................................................................................
Thermostat249................................................................................................................................................................
Thermostat Removal249................................................................................................................................................................
Thermostat Installation249................................................................................................................................................................
Thermostat Inspection250................................................................................................................................................................
Hose And Pipes251................................................................................................................................................................
Hose Installation251................................................................................................................................................................
Water Temperature Sensor252................................................................................................................................................................
Water Temperature Sensor Inspection252................................................................................................................................................................
Exhaust System Identification258................................................................................................................................................................
Clean Air System264................................................................................................................................................................
Air Suction Valve Removal264................................................................................................................................................................
Air Suction Valve Installation264................................................................................................................................................................
Air Suction Valve Inspection265................................................................................................................................................................
Air Switching Valve Removal265................................................................................................................................................................
Air Switching Valve Installation265................................................................................................................................................................
Air Switching Valve Operation Test265................................................................................................................................................................
Air Switching Valve Unit Test265................................................................................................................................................................
Clean Air System Hose Inspection266................................................................................................................................................................
Cylinder Head Cover267................................................................................................................................................................
Cylinder Head Cover Removal267................................................................................................................................................................
Cylinder Head Cover Installation268................................................................................................................................................................
Camshaft Chain Tensioner271................................................................................................................................................................
Camshaft Chain Tensioner Removal271................................................................................................................................................................
Camshaft Chain Tensioner Installation271................................................................................................................................................................
Camshaft, Camshaft Chain272................................................................................................................................................................
Camshaft Removal272................................................................................................................................................................
Camshaft Installation273................................................................................................................................................................
Camshaft, Camshaft Cap Wear Inspection276................................................................................................................................................................
Camshaft Runout Inspection276................................................................................................................................................................
Cam Wear Inspection277................................................................................................................................................................
Camshaft Chain Removal277................................................................................................................................................................
Cylinder Head278................................................................................................................................................................
Cylinder Compression Measurement278................................................................................................................................................................
Cylinder Head Removal279................................................................................................................................................................
Cylinder Head Installation279................................................................................................................................................................
Cylinder Head Warp Inspection281................................................................................................................................................................
Valves282................................................................................................................................................................
Valve Removal282................................................................................................................................................................
Valve Installation282................................................................................................................................................................
Valve Guide Removal282................................................................................................................................................................
Valve Guide Installation283................................................................................................................................................................
Valve-to-guide Clearance Measurement (wobble Method)284................................................................................................................................................................
Valve Seat Inspection284................................................................................................................................................................
Valve Seat Repair285................................................................................................................................................................
Cylinder, Pistons290................................................................................................................................................................
Cylinder Removal290................................................................................................................................................................
Cylinder Installation290................................................................................................................................................................
Piston Removal291................................................................................................................................................................
Piston Installation292................................................................................................................................................................
Cylinder Wear Inspection292................................................................................................................................................................
Piston Wear Inspection293................................................................................................................................................................
Piston Ring, Piston Ring Groove Wear Inspection293................................................................................................................................................................
Piston Ring Groove Width Inspection293................................................................................................................................................................
Piston Ring Thickness Inspection294................................................................................................................................................................
Piston Ring End Gap Inspection294................................................................................................................................................................
Throttle Body Assy Holder295................................................................................................................................................................
Throttle Body Assy Holder Removal295................................................................................................................................................................
Throttle Body Assy Holder Installation295................................................................................................................................................................
Muffler296................................................................................................................................................................
Muffler Body Removal296................................................................................................................................................................
Muffler Body Installation297................................................................................................................................................................
Exhaust Pipe Removal299................................................................................................................................................................
Exhaust Pipe Installation299................................................................................................................................................................
Exhaust Butterfly Valve Cable Removal299................................................................................................................................................................
Exhaust Butterfly Valve Cable Installation300................................................................................................................................................................
Special Tool And Sealant307................................................................................................................................................................
Clutch Lever And Cable308................................................................................................................................................................
Clutch Lever Free Play Inspection308................................................................................................................................................................
Clutch Lever Free Play Adjustment308................................................................................................................................................................
Clutch Cable Removal308................................................................................................................................................................
