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Kawasaki 1400GTR ABS - 2011 Service Manual

Other manuals for 1400GTR ABS - 2011: Datasheet, Service Manual
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Summary of 1400GTR ABS - 2011

  • Page 1

    1400gtr concours 14 abs concours 14 motorcycle service manual http://mototh.Com.

  • Page 2

    This product contains the encryption algorithm "misty" developed by mitsubishi electric corporation. Http://mototh.Com.

  • Page 3: Quick Reference Guide

    This quick reference guide will assist you in locating a desired topic or pro- cedure. •bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. •refer to the sectional table of contents for the exact pages to locate th...

  • Page 4

    Http://mototh.Com.

  • Page 5: 1400Gtr

    1400gtr concours 14 abs concours 14 motorcycle service manual all rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permissio...

  • Page 6

    List of abbreviations a ampere(s) lb pound(s) abdc after bottom dead center m meter(s) ac alternating current min minute(s) atdc after top dead center n newton(s) bbdc before bottom dead center pa pascal(s) bdc bottom dead center ps horsepower btdc before top dead center psi pound(s) per square inch...

  • Page 7

    Emission control information to protect the environment in which we all live, kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the united states environmental protection agency and california air resources board....

  • Page 8

    Tampering with noise control system prohibited federal law prohibits the following acts or the causing thereof. (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle ...

  • Page 9: Foreword

    Foreword this manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the prope...

  • Page 10

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  • Page 11: General Information

    General information 1-1 1 general information table of contents before servicing ..................................................................................................................... 1-2 model identification................................................................................

  • Page 12

    1-2 general information before servicing before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions...

  • Page 13

    General information 1-3 before servicing arrangement and cleaning of removed parts disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly. Storage of removed parts after all the parts including subas...

  • Page 14

    1-4 general information before servicing tightening sequence generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can l...

  • Page 15

    General information 1-5 before servicing press for items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball bearing and needle bearing do not remove presse...

  • Page 16

    1-6 general information before servicing lubrication it is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of engine rotati...

  • Page 17

    General information 1-7 model identification zg1400a8f left side view zg1400a8f right side view frame number engine number http://mototh.Com.

  • Page 18

    1-8 general information model identification zg1400a8f (united states and canada) left side view zg1400a8f (united states and canada) right side view http://mototh.Com.

  • Page 19

    General information 1-9 model identification zg1400b8f (united states and canada) left side view zg1400b8f (united states and canada) right side view http://mototh.Com.

  • Page 20

    1-10 general information general specifications items zg1400a8f, zg1400b8f dimensions overall length 2 270 mm (89.4 in.) overall width 1 000 mm (39.4 in.) overall height/high position 1 290 mm (50.8 in.)/1 405 mm (55.3 in.) wheelbase 1 520 mm (59.8 in.) road clearance 125 mm (4.9 in.) seat height 81...

  • Page 21

    General information 1-11 general specifications items zg1400a8f, zg1400b8f exhaust: open 52° (bbdc) close 22° (atdc) duration 254° lubrication system forced lubrication (wet sump with cooler) engine oil: type api se, sf or sg api sh, sj or sl with jaso ma viscosity sae10w-40 capacity 4.7 l (5.0 us q...

  • Page 22

    1-12 general information general specifications items zg1400a8f, zg1400b8f rim size: front 17 × 3.50 rear 17 × 6.00 front suspension: type telescopic fork (upside-down) wheel travel 113 mm (4.4 in.) rear suspension: type swingarm (uni-trak - tetra lever) wheel travel 136 mm (5.3 in.) brake type: fro...

  • Page 23

    General information 1-13 technical information-variable valve timing overview the camshafts that are provided in the engine determine the amount of valve overlap, which affects the engine’s characteristics. As a result, some engines are high-speed oriented while others are low -speed oriented. (gene...

  • Page 24

    1-14 general information technical information-variable valve timing components • variable valve timing actuator • oil control valve solenoid valve oil flow of parts • variable valve timing actuator http://mototh.Com.

  • Page 25

    General information 1-15 technical information-variable valve timing • oil control solenoid valve oil flow during control • retard position • advance position http://mototh.Com.

  • Page 26

    1-16 general information technical information-variable valve timing • neutral position • most retarded position lock mechanism • during idle, the lock mechanism locks the camshaft at the most retarded position. • when the engine is stopped, the force of the spring returns the solenoid valve to its ...

  • Page 27

    General information 1-17 technical information-electrical windshield overview wind protection for rider and passenger is based on a supersport-style design philosophy. Aero- dynamically curving wind around the riders reduces buffeting that occurs when wind curls around windshield that simply "block"...

  • Page 28

    1-18 general information technical information-kipass (kawasaki’s intelligent proximity activation start system) overview • for better user convenience, a system to wirelessly start the engine is used instead of the conven- tional mechanical key. This frees the rider from handling the ignition key, ...

  • Page 29

    General information 1-19 technical information-kipass (kawasaki’s intelligent proximity activation start system) key knob operation • the key knob consists of on, off, fss, and lock positions. *fss indicates the following positions in which the key knob can be released during opera- tion: f = fuel t...

  • Page 30

    1-20 general information technical information-kipass (kawasaki’s intelligent proximity activation start system) vehicle stopped • the system performs authentication of the fob key as the key knob is turned off. If the fob key is not there, a warning message will appear on the meter. • if the authen...

  • Page 31

    General information 1-21 technical information-kipass (kawasaki’s intelligent proximity activation start system) • communication method outputs electric potentials pivoted on 2.5 v to transmit "1" or "0" data to a terminal resistor. *hi and low transmission data are transmitted simultaneously. Elect...

  • Page 32

    1-22 general information technical information-kipass (kawasaki’s intelligent proximity activation start system) can communication contents transmission reception date contents dfi ecu → meter engine speed, water temperature, gear position, fuel consumption volume, dfi failure data kipass ecu → mete...

  • Page 33

    General information 1-23 technical information-kipass (kawasaki’s intelligent proximity activation start system) registering fob keys (additional registration) *registration requires one fob key that is already registered and the kds3 version kit. • the kipass ecu must be replaced if you lose all th...

  • Page 34

    1-24 general information technical information-kipass (kawasaki’s intelligent proximity activation start system) replacing kipass parts • registration status when all parts are new: steering lock unit (hereafter referred to as "sl"), kipass ecu, and dfi ecu. *the two fob keys that come with the kipa...

  • Page 35

    General information 1-25 technical information-kipass (kawasaki’s intelligent proximity activation start system) • registration errors replacing kipass-related parts individually if a kipass part is replaced individually, its smart authentication number must be registered. *registration of a smart a...

  • Page 36

    1-26 general information technical information-kipass (kawasaki’s intelligent proximity activation start system) if fob key battery is dead if the fob key battery is dead, authentication is performed by the transponder and not by the kipass. Authentication requires approximately 1 to 2 seconds. *it ...

  • Page 37

    General information 1-27 technical information-kipass (kawasaki’s intelligent proximity activation start system) tire air pressure sensor overview while the vehicle is running, this system alerts the rider of a reduction in running stability as a result of a sudden drop in the air pressure in the ti...

  • Page 38

    1-28 general information technical information-kipass (kawasaki’s intelligent proximity activation start system) meter indication in case of a voltage drop in the internal battery of a tire pressure measurement sensor • the meter will indicate the following alternately (when the voltage is 2.4 v or ...

  • Page 39

    General information 1-29 technical information-kipass (kawasaki’s intelligent proximity activation start system) replacing a tire pressure measurement sensor • to replace an pressure measurement sensor, it is necessary to use the kds3 version kit in order to register the id for activating the sensor...

  • Page 40

    1-30 general information technical information-tetra lever shaft drive system tetra lever shaft drive system reason for use: to improve the running feel when the drive force is applied to the rear wheel. Tetra lever shaft drive system when the drive force is applied to the rear wheel, a reaction for...

  • Page 41

    General information 1-31 technical information-tetra lever shaft drive system comparison to conventional shaft drive system http://mototh.Com.

  • Page 42

    1-32 general information unit conversion table prefixes for units prefix symbol power mega m × 1 000 000 kilo k × 1 000 centi c × 0.01 milli m × 0.001 micro µ × 0.000001 units of mass kg × 2.205 = lb g × 0.03527 = oz units of volume l × 0.2642 = gal (us) l × 0.2200 = gal (imp) l × 1.057 = qt (us) l ...

  • Page 43: Periodic Maintenance

    Periodic maintenance 2-1 2 periodic maintenance table of contents periodic maintenance chart ................................................................................................... 2-3 torque and locking agent..................................................................................

  • Page 44

    2-2 periodic maintenance electrical system ................................................................................................................. 2-39 lights and switches operation inspection........................................................................ 2-39 headlight aiming ins...

  • Page 45

    Periodic maintenance 2-3 periodic maintenance chart the scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Frequency whichever comes first * odometer reading × 1000 ...

  • Page 46

    2-4 periodic maintenance periodic maintenance chart frequency whichever comes first * odometer reading × 1000 km (× 1000 mile) 1 6 12 18 24 30 36 inspection every (0.6) (4) (7.5) (12) (15) (20) (24) see page final drive final gear case oil level - inspect • • • 2-32 brake system brake fluid leak (br...

  • Page 47

    Periodic maintenance 2-5 periodic maintenance chart periodic replacement parts frequency whichever come first * odometer reading × 1000 km (× 1000 mile) 1 12 24 36 48 change/replacement every (0.6) (7.5) (15) (24) (30) see page air cleaner element # every 18 000 km (12 000 mile) 2-48 fuel hose 4 yea...

  • Page 48

    2-6 periodic maintenance torque and locking agent the following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “remarks” column mean: al: tighten the two clamp bolts alternately two times to ensure...

  • Page 49

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks coolant fitting bolt 8.8 0.90 78 in·lb l water temperature sensor 25 2.5 18 reserve tank bolts 3.9 0.40 35 in·lb cylinder fitting bolts 9.8 1.0 87 in·lb radiator stay bolt 9.8 1.0 87 in·lb radiator lower bolt 9...

  • Page 50

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks oil filler cap – – – hand -tighten clutch reservoir cap screws 1.5 0.15 13 in·lb clutch reservoir mounting bolt 7.9 0.80 70 in·lb l clutch reservoir screw 1.0 0.10 8.9 in·lb l starter lockout switch screw 0.7 0...

  • Page 51

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks crankcase bolts (m6, l = 25 mm) 12 1.2 106 in·lb s shift drum bearing holder screws 4.9 0.50 43 in·lb l bearing position plate screws 4.9 0.50 43 in·lb l oil passage plug 20 2.0 15 l connecting rod big end nuts...

  • Page 52

    2-10 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks oil nozzles 2.9 0.30 26 in·lb pinion gear assembly nut 130 13.3 95.9 speed sensor bolt 9.8 1.0 87 in·lb l brakes bleed valves 7.8 0.80 69 in·lb brake caliper holder plate bolt 64 6.5 47 brake hose banjo bolts ...

  • Page 53

    Periodic maintenance 2-11 torque and locking agent torque fastener n·m kgf·m ft·lb remarks torque rod nuts 59 6.0 44 steering front fork clamp bolts (lower) 30 3.1 22 al front fork clamp bolts (upper) 20 2.0 15 handlebar bolts 34 3.5 25 l handlebar holder bolts 25 2.5 18 left switch housing screws 3...

  • Page 54

    2-12 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks oil control valve bolts 9.8 1.0 87 in·lb oil pressure switch 15 1.5 11 ss oil pressure switch terminal bolt 1.5 0.15 13 in·lb oxygen sensors (equipped models) 25 2.5 18 rear turn signal light mounting screws 1...

  • Page 55

    Periodic maintenance 2-13 specifications item standard service limit fuel system throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 1 100 ±50 r/min (rpm) – – – throttle body vacuum 33 ±1.33 kpa (250 ±10 mmhg) at idle speed – – – air cleaner element viscous paper element – – – coolin...

  • Page 56

    2-14 periodic maintenance specifications item standard service limit final drive final gear case oil hypoid gear oil – – – grade api service classification: gl-5 – – – viscosity when above 5°c (41°f) sae90 when below 5°c (41°f) sae80 oil level filler opening top – – – amount about 160 ml (5.41 us oz...

  • Page 57

    Periodic maintenance 2-15 special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 jack: 57001-1238 oil filter wrench: 57001-1249 pilot screw adjuster, c: 57001-1292 vacuum gauge: 57001-1369 pilot screw adjuster adapter, 5: 57001-1372 filler cap driver: 57001-1454 http://m...

  • Page 58

    2-16 periodic maintenance maintenance procedure fuel system (dfi) throttle control system inspection • check the throttle grip free play [a]. If the free play is incorrect, adjust the throttle cables. Throttle grip free play standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) • check that the throttle grip [b] mov...

  • Page 59

    Periodic maintenance 2-17 maintenance procedure • remove: subframe bolts [a] with washer right fairing bracket bolt (front side) • pull off the rubber caps [a] from the fittings of each throttle body. ○ for the rubber cap #2, remove the air cleaner duct. Front [b] • pull off the air switching valve ...

  • Page 60

    2-18 periodic maintenance maintenance procedure • start the engine and warm it up thoroughly. • check the idle speed, using a highly accurate tachometer [a]. If the idle speed is out of the specified range, adjust it with the adjust screw. Caution do not measure the idle speed by the tachometer of t...

  • Page 61

    Periodic maintenance 2-19 maintenance procedure if a value of measured vacuum pressure is out of the specified range after synchronization, adjust the bypass screws [a]. Special tool - pilot screw adjuster, c: 57001-1292 pilot screw adjuster adapter, 5: 57001 -1372 • adjust lower vacuum between #1 a...

  • Page 62

    2-20 periodic maintenance maintenance procedure • back out the same number of turns counted when first turned in. This is to set the screw to its original position. Note ○ a throttle body has different “turns out” of the bypass screw for each individual unit. On setting the bypass screw, use the “tu...

  • Page 63

    Periodic maintenance 2-21 maintenance procedure idle speed adjustment • start the engine and warm it up thoroughly. • turn the adjusting screw [a] until the idle speed is correct. ○ open and close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if ne...

  • Page 64

    2-22 periodic maintenance maintenance procedure cooling system coolant level inspection note ○ check the level when the engine is cold (room or ambi- ent temperature). • check the coolant level in the reserve tank [a] with the motorcycle held perpendicular (do not use the sidestand). If the coolant ...

  • Page 65

    Periodic maintenance 2-23 maintenance procedure evaporative emission control system (california model) evaporative emission control system inspection • remove: rear right middle fairing (see middle fairing removal in the frame chapter) band [a] canister [b] • disconnect the hoses from the canister. ...

  • Page 66

    2-24 periodic maintenance maintenance procedure • start the engine and run it at idle speed. • plug [a] the air switching valve hose end with your finger and feel vacuum pulsing in the hose. If there is no vacuum pulsation, check the hose line for leak. If there is no leak, check the air switching v...

  • Page 67

    Periodic maintenance 2-25 maintenance procedure note ○ thickness gauge is horizontally inserted on the valve lifter. Appropriateness [a] inadequacy [b] thickness gauge [c] horizontally inserts [d] cam [e] valve lifter [f] hits the valve lifter ahead [g] ○ when positioning #1 piston tdc at the end of...

  • Page 68

    2-26 periodic maintenance maintenance procedure • clean the shim to remove any dust or oil. • measure the thickness of the removed shim [a]. • select a new shim thickness calculation as follows. A + b – c = d [a] present shim thickness [b] measured valve clearance [c] specified valve clearance (mean...

  • Page 69

    Periodic maintenance 2-27 maintenance procedure adjustment shims thickness part number mark 1.750 92180-1212 –25 1.775 92180-0221 –23 1.800 92180-1211 –20 1.825 92180-0222 –18 1.850 92180-1210 –15 1.875 92180-0223 –13 1.900 92180-1209 –10 1.925 92180-0224 –8 1.950 92180-1208 –5 1.975 92180-0225 –3 2...

  • Page 70

    2-28 periodic maintenance maintenance procedure clutch and drive train clutch operation inspection • start the engine and check that the clutch does not slip and that it releases properly. If the clutch operation is insufficiency, inspect the clutch system. Warning when inspecting by running the veh...

  • Page 71

    Periodic maintenance 2-29 maintenance procedure clutch hose and pipe damage and installation condition inspection • inspect the clutch hoses and fittings for deterioration, cracks, corrosion and signs of leakage. ○ the high pressure inside the clutch line can cause fluid to leak [a] or the hose to b...

  • Page 72

    2-30 periodic maintenance maintenance procedure tire tread wear inspection as the tire tread wears down, the tire becomes more sus- ceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn). So it is false economy and u...

  • Page 73

    Periodic maintenance 2-31 maintenance procedure • raise the rear wheel off the ground with the center stand (see rear wheel removal in the wheels/tires chapter). • spin [a] the rear wheel lightly, and check for smoothly turn, roughness, binding or noise. If roughness, binding or noise is found, remo...

  • Page 74

    2-32 periodic maintenance maintenance procedure brake system brake fluid leak (brake hose and pipe) inspection • apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [a], pipes (abs equipped mod- els) [b] and fittings [c]. If the brake fluid leaked from any position, ...

  • Page 75

    Periodic maintenance 2-33 maintenance procedure brake hose and pipe damage and installation condition inspection • for abs equipped models; note the following. • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) battery (see battery removal in the electrical system chapter) ...

  • Page 76

    2-34 periodic maintenance maintenance procedure • remove the seat (see seat removal in the frame chap- ter). • check that the brake fluid level in the rear brake reservoir [a] is above the lower level line [b]. If the fluid level is lower than the lower level line, fill the reservoir to the upper le...

  • Page 77

    Periodic maintenance 2-35 maintenance procedure if it does not, adjust the brake light switch. • while holding the switch body, turn the adjusting nut to adjust the switch. Switch body [a] adjusting nut [b] light sooner as the body rises [c] light later as the body lowers [d] caution to avoid damagi...

  • Page 78

    2-36 periodic maintenance maintenance procedure front fork oil leak inspection • visually inspect the front forks [a] for oil leakage. Replace or repair any defective parts, if necessary. Rear shock absorber oil leak inspection • visually inspect the shock absorber [a] for oil leakage. If the oil le...

  • Page 79

    Periodic maintenance 2-37 maintenance procedure steering system steering play inspection • raise the front wheel off the ground with the jack. Special tools - jack: 57001-1238 • with the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing full...

  • Page 80

    2-38 periodic maintenance maintenance procedure • install the claw washer [a] so that its bent side [b] faces upward, and engage the bent claws with the grooves of stem locknut [c]. • hand tighten the stem locknut until it touches the claw washer. • tighten the stem locknut clockwise until the claws...

  • Page 81

    Periodic maintenance 2-39 maintenance procedure electrical system lights and switches operation inspection first step • push and turn the key knob to on. • the following lights should go on according to below table. City light [a] goes on taillight [b] goes on license plate light [c] goes on meter p...

  • Page 82

    2-40 periodic maintenance maintenance procedure third step • push and turn the key knob to on. • turn on the turn signal switch [a] (left or right position). • the left or right turn signal lights [b] (front and rear) ac- cording to the switch position should flash. • the either of turn signal indic...

  • Page 83

    Periodic maintenance 2-41 maintenance procedure fourth step • set the dimmer switch [a] to low beam position. • start the engine. • the low beam headlights [b] should go on. If the low beam headlight does not go on, inspect or re- place the following item. Headlight bulb (see headlight bulb replacem...

  • Page 84

    2-42 periodic maintenance maintenance procedure headlight beam horizontal adjustment • turn the horizontal adjuster [a] in both headlights in or out until the beam points straight ahead. If the headlight beam points too low or high, adjust the vertical beam. Headlight beam vertical adjustment • turn...

  • Page 85

    Periodic maintenance 2-43 maintenance procedure sidestand switch operation inspection • inspect the sidestand switch [a] operation accordance to table the below. Sidestand switch operation sidestand gear position clutch lever engine start engine run up neutral released starts continue running up neu...

  • Page 86

    2-44 periodic maintenance maintenance procedure engine stop switch operation inspection first step • push and turn the key knob to on. • set the neutral position. • turn the engine stop switch to stop position [a]. • push the starter button. • the engine does not start. If the engine starts, inspect...

  • Page 87

    Periodic maintenance 2-45 maintenance procedure cables: lubricate with rust inhibitor. Throttle cables • lubricate the cables by seeping the oil between the cable and housing. ○ the cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant. •...

  • Page 88

    2-46 periodic maintenance maintenance procedure bolt, nut and fastener to be checked engine: clutch lever pivot bolt locknut engine mounting bolts and nut muffler clamp bolts exhaust pipe manifold holder nuts muffler body mounting bolts wheels: front axle clamp bolts front axle nut rear axle nut rea...

  • Page 89

    Periodic maintenance 2-47 maintenance procedure • remove: left front middle fairing (see middle fairing removal in the frame chapter) bolts [a] relay bracket with relays [b] • unhook the insert portion [c] of the heat insulation rubber plate and turn up it. • remove: air cleaner element cover bolts ...

  • Page 90

    2-48 periodic maintenance maintenance procedure fuel hose replacement • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) sub engine bracket breather hose drain hose • be sure to place a piece of cloth [a] around the fuel hose joint. • push the joint lock claws [b], using th...

  • Page 91

    Periodic maintenance 2-49 maintenance procedure • insert the fuel hose joint [a] straight onto the delivery pipe until the hose joint clicks. • push [b] the joint lock [c] until the hose joint clicks. • push and pull the fuel hose joint [a] back and forth [b] more than two times and make sure it is ...

  • Page 92

    2-50 periodic maintenance maintenance procedure • remove: left middle fairing (see middle fairing removal in the frame chapter) left lower fairing (see lower fairing removal in the frame chapter) • place a containers under the drain plug [a] at the bottom of the water pump cover. • drain the coolant...

  • Page 93

    Periodic maintenance 2-51 maintenance procedure • bleed the air from the cooling system as follows. ○ start the engine with the radiator cap removed and run it until no more air bubbles [a] can be seen in the coolant. ○ tap the radiator hoses to force any air bubbles caught inside. ○ stop the engine...

  • Page 94

    2-52 periodic maintenance maintenance procedure engine oil change • situate the motorcycle so that it is vertical after warming up the engine. • remove the engine oil drain bolt [a] to drain the oil. ○ the oil in the oil filter can be drained by removing the filter (see oil filter replacement). Repl...

  • Page 95

    Periodic maintenance 2-53 maintenance procedure brake hose and pipe replacement caution brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • remove: radiator cover (see steering stem removal in the steering chapter) brake hose banjo bo...

  • Page 96

    2-54 periodic maintenance maintenance procedure • for abs equipped models; note the following. • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) battery (see battery removal in the electrical system chapter) upper fairing (see upper fairing removal in the frame chapter) br...

  • Page 97

    Periodic maintenance 2-55 maintenance procedure • remove the rubber cap from the bleed valve [a] on the caliper. • attach a clear plastic hose [b] to the bleed valve, and run the other end of the hose into a container. • fill the reservoir with fresh specified brake fluid. • change the brake fluid. ...

  • Page 98

    2-56 periodic maintenance maintenance procedure master cylinder rubber parts replacement front master cylinder disassembly • remove the front master cylinder (see front master cylin- der removal in the brakes chapter). • remove: screws [a] cap [b] diaphragm plate [c] diaphragm [d] float [e] screw [f...

  • Page 99

    Periodic maintenance 2-57 maintenance procedure master cylinder assembly • before assembly, clean all parts including the master cylinder with brake fluid or alcohol. Caution except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. D...

  • Page 100

    2-58 periodic maintenance maintenance procedure • using compressed air, remove the pistons. One way to remove the pistons is as follows. ○ install a rubber gasket [a] and a wooden board [b] more than 10 mm (0.4 in.) thick on the caliper half, and fas- ten them together with a suitable bolt and nut a...

  • Page 101

    Periodic maintenance 2-59 maintenance procedure • replace the fluid seals [a] with new ones. ○ apply silicone grease to the fluid seals, and install them into the cylinders by hand. • replace the dust seals [b] with new ones if they are dam- aged. ○ apply silicone grease to the dust seals, and insta...

  • Page 102

    2-60 periodic maintenance maintenance procedure • remove the right side piston as follows. • using the rear caliper assembly bolt [a], remove the pis- ton [b] as shown in the figure. • remove the dust seals [a] and fluid seals [b]. • remove the bleed valves [c] and rubber caps [d]. Note ○ if compres...

  • Page 103

    Periodic maintenance 2-61 maintenance procedure • apply brake fluid to the cylinder bores. • replace the fluid seals [a] with new ones. ○ apply silicone grease to the fluid seals, and install them into each cylinder by hand. • replace the dust seals [b] with new ones. • replace the o-ring [a]. • app...

  • Page 104

    2-62 periodic maintenance maintenance procedure • remove: left middle fairing (see middle fairing removal in the frame chapter) left lower fairing (see lower fairing removal in the frame chapter) left heat insulation plate (see fairing bracket removal in the frame chapter) banjo bolts [a] with washe...

  • Page 105

    Periodic maintenance 2-63 maintenance procedure rubber parts of clutch master cylinder/slave cylinder replacement clutch master cylinder cup and dust seal replacement • remove the clutch master cylinder (see clutch master cylinder removal in the clutch chapter). • remove: screws [a] cap [b] diaphrag...

  • Page 106

    2-64 periodic maintenance maintenance procedure clutch slave cylinder piston seal replacement • remove: left lower fairing (see lower fairing removal in the frame chapter) • loosen the banjo bolt [a] at the clutch pipe lower end, and tighten it loosely. • unscrew the slave cylinder bolts [b] and det...

  • Page 107

    Periodic maintenance 2-65 maintenance procedure clutch fluid change • level the clutch fluid reservoir and remove the reservoir cap. • remove the rubber cap from the bleed valve on the clutch slave cylinder. • attach a clear plastic hose [a] to the bleed valve and run the other end of the hose into ...

  • Page 108

    2-66 periodic maintenance maintenance procedure • replace the spark plug with a new one. Standard spark plug type: ngk cr9eia-9 • insert new spark plug in the plug hole, and finger-tighten it first. • using the plug wrench [a] vertically, tighten the plug. Caution the insulator of the spark plug may...

  • Page 109

    Periodic maintenance 2-67 maintenance procedure • fill the final gear case with the specified oil and quantity. ○ the oil level [a] should come to the top of the filler open- ing. Final gear case oil: amount: about 160 ml (5.41 us oz) grade: api gl-5 hypoid gear oil viscosity: when above 5°c (41°f) ...

  • Page 110

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  • Page 111: Fuel System (Dfi)

    Fuel system (dfi) 3-1 3 fuel system (dfi) table of contents exploded view........................................................................................................................ 3-4 dfi system...............................................................................................

  • Page 112

    3-2 fuel system (dfi) speed sensor input voltage inspection............................................................................ 3-68 speed sensor output voltage inspection ......................................................................... 3-69 gear position switch (service code 25) .....

  • Page 113

    Fuel system (dfi) 3-3 light (led) inspection ...................................................................................................... 3-110 fuel line................................................................................................................................. 3-111 f...

  • Page 114

    3-4 fuel system (dfi) exploded view http://mototh.Com.

  • Page 115

    Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 resonator mounting bolts 3.9 0.40 35 in·lb 2 front air inlet duct mounting bolts 3.9 0.40 35 in·lb 3 air inlet duct clamp bolts 2.9 0.30 26 in·lb 4 rear air inlet duct mounting bolts 9.8 1.0 87 in·lb 5 air cleaner elem...

  • Page 116

    3-6 fuel system (dfi) exploded view http://mototh.Com.

  • Page 117

    Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 speed sensor bolt 9.8 1.0 87 in·lb l 2 crankshaft sensor bolts 5.9 0.60 52 in·lb l 3 gear position switch screws 2.9 0.30 26 in·lb l 4 gear position switch lead clamp bolts 9.8 1.0 87 in·lb 5 vehicle-down sensor bolts ...

  • Page 118

    3-8 fuel system (dfi) exploded view http://mototh.Com.

  • Page 119

    Fuel system (dfi) 3-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 fuel pump bolts 9.8 1.0 87 in·lb l, s 2 separator bracket bolt 9.8 1.0 87 in·lb 3 oxygen sensor (europe models) 25 2.5 18 4 fuel level sensor bolts 6.9 0.70 61 in·lb l 5. Canister 6. Separator 7. Fitting 8. Red hose 9....

  • Page 120

    3-10 fuel system (dfi) dfi system dfi system http://mototh.Com.

  • Page 121

    Fuel system (dfi) 3-11 dfi system 1. Ecu 2. Crankshaft sensor 3. Inlet camshaft position sensor 4. Exhaust camshaft position sensor 5. Main throttle sensor 6. Subthrottle sensor 7. Subthrottle valve actuator 8. Inlet air pressure sensor 9. Atmospheric pressure sensor 10. Water temperature sensor 11....

  • Page 122

    3-12 fuel system (dfi) dfi system http://mototh.Com.

  • Page 123

    Fuel system (dfi) 3-13 dfi system part name 1. Steering lock unit 2. Joint connector 1 3. Engine stop switch 4. Starter button 5. Inlet camshaft position sensor 6. Exhaust camshaft position sensor 7. Stick coil #1, #2, #3, #4 8. Speed sensor 9. Oil control solenoid valve 10. Water temperature sensor...

  • Page 124

    3-14 fuel system (dfi) dfi system terminal numbers of ecu connectors terminal names 1. Stick coil #3 ignite signal 2. Stick coil #4 ignite signal 3. Fuel injector #3 drive signal 4. Unused 5. Unused 6. Air switching valve drive signal 7. Oil control valve solenoid drive signal 8. Unused 9. Unused 10...

  • Page 125

    Fuel system (dfi) 3-15 dfi parts location main throttle sensor [a] subthrottle sensor [b] battery 12 v 14 ah [c] water temperature sensor [d] fuel injectors #1, #2, #3, #4 [a] vehicle-down sensor [a] relay box (fuel pump relay) [b] immobilizer/kawasaki diagnostic system connector [c] dfi ecu [d] atm...

  • Page 126

    3-16 fuel system (dfi) dfi parts location exhaust camshaft position sensor [a] crankshaft sensor [b] oil control valve solenoid [c] oxygen sensor #1, #2 [d] speed sensor [a] gear position switch [b] key knob [a] steering lock unit [b] (immobilizer) air switching valve [a] subthrottle valve actuator ...

  • Page 127

    Fuel system (dfi) 3-17 specifications item standard digital fuel injection system idle speed 1 100 ±50 r/min (rpm) throttle assy: type four barrel type bore 40 mm (1.6 in.) throttle body vacuum 33 ±1.33 kpa (250 ±10 mmhg) bypass screws – – – ecu: make mitsubishi electric type digital memory type, wi...

  • Page 128

    3-18 fuel system (dfi) specifications item standard vehicle-down sensor: detection method magnetic flux detection method detection angle more than 60 ∼ 70° for each bank output voltage with sensor arrow mark pointed up: 3.55 ∼ 4.45 v with sensor tilted 60 ∼ 70° or more: 0.65 ∼ 1.35 v subthrottle sen...

  • Page 129

    Fuel system (dfi) 3-19 special tools and sealant oil pressure gauge, 5 kgf/cm²: 57001-125 fork oil level gauge: 57001-1290 vacuum gauge: 57001-1369 hand tester: 57001-1394 throttle sensor setting adapter #1: 57001-1400 peak voltage adapter: 57001-1415 needle adapter set: 57001-1457 throttle sensor s...

  • Page 130

    3-20 fuel system (dfi) special tools and sealant fuel hose: 57001-1607 kawasaki bond (silicone sealant): 56019-120 http://mototh.Com.

  • Page 131

    Fuel system (dfi) 3-21 dfi servicing precautions dfi servicing precautions there are a number of important precautions that should be followed servicing the dfi system. ○ this dfi system is designed to be used with a 12 v sealed battery as its power source. Do not use any other battery except for a ...

  • Page 132

    3-22 fuel system (dfi) dfi servicing precautions ○ replace the fuel hose [a] if it has been sharply bent or kinked. ○ the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak or the hose to burst. Bend and twist the fuel hose while examining it. Replace t...

  • Page 133

    Fuel system (dfi) 3-23 troubleshooting the dfi system outline when a problem occurs with dfi system, the warning in- dicator (led) [a] goes on and fi warning message [b] and fi warning symbol [c] are displayed alternately on the lcd (liquid crystal display) to alert the rider. This models equipped w...

  • Page 134

    3-24 fuel system (dfi) troubleshooting the dfi system with the engine stopped and turned in the self-diagnosis mode, the service code (error code) [a] is displayed on the lcd by the number of two digits. When the service code [a] is displayed, for first ask the rider about the conditions [b] of trou...

  • Page 135

    Fuel system (dfi) 3-25 troubleshooting the dfi system even when the dfi system is operating normally, the warning indicator light (led) goes on and fi warning message and fi warning symbol may be displayed under strong electrical interference. Additional measures are not required. Turn the key knob ...

  • Page 136

    3-26 fuel system (dfi) troubleshooting the dfi system • always check battery condition before replacing the dfi parts. A fully charged battery is a must for conducting accurate tests of the dfi system. • trouble may involve one or in some cases all items. Never replace a defective part without deter...

  • Page 137

    Fuel system (dfi) 3-27 troubleshooting the dfi system ○ if both ends of a harness [a] are far apart, ground [b] the one end [c], using a jumper lead [d] and check the con- tinuity between the end [e] and the ground [f]. This en- ables to check a long harness for continuity. If the harness is open, r...

  • Page 138

    3-28 fuel system (dfi) troubleshooting the dfi system dfi diagnosis flow chart inquiries to rider ○ each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ try to find out exactly what problem occurred under exactly what condi...

  • Page 139

    Fuel system (dfi) 3-29 troubleshooting the dfi system sample diagnosis sheet rider name: registration no. (license plate no.): year of initial registration: model: engine no.: frame no.: date problem occurred: mileage: environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ al...

  • Page 140

    3-30 fuel system (dfi) troubleshooting the dfi system □ very low idle speed, □ very high idle speed, □ rough idle speed. Poor running at low speed □ battery voltage is low (charge the battery). □ spark plug loose (tighten it). □ spark plug dirty, broken, or gap maladjusted (remedy it). □ backfiring....

  • Page 141

    Fuel system (dfi) 3-31 dfi system troubleshooting guide note ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in dfi system. ○ the ecu may be involved in t...

  • Page 142

    3-32 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) fuel pressure regulator trouble inspect fuel pressure and replace fuel pump (see chapter 16). Fuel line clogged inspect and repair (see chapter 3). Inlet air pressure sensor trouble inspect (see cha...

  • Page 143

    Fuel system (dfi) 3-33 dfi system troubleshooting guide symptoms or possible causes actions (chapter) main throttle sensor trouble inspect (see chapter 3). Subthrottle sensor trouble inspect (see chapter 3). Subthrottle valve actuator trouble inspect (see chapter 3). Inlet air pressure sensor troubl...

  • Page 144

    3-34 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) inlet air temperature sensor trouble inspect (see chapter 3). Other: intermittent any dfi fault and its recovery check that dfi connectors are clean and tight, and examine leads for signs of burning...

  • Page 145

    Fuel system (dfi) 3-35 dfi system troubleshooting guide symptoms or possible causes actions (chapter) atmospheric pressure sensor trouble inspect (see chapter 3). Water temperature sensor trouble inspect (see chapter 3). Inlet air temperature sensor trouble inspect (see chapter 3). Miscellaneous: su...

  • Page 146

    3-36 fuel system (dfi) self-diagnosis self-diagnosis outline the self-diagnosis system has two modes and can be switched to another mode by operating the meter unit. User mode the ecu notifies the rider of troubles in dfi system , igni- tion system and kipass system by lighting up the warning indica...

  • Page 147

    Fuel system (dfi) 3-37 self-diagnosis self-diagnosis procedures ○ when a problem occurs with dfi system and ignition sys- tem, the warning indicator (led) [a] goes on and fi warn- ing message [b] and fi warning symbol [c] are displayed alternately on the lcd (liquid crystal display) to alert the rid...

  • Page 148

    3-38 fuel system (dfi) self-diagnosis • push and turn the key knob to on. • push the upper button [a] and lower button [b] for more than two seconds. • the service code [c] is displayed on the lcd by the num- ber of two digits. ○ when pushing and holding the upper button while the warning massage an...

  • Page 149

    Fuel system (dfi) 3-39 self-diagnosis self-diagnosis flow chart http://mototh.Com.

  • Page 150

    3-40 fuel system (dfi) self-diagnosis service code reading ○ the service code(s) is displayed on the lcd by the number of two digits. ○ when there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical or...

  • Page 151

    Fuel system (dfi) 3-41 self-diagnosis service code table service code problems 11 main throttle sensor malfunction, wiring open or short 12 inlet air pressure sensor malfunction, wiring open or short 13 inlet air temperature sensor malfunction, wiring open or short 14 water temperature sensor malfun...

  • Page 152

    3-42 fuel system (dfi) self-diagnosis backups ○ the ecu takes the following measures to prevent engine damage when the dfi, ignition, kipass or immobilizer system parts have troubles. Service codes parts output signal usable range or criteria backups by ecu 11 main throttle sensor main throttle sens...

  • Page 153

    Fuel system (dfi) 3-43 self-diagnosis service codes parts output signal usable range or criteria backups by ecu 37 steering lock unit steering lock unit send the date to the kipass ecu with can communication line. – 38 fi ecu fi ecu send the date to the kipass ecu with can communication line. – 46 f...

  • Page 154

    3-44 fuel system (dfi) self-diagnosis service codes parts output signal usable range or criteria backups by ecu 67 oxygen sensor heater (equipped models) the oxygen sensor heater raise temperature of the sensor for its earlier activation. 12 v-3.6 w, 1.5 a if the oxygen sensor heater fails (wiring s...

  • Page 155

    Fuel system (dfi) 3-45 main throttle sensor (service code 11) the main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ecu senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm,...

  • Page 156

    3-46 fuel system (dfi) main throttle sensor (service code 11) • remove: right middle fairing (see middle fairing removal in the frame chapter) right subframe (see sub frame removal in the frame chapter) • disconnect the main throttle sensor connector [a]. • connect the harness adapter [a] between th...

  • Page 157

    Fuel system (dfi) 3-47 main throttle sensor (service code 11) main throttle sensor output voltage inspection • measure the output voltage at the ecu in the same way as input voltage inspection. Note the following. Digital meter [a] connector [b] special tool - needle adapter set: 57001-1457 main thr...

  • Page 158

    3-48 fuel system (dfi) main throttle sensor (service code 11) note ○ the standard voltage refers to the value when the volt- age reading at the input voltage inspection shows 5 v exactly. ○ when the input voltage reading shows other than 5 v, derive a voltage range as follows. Example: in the case o...

  • Page 159

    Fuel system (dfi) 3-49 main throttle sensor (service code 11) caution do not remove or adjust the main throttle sensor. It has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. A shock to the sensor can damage it. Note ○ the standard voltage re...

  • Page 160

    3-50 fuel system (dfi) main throttle sensor (service code 11) main throttle sensor circuit 1. Ecu 2. Subthrottle valve actuator 3. Subthrottle sensor 4. Main throttle sensor 5. Water-proof joint 2 http://mototh.Com.

  • Page 161

    Fuel system (dfi) 3-51 inlet air pressure sensor (service code 12) caution never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Inlet air pressure sensor removal • remove: left subframe (see subframe removal in the frame chapter) bolts [a] relay bracket [b] wi...

  • Page 162

    3-52 fuel system (dfi) inlet air pressure sensor (service code 12) inlet air pressure sensor input voltage inspection note ○ be sure the battery is fully charged. ○ the inspection is the same as “input voltage inspection” of the throttle sensor and the atmospheric pressure sen- sor. • turn the key k...

  • Page 163

    Fuel system (dfi) 3-53 inlet air pressure sensor (service code 12) output voltage inspection • measure the output voltage at the ecu in the same way as input voltage inspection. Note the following. Digital meter [a] connector [b] special tool - needle adapter set: 57001-1457 inlet air pressure senso...

  • Page 164

    3-54 fuel system (dfi) inlet air pressure sensor (service code 12) inlet air pressure sensor circuit 1. Ecu 2. Inlet air pressure sensor 3. Water-proof joint 2 if you need to check the inlet air pressure sensor for vac- uum other than 76 cmhg (abs.), check the output voltage as follows. Http://motot...