Clutch Cable Installation308................................................................................................................................................................
Clutch Cable Lubrication308................................................................................................................................................................
Clutch Lever Assembly Installation308................................................................................................................................................................
Clutch Cover309................................................................................................................................................................
Clutch Cover Removal309................................................................................................................................................................
Clutch Cover Installation309................................................................................................................................................................
Release Shaft Removal309................................................................................................................................................................
Release Shaft Installation310................................................................................................................................................................
Clutch Cover Disassembly310................................................................................................................................................................
Clutch Cover Assembly311................................................................................................................................................................
Clutch Removal312................................................................................................................................................................
Clutch Installation312................................................................................................................................................................
Clutch Plate Assembly Inspection315................................................................................................................................................................
Clutch Plate Assembly Adjustment315................................................................................................................................................................
Clutch Plate, Wear, Damage Inspection316................................................................................................................................................................
Clutch Plate Warp Inspection316................................................................................................................................................................
Clutch Spring Free Length Measurement316................................................................................................................................................................
Clutch Housing Finger Inspection316................................................................................................................................................................
Clutch Housing Spline Inspection316................................................................................................................................................................
Engine Lubrication System319................................................................................................................................................................
Engine Oil Flow Chart320................................................................................................................................................................
Special Tools And Sealants322................................................................................................................................................................
Engine Oil And Oil Filter323................................................................................................................................................................
Oil Level Inspection323................................................................................................................................................................
Oil Pan324................................................................................................................................................................
Oil Pan Removal324................................................................................................................................................................
Oil Pan Installation324................................................................................................................................................................
Oil Screen326................................................................................................................................................................
Oil Screen Removal326................................................................................................................................................................
Oil Screen Installation326................................................................................................................................................................
Oil Screen Cleaning326................................................................................................................................................................
Oil Pressure Relief Valve327................................................................................................................................................................
Oil Pressure Relief Valve Removal327................................................................................................................................................................
Oil Pressure Relief Valve Installation327................................................................................................................................................................
Oil Pressure Relief Valve Inspection327................................................................................................................................................................
Oil Pump328................................................................................................................................................................
Oil Pump Removal328................................................................................................................................................................
Oil Pump Installation328................................................................................................................................................................
Oil Pump Drive Gear Removal329................................................................................................................................................................
Oil Pump Drive Gear Installation329................................................................................................................................................................
Oil Cooler330................................................................................................................................................................
Oil Cooler Removal330................................................................................................................................................................
Oil Cooler Installation330................................................................................................................................................................
Oil Pressure Measurement331................................................................................................................................................................
Oil Pressure Switch332................................................................................................................................................................
Oil Pressure Switch Removal332................................................................................................................................................................
Oil Pressure Switch Installation332................................................................................................................................................................
Oil Pipe333................................................................................................................................................................
Oil Pipe Removal333................................................................................................................................................................
Oil Pipe Installation333................................................................................................................................................................
Special Tool338................................................................................................................................................................
Engine Removal/installation339................................................................................................................................................................
Engine Removal339................................................................................................................................................................
Engine Installation342................................................................................................................................................................
Crankcase Splitting353................................................................................................................................................................
Crankcase Assembly354................................................................................................................................................................
Crankshaft And Connecting Rods360................................................................................................................................................................
Crankshaft Removal360................................................................................................................................................................
Crankshaft Installation360................................................................................................................................................................
Connecting Rod Removal360................................................................................................................................................................
Connecting Rod Installation360................................................................................................................................................................
Crankshaft/connecting Rod Cleaning364................................................................................................................................................................
Connecting Rod Bend Inspection364................................................................................................................................................................
Connecting Rod Twist Inspection364................................................................................................................................................................
Connecting Rod Big End Side Clearance Inspection364................................................................................................................................................................
Connecting Rod Big End Bearing Insert/crankpin Wear Inspection365................................................................................................................................................................
Crankshaft Side Clearance Inspection366................................................................................................................................................................
Crankshaft Runout Inspection367................................................................................................................................................................
Crankshaft Main Bearing Insert/journal Wear Inspection367................................................................................................................................................................
Balancer369................................................................................................................................................................
Balancer Removal369................................................................................................................................................................
Balancer Installation369................................................................................................................................................................
Balancer Adjustment370................................................................................................................................................................
Balancer Damper Inspection370................................................................................................................................................................
Starter Motor Clutch371................................................................................................................................................................
Starter Motor Clutch Removal/installation371................................................................................................................................................................
Starter Motor Clutch Inspection371................................................................................................................................................................
Starter Motor Clutch Disassembly371................................................................................................................................................................
Starter Motor Clutch Assembly371................................................................................................................................................................
External Shift Mechanism372................................................................................................................................................................
Shift Pedal Removal372................................................................................................................................................................
Shift Pedal Installation372................................................................................................................................................................
External Shift Mechanism Removal372................................................................................................................................................................
External Shift Mechanism Installation373................................................................................................................................................................
External Shift Mechanism Inspection374................................................................................................................................................................
Transmission376................................................................................................................................................................
Transmission Shaft Removal376................................................................................................................................................................
Transmission Shaft Installation376................................................................................................................................................................
Transmission Shaft Disassembly376................................................................................................................................................................
Transmission Shaft Assembly377................................................................................................................................................................
Shift Drum And Fork Removal382................................................................................................................................................................
Shift Drum And Fork Installation382................................................................................................................................................................
Shift Drum Disassembly382................................................................................................................................................................
Shift Drum Assembly382................................................................................................................................................................
Shift Fork Bending Inspection382................................................................................................................................................................
Shift Fork/gear Groove Wear Inspection383................................................................................................................................................................
Shift Fork Guide Pin/drum Groove Wear Inspection383................................................................................................................................................................
Gear Dog And Gear Dog Hole Damage Inspection383................................................................................................................................................................
Ball Bearing, Needle Bearing, And Oil Seal384................................................................................................................................................................
Ball And Needle Bearing Replacement384................................................................................................................................................................
Ball And Needle Bearing Wear384................................................................................................................................................................
Oil Seal Inspection384................................................................................................................................................................
Wheels (rims)390................................................................................................................................................................
Front Wheel Removal390................................................................................................................................................................
Front Wheel Installation390................................................................................................................................................................
Rear Wheel Removal391................................................................................................................................................................
Rear Wheel Installation393................................................................................................................................................................
Wheel Inspection394................................................................................................................................................................
Axle Inspection394................................................................................................................................................................
Balance Inspection395................................................................................................................................................................
Balance Adjustment395................................................................................................................................................................
Balance Weight Removal395................................................................................................................................................................
Balance Weight Installation395................................................................................................................................................................
Tires397................................................................................................................................................................
Air Pressure Inspection/adjustment397................................................................................................................................................................
Tire Inspection397................................................................................................................................................................
Tire Removal397................................................................................................................................................................
Tire Installation397................................................................................................................................................................
Tire Repair399................................................................................................................................................................
Hub Bearing400................................................................................................................................................................
Hub Bearing Removal400................................................................................................................................................................
Hub Bearing Installation400................................................................................................................................................................
Hub Bearing Inspection401................................................................................................................................................................
Hub Bearing Lubrication401................................................................................................................................................................
Drive Chain408................................................................................................................................................................
Wheel Alignment Inspection/adjustment408................................................................................................................................................................
Drive Chain Lubrication408................................................................................................................................................................
Drive Chain Removal408................................................................................................................................................................
Drive Chain Installation409................................................................................................................................................................
Drive Chain Replacement409................................................................................................................................................................
Sprocket, Coupling413................................................................................................................................................................
Engine Sprocket Cover Removal413................................................................................................................................................................
Engine Sproket Cover Installation413................................................................................................................................................................
Engine Sprocket Removal414................................................................................................................................................................
Engine Sprocket Installation414................................................................................................................................................................
Rear Sprocket Removal414................................................................................................................................................................
Rear Sprocket Installation415................................................................................................................................................................
Coupling Installation415................................................................................................................................................................
Coupling Bearing Removal415................................................................................................................................................................
Coupling Bearing Installation416................................................................................................................................................................
Coupling Bearing Inspection416................................................................................................................................................................