  • Page 165

    Fuel system (dfi) 3-55 inlet air pressure sensor (service code 12) • remove the inlet air pressure sensor [a] and disconnect the vacuum hose from the sensor. • connect an auxiliary hose [b] to the inlet air pressure sen- sor. • temporarily install the inlet air pressure sensor. ○ connect a digital m...

  • Page 166

    3-56 fuel system (dfi) inlet air pressure sensor (service code 12) id: idling pv: throttle vacuum pressure (abs.) ps: standard atmospheric pressure (abs.) st: standard of sensor output voltage (v) to: throttle full open ur: usable range of sensor output voltage (v) vv: inlet air pressure sensor outp...

  • Page 167

    Fuel system (dfi) 3-57 inlet air temperature sensor (service code 13) inlet air temperature sensor removal caution never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove the fuel tank (see fuel tank removal). • open the clamp [a] • disconnect the conn...

  • Page 168

    3-58 fuel system (dfi) inlet air temperature sensor (service code 13) if the output voltage is out of the specified, check the ecu for its ground, and power supply (see ecu power supply inspection). If the ground and power supply are good, replace the ecu (see ecu section). If the output voltage is ...

  • Page 169

    Fuel system (dfi) 3-59 inlet air temperature sensor (service code 13) inlet air temperature sensor circuit 1. Ecu 2. Inlet air temperature sensor 3. Water-proof joint 2 http://mototh.Com.

  • Page 170

    3-60 fuel system (dfi) water temperature sensor (service code 14) water temperature sensor removal/installation caution never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • drain the coolant (see coolant change in the periodic maintenance chapter). • remov...

  • Page 171

    Fuel system (dfi) 3-61 water temperature sensor (service code 14) sensor resistance inspection • refer to the water temperature sensor inspection in the electrical system chapter (see water temperature sen- sor inspection in the electrical system chapter). Water temperature sensor circuit 1. Ecu 2. ...

  • Page 172

    3-62 fuel system (dfi) atmospheric pressure sensor (service code 15) caution never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Removal • remove: left saddlebag (see saddlebag removal in the frame chapter) seat (see seat removal in the frame chapter) atmos...

  • Page 173

    Fuel system (dfi) 3-63 atmospheric pressure sensor (service code 15) if the reading is within the standard range, remove the seat, and check the input voltage again at the sensor con- nector. • disconnect the atmospheric pressure sensor connector and connect the harness adapter [a] between the harne...

  • Page 174

    3-64 fuel system (dfi) atmospheric pressure sensor (service code 15) if the output voltage is far out of the usable range, check the output voltage at the sensor connector [a] (when the wiring is open, the output voltage is about 1.8 v). • connect a digital meter [a] to the harness adapter leads. At...

  • Page 175

    Fuel system (dfi) 3-65 atmospheric pressure sensor (service code 15) if you know the local atmospheric pressure using a barometer, substitute the atmospheric pressure for throt- tle vacuum pressure in the inlet air pressure sensor chart (see inlet air pressure sensor section). And get the usable ran...

  • Page 176

    3-66 fuel system (dfi) crankshaft sensor (service code 21) crankshaft sensor removal/installation • refer to the crankshaft sensor removal/installation in the electrical system chapter (see crankshaft sensor re- moval/installation in the electrical system chapter). Crankshaft sensor inspection ○ the...

  • Page 177

    Fuel system (dfi) 3-67 camshaft position sensor (service code 23, 26) camshaft position sensor removal/installation the camshaft position sensor detects the position of the camshaft, and distinguishes the cylinder. • refer to the camshaft position sensor removal/installa- tion in the electrical syst...

  • Page 178

    3-68 fuel system (dfi) speed sensor (service code 24) speed sensor removal/installation • refer to the speed sensor removal/installation in the electrical system chapter (see speed sensor re- moval/installation in the electrical system chapter). Speed sensor inspection • refer to the speed sensor in...

  • Page 179

    Fuel system (dfi) 3-69 speed sensor (service code 24) speed sensor output voltage inspection • before this inspection, inspect the input voltage (see speed sensor input voltage inspection). Note ○ be sure the battery is fully charged. • turn the key knob to off. • using the stand, raise the rear whe...

  • Page 180

    3-70 fuel system (dfi) speed sensor (service code 24) 1. Ecu 2. Speed sensor 3. Joint connector 8 4. Meter unit 5. Frame ground 6. Frame ground 7. Battery 12 v 14 ah http://mototh.Com.

  • Page 181

    Fuel system (dfi) 3-71 gear position switch (service code 25) gear position switch removal/installation • refer to the gear position switch removal/installation in the electrical system chapter (see gear position switch removal/installation in the electrical system chapter). Gear position switch ins...

  • Page 182

    3-72 fuel system (dfi) gear position switch (service code 25) gear position switch circuit 1. Ecu 2. Gear position switch 3. Joint connector 8 4. Frame ground 5. Frame ground 6. Battery 12 v 14 ah http://mototh.Com.

  • Page 183

    Fuel system (dfi) 3-73 vehicle-down sensor (service code 31) this sensor has a weight [a] with two magnets inside, and sends a signal to the ecu. But when the motorcycle banks 60 ∼ 70° or more to either side (in fact falls down), the weight turns and shuts off the signal. The ecu senses this change,...

  • Page 184

    3-74 fuel system (dfi) vehicle-down sensor (service code 31) vehicle-down sensor inspection note ○ be sure the battery is fully charged. • remove the rear fender (see rear fender removal in the frame chapter). • connect a digital meter [a] to the connector of the vehicle -down sensor [b], with the n...

  • Page 185

    Fuel system (dfi) 3-75 vehicle-down sensor (service code 31) • turn the key knob to off. • remove the vehicle-down sensor. ○ do not disconnect the sensor connector. • connect a digital meter [a] to the connector, with needle adapter set [b]. Special tool - needle adapter set: 57001-1457 vehicle-down...

  • Page 186

    3-76 fuel system (dfi) subthrottle sensor (service code 32) the subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ecu senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and...

  • Page 187

    Fuel system (dfi) 3-77 subthrottle sensor (service code 32) • remove: right middle fairing (see middle fairing removal in the frame chapter). Right subframe • disconnect the subthrottle sensor connector [a]. • connect the harness adapter [a] between the harness connector and subthrottle sensor conne...

  • Page 188

    3-78 fuel system (dfi) subthrottle sensor (service code 32) output voltage inspection • measure the output voltage at the ecu in the same way as input voltage inspection. Note the following. Digital meter [a] connector [b] special tool - needle adapter set: 57001-1457 subthrottle sensor output volta...

  • Page 189

    Fuel system (dfi) 3-79 subthrottle sensor (service code 32) • disconnect the subthrottle sensor connector [a] and con- nect the harness adapter [b] between the harness con- nector and subthrottle sensor connector. Special tool - throttle sensor harness adapter: 57001 -1538 • connect a digital meter ...

  • Page 190

    3-80 fuel system (dfi) subthrottle sensor (service code 32) resistance inspection • turn the key knob to off. • disconnect the subthrottle sensor connector. • connect a digital meter [a] to the subthrottle sensor con- nector [b]. • measure the subthrottle sensor resistance. Subthrottle sensor resist...

  • Page 191

    Fuel system (dfi) 3-81 oxygen sensor-not activated (#1, #2: service code 33, 83) - equipped models oxygen sensor #2 removal/installation • refer to the oxygen sensor removal (equipped models) in the electrical system chapter (see oxygen sensor re- moval in the electrical system chapter). Oxygen sens...

  • Page 192

    3-82 fuel system (dfi) oxygen sensor-not activated (#1, #2: service code 33, 83) - equipped models • install the suitable plugs [a] on the fittings of the air suction valve covers [b], and shut off the secondary air. • connect or install the following parts temporary. Fuel tank (see fuel tank instal...

  • Page 193

    Fuel system (dfi) 3-83 oxygen sensor-not activated (#1, #2: service code 33, 83) - equipped models oxygen sensor circuit 1. Ecu 2. Joint connector 9 3. Oxygen sensor #2 4. Oxygen sensor #1 5. Steering lock unit 6. Oxygen sensor heater fuse 15 a 7. Main fuse 30 a 8. Battery 12 v 14 ah 9. Joint connec...

  • Page 194

    3-84 fuel system (dfi) steering lock unit and ecu communication error (service code 37, 38) steering lock unit and ecu communication line inspection ○ when the data is not sent from the steering lock unit and ecu to kipass ecu, the service code 37, 38 is dis- played. • check the ecu (see ecu power s...

  • Page 195

    Fuel system (dfi) 3-85 fuel pump relay (service code 46) fuel pump relay removal caution never drop the relay, especially on a hard surface. Such a shock to the relay can damage it. ○ the fuel pump relay is included in the relay box. • remove the seat (see seat removal in the frame chap- ter). • rem...

  • Page 196

    3-86 fuel system (dfi) fuel pump relay (service code 46) fuel pump relay circuit 1. Steering lock unit 2. Joint connector 1 3. Engine stop switch 4. Water-proof joint 1 5. Ecu 6. Ignition fuse 10 a 7. Ecu fuse 15 a 8. Fuse box 2 9. Joint connector 9 10. Fuel pump relay 11. Relay box 12. Joint connec...

  • Page 197

    Fuel system (dfi) 3-87 stick coils #1, #2, #3, #4: (service code 51, 52, 53, 54) stick coil #1: service code 51 stick coil #2: service code 52 stick coil #3: service code 53 stick coil #4: service code 54 stick coil removal/installation caution never drop the stick coils, especially on a hard sur- f...

  • Page 198

    3-88 fuel system (dfi) stick coils #1, #2, #3, #4: (service code 51, 52, 53, 54) stick coil circuit 1. Ecu 2. Stick coil #4 3. Stick coil #3 4. Stick coil #2 5. Stick coil #1 6. Engine stop switch 7. Steering lock unit 8. Ignition fuse 10 a 9. Fuse box 2 10. Joint connector 9 11. Main fuse 30 a 12. ...

  • Page 199

    Fuel system (dfi) 3-89 radiator fan relay (service code 56) radiator fan relay removal/installation ○ the radiator fan relay is built in the relay box [a]. • refer to the relay box removal in the electrical system chapter. Radiator fan relay inspection • refer to the relay circuit inspection in the ...

  • Page 200

    3-90 fuel system (dfi) variable valve timing and oil control solenoid valve (service code 59, 65) oil control solenoid valve removal/installation caution never drop the oil control solenoid valve, on a hard surface, as it may be damage. • refer to the oil control solenoid valve removal/instal- latio...

  • Page 201

    Fuel system (dfi) 3-91 variable valve timing and oil control solenoid valve (service code 59, 65) • turn the key knob to off. If the reading is incorrect, check the following. Battery (see charging condition inspection in the elec- trical system chapter) main fuse 30 a (see fuse inspection in the el...

  • Page 202

    3-92 fuel system (dfi) subthrottle valve actuator (service code 62) subthrottle valve actuator removal caution do not remove the subthrottle valve actuator [a] since it has been adjusted and set with precision at the factory. Never drop the actuator , especially on a hard sur- face. Such a shock to ...

  • Page 203

    Fuel system (dfi) 3-93 subthrottle valve actuator (service code 62) input voltage inspection note ○ be sure the battery is fully charged. • push and turn the key knob to off. • connect the peak voltage adapter [a] and a digital meter [b] to the connector [c], using the needle adapter set [d]. Specia...

  • Page 204

    3-94 fuel system (dfi) subthrottle valve actuator (service code 62) subthrottle valve actuator circuit 1. Ecu 2. Subthrottle valve actuator 3. Subthrottle sensor 4. Main throttle sensor 5. Water-proof joint 2 http://mototh.Com.

  • Page 205

    Fuel system (dfi) 3-95 air switching valve (service code 64) air switching valve removal/installation • refer to clean air system section in the engine top end chapter. Air switching valve inspection • refer to air switching valve unit test in the electrical sys- tem chapter. • check the wiring cont...

  • Page 206

    3-96 fuel system (dfi) oxygen sensor heaters (#1 and/or #2: service code 67) - equipped models oxygen sensor heaters removal/installation the oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensors (see oxygen sensor removal in the el...

  • Page 207

    Fuel system (dfi) 3-97 oxygen sensor heaters (#1 and/or #2: service code 67) - equipped models if he tester reading is specified, check the power source voltage inspection. Note ○ be sure the battery is fully charged. • connect a digital meter [a] to each oxygen sensor con- nector [b], using the nee...

  • Page 208

    3-98 fuel system (dfi) oxygen sensor heaters (#1 and/or #2: service code 67) - equipped models oxygen sensor circuit 1. Ecu 2. Joint connector 9 3. Oxygen sensor #2 4. Oxygen sensor #1 5. Steering lock unit 6. Oxygen sensor heater fuse 15 a 7. Main fuse 30 a 8. Battery 12 v 14 ah 9. Joint connector ...

  • Page 209

    Fuel system (dfi) 3-99 steering lock unit (service code 68) steering lock unit inspection • remove : left inner cover (see inner cover removal in the frame chapter) • turn the key knob to off. • open the rubber cap [a]. • pull the connectors [b]. • connect a digital voltmeter [a] to the steering loc...

  • Page 210

    3-100 fuel system (dfi) steering lock unit (service code 68) • push and turn on the key knob and check the voltage. Steering lock unit voltage connections for main harness side connector meter (+) → w lead meter (–) → bk/y lead standard voltage: battery voltage meter (+) → br/w lead meter (–) → bk/y...

  • Page 211

    Fuel system (dfi) 3-101 steering lock unit and dfi ecu - identify authentification error (service code 87, 88) ○ when the service code 87, 88 is displayed, perform the registration of kipass id by using the kds 3. • if kipass id can not be registered, replace the ecu or steering lock unit. Note ○ th...

  • Page 212

    3-102 fuel system (dfi) ecu caution never drop the ecu, especially on a hard surface. Such a shock to the ecu can damage it. Ecu identification ○ most countries have their own regulations, so each ecu has different characteristic. So, do not confuse ecu with each other and use only the ecu for your ...

  • Page 213

    Fuel system (dfi) 3-103 ecu • remove: fuse box [a] bolts [b] tool kit case [c] • pull of the connectors [d] • for europe models, using a suitable tool cut of the screws [a]. • remove: connectors [a] relay box [b] • lift up the ecu [c] with rubber protector [d]. • remove: ecu connectors [a] ecu [b] •...

  • Page 214

    3-104 fuel system (dfi) ecu • install: relay box connector [a] relay box [b] connector holder with connectors [c] • install the tool kit case [a] and tighten the bolts [b]. • insert the stopper [c] of the fuse box [d] into the groove of the tool case. • for europe models, tighten new screws [a] of t...

  • Page 215

    Fuel system (dfi) 3-105 ecu • with the ecu connectors [b] connected, check the fol- lowing ground lead for continuity with the key knob off, using a digital meter [a] and needle adapter set. Special tool - needle adapter set: 57001-1457 ecu grounding inspection 21, 22, or 52 terminal ←→ frame ground...

  • Page 216

    3-106 fuel system (dfi) ecu ecu power source circuit 1. Ecu 2. Water-proof joint 1 3. Steering lock unit 4. Joint connector 9 5. Fuse box 2 6. Ecu fuse 15 a 7. Main fuse 30 a 8. Starter relay 9. Battery 12 v 14 ah 10. Frame ground 11. Frame ground 12. Joint connector 3 http://mototh.Com.

  • Page 217

    Fuel system (dfi) 3-107 ecu can communication line resistance inspection ○ in this model, resistors for can communication line are built in the dfi ecu, kipass ecu and meter unit. • turn the key knob to off. • disconnect the dfi ecu connector [a] and kipass ecu connector [b]. • connect a digital met...

  • Page 218

    3-108 fuel system (dfi) ecu can communication line circuit 1. Steering lock unit 2. Joint connector 4 3. Joint connector 5 4. Kipass ecu 5. Meter unit 6. Joint connector 6 7. Joint connector 7 8. Kawasaki diagnostic system connector 9. Ecu http://mototh.Com.

  • Page 219

    Fuel system (dfi) 3-109 dfi power source ecu fuse removal • refer to the ecu fuse 15 a removal in the electrical sys- tem chapter (see ecu fuse 15 a removal in the electri- cal system chapter). Ecu fuse installation if a fuse fails during operation, inspect the dfi system to determine the cause, and...

  • Page 220

    3-110 fuel system (dfi) warning indicator light (led) light (led) inspection ○ the warning indicator light (led) [a] is used for the fi indicator and kipass indicator. ○ in this model, the warning indicator light (led) goes on or blinks by the special signal sent from the ecu. • refer to the fuel le...

  • Page 221

    Fuel system (dfi) 3-111 fuel line fuel pressure inspection note ○ be sure the battery is fully charged. • remove the fuel tank bolts [a] (see fuel tank removal). ○ do not disconnect the fuel pump and fuel level sensor lead connector. • remove the fuel hose (see fuel hose replacement in the periodic ...

  • Page 222

    3-112 fuel system (dfi) fuel line warning do not try to start the engine with the fuel hoses disconnected. • push and turn the key knob to on. The fuel pump will turn for 3 seconds, and then stop. Caution do not drive the fuel pump 3 seconds or more with- out the fuel in the fuel tank. If the fuel p...

  • Page 223

    Fuel system (dfi) 3-113 fuel line fuel flow rate inspection note ○ be sure the battery is fully charged. Warning gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appli...

  • Page 224

    3-114 fuel system (dfi) fuel line warning wipe off spilled out fuel immediately. Be sure to hold the measuring cylinder vertical. • close the fuel tank cap. • with the engine stopped, turn the ignition switch on. The fuel pump should operate for 3 seconds, and then should stop. Caution do not drive ...

  • Page 225

    Fuel system (dfi) 3-115 fuel pump fuel pump removal caution never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. Warning gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from a...

  • Page 226

    3-116 fuel system (dfi) fuel pump • check that the fuel pump terminals [a], fuel reserve switch terminal [b] and band [c] are in place. Left [d] • apply a non-permanent locking agent to the threads of the fuel pump bolts. • tighten the fuel pump bolts to a snug fit following the tight- ening sequenc...

  • Page 227

    Fuel system (dfi) 3-117 fuel pump fuel pump circuit 1. Steering lock unit 2. Joint connector 1 3. Engine stop switch 4. Water-proof joint 1 5. Ecu 6. Ignition fuse 10 a 7. Ecu fuse 15 a 8. Fuse box 2 9. Joint connector 9 10. Fuel pump relay 11. Relay box 12. Joint connector 2 13. Main fuse 30 a 14. ...

  • Page 228

    3-118 fuel system (dfi) fuel injectors fuel injector removal/installation • refer to the throttle body assy disassembly/assembly (see throttle body assy disassembly/assembly). Caution never drop the injector, especially on a hard sur- face. Such a shock to the injector can damage it. Power source vo...

  • Page 229

    Fuel system (dfi) 3-119 fuel injectors • connect a digital meter [a] to the throttle body subharness connector [b], using the needle adapter set [c]. Special tool - needle adapter set: 57001-1457 injector power source voltage at injector connections to injector #1, #2, #3, #4 meter (+) → w/r lead [e...

  • Page 230

    3-120 fuel system (dfi) fuel injectors if the output voltage is out of the standard, check the out- put voltage at the throttle body subharness connector [b] using a digital meter [a] and needle adapter set [c] (when the lead is open, the output voltage is 0 v). Special tool - needle adapter set: 57...

  • Page 231

    Fuel system (dfi) 3-121 fuel injectors injector signal test • prepare two test light sets with male terminals as shown. Rating of bulb [a]: 12 v × 3 ∼ 3.4 w terminal width [b]: 1.8 mm (0.07 in.) terminal thickness [c]: 0.8 mm (0.03 in.) caution do not use larger terminals than specified above. A lar...

  • Page 232

    3-122 fuel system (dfi) fuel injectors injector unit test • use two leads [a] and the same test light set [b] as in “injector signal test”. Rating of bulb [c]: 12 v × (3 ∼ 3.4) w 12 v mf battery [d] caution be sure to connect the bulb in series. The bulb works as a current limiter to protect the sol...