Coupling Bearing Lubrication416................................................................................................................................................................
Coupling Damper Inspection416................................................................................................................................................................
Sprocket Wear Inspection417................................................................................................................................................................
Rear Sprocket Warp Inspection417................................................................................................................................................................
Brake Lever, Brake Pedal428................................................................................................................................................................
Brake Lever Position Adjustment430................................................................................................................................................................
Brake Pedal Position Inspection430................................................................................................................................................................
Brake Pedal Position Adjustment430................................................................................................................................................................
Brake Pedal Removal430................................................................................................................................................................
Brake Pedal Installation431................................................................................................................................................................
Calipers432................................................................................................................................................................
Front Caliper Removal432................................................................................................................................................................
Rear Caliper Removal432................................................................................................................................................................
Caliper Installation433................................................................................................................................................................
Front Caliper Disassembly433................................................................................................................................................................
Front Caliper Assembly433................................................................................................................................................................
Rear Caliper Disassembly433................................................................................................................................................................
Rear Caliper Assembly433................................................................................................................................................................
Caliper Fluid Seal Damage434................................................................................................................................................................
Rear Caliper Dust Boot And Friction Boot Damage434................................................................................................................................................................
Caliper Piston And Cylinder Damage434................................................................................................................................................................
Rear Caliper Holder Shaft Wear435................................................................................................................................................................
Brake Pads436................................................................................................................................................................
Front Brake Pad Removal436................................................................................................................................................................
Front Brake Pad Installation436................................................................................................................................................................
Rear Brake Pad Removal437................................................................................................................................................................
Rear Brake Pad Installation437................................................................................................................................................................
Master Cylinder438................................................................................................................................................................
Front Master Cylinder Removal438................................................................................................................................................................
Front Master Cylinder Installation438................................................................................................................................................................
Rear Master Cylinder Removal438................................................................................................................................................................
Rear Master Cylinder Installation439................................................................................................................................................................
Front Master Cylinder Disassembly439................................................................................................................................................................
Rear Master Cylinder Disassembly439................................................................................................................................................................
Master Cylinder Assembly439................................................................................................................................................................
Master Cylinder Inspection (visual Inspection)440................................................................................................................................................................
Brake Disc441................................................................................................................................................................
Brake Disc Removal441................................................................................................................................................................
Brake Disc Installation441................................................................................................................................................................
Brake Disc Wear441................................................................................................................................................................
Brake Disc Warp441................................................................................................................................................................
Brake Fluid442................................................................................................................................................................
Brake Line Bleeding442................................................................................................................................................................
Brake Hose446................................................................................................................................................................
Brake Hose Removal/installation446................................................................................................................................................................
Brake Hose And Pipe Inspection446................................................................................................................................................................
Anti-lock Brake System (equipped Models)447................................................................................................................................................................
Parts Location447................................................................................................................................................................
Abs Servicing Precautions451................................................................................................................................................................
Abs Troubleshooting Outline453................................................................................................................................................................
Service Code Clearing Procedures459................................................................................................................................................................
How To Read Service Codes462................................................................................................................................................................
How To Erase Service Codes462................................................................................................................................................................
Abs Indicator Light (led) Inspection464................................................................................................................................................................
Solenoid Coil Temperature Abnormal [high-temperature] (service Code 11)464................................................................................................................................................................
Solenoid Valve Inspection (service Code 13, 14, 17, 18)464................................................................................................................................................................
Abs Solenoid Valve Relay Inspection (service Code 19)465................................................................................................................................................................
Front, Rear Wheel Rotation Difference Abnormal (service Code 25)465................................................................................................................................................................
Abs Motor Relay Inspection (service Code 35)466................................................................................................................................................................
Front Wheel Rotation Sensor Signal Abnormal (service Code 42)466................................................................................................................................................................
Front Wheel Rotation Sensor Wiring Inspection (service Code 43)467................................................................................................................................................................
Rear Wheel Rotation Sensor Signal Abnormal (service Code 44)468................................................................................................................................................................
Rear Wheel Rotation Sensor Wiring Inspection (service Code 45)468................................................................................................................................................................
Power Supply Voltage Abnormal (low-voltage) (service Code 52)469................................................................................................................................................................
Power Supply Voltage Abnormal (over-voltage) (service Code 53)469................................................................................................................................................................
Ecu Inspection (service Code 55)470................................................................................................................................................................
Wheel Rotation Sensor Signal Abnormal [too High Speed] (service Code 93)470................................................................................................................................................................
Abs Hydraulic Unit Removal470................................................................................................................................................................
Abs Hydraulic Unit Installation472................................................................................................................................................................
Abs Hydraulic Unit Inspection472................................................................................................................................................................
Front Wheel Rotation Sensor Removal473................................................................................................................................................................
Front Wheel Rotation Sensor Installation473................................................................................................................................................................
Rear Wheel Rotation Sensor Removal474................................................................................................................................................................
Rear Wheel Rotation Sensor Installation474................................................................................................................................................................
Wheel Rotation Sensor Inspection475................................................................................................................................................................
Wheel Rotation Sensor Air Gap Inspection475................................................................................................................................................................
Wheel Rotation Sensor Rotor Inspection476................................................................................................................................................................
Abs Solenoid Valve Relay Fuse (20 A) Removal476................................................................................................................................................................
Abs Motor Relay Fuse (30 A) Removal476................................................................................................................................................................
Abs Ecu Fuse (10 A) Removal476................................................................................................................................................................
Fuse Installation477................................................................................................................................................................
Fuse Inspection477................................................................................................................................................................
Front Fork487................................................................................................................................................................
Rebound Damping Force Adjustment487................................................................................................................................................................
Spring Preload Adjustment487................................................................................................................................................................
Compression Damping Force Adjustment (right Side Only)488................................................................................................................................................................
Front Fork Removal (each Fork Leg)488................................................................................................................................................................
Front Fork Installation489................................................................................................................................................................
Fork Oil Change489................................................................................................................................................................
Front Fork Disassembly495................................................................................................................................................................
Front Fork Assembly496................................................................................................................................................................
Inner Tube, Outer Tube Inspection497................................................................................................................................................................
Dust Seal Inspection497................................................................................................................................................................
Spring Tension Inspection497................................................................................................................................................................
Rear Shock Absorber498................................................................................................................................................................
Rear Shock Absorber Removal499................................................................................................................................................................
Rear Shock Absorber Installation499................................................................................................................................................................
Rear Shock Absorber Inspection500................................................................................................................................................................
Rear Shock Absorber Scrapping500................................................................................................................................................................
Rear Shock Absorber Bearing Removal500................................................................................................................................................................
Rear Shock Absorber Bearing Installation500................................................................................................................................................................
Swingarm501................................................................................................................................................................
Swingarm Removal501................................................................................................................................................................
Swingarm Installation502................................................................................................................................................................
Swingarm Bearing Removal503................................................................................................................................................................
Swingarm Bearing Installation503................................................................................................................................................................
Swingarm Bearing, Sleeve Inspection504................................................................................................................................................................
Swingarm Bearing Lubrication504................................................................................................................................................................
Chain Guide Inspection504................................................................................................................................................................
Tie-rod, Rocker Arm505................................................................................................................................................................
Tie-rod Removal505................................................................................................................................................................
Tie-rod Installation505................................................................................................................................................................
Rocker Arm Removal505................................................................................................................................................................
Rocker Arm Installation505................................................................................................................................................................
Tie-rod And Rocker Arm Bearing Removal506................................................................................................................................................................
Tie-rod And Rocker Arm Bearing Installation506................................................................................................................................................................
Rocker Arm/tie-rod Bearing, Sleeve Inspection507................................................................................................................................................................
Rocker Arm/tie-rod Bearing Lubrication507................................................................................................................................................................
Steering Inspection513................................................................................................................................................................
Steering Adjustment513................................................................................................................................................................
Steering Stem514................................................................................................................................................................
Stem, Stem Bearing Removal514................................................................................................................................................................
Stem, Stem Bearing Installation515................................................................................................................................................................
Steering Stem Warp517................................................................................................................................................................