  • Page 233

    Fuel system (dfi) 3-123 fuel injectors fuel injector circuit 1. Steering lock unit 2. Ignition fuse 10 a 3. Ecu fuse 15 a 4. Fuse box 2 5. Joint connector 9 6. Engine stop switch 7. Fuel injector #1 8. Fuel injector #2 9. Fuel injector #3 10. Fuel injector #4 11. Water-proof joint 1 12. Ecu 13. Rela...

  • Page 234

    3-124 fuel system (dfi) throttle grip and cables free play inspection • refer to the throttle control system inspection in the pe- riodic maintenance chapter (see throttle control system inspection in the periodic maintenance chapter). Free play adjustment • refer to the throttle control system insp...

  • Page 235

    Fuel system (dfi) 3-125 throttle body assy idle speed inspection • refer to the idle speed inspection in the periodic mainte- nance chapter (see idle speed inspection in the periodic maintenance chapter). Throttle bore cleaning • check the throttle bore for cleanliness as follows. ○ remove the throt...

  • Page 236

    3-126 fuel system (dfi) throttle body assy • remove: right subframe bolt [a] with washer right fairing bracket bolt (front side) • disconnect the throttle body subharness connector [a]. • remove the connector [a] from the connector bracket. ○ insert the thin blade screw driver into the connector sto...

  • Page 237

    Fuel system (dfi) 3-127 throttle body assy • remove: fuel tank (see fuel tank removal) inlet air temperature sensor [a] bolts [b] left and right air cleaner caps [c] ○ do not disconnect the inlet air temperature sensor lead connector. • pull out the ducts [a] upward. ○ remove the grommets [a] as nec...

  • Page 238

    3-128 fuel system (dfi) throttle body assy • remove the adjuster screw [a] from the clamp [b]. • loosen the throttle body assy holder clamp bolts [a] on both sides. • pull out the throttle body assy [b] from the holder. • disconnect the fuel hose joint from the delivery pipe of the throttle body ass...

  • Page 239

    Fuel system (dfi) 3-129 throttle body assy if the grommet [a] was removed, install it. ○ install the grommet from the inside of the frame. • insert the duct [b] to the grommet. ○ apply a soap and water solution or rubber lubricant to the oblique portion [c] on the duct for easy installation. • fit t...

  • Page 240

    3-130 fuel system (dfi) throttle body assy throttle body assy disassembly 1. Subthrottle valve actuator 2. Subthrottle sensor 3. Main throttle sensor 4. Throttle body assy 5. Injector 6. Delivery pipe 7. Throttle body subharness caution do not remove, disassemble or adjust the main throttle sensor, ...

  • Page 241

    Fuel system (dfi) 3-131 throttle body assy • disconnect the main throttle sensor [a] and subthrottle sensor [b] connector. • disconnect: subthrottle valve actuator lead connector [a] inlet air pressure sensor connector [b] • remove the inlet air pressure sensor [a] with hose [b]. • separate the hose...

  • Page 242

    3-132 fuel system (dfi) throttle body assy throttle body assy assembly • before assembling, blow away dirt or dust from the throttle body and delivery pipe by applying compressed air. • apply daphne oil or engine oil to the new o-rings [a] of each injector, insert them to the delivery pipe [b] and c...

  • Page 243

    Fuel system (dfi) 3-133 air line element removal • refer to the air cleaner element replacement in the pe- riodic maintenance chapter (see air cleaner element re- placement in the periodic maintenance chapter). Element installation • refer to the air cleaner element replacement in the pe- riodic mai...

  • Page 244

    3-134 fuel system (dfi) air line oil draining a drain hose is connected to the bottom of the air cleaner part to drain water or oil accumulated in the cleaner part. • visually check the catch tank [a] of the drain hose, if the water or oil accumulates in the tank. If any water or oil accumulates in ...

  • Page 245

    Fuel system (dfi) 3-135 air line • insert the rear air inlet duct [a] until the duct end [b] align the line [c] of middle air inlet duct [d]. • tighten torque - rear air inlet duct mounting bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install the clamp bolts so that bolt heads [a] faces direc- tion as sho...

  • Page 246

    3-136 fuel system (dfi) fuel tank fuel tank removal warning gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignit...

  • Page 247

    Fuel system (dfi) 3-137 fuel tank • disconnect: fuel pump lead connector [a] fuel level sensor lead connector [b] • open the fuel tank cap [a] to lower the pressure in the tank. ○ during tank removal, keep the tank cap open to release pressure in the tank. This makes fuel spillage less. • draw the f...

  • Page 248

    3-138 fuel system (dfi) fuel tank • for the california model, note the following. Caution for the california model, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become contaminated, replace it wi...

  • Page 249

    Fuel system (dfi) 3-139 fuel tank • pull the joint lock [a] as shown. • insert the fuel hose joint [a] straight onto the delivery pipe until the hose joint clicks. • push the joint lock [b] until the hose joint clicks. • push and pull [a] the hose joint [b] back and forth more than two times and mak...

  • Page 250

    3-140 fuel system (dfi) fuel tank fuel tank and cap inspection • visually inspect the gasket [a] on the tank cap for any damage. Replace the gasket if it is damaged. • check to see if the water drain pipe [b] and fuel breather pipe [c] (california model) in the tank are not clogged. Check the tank c...

  • Page 251

    Fuel system (dfi) 3-141 evaporative emission control system the evaporative emission control system routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection ...

  • Page 252

    3-142 fuel system (dfi) evaporative emission control system separator operation test warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch off. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...

  • Page 253: Cooling System

    Cooling system 4-1 4 cooling system table of contents exploded view........................................................................................................................ 4-2 coolant flow chart.............................................................................................

  • Page 254

    4-2 cooling system exploded view http://mototh.Com.

  • Page 255

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 radiator hose clamp screws 2.0 0.20 18 in·lb 2 coolant drain plug 12 1.2 106 in·lb 3 water pump cover bolts 9.8 1.0 87 in·lb 4 oil cooler mounting bolts 12 1.2 106 in·lb s 5 thermostat housing cover bolts 5.9 0.60 52 in·l...

  • Page 256

    4-4 cooling system coolant flow chart http://mototh.Com.

  • Page 257

    Cooling system 4-5 coolant flow chart permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature chan...

  • Page 258

    4-6 cooling system specifications item standard coolant provided when shipping type (recommended) permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) color green mixed ratio soft water 50%, coolant 50% freezing ...

  • Page 259

    Cooling system 4-7 coolant coolant deterioration inspection • visually inspect the coolant in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling sy...

  • Page 260

    4-8 cooling system coolant cooling system flushing over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water...

  • Page 261

    Cooling system 4-9 water pump water pump removal • drain: coolant (see coolant change in the periodic mainte- nance chapter) engine oil (see engine oil change in the periodic main- tenance chapter) • remove: lower fairing (see lower fairing removal in the frame chapter) • remove: clamp screw [a] rad...

  • Page 262

    4-10 cooling system water pump • turn the pump drive gear shaft so that the slot [a] in its shaft fits onto the projection [b] of the impeller shaft. • install: radiator hose • tighten: torque - radiator hose clamp screw: 2.0 n·m (0.20 kgf·m, 18 in·lb) • install the water pump cover [a]. Torque - wa...

  • Page 263

    Cooling system 4-11 radiator radiator and radiator fan removal • drain: coolant (see coolant change in the periodic mainte- nance chapter) • remove: middle fairings (see middle fairing removal in the frame chapter) right side radiator fan lead connector [a] reservoir tank hose [b] air bleeder hose [...

  • Page 264

    4-12 cooling system radiator radiator and radiator fan installation • be sure that the trim seals [a] are in position on the radi- ator as shown. • install the dampers [b], radiator bracket collars [c] and bolts as shown. Radiator inspection • check the radiator core. If there are obstructions to ai...

  • Page 265

    Cooling system 4-13 radiator radiator cap inspection • remove: front right middle fairing (see middle fairing removal in the frame chapter) radiator cap [a] • check the condition of the bottom [a] and top [b] valve seals and valve spring [c]. If any one of them shows visible damage, replace the cap ...

  • Page 266

    4-14 cooling system thermostat thermostat removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: right rear middle fairing (see middle fairing removal in the frame chapter) battery compartment cover (see battery removal in the electrical system chapter) crank...

  • Page 267

    Cooling system 4-15 thermostat • to check valve opening temperature, suspend the ther- mostat [a] in a container of water and raise the tempera- ture of the water. ○ the thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [b] in...

  • Page 268

    4-16 cooling system hoses and pipes hose installation • install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • run the hoses (see cable, wire, and hose routing sec- tion in the appendix chapter). • install the clamp [a] as ne...

  • Page 269

    Cooling system 4-17 water temperature sensor caution the water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to their parts can damage them. Water temperature sensor removal • refer to the water temperature sensor removal in the fuel system (dfi) chapter. Water...

  • Page 270

    Http://mototh.Com.

  • Page 271: Engine Top End

    Engine top end 5-1 5 engine top end table of contents exploded view........................................................................................................................ 5-2 exhaust system.................................................................................................

  • Page 272

    5-2 engine top end exploded view http://mototh.Com.

  • Page 273

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air suction valve cover bolts 9.8 1.0 87 in·lb l 2 cylinder head cover bolts 9.8 1.0 87 in·lb s 3 camshaft cap bolts 12 1.2 106 in·lb s 4 camshaft chain guide bolts 12 1.2 106 in·lb s cylinder head bolts (m11, first) 39 4...

  • Page 274

    5-4 engine top end exploded view http://mototh.Com.

  • Page 275

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 muffler body mounting bolts 34 3.5 25 2 crankshaft sensor cover bolts 9.8 1.0 87 in·lb l (1) 3 oxygen sensor (europe models) 25 2.5 18 4. Muffler body clamp bolt 5. Exhaust pipe manifold holder nuts 6. Europe models l: ap...

  • Page 276

    5-6 engine top end exhaust system full: full power h: honeycomb type catalyst 78.2: hosepower 78.2 kw (106.3 ps) manifold mark position [a] http://mototh.Com.

  • Page 277

    Engine top end 5-7 exhaust system silencer mark position [a] manifold [a] with holes [b] for oxygen sensors [c]. Honeycomb type catalysts [a] http://mototh.Com.

  • Page 278

    5-8 engine top end specifications item standard service limit camshafts cam height: exhaust 33.642 ∼ 33.756 mm (1.3245 ∼ 1.3290 in.) 33.54 mm (1.32 in.) inlet 34.243 ∼ 34.357 mm (1.3481 ∼ 1.3526 in.) 34.14 mm (1.344 in.) camshaft journal, camshaft cap clearance 0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.)...

  • Page 279

    Engine top end 5-9 special tools and sealant compression gauge, 20 kgf/cm²: 57001-221 valve spring compressor assembly: 57001-241 valve seat cutter, 45° - 35: 57001-1116 valve seat cutter, 32° - 30: 57001-1120 valve seat cutter, 32° - 35: 57001-1121 valve seat cutter, 60° - 30: 57001-1123 valve seat...

  • Page 280

    5-10 engine top end special tools and sealant valve seat cutter holder, 5: 57001-1208 valve seat cutter, 60° - 33: 57001-1334 compression gauge adapter, m10 × 1.0: 57001-1486 valve guide driver: 57001-1564 valve spring compressor adapter, 24: 57001-1586 valve guide driver attachment, e: 57001-1677 k...

  • Page 281

    Engine top end 5-11 clean air system air suction valve removal • remove: middle fairings (see middle fairing removal in the frame chapter) subframes engine bracket • remove the air switching valve with the hoses [a] (see air switching valve removal). • remove: air suction valve cover bolts [a] air s...

  • Page 282

    5-12 engine top end clean air system air suction valve inspection • remove the air suction valve (see air suction valve re- moval). • visually inspect the reeds [a] for cracks, folds, warps, heat damage, or other damage. If there is any doubt as to the condition of the reed, replace the air suction ...

  • Page 283

    Engine top end 5-13 clean air system air switching valve installation • install the air switching valve so that the air duct [a] faces left side. • route the hoses correctly (see cable, wire, and hose routing section in the appendix chapter). Air switching valve operation test • refer to the air swi...

  • Page 284

    5-14 engine top end cylinder head cover cylinder head cover removal • remove: middle fairings (see middle fairing removal in the frame chapter) air suction valve cover bolts (see air suction valve cover removal) left subframe (see subframe removal in the frame chapter). Stick coils [a] bolt [b] inle...

  • Page 285

    Engine top end 5-15 cylinder head cover • install: dowel pins [a] plug hole gaskets [b] • apply a soap solution to the upper and lower surfaces [a] to the washer. • install the washer [b] with the metal side faces [c] upward. • tighten the cover bolt [a], following the specified tighten- ing sequenc...

  • Page 286

    5-16 engine top end camshaft chain tensioner camshaft chain tensioner removal caution do not turn over the crankshaft while the tensioner is removed. This could upset the camshaft chain timing, and damage the valves. • remove the right rear middle fairing (see middle fairing removal in the frame cha...

  • Page 287

    Engine top end 5-17 camshaft, camshaft chain camshaft removal • remove: cylinder head cover (see cylinder head cover re- moval) • position the crankshaft at #1, 4 piston tdc. Tdc mark [a] for #1, 4 pistons timing mark (crankcase halves mating surface) [b] • remove: camshaft chain tensioner (see cams...

  • Page 288

    5-18 engine top end camshaft, camshaft chain • remove the variable valve actuator and cam sprocket mounting bolts [a]. • remove the variable valve actuator and cam sprocket. Caution the crankshaft may be turned while the camshafts are removed. Always pull the chain taut while turn- ing the crankshaf...

  • Page 289

    Engine top end 5-19 camshaft, camshaft chain note ○ the exhaust camshaft has the projection [a] for camshaft position sensor. ○ the inlet camshaft has two projections [b] for camshaft position sensor. • position the crankshaft at #1, 4 piston tdc. • pull the tension side (exhaust side) [a] of the ch...

  • Page 290

    5-20 engine top end camshaft, camshaft chain • first install the camshaft cap [a] temporary to fix the po- sition of the camshaft. • next install the camshaft caps, following the identification no. And/or name [b] and chain guide [c]. ○ install the camshaft chain tensioner temporary (see camshaft ch...

  • Page 291

    Engine top end 5-21 camshaft, camshaft chain • be sure to install the following parts. Plug hole gaskets [a] dowel pins [b] • install the cylinder head cover (see cylinder head cover installation). Camshaft, camshaft cap wear • remove: camshaft chain guide camshaft cap (see camshaft removal) • cut s...

  • Page 292

    5-22 engine top end camshaft, camshaft chain camshaft runout • remove the camshaft (see camshaft removal). • set the camshaft in a camshaft alignment jig or on v blocks. • measure runout with a dial gauge at the specified place as shown. If the runout exceeds the service limit, replace the shaft. Ca...

  • Page 293

    Engine top end 5-23 camshaft, camshaft chain camshaft chain installation • install the camshaft chain from head side. • install the crankshaft sprocket [a] on the crankshaft [b] with their teeth [c] aligned. • install: camshaft chain guides (see cylinder head installation) timing rotor (see timing r...

  • Page 294

    5-24 engine top end cylinder head cylinder compression measurement note ○ use the battery which is fully charged. • warm up the engine thoroughly. • stop the engine. • remove: stick coils (see stick coil removal in the electrical sys- tem chapter) spark plugs (see spark plug replacement in the peri-...

  • Page 295

    Engine top end 5-25 cylinder head cylinder head removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) throttle body assy (see throttle body assy removal in the fuel system (dfi) chapter) exha...

  • Page 296

    5-26 engine top end cylinder head cylinder head installation note ○ the camshaft cap is machined with the cylinder head, so if a new cylinder head is installed, use the cap that is supplied with the new head. • install a new cylinder head gasket [a] and dowel pins [b]. • replace the cylinder head bo...

  • Page 297

    Engine top end 5-27 cylinder head cylinder head warp • clean the cylinder head. • lay a straightedge across the lower surface of the cylinder head at several positions. • use a thickness gauge [a] to measure the space between the straightedge [b] and the head. Cylinder head warp standard: – – – serv...

  • Page 298

    5-28 engine top end valves valve clearance inspection • refer to the valve clearance inspection in the periodic maintenance chapter (see valve clearance inspection the periodic maintenance chapter). Valve removal • remove the cylinder head (see cylinder head removal). • remove the valve lifter and s...

  • Page 299

    Engine top end 5-29 valves • assembly the valve guide driver parts (holder and attach- ment e). • insert the rod of the driver into the valve guide bore and hammer the end of the driver until it bottoms. Valve guide driver attachment e [a] valve guide driver (holder) [b] valve guide [c] cylinder hea...

  • Page 300

    5-30 engine top end valves valve seat inspection • remove the valve (see valve removal). • check the valve seating surface [a] between the valve [b] and valve seat [c]. ○ measure the outside diameter [d] of the seating pattern on the valve seat. If the outside diameter is too large or too small, rep...

  • Page 301

    Engine top end 5-31 valves seat cutter operation care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. 3. Do not fai...

  • Page 302

    5-32 engine top end valves • measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range. Widened width [a] of engagement by machining with 45° cutter ...

  • Page 303

    Engine top end 5-33 valves if the seat width is too wide, make the 60° [a] grind de- scribed below. If the seat width is within the specified range, lap the valve to the seat as described below. • grind the seat at a 60° angle until the seat width is within the specified range. ○ to make the 60° gri...

  • Page 304

    5-34 engine top end valves http://mototh.Com.

  • Page 305

    Engine top end 5-35 throttle body holder throttle body holder installation • be sure to install the o-rings [a]. • tighten the holder bolts following the tightening sequence [1 ∼ 3]. Torque - throttle body holder bolts [c]: 9.8 n·m (1.0 kgf·m, 87 in·lb) throttle body assy holder clamp bolts [d]: 2.0...

  • Page 306

    5-36 engine top end muffler warning to avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. Muffler body removal • remove: right saddlebag (see saddlebag removal in the frame chapter) muffler clamp bolts [a] muffler mounting bolts and nuts [...

  • Page 307

    Engine top end 5-37 muffler • for the oxygen sensor was equipped models as follows. ○ disconnect the sensor connectors [a]. • remove the sensor [b]. Exhaust pipe installation • replace the exhaust pipe gaskets [a], muffler gasket with new ones and install them. ○ install the muffler gasket until it ...

  • Page 308

    Http://mototh.Com.

  • Page 309: Clutch

    Clutch 6-1 6 clutch table of contents exploded view........................................................................................................................ 6-2 specifications ................................................................................................................

  • Page 310

    6-2 clutch exploded view http://mototh.Com.

  • Page 311

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 clutch lever pivot bolt 1.0 0.10 8.9 in·lb 2 clutch lever pivot bolt locknut 5.9 0.60 52 in·lb 3 clutch master cylinder bleed valve 7.8 0.80 69 in·lb 4 clutch reservoir cap screws 1.5 0.15 13 in·lb 5 clutch reservoir mounting bol...

  • Page 312

    6-4 clutch specifications item standard service limit clutch fluid grade dot4 – – – clutch lever – – – clutch lever position 5-way adjustable (to suit rider) – – – clutch lever free play non-adjustable – – – clutch friction plate thickness (13088-0031) 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) 2.7 mm (0.10...

  • Page 313

    Clutch 6-5 special tools and sealant inside circlip pliers: 57001-143 clutch spring compressor: 57001-1162 clutch holder: 57001-1243 kawasaki bond (silicone sealant): 92104-0004 http://mototh.Com.

  • Page 314

    6-6 clutch clutch master cylinder clutch lever adjustment ○ the adjuster has 5 positions so that the clutch lever posi- tion can be adjusted to suit the operator’s hand. • push the lever forward and turn the adjuster [a] to align the number with the triangular mark [b] on the lever holder. ○ the dis...

  • Page 315

    Clutch 6-7 clutch master cylinder clutch master cylinder disassembly • refer to the clutch master cylinder cap and dust seal replacement in the periodic maintenance chapter. Clutch master cylinder assembly • refer to the clutch master cylinder cap and dust seal replacement in the periodic maintenanc...

  • Page 316

    6-8 clutch clutch slave cylinder clutch slave cylinder removal • remove: left rear middle fairing (see middle fairing removal in the frame chapter) left lower fairing (see lower fairing removal in the frame chapter) banjo bolt [a] clutch slave cylinder bolts [b] slave cylinder [c] caution immediatel...

  • Page 317

    Clutch 6-9 clutch slave cylinder • apply a non-permanent locking agent to the threads of the slave cylinder bolts [a]. • finger tighten all the clutch slave cylinder bolts. • remove the band from the clutch lever and release the clutch lever. • tighten the slave cylinder bolts. • replace the washer ...

  • Page 318

    6-10 clutch clutch fluid clutch fluid level inspection • refer to the clutch fluid level inspection in the periodic maintenance chapter (see clutch fluid level inspection in the periodic maintenance chapter). Clutch fluid change • refer to the clutch fluid change in the periodic mainte- nance chapte...

  • Page 319

    Clutch 6-11 clutch fluid • bleed the clutch line and the master cylinder. ○ repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the clutch lever until it becomes hard, and apply the clutch lever and hold it [c]. 2. Quickly open and close [b] the bleed valv...

  • Page 320

    6-12 clutch clutch cover clutch cover removal • remove: engine oil (drain, see engine oil change in the periodic maintenance chapter) right lower fairing (see lower fairing removal in the frame chapter) clutch cover bolts [a] clutch cover [b] clutch cover installation • apply silicone sealant to the...

  • Page 321

    Clutch 6-13 clutch clutch removal • remove: right lower fairing (see lower fairing removal in the frame chapter) clutch cover (see clutch cover removal) clutch spring bolts [a] with spring holder clutch springs clutch spring plate [b] (with thrust bearing and washer [c]) • remove: pusher [a] frictio...

  • Page 322

    6-14 clutch clutch • pull out the sleeve [b] from the clutch housing [d], and remove the housing. ○ if the sleeve does not pull out easily, insert m4 bolts [a] into the threaded hole of the sleeve, and pull out the sleeve and needle bearing [c]. • remove the thrust washer. Clutch installation • when...

  • Page 323

    Clutch 6-15 clutch • install the spacer [a] and clutch shaft [b]. ○ install the clutch shaft so that the tooth side faces [c] in. • if the sub clutch hub bolts was removed, install it. ○ apply a non-permanent locking agent to the threads of the sub clutch hub bolts, and tighten it. Torque - sub clut...

  • Page 324

    6-16 clutch clutch ○ install the friction plates (between the first and outer-end friction plate), that has notches [a] among others. ○ install outer-end friction plate, that has the thin thickness body [a] among others [b]. • install the last friction plate [a] fitting the tangs in the grooves in t...

  • Page 325

    Clutch 6-17 clutch clutch hub disassembly • remove the clutch hub (see clutch removal). • using a press [a], and the clutch spring compressor [b], push the damper spring holder [c] to remove the retaining ring [d]. Special tool - clutch spring compressor: 57001-1162 • remove: retaining ring [a] spri...

  • Page 326

    6-18 clutch clutch • engage the clutch hub with the sub clutch hub. • to measure the free play, set a dial gauge [a] against the raised center [b] of the clutch spring plate. • move the clutch housing gear back and forth [c]. The dif- ference between the highest and lowest gauge readings is the amou...

  • Page 327

    Clutch 6-19 clutch clutch plate assembly length (reference information) • inspect the friction plate thickness (see clutch plate, wear, damage inspection). • assemble: clutch hub [a] friction plates [b] steel plates [c] sub clutch hub [d] spring plate [e] clutch spring [f] spring holder [g] spring b...

  • Page 328

    6-20 clutch clutch clutch spring free length measurement • measure the free length of the clutch springs [a]. If any spring is shorter than the service limit, it must be replaced. Clutch spring free length standard: 65.0 mm (2.56 in.) service limit: 62.0 mm (2.44 in.) damper cam inspection • remove ...

  • Page 329: Engine Lubrication System

    Engine lubrication system 7-1 7 engine lubrication system table of contents exploded view........................................................................................................................ 7-2 engine oil flow chart....................................................................

  • Page 330

    7-2 engine lubrication system exploded view http://mototh.Com.

  • Page 331

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine oil drain bolt 30 3.0 22 2 oil filter 17 1.7 13 g, r 3 holder mounting bolt 35 3.6 26 l 4 oil pan bolts 9.8 1.0 87 in·lb 5 oil pressure relief valve 15 1.5 11 l 6 oil pressure switch 15 1.5 11 ss 7 oil p...

  • Page 332

    7-4 engine lubrication system engine oil flow chart http://mototh.Com.

  • Page 333

    Engine lubrication system 7-5 engine oil flow chart http://mototh.Com.

  • Page 334

    7-6 engine lubrication system engine oil flow chart http://mototh.Com.

  • Page 335

    Engine lubrication system 7-7 specifications item standard engine oil type api se, sf or sg api sh, sj or sl with jaso ma viscosity sae 10w-40 capacity 4.0 l (4.2 us gt) (when filter is not removed) 4.4 l (4.7 us gt) (when filter is removed) 4.7 l (5.0 us gt) (when engine is completely dry) level be...

  • Page 336

    7-8 engine lubrication system special tools and sealant oil pressure gauge, 10 kgf/cm²: 57001-164 oil pressure gauge adapter, pt3/8 × 19/in.: 57001-1233 oil filter wrench: 57001-1249 kawasaki bond (silicone sealant): 56019-120 http://mototh.Com.

  • Page 337

    Engine lubrication system 7-9 engine oil and oil filter warning motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil level inspection • check that the engine oil le...

  • Page 338

    7-10 engine lubrication system oil pan oil pan removal • remove: engine oil (drain, see engine oil change in the periodic maintenance chapter) muffler bodies (see muffler body removal/installation in the engine top end chapter) exhaust pipe (see exhaust pipe removal in the engine top end chapter) • ...

  • Page 339

    Engine lubrication system 7-11 oil pan • replace the o-rings with new ones. • apply grease the oil pipe o-rings [a] and install the oil pipes [b]. If the oil pressure relief valve [c] was removed, install it (see oil pressure relief valve installation). • put new o-ring [d] on the lower crankcase [e...

  • Page 340

    7-12 engine lubrication system oil pressure relief valve oil pressure relief valve removal • remove: oil pan (see oil pan removal) oil pipe (see oil pan removal) • hold the pipe [a] in a vise [b]. • remove the oil pressure relief valve [c]. Oil pressure relief valve installation • apply a non-perman...

  • Page 341

    Engine lubrication system 7-13 oil pump oil pump removal • drain: engine oil (see engine oil change in the periodic main- tenance chapter) • remove: clutch (see clutch removal in the clutch chapter) oil pump cover bolts [a] oil pump cover [b] oil pump drive gear shaft [c] outer rotor inner rotor oil...

  • Page 342

    7-14 engine lubrication system oil pump • after tighten tightening the cover bolts [a], check the fol- lowing. ○ oil pump drive gear turn freely [b]. Torque - oil pump cover bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) http://mototh.Com.

  • Page 343

    Engine lubrication system 7-15 oil cooler oil cooler removal • remove: left lower fairings (see lower fairing removal in the frame chapter) • drain: coolant (see coolant change in the periodic mainte- nance chapter) engine oil (see engine oil change in the periodic main- tenance chapter) • remove th...

  • Page 344

    7-16 engine lubrication system oil pressure measurement oil pressure measurement • remove the left lower fairing (see lower fairing removal in the frame chapter). • remove the oil passage plug, and attach the adapter [a] and gauge [b] to the plug hole. Special tools - oil pressure gauge, 10 kgf/cm²:...

  • Page 345

    Engine lubrication system 7-17 oil pressure switch oil pressure switch removal • remove: engine oil (drain, see engine oil change in the periodic maintenance chapter) left lower fairing (see lower fairing removal in the frame chapter) rubber boot [a] • loosen the oil pressure switch terminal bolt [b...

  • Page 346

    7-18 engine lubrication system vvt (variable valve taiming) oil pipe removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: right middle fairings (see middle fairing removal in the frame chapter) lower fairing (see lower fairing removal in the frame c...

  • Page 347

    Engine lubrication system 7-19 vvt (variable valve taiming) oil control solenoid valve installation • install the gasket [a] as shown. Cylinder head mating surface [b] • tighten the bolts. Torque - oil control solenoid valve bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) variable valve taiming actuator remova...

  • Page 348

    Http://mototh.Com.

  • Page 349: Engine Removal/installation

    Engine removal/installation 8-1 8 engine removal/installation table of contents exploded view........................................................................................................................ 8-2 engine removal/installation .........................................................

  • Page 350

    8-2 engine removal/installation exploded view http://mototh.Com.

  • Page 351

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine mounting nuts (m12) 59 6.0 44 s 2 adjusting collars 25 2.5 18 m 3 front engine mounting bolts (m10) 59 6.0 44 s, r 4 engine bracket bolts (m8) 25 2.5 18 s, r 5 subframe bolts 23 2.3 17 r m: apply molyb...

  • Page 352

    8-4 engine removal/installation engine removal/installation engine removal • support the rear part of the swingarm with a stand. • squeeze the brake lever slowly and hold it with a band [a]. Warning be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It could c...

  • Page 353

    Engine removal/installation 8-5 engine removal/installation • remove: pad [a] right heat insulation cover [b] (see fairing bracket re- moval in the frame chapter) right subframe [c] (see subframe removal in the frame chapter) bolts [d] right engine bracket [e] ground terminals [f] • loosen the clamp...

  • Page 354

    8-6 engine removal/installation engine removal/installation • disconnect: fuel hose [a] on the delivery pipe • remove: clamp [a] throttle cable lower ends [b] • loosen the clamp bolts [c] and pull the ducts [d] upward. • support the engine with a suitable stand [a]. ○ put a plank [b] onto the suitab...

  • Page 355

    Engine removal/installation 8-7 engine removal/installation • remove the starter motor cable terminal nut [a]. • using the stand, take out the engine. Engine installation • support the engine with a suitable stand. ○ put a plank onto the suitable stand for engine balance. • install the heat insulati...

  • Page 356

    8-8 engine removal/installation engine removal/installation a: after installation, set the projection in the hole. B: to water temperature sensor c: to breather hose d: to throttle body subharness bracket e: to throttle body holder f: to throttle pulley g: to inlet cam position sensor h: to air suct...

  • Page 357

    Engine removal/installation 8-9 engine removal/installation • before installing the engine. Confirm the routing of the water temperature sensor lead [a] and inlet camshaft po- sition sensor lead [b]. ○ run [c] the water temperature sensor lead of the sub- harness between the #3 and #4 throttle body ...

  • Page 358

    8-10 engine removal/installation engine removal/installation ○ secondly, insert the mounting bolts [a] until they fit [b] in the adjusting collars [c]. ○ be sure that the collar [d] is in position. Note ○ replace the following bolts with new bolts pre-coated with locking agent. Engine bracket bolts ...

  • Page 359

    Engine removal/installation 8-11 engine removal/installation ○ fifthly, tighten the left engine bracket bolts [a]. ○ sixthly, tighten the upper engine mounting nut [b] and then the lower engine mounting nut [c]. ○ seventhly, install the right engine bracket and tighten the right engine bracket bolts...

  • Page 360

    8-12 engine removal/installation engine removal/installation • run the leads, cable and hoses correctly (see cable, wire, and hose routing section in the appendix chap- ter). • install the removed parts (see appropriate chapters). • adjust: throttle cables (see throttle control system inspection in ...

  • Page 361: Crankshaft/transmission

    Crankshaft/transmission 9-1 9 crankshaft/transmission table of contents exploded view................................... 9-2 specifications .................................... 9-6 special tools and sealants ............... 9-9 crankcase splitting............................ 9-10 crankcase splitting...

  • Page 362

    9-2 crankshaft/transmission exploded view http://mototh.Com.

  • Page 363

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 breather cover bolts 9.8 1.0 87 in·lb 2 breather plate screws 9.8 1.0 87 in·lb l 3 crankcase bolts (m10, l = 90 mm) 47 4.8 35 mo, s 4 crankcase bolts (m10, l = 120 mm) 47 4.8 35 mo, s 5 crankcase bolt (m7, l = 11...

  • Page 364

    9-4 crankshaft/transmission exploded view http://mototh.Com.

  • Page 365

    Crankshaft/transmission 9-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 balancer shaft clamp bolts 9.8 1.0 87 in·lb 2 balancer shaft clamp lever bolts 25 2.5 18 3 starter clutch shaft bolt 9.8 1.0 87 in·lb l 4 starter clutch shaft plate bolt 9.8 1.0 87 in·lb l 5 torque limiter bolt 2...

  • Page 366

    9-6 crankshaft/transmission specifications item standard service limit crankcase, crankshaft, connecting rods connecting rod bend – – – tir 0.2/100 mm (0.008/3.94 in.) connecting rod twist – – – tir 0.2/100 mm (0.008/3.94 in.) connecting rod big end side clearance 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in....

  • Page 367

    Crankshaft/transmission 9-7 specifications item standard service limit marking ○ 41.000 ∼ 41.008 mm (1.6142 ∼ 1.6145 in.) – – – none 41.009 ∼ 41.016 mm (1.6145 ∼ 1.6148 in.) – – – crankshaft main bearing insert thickness: brown 1.490 ∼ 1.494 mm (0.0587 ∼ 0.0588 in.) – – – black 1.494 ∼ 1.498 mm (0.0...

  • Page 368

    9-8 crankshaft/transmission specifications connecting rod big end bearing insert selection bearing insert con-rod big end bore diameter marking crankpin diameter marking size color part number none ○ brown 92139-0131 none none ○ ○ black 92139-0130 ○ none blue 92139-0129 crankshaft main bearing inser...

  • Page 369

    Crankshaft/transmission 9-9 special tools and sealants bearing puller: 57001-135 bearing puller adapter: 57001-317 piston pin puller assembly: 57001-910 piston ring compressor grip: 57001-1095 piston ring compressor belt, 80 ∼ 91: 57001-1320 kawasaki bond (silicone sealant): 56019-120 kawasaki bond:...

  • Page 370

    9-10 crankshaft/transmission crankcase splitting crankcase splitting • remove the engine (see engine removal/installation in the engine removal/installation chapter). • set the engine on a clean surface and hold the engine steady while parts are being removed. • remove: clutch (see clutch removal in...

  • Page 371

    Crankshaft/transmission 9-11 crankcase splitting ○ next, loosen the m10 bolts [1 ∼ 10] (sequence numbers). • tap lightly around the crankcase mating surface with a plastic mallet, and split the crankcase. Take care not to damage the crankcase. If the crankshaft is to be removed [a], remove the pisto...

  • Page 372

    9-12 crankshaft/transmission crankcase splitting • install the new drive shaft bearing [a] so that its stepped side [b] faces as shown using a press. • install the bearing plate [a] with the screws [b]. ○ install the plate so that the stepped hole side [c] faces outside. ○ apply a non-permanent lock...

  • Page 373

    Crankshaft/transmission 9-13 crankcase splitting • before fitting the lower case on the upper case, check the following. ○ check to see that the shift drum and transmission gears are in the neutral position [a]. • apply liquid gasket [a] to the mating surface of the lower crankcase half. Sealant - k...

  • Page 374

    9-14 crankshaft/transmission crankcase splitting • tighten the lower crankcase bolts using the following steps. ○ following the sequence numbers on the lower crankcase half, tighten the m10 bolts [1 ∼ 10] with washers. Torque - crankcase bolts (m10): 47 n·m (4.8 kgf·m, 35 ft·lb) ○ tighten the m7 bol...

  • Page 375

    Crankshaft/transmission 9-15 crankshaft and connecting rods crankshaft removal • split the crankcase (see crankcase splitting). • remove the crankshaft (see connecting rod removal). Crankshaft installation caution if the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, se...

  • Page 376

    9-16 crankshaft/transmission crankshaft and connecting rods connecting rod removal • split the crankcase (see crankcase splitting). • remove the connecting rod nuts [a]. • remove the crankshaft. Note ○ mark and record the locations of the connecting rods and their big end caps so that they can be re...

  • Page 377

    Crankshaft/transmission 9-17 crankshaft and connecting rods • install the crankshaft (see crankshaft installation). • install each connecting rod on its original crankpin. ○ the connecting rod big end is bolted using the “plastic region fastening method”. ○ this method precisely achieves the needed ...

  • Page 378

    9-18 crankshaft/transmission crankshaft and connecting rods • install new bolts in reused connecting rods. • dent both bolt head and bolt tip with a punch as shown. • before tightening, use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt st...

  • Page 379

    Crankshaft/transmission 9-19 crankshaft and connecting rods • install new bolts in reused connecting rods. • apply a small amount of molybdenum disulfide oil to the following. Threads [a] of bolts seating surfaces [b] of nuts on the connecting rods • first, tighten the nuts to the specified torque. ...

  • Page 380

    9-20 crankshaft/transmission crankshaft and connecting rods connecting rod twist • with the big-end arbor [a] still on v block [c], hold the connecting rod horizontally and measure the amount that the arbor [b] varies from being paralleled with the surface plate over a 100 mm (3.94 in.) length of th...

  • Page 381

    Crankshaft/transmission 9-21 crankshaft and connecting rods if the clearance is within the standard, no bearing replace- ment is required. If the clearance is between 0.087 mm (0.0034 in.) and the service limit (0.12 mm, 0.0047 in.), replace the bear- ing inserts [a] with inserts painted blue [b]. C...

  • Page 382

    9-22 crankshaft/transmission crankshaft and connecting rods • select the proper bearing insert [a] in accordance with the combination of the connecting rod and crankshaft coding. Size color [b] bearing insert con-rod big end inside diameter marking crankpin diameter marking size color part number no...

  • Page 383

    Crankshaft/transmission 9-23 crankshaft and connecting rods • measure the crankshaft #3 main journal width [a]. If the measurement exceeds the standard, replace the crankshaft [b]. Crankshaft #3 main journal width standard: 27.45 ∼ 27.50 mm (1.0807 ∼ 1.0827 in.) crankshaft runout • measure the crank...

  • Page 384

    9-24 crankshaft/transmission crankshaft and connecting rods crankshaft main journal diameter standard: 37.984 ∼ 38.000 mm (1.4954 ∼ 1.4961 in.) service limit: 37.96 mm (1.4945 in.) if any journal has worn past the service limit, replace the crankshaft with a new one. If the measured journal diameter...

  • Page 385

    Crankshaft/transmission 9-25 crankshaft and connecting rods bearing insert crankcase main bearing inside diameter marking crankshaft main journal diameter marking size color part number journal nos. 92139-0134 1, 3, 5 ○ 1 brown 92139-0137 2, 4 none 1 92139-0133 1, 3, 5 ○ none black 92139-0136 2, 4 9...

  • Page 386

    9-26 crankshaft/transmission pistons piston removal • split the crankcase (see crankcase splitting). • remove the connecting rod nuts [a]. • remove the connecting rod big end caps. • remove the crankshaft. • remove the piston [a] with connecting rod to the cylinder head side. • remove the piston pin...

  • Page 387

    Crankshaft/transmission 9-27 pistons piston installation • apply molybdenum disulfide oil solution to the oil ring ex- pander, and install the oil ring expander [a] in the bottom piston ring groove so the ends [b] butt together. • apply molybdenum disulfide oil solution to the oil ring steel rails, ...

  • Page 388

    9-28 crankshaft/transmission pistons • install the piston with its marking in [a] facing inlet side. • using the piston ring compressor assy [b] to install the piston from the cylinder head side. Special tools - piston ring compressor grip: 57001-1095 piston ring compressor belt, 80 ∼ 91: 57001-1320...

  • Page 389

    Crankshaft/transmission 9-29 pistons piston ring groove width • measure the piston ring groove width. ○ use a vernier caliper at several points around the piston. Piston ring groove width standard: top [a] 0.92 ∼ 0.94 mm (0.0362 ∼ 0.0370 in.) second [b] 1.01 ∼ 1.03 mm (0.0398 ∼ 0.0406 in.) service l...

  • Page 390

    9-30 crankshaft/transmission balancer front balancer removal • remove: engine (see engine removal in the engine removal/in- stallation chapter) • unscrew: balancer shaft clamp bolt [a] balancer shaft clamp lever bolt [b] balancer shaft clamp lever [c] • split the crankcase (see crankcase splitting)....

  • Page 391

    Crankshaft/transmission 9-31 balancer • insert the pin [a] as shown. • set the front balancer on the upper crankcase half. ○ align the punch mark [b] on the balancer gear [c] with the mark [d] (crankshaft at 2, 3 position tdc) on the balancer drive gear [e] of crankshaft. • assemble the crankcase (s...