Stem Cap Deterioration, Damage517................................................................................................................................................................
Handlebar518................................................................................................................................................................
Handlebar Removal518................................................................................................................................................................
Handlebar Installation518................................................................................................................................................................
Seats528................................................................................................................................................................
Rear Seat Removal528................................................................................................................................................................
Rear Seat Installation528................................................................................................................................................................
Front Seat Removal528................................................................................................................................................................
Front Seat Installation528................................................................................................................................................................
Fairings529................................................................................................................................................................
Lower Fairing Removal529................................................................................................................................................................
Lower Fairing Installation530................................................................................................................................................................
Lower Fairing Disassembly531................................................................................................................................................................
Lower Fairing Assembly532................................................................................................................................................................
Rear Lower Fairing Removal533................................................................................................................................................................
Rear Lower Fairing Installation533................................................................................................................................................................
Windshield Removal533................................................................................................................................................................
Windshield Installation533................................................................................................................................................................
Upper Fairing Removal533................................................................................................................................................................
Upper Fairing Installation534................................................................................................................................................................
Upper Fairing Disassembly535................................................................................................................................................................
Upper Fairing Assembly535................................................................................................................................................................
Windshield Bracket Disassembly535................................................................................................................................................................
Windshield Bracket Assembly536................................................................................................................................................................
Windshield Bracket Assembly Removal538................................................................................................................................................................
Windshield Bracket Assembly Installation538................................................................................................................................................................
Side Covers539................................................................................................................................................................
Side Cover Removal539................................................................................................................................................................
Side Cover Installation539................................................................................................................................................................
Left Lower Side Fairing Removal539................................................................................................................................................................
Left Lower Side Fairing Installation539................................................................................................................................................................
Seat Covers540................................................................................................................................................................
Seat Cover Removal540................................................................................................................................................................
Seat Cover Installation540................................................................................................................................................................
Fenders541................................................................................................................................................................
Front Fender Removal541................................................................................................................................................................
Front Fender Installation541................................................................................................................................................................
Flap And Rear Fender Removal541................................................................................................................................................................
Flap And Rear Fender Installation542................................................................................................................................................................
15-22 Frame542................................................................................................................................................................
Frame Inspection543................................................................................................................................................................
Rear Frame Removal543................................................................................................................................................................
Rear Frame Installation543................................................................................................................................................................
Rear Frame Bracket Removal543................................................................................................................................................................
Rear Frame Bracket Installation543................................................................................................................................................................
Battery Case544................................................................................................................................................................
Battery Case Removal544................................................................................................................................................................
Battery Case Installation544................................................................................................................................................................
Guard545................................................................................................................................................................
Mud Guard Removal545................................................................................................................................................................
Mud Guard Installation545................................................................................................................................................................
Sidestand546................................................................................................................................................................
Sidestand Removal546................................................................................................................................................................
Sidestand Installation546................................................................................................................................................................
Wiring Diagram (us, Ca And Cal Models)562................................................................................................................................................................
Wiring Diagram (other Than Us, Ca And Cal Models)564................................................................................................................................................................
Wiring Diagram (ca With Abs Models)566................................................................................................................................................................
Wiring Diagram (other Than Ca With Abs Models)568................................................................................................................................................................
Precautions570................................................................................................................................................................
Electrical Wiring571................................................................................................................................................................
Wiring Inspection571................................................................................................................................................................
Battery572................................................................................................................................................................
Battery Removal572................................................................................................................................................................
Battery Installation572................................................................................................................................................................
Battery Activation572................................................................................................................................................................
Interchange576................................................................................................................................................................
Charging Condition Inspection576................................................................................................................................................................
Refreshing Charge576................................................................................................................................................................
Charging System578................................................................................................................................................................
Alternator Cover Removal578................................................................................................................................................................
Alternator Cover Installation578................................................................................................................................................................
Stator Coil Removal579................................................................................................................................................................
Stator Coil Installation579................................................................................................................................................................
Alternator Rotor Removal579................................................................................................................................................................
Alternator Rotor Installation580................................................................................................................................................................
Alternator Inspection582................................................................................................................................................................