  • Page 392

    9-32 crankshaft/transmission balancer • unscrew the balancer shaft clamp lever bolt [a]. • pry off the clamp lever [a] until the oil seal [b] removed. • pull the balancer shaft [c] out of the crankcase. The bal- ancer weight and gear assembly [d] come off with needle bearings and copper washers. Rea...

  • Page 393

    Crankshaft/transmission 9-33 balancer • position the crankshaft at # 2, 3 position tdc or at # 1, 4 position tdc. • aligin the mark [a] on the balancer gear [b] with the mat- ing surface [c] of the upper crankcase half. • install the balancer shaft [d] and then align the balancer gear with the start...

  • Page 394

    9-34 crankshaft/transmission balancer balancer damper inspection • remove the balancer and disassemble the weight and gear assembly. • visually inspect the rubber dampers [a]. If they appear damaged or deteriorated, replace them. Http://mototh.Com.

  • Page 395

    Crankshaft/transmission 9-35 starter motor clutch and torque limiter starter motor clutch removal • remove: engine (see engine removal in the engine removal/in- stallation chapter) starter motor (see starter motor removal in the electri- cal system chapter) rear balancer (see rear balancer removal) ...

  • Page 396

    9-36 crankshaft/transmission starter motor clutch and torque limiter • holding the drive gear [a] with a hand, take off the one -way clutch [b] from the gear by using the screw driver [c]. Starter motor clutch assembly • be sure to install the one-way clutch [a] so that its arrow [b] faces the side ...

  • Page 397

    Crankshaft/transmission 9-37 starter motor clutch and torque limiter • holding the torque limiter [a], remove the torque limiter shaft [b] and the torque limiter. Torque limiter installation • replace the washer with a new one. • apply molybdenum disulfide grease to the torque limiter shaft and toot...

  • Page 398

    9-38 crankshaft/transmission transmission shift pedal removal • remove: shift lever bolt [a] shift lever [b] • remove: shift pedal mounting bolt [a] shift pedal [b] with tie-rod [c] shift pedal installation • tighten: torque - shift pedal mounting bolt [a]: 25 n·m (2.5 kgf·m, 18 ft·lb) footpeg brack...

  • Page 399

    Crankshaft/transmission 9-39 transmission external shift mechanism removal • remove: bolt [a] shift lever [b] snap ring [c] washer [d] clutch (see clutch removal in the clutch chapter) • remove the shift shaft assembly [a]. • remove: gear positioning lever bolt [a] gear positioning lever [b] collar ...

  • Page 400

    9-40 crankshaft/transmission transmission • install the gear positioning lever [a] as shown. Spring [b] collar [c] bolt [d] • tighten: torque - gear positioning lever bolt: 12 n·m (1.2 kgf·m, 106 in·lb) • be sure to install the washer [a]. • insert the shift shaft [b]. • install: washer new snap rin...

  • Page 401

    Crankshaft/transmission 9-41 transmission transmission shaft removal • split the crankcase (see crankcase splitting). • remove the output shaft [a]. • remove the shift forks (see shift drum and fork re- moval). • remove the cover bolts [a] and cover [b]. • pull out the drive shaft. Transmission shaf...

  • Page 402

    9-42 crankshaft/transmission transmission transmission shaft disassembly • remove the transmission shafts (see transmission shaft removal). • remove the circlips, disassemble the transmission shafts. • the 5th gear [a] on the output shaft has three steel balls assembled into it for the positive neut...

  • Page 403

    Crankshaft/transmission 9-43 transmission • fit the steel balls into the 5th gear holes in the output shaft, aligning three oil holes [d]. 5th gear [a] output shaft [b] steel balls [c] caution do not apply grease to the balls to hold them in place. This will cause the positive neutral finder mechani...

  • Page 404

    9-44 crankshaft/transmission transmission 1. Drive shaft 2. Circlip, 33 mm (1.30 in.) 3. 2nd gear 4. Toothed washer, 37 mm (1.46 in.) 5. Toothed washer, 40.5 mm (1.59 in.) 6. Bushing 7. 6th (top) gear 8. Toothed washer, 35.5 mm (1.40 in.) 9. 4th gear 10. 3rd gear 11. 5th gear 12. Bushing 13. 1st gea...

  • Page 405

    Crankshaft/transmission 9-45 transmission shift drum and fork removal • remove: lower crankcase half (see crankcase splitting) external shift mechanism (see external shift mecha- nism removal) screws [a] shift drum bearing holder [b] • pull out the shift rods [c], and take off the shift forks. • pul...

  • Page 406

    9-46 crankshaft/transmission transmission shift drum assembly • be sure to install the dowel pin. • apply a non-permanent locking agent to the threads of the shift drum cam holder bolt, and tighten it. Torque - shift drum cam holder bolt: 12 n·m (1.2 kgf·m, 106 in·lb) shift fork bending • visually i...

  • Page 407

    Crankshaft/transmission 9-47 transmission gear dog and gear dog hole damage • visually inspect the gear dogs [a] and gear dog holes [b]. Replace any damaged gears or gears with excessively worn dogs or dog holes. Http://mototh.Com.

  • Page 408

    Http://mototh.Com.

  • Page 409: Wheels/tires

    Wheels/tires 10-1 10 wheels/tires table of contents exploded view........................................................................................................................ 10-2 specifications .................................................................................................

  • Page 410

    10-2 wheels/tires exploded view http://mototh.Com.

  • Page 411

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front axle clamp bolts 20 2.0 15 al 2 front axle nut 127 13.0 93.7 3 front tire pressure measurement sensor bolt 4.5 0.46 40 in·lb 4 rear axle nut 127 13.0 93.7 5 rear tire pressure measurement sensor bolt 4.5 0.46 40 in·l...

  • Page 412

    10-4 wheels/tires specifications item standard service limit wheels (rims) rim runout: axial tir 0.5 mm (0.02 in.) or less tir 1.0 mm (0.04 in.) radial tir 0.8 mm (0.03 in.) or less tir 1.0 mm (0.04 in.) axle runout/100 mm (3.94 in.) tir 0.03 mm (0.0012 in.) or less tir 0.2 mm (0.01 in.) wheel balan...

  • Page 413

    Wheels/tires 10-5 special tools bearing driver set: 57001-1129 jack: 57001-1238 bearing remover head, 20 × 22: 57001-1293 bearing remover head, 25 × 28: 57001-1346 bearing remover shaft, 13: 57001-1377 http://mototh.Com.

  • Page 414

    10-6 wheels/tires wheels (rims) front wheel removal • remove: front caliper mounting bolts [a] front calipers [b] front fender [c] (see front fender removal in the frame chapter) ○ for the zg1400a models, remove the bolts [d] and rota- tion sensor [e]. • loosen: axle clamp bolts [a] (right side) axl...

  • Page 415

    Wheels/tires 10-7 wheels (rims) • apply high-temperature grease to the grease seal lip. • fit the collars [a] on the both sides of the hub. ○ the collars are identical. • insert the axle from the right side. • tighten the axle nut [b]. Right axle clamp bolts [c] left axle clamp bolts [d] viewed from...

  • Page 416

    10-8 wheels/tires wheels (rims) • remove: saddlebags (see rear caliper mounting bolts [a] rear caliper [b] caliper bracket bolt [c] • for the zg1400a models, remove the bolts [d] and rear wheel rotation sensor [e]. • remove: cotter pin [a] axle nut [b] washer [c] caliper bracket [d] • pull out the a...

  • Page 417

    Wheels/tires 10-9 wheels (rims) • pull the axle little and install the caliper bracket [a]. • temporary install the caliper bracket bolt. • tighten: torque - rear axle nut: 127 n·m (13.0 kgf·m, 94 ft·lb) caliper bracket bolt: 64 n·m (6.5 kgf·m, 47 ft·lb) • insert a new cotter pin [a]. Note ○ when in...

  • Page 418

    10-10 wheels/tires wheels (rims) wheel coupling removal • remove the rear wheel (see rear wheel removal). • remove the coupling retaining ring [a]. • remove the wheel coupling [b] with a bearing puller if necessary. Wheel coupling installation • replace the o-ring [a] and the retaining ring [b]. • g...

  • Page 419

    Wheels/tires 10-11 wheels (rims) axle inspection • remove the front and rear axles (see front/rear wheel removal). • visually inspect the front and rear axle for damages. If the axle is damaged or bent, replace it. • place the axle in v blocks that are 100 mm (3.94 in.) [a] apart, and set a dial gau...

  • Page 420

    10-12 wheels/tires wheels (rims) balance weight removal • insert a regular tip screwdrivers [a] [b] between the rib [c] and weight [d] as shown. • pry the balance weight with two screwdrivers and remove the balance weight. • discard the used balance weight. Caution do not tap the screwdrivers. The r...

  • Page 421

    Wheels/tires 10-13 wheels (rims) • check that the blade [a] and clip [b] are fully seated on the rim [c] and that the clip is hooked over the rib [d]. Left side [e] right side [f] http://mototh.Com.

  • Page 422

    10-14 wheels/tires tires air pressure inspection/adjustment • refer to the air pressure inspection in the periodic main- tenance chapter. Tire inspection • refer to the wheel/tire damage inspection in the peri- odic maintenance chapter. Tire removal • remove: wheel (see front/rear wheel removal) val...

  • Page 423

    Wheels/tires 10-15 tires ○ pull the opposite bead of the tire [a] upward. ○ unscrew the bolt [b] and remove the tire pressure mea- surement sensor [c], spring and air valve. ○ step on the side of the tire opposite the air valve, and start plying the tire off the rim near the air valve with tire iron...

  • Page 424

    10-16 wheels/tires tires • lubricate the valve seal with a soap and water solution or rubber lubricant. • install the air valve [a] and sensor [b]. ○ install the sensor position parallel to the rim line in either direction. Torque - tire pressure measurement sensor: 4.5 n·m (0.46 kgf·m, 40 in·lb) re...

  • Page 425

    Wheels/tires 10-17 tires • install the tire bead over the rim flange using a suitable commercially available tire changer. ○ install the beads of the tire onto the rim followings the steps shown. Tire pressure measurement sensor [a] opposite side of rim (180° from sensor) [b] push on the first bead ...

  • Page 426

    10-18 wheels/tires tires tire repair currently two types of repair for tubeless tires have come into wide use. One type is called a temporary (external) re- pair which can be carried out without removing the tire from the rim, and the other type is called permanent (internal) repair which requires t...

  • Page 427

    Wheels/tires 10-19 hub bearing hub bearing removal • remove the wheel (see front/rear wheel removal), and take out the following. Collars coupling (out of rear hub) grease seals • use the bearing remover to remove the hub bearing [a]. Caution do not lay the wheel on the ground with the disc facing d...

  • Page 428

    10-20 wheels/tires hub bearing hub bearing lubrication note ○ since the hub bearings are packed with grease and sealed, lubrication is not required. Http://mototh.Com.

  • Page 429: Final Drive

    Final drive 11-1 11 final drive table of contents exploded view................................... 11-2 specifications .................................... 11-6 special tools ..................................... 11-7 final gear case and oil .................... 11-9 oil level inspection...............

  • Page 430

    11-2 final drive exploded view http://mototh.Com.

  • Page 431

    Final drive 11-3 exploded view front gear case torque no. Fastener n·m kgf·m ft·lb remarks 1 adjuster locknut 40 4.1 30 l 2 bearing retainer 540 55.1 398 lh 3 bearing retainer screw 7.0 0.71 62 in·lb l 4 filler plug 2.0 0.20 18 in·lb 5 final gear case cover bolts (m10) 34 3.5 25 l 6 final gear case ...

  • Page 432

    11-4 final drive exploded view http://mototh.Com.

  • Page 433

    Final drive 11-5 exploded view final gear case torque no. Fastener n·m kgf·m ft·lb remarks 1 bearing retainer bolts 8.8 0.90 78 in·lb l 2 damper cam nut 210 21.4 155 mo, r 3 driven gear assy mounting bolts 25 2.5 18 4 driven gear bolt 130 13.3 95.9 mo 5 drive gear nut 265 27.0 195 mo, s 6 front gear...

  • Page 434

    11-6 final drive specifications item standard final gear case oil grade api gl-5 hypoid gear oil viscosity when above 5°c (41°f) sae90 when below 5°c (41°f) sae80 oil level filler opening top amount about 160 ml (5.41 us oz.) final bevel gear backlash 0.10 ∼ 0.20 mm (0.0039 ∼ 0.0079 in.) (at gear hu...

  • Page 435

    Final drive 11-7 special tools bearing puller: 57001-158 bearing puller adapter: 57001-317 bearing driver, 32: 57001-382 damper cam holder: 57001-1025 driven gear holder, m2: 57001-1027 oil seal & bearing remover: 57001-1058 bearing driver set: 57001-1129 drive shaft holder, m1.25: 57001-1702 retain...

  • Page 436

    11-8 final drive special tools bevel gear holder: 57001-1706 http://mototh.Com.

  • Page 437

    Final drive 11-9 final gear case and oil oil level inspection • refer to final gear case oil level inspection in periodic maintenance chapter (see final gear case oil level in- spection in periodic maintenance chapter). Oil change • refer to final gear case oil change in periodic mainte- nance chapt...

  • Page 438

    11-10 final drive final gear case and oil • remove the upper side bolt. • remove the final gear case [a] by taking off the lower bolts [b]. Note ○ if the final gear case is full of oil, place the case so that the breather [a] is on top, and joint portion [b] of the case is upward [c] for pervent the...

  • Page 439

    Final drive 11-11 final gear case and oil final gear case disassembly • drain the oil (see oil change). • remove the final gear case. • using the hub assembly [a], remove the pinion gear as- sembly nut. ○ insert the wooden bar [c] between the spokes. Caution do not lay the wheel down on one of the d...

  • Page 440

    11-12 final drive final gear case and oil • remove the sliding joint [a] with washer [b], pinion gear assembly [c] and lock plate. • remove the lock pin and plug. • final gear case cover bolts [a]. • use three tapped holes [a] to lift the ring gear assy from the gear case. The shim(s) comes off with...

  • Page 441

    Final drive 11-13 final gear case and oil ○ remove the small ring gear oil seal if damaged. Special tool - oil seal & bearing remover [d]: 57001-1058 • unscrew the bearing retainer bolt [a] and washer [b]. • pull out the needle bearing [c]. Special tool - oil seal & bearing remover: 57001-1058 http:...

  • Page 442

    11-14 final drive final gear case and oil final gear case 1. Sliding joint 2. Pinion gear nut 3. Washer 4. O-ring 5. Pin 6. Lock plate 7. Adjuster 8. Ring gear oil seal 9. Ring gear hub 10. Ball bearing 11. Final gear case cover 12. Cover mounting bolts 13. Ring gear shim(s) 14. Ring gear 15. Ball b...

  • Page 443

    Final drive 11-15 final gear case and oil • replace the needle bearings [a] with new ones. • apply a hypoid gear oil to the roller parts of the needle bearings. Note ○ install the bearing so that the marked side faces out. ○ press in the bearings until they are bottomed. Special tool - bearing drive...

  • Page 444

    11-16 final drive final gear case and oil • blow the breather hole [a] in the final gear case clean with compressed air. • install the shim(s) [a] and final gear case cover [b]. ○ reinstall the original ring gear shim(s) to keep the gear backlash and the tooth contact unchanged. ○ when final gear ca...

  • Page 445

    Final drive 11-17 final gear case and oil • install the sliding joint [a]. • using the hub assembly [b], tighten the pinion gear as- sembly nut. ○ insert the wooden bar [c] between the sporks. Torque - pinion gear assembly nut: 130 n·m (13.3 kgf·m, 95.9 ft·lb) • install the final gear case (see fina...

  • Page 446

    11-18 final drive final gear case and oil ring gear shims for backlash adjustment pinion gear shims for tooth contact adjustment thickness (mm) parts number thickness (mm) parts number 0.15 (0.0059 in.) 92180-0263 0.10 (0.0039 in.) 92025-1733 0.5 (0.02 in.) 92180-0264 0.15 (0.0059 in.) 92025-1734 0....

  • Page 447

    Final drive 11-19 final gear case and oil • mount a dial gage [a] on a vise so that the tip of the gage is against the splines of the ring gear hub. • to measure the backlash, turn the ring gear hub [b] back and forth [c]. The difference between the highest and the lowest gage reading is the amount ...

  • Page 448

    11-20 final drive final gear case and oil • remove the ring gear assy and pinion gear assy to check the couvex side pattern and concave side pattern of the bevel gear teeth. Good contact is achieved when the pat- tern of tooth contact is visible in the inside diameter side and center of the tooth fl...

  • Page 449

    Final drive 11-21 propeller shaft propeller shaft removal • remove: final gear case (see final gear case removal) bolts [a] • remove the frame side bracket [b] with the footpeg [c] and shift rod [d]. • open the clamp portion [a] and remove the band [b]. • pull out the rear side of the rubber boot [c...

  • Page 450

    11-22 final drive propeller shaft ○ move back the propeller shaft and slip the propeller shaft off the driven gear joint while pushing on the lockpin. Propeller shaft [a] universal joint [b] lockpin [c] spring [d] driven gear joint [e] propeller shaft installation • replace the o-ring on the rear en...

  • Page 451

    Final drive 11-23 propeller shaft • pinch the clamp portion [b] of the band [b]. Propeller shaft inspection • check that the universal joints [a] works smoothly without rattling or sticking. If it does not work smoothly, the needle bearings of the universal joint are damaged. Replace the propeller s...

  • Page 452

    11-24 final drive front bevel gears front gear case removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: propeller shaft (see propeller shaft removal) clutch slave cylinder (see clutch slave cylinder re- moval in the clutch chapter) water pump (see water pu...

  • Page 453

    Final drive 11-25 front bevel gears • tighten the front gear case bolts to the specified torque. Bolts m8 × 92 [a] bolts m8 × 95 [b] [f] bolts m8 × 35 [c] [d] bolts m8 × 50 [e] torque - front gear case bolts: bolts [a] [b] [e]: 29 n·m (3.0 kgf·m, 22 ft·lb) bolts [c] [d] [f] : 20 n·m (2.0 kgf·m, 15 f...

  • Page 454

    11-26 final drive front bevel gears ○ unscrew the drive gear nut [a] while holding the drive gear shaft with the drive gear holder [b]. Front gear case [c] vise [d] special tool - drive gear holder, m1.25: 57001-1702 • pull off the drive gear shaft [a], the drive gear [b], and shim(s) [c]. • remove ...

  • Page 455

    Final drive 11-27 front bevel gears ○ stake [a] the nut [b] to secure it in place. Caution when staking the nut, be careful not to apply shock to the shaft and its bearing. Such a shock could damage the shaft and/or bearing. • install the shim [a]. • install the driven gear assy so that the pry ribs...

  • Page 456

    11-28 final drive front bevel gears driven gear assembly • replace the driven gear bolt with a new one. ○ the drive and driven gears are lapped as a set at the fac- tory to get the best tooth contact. They must be replaced as a set. • be sure to check and adjust the bearing preload, the bevel gear b...

  • Page 457

    Final drive 11-29 front bevel gears damper cam installation • replace the damper cam nut with a new one. • fit the damper cam holder [a] on the damper cam [b] and touch in to the frame. • apply molybdenum disulfide oil to the threads and the seating surface of the damper cam nut [c]. • tighten the d...

  • Page 458

    11-30 final drive front bevel gears front bevel gear adjustment ○ when any of the backlash-related parts are replaced, or the driven gear bolt is loosened; even if the purpose is not to replace the parts, be sure to check and adjust the bearing preload, the bevel gear backlash, and tooth con- tact b...

  • Page 459

    Final drive 11-31 front bevel gears preload measurement with spring scale • hold the bearing housing in a vise so that the gear shaft axis is vertical. • hook [c] the spring scale [b] on the driven gear holder [a] at a point 200 mm (7.9 in.) [d] apart from the center of the gear shaft. • apply force...

  • Page 460

    11-32 final drive front bevel gears bearing preloading mechanism 1. Bearing housing 2. Tapered roller bearing before tightening [a] after tightening [b] 3. Spacer 4. Collar under no preload [c] initial clearance [d] 5. Tapered roller bearing under preload [e] no clearance [f] backlash adjustment • c...

  • Page 461

    Final drive 11-33 front bevel gears • install a holder [a] with 6 mm bolts and nuts on the front gear case to mount a dial gage. • set up a dial gage against a drive gear tooth to check gear backlash. The gage stem must be in line with the direction of tooth travel. • to measure the backlash, move t...

  • Page 462

    11-34 final drive front bevel gears • turn the driven gear for 3 or 4 revolutions back and forth, while creating a drag on the drive gear. • check the couvex side pattern and concave side pattern of the bevel gear teeth. Good contact is achieved when pattern of tooth contact is visible in the inside...

  • Page 463

    Final drive 11-35 front bevel gears cam damper inspection • visually inspect the spring [a], cam follower [b], damper cam [c], and output shaft [d]. Replace the damaged parts. Http://mototh.Com.

  • Page 464

    11-36 final drive bearing and oil seal ball or needle bearing replacement • using the bearing driver set or the oil seal & bearing re- mover, remove the bearings. Special tools - oil seal & bearing remover: 57001-1058 bearing driver set: 57001-1129 note ○ in the absence of the above mentioned tools,...

  • Page 465

    Final drive 11-37 bearing and oil seal tapered roller bearing inspection caution do not remove the tapered roller bearing for inspec- tion. Removal may damage them. • visually inspect the bearing in the front for abrasion, color change, or other damage. If there is any doubt as to the condition of t...

  • Page 466

    Http://mototh.Com.

  • Page 467: Brakes

    Brakes 12-1 12 brakes table of contents exploded view ....................................................................................................................... 12-3 specifications .............................................................................................................

  • Page 468

    12-2 brakes inquiries to rider............................................................................................................... 12-39 self-diagnosis outline ....................................................................................................... 12-41 self-diagnosis proc...

  • Page 469

    Brakes 12-3 exploded view dummy page http://mototh.Com.

  • Page 470

    12-4 brakes exploded view zg1400a models http://mototh.Com.

  • Page 471

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bleed valves 7.8 0.80 69 in·lb 2 brake hose banjo bolts 25 2.5 18 3 brake lever pivot bolt 1.0 0.10 9 in·lb si 4 brake lever pivot bolt locknut 5.9 0.60 52 in·lb 5 brake pipe joint nuts 18 1.8 13 6 brake reservoir bolt 7.8 0.80 ...

  • Page 472

    12-6 brakes exploded view http://mototh.Com.

  • Page 473

    Brakes 12-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bleed valves 7.8 0.80 69 in·lb 2 brake caliper holder plate bolt 64 6.5 47 3 brake hose banjo bolts 25 2.5 18 4 brake pedal bolt 8.8 0.90 78 in·lb 5 brake pipe joint nuts 18 1.8 13 6 rear brake disc mounting bolts 27 2.8 20 l 7 ...

  • Page 474

    12-8 brakes exploded view zg1400b models http://mototh.Com.

  • Page 475

    Brakes 12-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bleed valves 7.8 0.80 69 in·lb 2 brake hose banjo bolts 25 2.5 18 3 brake lever pivot bolt 1.0 0.10 9 in·lb si 4 brake lever pivot bolt locknut 5.9 0.60 52 in·lb 5 brake reservoir bolt 7.8 0.80 69 in·lb l 6 brake reservoir screw...

  • Page 476

    12-10 brakes exploded view http://mototh.Com.

  • Page 477

    Brakes 12-11 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bleed valves 7.8 0.80 69 in·lb 2 brake caliper holder plate bolt 64 6.5 47 3 brake hose banjo bolts 25 2.5 18 4 brake pedal bolt 8.8 0.90 78 in·lb 5 rear brake disc mounting bolts 27 2.8 20 l 6 rear brake pad pin 17.2 1.8 13 7 ...

  • Page 478

    12-12 brakes specifications item standard service limit brake lever, brake pedal brake lever position 6-way adjustable (to suit rider) – – – brake lever free play non-adjustable – – – pedal free play non-adjustable – – – pedal position about 35 mm (1.38 in.) below footpeg top – – – brake pads lining...

  • Page 479

    Brakes 12-13 special tools inside circlip pliers: 57001-143 jack: 57001-1238 hand tester: 57001-1394 http://mototh.Com.

  • Page 480

    12-14 brakes brake lever, brake pedal brake lever position adjustment the brake lever adjuster has 6 positions so that the brake lever position can be adjusted to suit the operator’s hand. • push the lever forward and turn the adjuster [a] to align the number with the arrow mark [b] on the lever hol...

  • Page 481

    Brakes 12-15 brake lever, brake pedal • remove: hook bolt [a] rear brake light switch spring [b] return spring [c] cotter pin [d] joint pin [e] • remove the mounting bolt [f] and take out the brake pedal. Brake pedal installation • apply grease to the pivot shaft [a] and install the washer [b]. • in...

  • Page 482

    12-16 brakes calipers front caliper removal • loosen the banjo bolt [a] at the brake hose lower end, and tighten it loosely. • unscrew the caliper mounting bolts [b], and detach the caliper [c] from the disc. Caution do not loosen the caliper assembly bolts. Take out only the caliper mounting bolts ...

  • Page 483

    Brakes 12-17 calipers caliper installation • install the caliper and brake hose lower end. ○ replace the washers on each side of hose fitting with new ones. • tighten: torque - caliper mounting bolts front: 34 n·m (3.5 kgf·m, 25 ft·lb) rear: 25 n·m (2.5 kgf·m, 18 ft·lb) brake hose banjo bolts: 25 n·...

  • Page 484

    12-18 brakes calipers caliper fluid seal damage the fluid seal (piston seal) [a] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- perature of ...

  • Page 485

    Brakes 12-19 calipers caliper piston and cylinder damage • visually inspect the pistons [a] and cylinder surfaces [b]. Replace the caliper if the cylinder and piston are badly scores or rusty. Http://mototh.Com.

  • Page 486

    12-20 brakes brake pads front brake pad removal • unscrew the pad pins [a]. • remove: pad pins [a] pad springs [b] brake pads [c] front brake pad installation • push the caliper pistons in by hand as far as they will go. • install the outside pad [a] and insert the pad pin [b] as shown in the figure...

  • Page 487

    Brakes 12-21 brake pads rear brake pad removal • remove: pad pin [a] pad spring [b] brake pads [c] rear brake pad installation • push the caliper pistons in by hand as far as they will go. • install the outside pad [a] and insert the pad pin [b] as shown in the figure. • set: inside pad [c] pad spri...

  • Page 488

    12-22 brakes master cylinder front master cylinder removal • remove the banjo bolt [a] to disconnect the brake hose from the master cylinder (see brake hose removal/in- stallation). • unscrew the clamp bolts [b], and take off the master cylin- der [c] as an assembly with the reservoir, brake lever, ...

  • Page 489

    Brakes 12-23 master cylinder rear master cylinder removal • unscrew the brake hose banjo bolt [a] and brake hose [b]. • remove: bolts [c] foot guard [d] cotter pin [e] joint pin [e] rear master cylinder • slide out the clamp [g]. • pull off the reservoir hose lower end, and drain the brake fluid int...

  • Page 490

    12-24 brakes master cylinder • check the dust covers [e] for damage. If they are damaged, replace them. • check the piston return spring [f] for any damage. If the springs are damaged, replace them. • check that relief port [g] and supply port [h] are not plugged. If the relief port becomes plugged,...

  • Page 491

    Brakes 12-25 brake disc brake disc removal • remove the wheels (see front/rear wheel removal in the wheels/tires chapter). • unscrew the mounting bolts, and take off the disc. ○ remove the sensor rotor (zg1400a models). Brake disc installation • install the brake disc on the wheel so that the marked...

  • Page 492

    12-26 brakes brake fluid brake fluid level inspection • refer to the brake fluid level inspection in the periodic maintenance chapter. Brake fluid change • refer to the brake fluid change in the periodic mainte- nance chapter. Brake line bleeding the brake fluid has a very low compression coefficien...

  • Page 493

    Brakes 12-27 brake fluid • remove the rubber cap from the bleed valve [a] on the front master cylinder. • attach a clear plastic hose [b] to the bleed valve, and run the other end of the hose into a container. • bleed the brake line and the master cylinder. ○ repeat this operation until no more air ...

  • Page 494

    12-28 brakes brake fluid • bleed the brake line and the caliper. ○ repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [a]. 2. Quickly open and close [b] the bleed valve while hold- ing...

  • Page 495

    Brakes 12-29 brake fluid warning when working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types and brands of fluid for use in th...

  • Page 496

    12-30 brakes brake hose brake hose and pipe removal/installation • refer to the brake hose and pipe replacement in the periodic maintenance chapter. Brake hose and pipe inspection • refer to the brake hose and pipe damage and instal- lation condition inspection in the periodic maintenance chapter. H...

  • Page 497

    Brakes 12-31 anti-lock brake system (equipped models) parts location 1. Front wheel rotation sensor 2. Front wheel rotation sensor rotor 3. Rear wheel rotation sensor 4. Rear wheel rotation sensor rotor 5. Abs indicator light (led) 6. Abs hydraulic unit 7. Abs fuse box 8. Abs kawasaki self-diagnosis...

  • Page 498

    12-32 brakes anti-lock brake system (equipped models) abs system wiring diagram 1. Steering lock unit 2. Abs self-diagnosis terminal 3. Rear wheel rotation sensor 4. Front wheel rotation sensor 5. Abs kawasaki self-diagnosis system connector 6. Abs hydraulic unit 7. Meter unit 8. Joint connector 8 9...

  • Page 499

    Brakes 12-33 anti-lock brake system (equipped models) terminal names 1. Unused 2. Power supply to rear wheel rotation sensor 3. Front wheel rotation sensor signal 4. Front and rear brake light switch 5. Unused 6. Unused 7. Unused 8. Power supply to abs solenoid valve relay 9. Power supply to abs mot...

  • Page 500

    12-34 brakes anti-lock brake system (equipped models) abs servicing precautions there are a number of important precautions that should be followed servicing the abs system. ○ this abs system is designed to be used with a 12 v sealed battery as its power source. Do not use any other battery except f...

  • Page 501

    Brakes 12-35 anti-lock brake system (equipped models) ○ the abs indicator light (led) [a] may light if the tire pres- sure is incorrect, a non-recommended tire is installed, or the wheel is deformed. If the indicator light lights, remedy the problem and clear the service code. Warning use of non-rec...

  • Page 502

    12-36 brakes anti-lock brake system (equipped models) abs troubleshooting outline when an abnormality in the system occurs, the abs in- dicator light (led) lights up to alert the rider. In addition, the nature of the fault is stored in the memory of the abs hydraulic unit and when in the self-diagno...

  • Page 503

    Brakes 12-37 anti-lock brake system (equipped models) • visually inspect the wiring for signs of burning or fraying. If any wiring is poor, replace the damaged wiring. • pull each connector [a] apart and inspect it for corrosion, dirt and damage. If the connector is corroded or dirty, clean it caref...

  • Page 504

    12-38 brakes anti-lock brake system (equipped models) abs diagnosis flow chart http://mototh.Com.

  • Page 505

    Brakes 12-39 anti-lock brake system (equipped models) inquiries to rider ○ each rider reacts to problems in different ways, so it is important to confirm what kind of condition the rider is dissatisfied with. ○ try to find out exactly what problem occurs under exactly what conditions by asking the r...

  • Page 506

    12-40 brakes anti-lock brake system (equipped models) pre-diagnosis inspection 1 http://mototh.Com.

  • Page 507

    Brakes 12-41 anti-lock brake system (equipped models) pre-diagnosis inspection 2 self-diagnosis outline when the indicator light has blinked or come on, the abs hydraulic unit memorizes and stores the service code for the service person to troubleshoot easily. The service code memory is powered dire...

  • Page 508

    12-42 brakes anti-lock brake system (equipped models) • remove the seat (see seat removal in the frame chap- ter). • ground the self-diagnosis terminal [a] (gray) to the ground terminal [b] (black/yellow), using a lead. • push and turn the key knob to on. ○ count the blinks of the light to read the ...

  • Page 509

    Brakes 12-43 anti-lock brake system (equipped models) self-diagnosis flow chart http://mototh.Com.

  • Page 510

    12-44 brakes anti-lock brake system (equipped models) how to read service codes ○ service codes are shown by a series of long and short blinks of the abs indicator light (led) as shown below. ○ read 10th digit and unit digit as the abs indicator light (led) blinks. ○ when there are a number of fault...

  • Page 511

    Brakes 12-45 anti-lock brake system (equipped models) service code table service code abs indicator light (led) problems light state 13 rear inlet solenoid valve trouble (shorted or open, stuck valve (on)) on 14 rear outlet solenoid valve trouble (shorted or open, stuck valve (on)) on 17 front inlet...

  • Page 512

    12-46 brakes anti-lock brake system (equipped models) abs indicator light (led) inspection • push and turn the key knob to on. If the abs indicator light (led) [a] lights, it is normal. If the abs indicator light (led) does not light, go to step “abs indicator light (led) is unlit (when the key knob...

  • Page 513

    Brakes 12-47 anti-lock brake system (equipped models) • do the 3rd step test. ○ disconnect the abs hydraulic unit connector. ○ check for continuity between the black/white lead termi- nal of the main harness side connector [a] and black/white lead terminal of the main harness side connector [b]. If ...

  • Page 514

    12-48 brakes anti-lock brake system (equipped models) • do the 2nd step test. ○ disconnect the abs hydraulic unit connector [a]. ○ check for continuity between the light green and black/yellow lead terminals of the abs hydraulic unit connector. If there is the continuity in the lead, replace the abs...

  • Page 515

    Brakes 12-49 anti-lock brake system (equipped models) front, rear wheel rotation difference abnormal (service code 25) • do the 1st step test. ○ check the following and correct the faulty part. Incorrect the tire pressure. Tires not recommended for the motorcycle were installed (incorrect tire size)...

  • Page 516

    12-50 brakes anti-lock brake system (equipped models) • do the 4th step test. ○ check the battery terminal voltage between the red lead terminal of the fuse box [a] and ground. Special tool - hand tester: 57001-1394 battery terminal voltage standard: battery voltage if the battery terminal voltage i...

  • Page 517

    Brakes 12-51 anti-lock brake system (equipped models) • do the 2nd step test. ○ check that there is iron or other magnetic deposits be- tween the sensor [a] and sensor rotor [b], and the sensor rotor slots for obstructions. ○ check the installation condition of the sensor for loose- ness. ○ check th...

  • Page 518

    12-52 brakes anti-lock brake system (equipped models) • do the 3rd step test. ○ recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the abs indicator light (led) [a] lit, faulty ecu in the abs hydraulic unit. Re...

  • Page 519

    Brakes 12-53 anti-lock brake system (equipped models) rear wheel rotation sensor wiring inspection (service code 45) • do the 1st step test. ○ disconnect the abs hydraulic unit connector and rear wheel rotation sensor connector. ○ short the black and white/red lead terminals of the main harness side...

  • Page 520

    12-54 brakes anti-lock brake system (equipped models) • do the 2nd step test. ○ connect the ignition switch connector and abs hydraulic unit connector. ○ check the battery terminal voltage, connect the hand tester to the brown terminal of ignition switch connector [a] and ground. Special tool - hand...

  • Page 521

    Brakes 12-55 anti-lock brake system (equipped models) • do the 2nd step test. ○ connect the steering lock connector and abs hydraulic unit connector. ○ check the battery terminal voltage, connect the hand tester to the brown terminal of ignition switch connector [a] and ground. Special tool - hand t...

  • Page 522

    12-56 brakes anti-lock brake system (equipped models) • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) battery (see battery removal in the electrical system chapter) bolts [a] cover [b] • clean the abs hydraulic unit. Caution clean all fittings on the abs hydraulic unit a...

  • Page 523

    Brakes 12-57 anti-lock brake system (equipped models) • remove the bolts [a] and bracket [b]. Caution the abs hydraulic unit has been adjusted and set with precision at the factory. Do not try to disas- semble and repair the abs hydraulic unit. Abs hydraulic unit installation • install the abs hydra...

  • Page 524

    12-58 brakes anti-lock brake system (equipped models) abs hydraulic unit inspection • remove the abs hydraulic unit (see abs hydraulic unit removal). • visually inspect the abs hydraulic unit. Replace the abs hydraulic unit if any of them are cracked, or otherwise damaged. • visually inspect the con...

  • Page 525

    Brakes 12-59 anti-lock brake system (equipped models) rear wheel rotation sensor removal caution the wheel rotation sensor should be handled care- fully, never struck sharply, as with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made. Be careful not...

  • Page 526

    12-60 brakes anti-lock brake system (equipped models) wheel rotation sensor inspection • remove the front wheel rotation sensor [a]. • remove the rear wheel rotation sensor [b]. • visually inspect the wheel rotation sensors. Replace the wheel rotation sensor if it is cracked, bent, or otherwise dama...

  • Page 527

    Brakes 12-61 anti-lock brake system (equipped models) if the rotor is deformed or damaged (chipped teeth [a]), replace the sensor rotor with a new one. If there is iron or other magnetic deposits [b], remove the deposits. Abs solenoid valve relay fuse (20 a) removal • refer to the fuse box fuse remo...

  • Page 528

    Http://mototh.Com.

  • Page 529: Suspension

    Suspension 13-1 13 suspension table of contents exploded view........................................................................................................................ 13-2 specifications .....................................................................................................

  • Page 530

    13-2 suspension exploded view http://mototh.Com.

  • Page 531

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front axle clamp bolts 20 2.0 15 al 2 front fork bottom allen bolts 23 2.3 17 l 3 front fork clamp bolts (lower) 30 3.1 22 al 4 front fork clamp bolts (upper) 20 2.0 15 5 front fork top plugs 22 2.2 16 6 piston rod nuts 28 2...

  • Page 532

    13-4 suspension exploded view http://mototh.Com.

  • Page 533

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 axle bracket locknut 98 10.0 72.3 2 final gear case locknut 98 10.0 72.3 3 rear shock absorber nut (lower) 34 3.5 25 4 rear shock absorber nut (upper) 34 3.5 25 5 rocker arm nut 34 3.5 25 6 swingarm pivot collar locknut 98 1...

  • Page 534

    13-6 suspension specifications item standard front fork (per one unit) fork inner tube diameter 43 mm (1.7 in.) air pressure atmospheric pressure (non-adjustable) rebound damper setting 5th click from the 1st click of the fully clockwise position (usable range: 0 ←→ 11 clicks) fork spring preload se...

  • Page 535

    Suspension 13-7 special tools inside circlip pliers: 57001-143 oil seal & bearing remover: 57001-1058 bearing driver set: 57001-1129 jack: 57001-1238 fork cylinder holder: 57001-1287 fork piston rod puller, m12 × 1.25: 57001-1289 fork oil level gauge: 57001-1290 bearing remover head, 20 × 22: 57001-...

  • Page 536

    13-8 suspension special tools fork spring compressor: 57001-1540 fork spring compressor: 57001-1587 swingarm pivot nut wrench: 57001-1597 needle bearing driver, 17/ 18: 57001-1609 stem bearing driver, 28: 57001-1610 spacer, 18: 57001-1636 spacer 28: 57001-1663 needle bearing driver, 20 & spacer, 28:...

  • Page 537

    Suspension 13-9 front fork rebound damping force adjustment • to adjust the rebound damping force, turn the rebound damping adjuster [a] until you feel a click. ○ the standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 5th click from th...

  • Page 538

    13-10 suspension front fork front fork removal (each fork leg) • remove: front wheel (see front wheel removal in the wheels/tires chapter) front fender (see front fender removal in the frame chapter) loosen the upper fork clamp bolt [a] and fork top plug [b] beforehand if the fork leg is to be disas...

  • Page 539

    Suspension 13-11 front fork front fork oil change • remove the front fork (see front fork removal). • unscrew the top plug [a] out of the outer tube. • install the clamps [a] as shown in the figure. Note ○ set the clamps so that the cutout [b] of the upper side does not touch the tongue shape of sto...

  • Page 540

    13-12 suspension front fork • screw in nuts [a] come out the piston rod nut. • holding the piston rod nut with a wrench [a], remove the top plug [b] from the piston rod. • remove: washer [a] collar [b] rebound damping adjuster rod [c] fork spring [d] • drain the fork oil into a suitable container. ○...