Regulator/rectifier Inspection583................................................................................................................................................................
Charging Voltage Inspection585................................................................................................................................................................
Ignition System587................................................................................................................................................................
Crankshaft Sensor Removal587................................................................................................................................................................
Crankshaft Sensor Installation588................................................................................................................................................................
Crankshaft Sensor Inspection589................................................................................................................................................................
Timing Rotor Removal590................................................................................................................................................................
Timing Rotor Installation590................................................................................................................................................................
Stick Coil Removal590................................................................................................................................................................
Stick Coil Installation590................................................................................................................................................................
Stick Coil Inspection591................................................................................................................................................................
Stick Coil Primary Peak Voltage591................................................................................................................................................................
Spark Plug Removal592................................................................................................................................................................
Spark Plug Installation592................................................................................................................................................................
Spark Plug Condition Inspection592................................................................................................................................................................
Interlock Operation Inspection592................................................................................................................................................................
Ic Igniter Inspection593................................................................................................................................................................
Electric Starter System596................................................................................................................................................................
Starter Motor Removal596................................................................................................................................................................
Starter Motor Installation597................................................................................................................................................................
Starter Motor Disassembly597................................................................................................................................................................
Starter Motor Assembly598................................................................................................................................................................
Brush Inspection600................................................................................................................................................................
Commutator Cleaning And Inspection600................................................................................................................................................................
Armature Inspection601................................................................................................................................................................
Brush Lead Inspection601................................................................................................................................................................
Right-hand End Cover Inspection601................................................................................................................................................................
Starter Relay Inspection601................................................................................................................................................................
Lighting System604................................................................................................................................................................
Headlight Beam Horizontal Adjustment604................................................................................................................................................................
Headlight Beam Vertical Adjustment604................................................................................................................................................................
Headlight Bulb Replacement604................................................................................................................................................................
Headlight Removal/installation605................................................................................................................................................................
City Light Bulb Replacement606................................................................................................................................................................
Tail/brake Light (led) Removal606................................................................................................................................................................
Tail/brake Light (led) Installation606................................................................................................................................................................
License Plate Light Bulb Replacement607................................................................................................................................................................
Turn Signal Light Bulb Replacement609................................................................................................................................................................
Turn Signal Relay Inspection610................................................................................................................................................................
Air Switching Valve613................................................................................................................................................................
Radiator Fan System615................................................................................................................................................................
Fan Motor Inspection615................................................................................................................................................................
Meter, Gauge, Indicator Unit617................................................................................................................................................................
Meter Unit Removal/installation617................................................................................................................................................................
Meter Unit Disassembly617................................................................................................................................................................
Electronic Combination Meter Unit Inspection618................................................................................................................................................................
Fuel Level Sensor Line Self-diagnosis Mode Inspection627................................................................................................................................................................
Immobilizer System (equipped Models)629................................................................................................................................................................
Operational Cautions629................................................................................................................................................................
Key Registration629................................................................................................................................................................
Immobilizer System Parts Replacement647................................................................................................................................................................
Immobilizer System Inspection648................................................................................................................................................................
Switches And Sensors650................................................................................................................................................................
Brake Light Timing Inspection650................................................................................................................................................................
Brake Light Timing Adjustment650................................................................................................................................................................
Switch Inspection650................................................................................................................................................................
Speed Sensor Removal651................................................................................................................................................................
Speed Sensor Installation652................................................................................................................................................................
Oxygen Sensor Removal (equipped Models)652................................................................................................................................................................
Oxygen Sensor Installation (equipped Models)653................................................................................................................................................................
Oxygen Sensor Inspection (equipped Models)653................................................................................................................................................................
Fuel Level Sensor Inspection653................................................................................................................................................................
Relay Box654................................................................................................................................................................
Relay Box Removal654................................................................................................................................................................
Relay Circuit Inspection654................................................................................................................................................................
Diode Circuit Inspection655................................................................................................................................................................
Fuse657................................................................................................................................................................
30 A Main Fuse Removal657................................................................................................................................................................
Fuse Box Fuse Removal657................................................................................................................................................................
15 A Fi Fuse Removal657................................................................................................................................................................

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