  • Page 541

    Suspension 13-13 front fork if necessary, measure the oil level as follows. ○ hold the inner tube vertically in a vise. ○ pump the inner tube several times to expel air bubbles. ○ using the piston rod puller [a], move the piston rod [b] up and down more than ten times in order to expel all the air f...

  • Page 542

    13-14 suspension front fork • set the fork spring compressor on the washer using the outer tube as a guide. Special tools - fork spring compressor: 57001-1540 fork spring compressor: 57001-1587 note ○ set the clamps so that the cutout [a] of the upper side does not fit the hole [b] of washer [c], pu...

  • Page 543

    Suspension 13-15 front fork • check the o-ring [a] on the top plug and replace it with a new one if damaged. • screw in the top plug [b] stopped onto the piston rod. • holding the top plug with a wrench [c], tighten the piston rod nut [d] against the top plug. Torque - piston rod nut: 28 n·m (2.9 kg...

  • Page 544

    13-16 suspension front fork front fork assembly • replace the following parts with a new one. Oil seal bottom allen bolt gasket • insert the cylinder unit [a] into the inner tube [b]. • stop the cylinder from turning by using the fork cylinder holder. Special tool - fork cylinder holder: 57001-1287 ...

  • Page 545

    Suspension 13-17 front fork inner tube inspection • visually inspect the inner tube [a], and repair any dam- age. • nicks or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage. If the damage is not repairable, replace the inner tu...

  • Page 546

    13-18 suspension rear shock absorber rebound damping force adjustment • to adjust the rebound damping force, turn the lower damping adjuster [a] to the desired position, until you feel a click. ○ the standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no acce...

  • Page 547

    Suspension 13-19 rear shock absorber • remove: bolts [a] • clear the hose form the clamp [b]. • squeeze the brake lever slowly and it with a band [a]. Warning be sure to hold the front brake when removing the shock absorber, or the motorcycle may fall over. It could cause an accident and injury. • r...

  • Page 548

    13-20 suspension rear shock absorber rear shock absorber inspection • remove the rear shock absorber [a] (see rear shock absorber removal). • visually inspect the following items. Smooth stroke oil leakage crack or dent if there is any damage to the rear shock absorber, replace it. • visually inspec...

  • Page 549

    Suspension 13-21 swingarm swingarm removal • use the center stand to support the motorcycle uptight. • remove: rear wheel (see rear wheel removal in the wheels/tires chapter) propeller shaft (see propeller shaft removal in the final drive chapter) muffler body (see muffler body removal in the engine...

  • Page 550

    13-22 suspension swingarm • unscrew the swingarm pivot shaft [a] few times. ○ turn out the swingarm pivot adjusting collar. • pull out the pivot shaft right side of the motorcycle and remove the swingarm. Swingarm installation • apply plenty of grease to the lip of the oil seals [a]. • install the c...

  • Page 551

    Suspension 13-23 swingarm • tighten the pivot shaft nut [a]. Torque - swingarm pivot shaft nut: 108 n·m (11.0 kgf·m, 80 ft·lb) • install the removed parts (see appropriate chapters). Swingarm bearing removal • remove: swingarm (see swingarm removal) collar [a] grease seals [b] sleeve [c] circlip [d]...

  • Page 552

    13-24 suspension swingarm • install the needle bearings [a], ball bearing [b] and oil seals [c] position as shown in the figure. ○ press in the ball bearing until it is bottomed. Circlip [d] 31.6 ∼ 32.4 mm (1.24 ∼ 1.28 in.) [e] 27.1 ∼ 27.9 mm (1.07 ∼ 1.10 in.) [f] 8.8 ∼ 9.6 mm (0.35 ∼ 0.38 in.) [g] ...

  • Page 553

    Suspension 13-25 swingarm • turn the bearing in the swingarm back and forth [a] while checking for play, roughness, or binding. If bearing play, roughness, or binding is found, replace the bearing. • examine the bearing seal [b] for tears or leakage. If the seal is torn or is leaking, replace the be...

  • Page 554

    13-26 suspension swingarm • install the front bolt [a] with washer [b]. • tighten: torque - torque rod bolts: 59 n·m (6.0 kgf·m, 44 ft·lb) torque rod bearing removal • remove: torque rod sleeve [a] grease seals [b] needle bearing [c] ○ hold the torque rod and remove the needle bearing. Special tool ...

  • Page 555

    Suspension 13-27 swingarm note ○ install the needle bearing of the frame so that the man- ufacture’s marks side out. • install the needle bearing [a] position as shown in the figure. 5.1 ∼ 5.9 mm (0.20 ∼ 0.23 in.) [b] sleeve [c] frame [d] left side [e] right side [f] ○ apply grease to the lip of the...

  • Page 556

    13-28 suspension tie-rod, rocker arm tie-rod removal • use the center stand to support the motorcycle upright. • squeeze the brake lever slowly and hold it with a band [a]. • remove: upper tie-rod nut and bolt [a] lower tie-rod nut and bolt [b] tie-rods [c] tie-rod installation • apply grease to the...

  • Page 557

    Suspension 13-29 tie-rod, rocker arm tie-rod and rocker arm bearing removal • remove: tie-rods (see tie-rod removal) rocker arm (see rocker arm removal) sleeves [a] grease seals [b] swingarm [c] (see swingarm removal) • remove the needle bearings [d], using the bearing re- mover head and bearing rem...

  • Page 558

    13-30 suspension tie-rod, rocker arm ○ screw the needle bearing driver [a] into the driver holder [b]. ○ insert the needle bearing driver into the needle bearing [c] and press the needle bearing into the housing until the driver contacts the end surface of the housing. Bearing pressing depth: 5.5 mm...

  • Page 559

    Suspension 13-31 tie-rod, rocker arm rocker arm/tie-rod bearing, sleeve inspection caution do not remove the bearings for inspection. Re- moval may damage them. • visually inspect the locker arm, or tie-rod sleeves [a] and needle bearings [b]. • the rollers in a needle bearing normally wear very lit...

  • Page 560

    Http://mototh.Com.

  • Page 561: Steering

    Steering 14-1 14 steering table of contents exploded view........................................................................................................................ 14-2 special tools ..........................................................................................................

  • Page 562

    14-2 steering exploded view http://mototh.Com.

  • Page 563

    Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fork clamp bolts (lower) 30 3.1 22 al 2 front fork clamp bolts (upper) 20 2.0 15 3 handlebar bolts 34 3.5 25 l 4 handlebar holder bolts 25 2.5 18 5 left switch housing screws 3.5 0.36 31 in·lb 6 right switch housing scre...

  • Page 564

    14-4 steering special tools head pipe outer race press shaft: 57001-1075 steering stem nut wrench: 57001-1100 bearing driver set: 57001-1129 steering stem bearing driver, 42.5: 57001-1344 steering stem bearing driver adapter, 41.5: 57001-1345 head pipe outer race driver, 55: 57001-1446 http://mototh...

  • Page 565

    Steering 14-5 steering steering inspection • refer to the steering play inspection in the periodic main- tenance chapter (see steering play inspection in the pe- riodic maintenance chapter). Steering adjustment • refer to the steering play adjustment in the periodic maintenance chapter (see steering...

  • Page 566

    14-6 steering steering stem stem, stem bearing removal • remove: inner cover (see inner cover removal in the frame chapter) storage compartment cover (see storage compart- ment removal in the frame chapter) front wheel (see front wheel removal in the wheels/tires chapter) handlebars holders [a] with...

  • Page 567

    Steering 14-7 steering stem • bend the claws [a] of lock washer straighten. • remove the steering stem locknut [b]. Special tool - steering stem nut wrench: 57001-1100 • remove the lock washer. • pulling up the stem base, and remove the steering stem nut [a] with stem cap [b]. Special tool - steerin...

  • Page 568

    14-8 steering steering stem • replace the bearing inner races and oil seal with new ones. • apply grease to the oil seal. • install the oil seal [a] on the steering stem, and drive the lower ball bearing inner race [b] applied the grease onto the stem. Special tools - steering stem bearing driver, 4...

  • Page 569

    Steering 14-9 steering stem • first tighten the steering stem locknut by hand until the resistance is felt fully, then tighten the steering stem lock nut so that align the claw [a] of stem lock nut to the notch [b] of stem nut by hand. • check that there is no play and the steering stem turns smooth...

  • Page 570

    14-10 steering steering stem steering stem warp • whenever the steering stem is removed, or if the steering can not be adjusted for smooth action, check the steering stem for straightness. If the steering stem [a] is bent, replace the steering stem. Stem cap deterioration, damage replace the stem ca...

  • Page 571

    Steering 14-11 handlebar handlebar removal • remove: clutch lever clamp bolts [a] clutch master cylinder [b] left switch housing [c] handlebar weight [d] handlebar bolt [e] left handlebar • remove: front brake master cylinder [a] (see front brake master cylinder removal in the brakes chapter) right ...

  • Page 572

    14-12 steering handlebar • install: throttle grip throttle cable tips throttle cases ○ fit the projection [a] into a small hole [b] in the handlebar. • apply a non-permanent locking agent to the threads of the handlebar weight bolts, and tighten them. Handlebar holder removal • remove: left and righ...

  • Page 573: Frame

    Frame 15-1 15 frame table of contents exploded view................................... 15-2 seat ................................................... 15-10 seat removal .............................. 15-10 seat installation ........................... 15-10 fairings......................................

  • Page 574

    15-2 frame exploded view http://mototh.Com.

  • Page 575

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 center stand bolts 44 4.5 32 2 front footpeg bracket bolts 25 2.5 18 3 sidestand bolt 44 4.5 32 4 sidestand bracket bolts 49 5.0 36 l 5 sidestand switch bolt 8.8 0.90 78 in·lb l g: apply grease. L: apply a non-permanent locking a...

  • Page 576

    15-4 frame exploded view http://mototh.Com.

  • Page 577

    Frame 15-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 carrier bracket bolts (m10) 34 3.5 25 2 carrier bracket bolts (m8) 25 2.5 18 3 frame side bracket bolts 25 2.5 18 4 hook bracket bolts 25 2.5 18 5 rear footpeg bracket bolts 34 3.5 25 6 rear frame bolts 44 4.5 32 l g: apply greas...

  • Page 578

    15-6 frame exploded view http://mototh.Com.

  • Page 579

    Frame 15-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fender cover screws 1.2 0.12 11 in·lb 2 seat lock guard screws 1.2 0.12 11 in·lb 3. License plate bracket (ca and us models) 4. Reflectors (au, ca and us models) 5. Reflectors (ca and us models) http://mototh.Com.

  • Page 580

    15-8 frame exploded view http://mototh.Com.

  • Page 581

    Frame 15-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper fairing bracket nuts 25 2.5 18 2. Bolts and washers 3. Canister bracket (cal model) http://mototh.Com.

  • Page 582

    15-10 frame seat seat removal • insert the key knob [a] into the seat lock and, turning the key counterclockwise, pulling up on the rear of the seat [b], and pulling the seat backward. Seat installation • insert the brackets [a] of the fuel tank into the slots [b] of the seat. • fit the hooks [a] of...

  • Page 583

    Frame 15-11 fairings lower fairing removal • remove: rear middle fairings (see rear middle fairing removal) ○ pull up the core by the thin blade driver. ○ remove the quick rivet [a]. • remove the bolts [b] with washers. • clear the hook portion [c] from the slot. • separate the left lower fairing fr...

  • Page 584

    15-12 frame fairings middle fairing removal • remove: storage compartment cover (see storage compart- ment removal) inner covers (see inner cover removal) fairing covers (see fairing cover removal) • for the right side, remove the bolt [a] and sub front right side cover [b]. • remove: bolts [a] • pu...

  • Page 585

    Frame 15-13 fairings middle fairing installation • install the turn signal light to the front middle fairing, and tighten the screws. • install the inner fairing (see inner fairing installation). • connect the turn signal lead connector. • fit the rear side hook [a] of the fairing first, and then fi...

  • Page 586

    15-14 frame fairings • remove: rubber damper [a] bolts [b] windshield [c] windshield installation • put the rabber damper [a] onto the shape area of the damper [b]. • tighten: upper fairing removal • remove: inner cover (see inner cover removal) windshield screws [a] electric windshield actuator cov...

  • Page 587

    Frame 15-15 fairings • remove: bolt [a] right resonator [b] • turn the fittings [a] of the aiming cable counter-clockwise and remove them. • pull out the upper fairing [a] forward. ○ pull the both side of the fairing to clear the rear view mirror bracket [b]. Upper fairing installation • installatio...

  • Page 588

    15-16 frame fairings upper fairing disassembly • remove: upper fairing (see upper fairing removal) screws [a] bolts [b] headlights [c] upper fairing assembly • set up the and fairing damper bracket [a] inlet fairing [b]. • install the headlight. • installation is the reverse of removal. Inner cover ...

  • Page 589

    Frame 15-17 fairings upper inner fairing installation • engage the engage parts [a] of the inner fairing front por- tion and counters [b]. • install the quick revets. Lower inner fairing removal • remove: quick rivet [a] bolts [b] • clear the slots [c] from the hooks. • remove the inner fairing [d] ...

  • Page 590

    15-18 frame fairings fairing stay removal • remove: middle fairings (see middle fairing removal) bolts [a] relay bracket [b] with pad [c] bolt [d] left heat insulation cover [e] • remove: bolts [a] left fairing stay [b] • for the california model, remove the band [a], canister [b], bolt [c] and brac...

  • Page 591

    Frame 15-19 fairings • remove: bolt [a] right fan motor lead connector [b] (disconnect) clamp [c] (open) right fairing stay [d] • for the california mode, remove the bolt [a] and sepa- rater [b]. Fairing stay installation • installation is the reverse of removal. Upper fairing bracket removal • remo...

  • Page 592

    15-20 frame seat cover seat cover removal • remove: seat (see seat removal) screws [a] center seat cover [b] • remove: screws [a] • remove the quick rivets [a]. • clear the side seat covers [b] from the holders [c] of the saddlebag. • for the left side seat cover, remove the screws [a] and seat lock...

  • Page 593

    Frame 15-21 seat cover • insert the projection [a] of the seat cover [b] into the hole [c] of the tail light cover [d]. • tighten the screws. Tail cover removal • remove: tail/brake light (see tail/brake light removal in the electrical system chapter) seat covers bolts [a] quick revets [b] ○ pull ou...

  • Page 594

    15-22 frame fenders front fender removal • remove: brake hose clamps [a] (both sides) bolts [b] with washer (both sides) bolts [c] (both sides) bracket [d] (except the zg1400b european models) • remove the front fender assy [e]. • remove the screws [a]. • separate the front fender covers [b] and fro...

  • Page 595

    Frame 15-23 fenders • remove: lisense plate light lead connector [a] nuts [b] flaps [c] • remove: band [a] kipass ecu [b] fuse box [c] clamps (open) [d] • remove: tail/brake light (led) (see tail/brake light (led) re- moval in the electrical system chaoter) bolts [a] • disconnect the connector [a]. ...

  • Page 596

    15-24 frame fenders • pull out the rear fender [a] backward and downward. ○ cleare the fender from the frame brackets [b]. Flap and rear fender installation • put the front portion [a] of the rear fender on the frame [b]. • before installing the flap, run license plate light lead [a] to the holes of...

  • Page 597

    Frame 15-25 storage compartment storage compartment removal • unlock the lid [a] of the storage compartment [b]. ○ pushing the lever [c] in with holding the button [d] down. • remove: screws [a] storage compartment cover [b] with lid [c] • remove: bolts [a] storage compartment case [b] • unhook the ...

  • Page 598

    15-26 frame storage compartment storage compartment installation • installe the end of the springs [a] position as shown. Http://mototh.Com.

  • Page 599

    Frame 15-27 frame rear frame removal • remove: frame side cover (see propeller shaft removal in the final drive chapter) rear fender (see rear fender removal) muffler body bolt [a] rear footpeg bracket bolts [b] and brackets (both sides) rear frame bolts [c] rear frame installation • apply a non-per...

  • Page 600

    15-28 frame frame frame inspection • visually inspect the frame [a] for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. Warning a repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it. Http://motot...

  • Page 601

    Frame 15-29 cover meter cover removal • remove: meter unit (see meter unit removal in the electrical sys- tem chapter) • open the clamp [a]. • unscrew the bolt [b]. • turn the fitting [c] of the aiming cable counter-clockwise and remove it. • open the clamp [a]. • unscrew the bolt [b]. • disconnect ...

  • Page 602

    15-30 frame cover • insert the cap [a] onto the cable [b]. • install the meter cover [a] and tighten the bolts [b]. • install the removed parts. Http://mototh.Com.

  • Page 603

    Frame 15-31 center stand, sidestand center stand removal • remove: muffler bodies (see muffler body removal in the engine top end chapter) • using the jack [a] rais the rear wheel off the ground special tools - jack [a]: 57001-1238 jack attachment [b]: 57001-1608 • remove: lower tie-rod bolt (see ti...

  • Page 604

    15-32 frame center stand, sidestand sidestand installation • apply grease to the sliding area [a] of the sidestand [b]. • apply a non-permanent locking agent to the bracket bolts [c]. • tighten the bolt and lock them with the nut. Torque - sidestand bracket bolts: 49 n·m (5.0 kgf·m, 36 ft·lb) sidest...

  • Page 605

    Frame 15-33 saddlebag saddlebag removal • insert the key knob [a] into the lid lock. • turn the key knob clockwise. • pull up the handle [a] on the top of the saddlebag [b]. • remove the saddlebag by pulling it up. Saddlebag installation • turn the key knob clockwise. • while aligning the holder [a]...

  • Page 606

    15-34 frame saddlebag • unscrew the screws [a] of the saddlebag lock assy. • remove the saddlebag lock assy. • unscrew the hinge nuts [a] and separate the lid [b] and case [c]. • unscrew: screws [d] • remove: hooks [e] lid cover [f] • drill the surface of the rivet using a 1.0 to 1.5 mm drill bit no...

  • Page 607

    Frame 15-35 carrier carrier removal • unscrew the bolts [a] and remove the carrier [b]. • remove: saddlebags (see saddlebag removal) seat cover (seat cover removal) carrier bolts [a] right and left carrier bracket [b] • remove: bolts [a] right and left hook brackets [b] carrier installation ○ set th...

  • Page 608

    15-36 frame rear view mirror rear view mirror removal • remove: fairing cover (see fairing cover removal) rear middle fairings (see middle fairing removal) nuts [a] rear view mirror [b] rear view mirror installation • installation is the reverse of removal. Http://mototh.Com.

  • Page 609

    Frame 15-37 pads dummy page http://mototh.Com.

  • Page 610

    15-38 frame pads http://mototh.Com.

  • Page 611

    Frame 15-39 pads 1. Fuel tank 2. Align the pad with plate of the fuel tank. 3. Align the pad with weld of the fuel tank. 4. Pad 5. Pad 6. Pad 7. Pad 8. Pad 9. Guard http://mototh.Com.

  • Page 612

    15-40 frame pads http://mototh.Com.

  • Page 613

    Frame 15-41 pads 1. Front view 2. Damper 3. Damper 4. Electric windshield actuator cover 5. Left and right inner fairings 6. Pad 7. 0 ∼ 10 mm (0 ∼ 0.39 in.) 8. 10 mm (0.39 in.) 9. Left and right front middle fairings 10. Pad 11. Left and right inner covers 12. Line 13. Pad 14. Pad 15. 0 ∼ 5 mm (0 ∼ ...

  • Page 614

    15-42 frame pads http://mototh.Com.

  • Page 615

    Frame 15-43 pads 1. Left side 2. Rear middle fairing 3. 10 mm (0.39 in.) 4. Pad 5. Pad 6. 0 ∼ 10 mm (0 ∼ 0.39 in.) 7. Pad (install the pad from the outside.) 8. 10 ∼ 15 mm (0.39 ∼ 0.59 in.) 9. 60 mm (2.36 in.) 10. Pad 11. Pad 12. Pad 13. Heat insulation plate 14. Pad 15. Front view 16. Heat insulati...

  • Page 616

    Http://mototh.Com.

  • Page 617: Electrical System

    Electrical system 16-1 16 electrical system table of contents exploded view........................................................................................................................ 16-4 parts location........................................................................................

  • Page 618

    16-2 electrical system starter motor disassembly................................................................................................ 16-51 starter motor assembly .................................................................................................... 16-51 brush inspection .....

  • Page 619

    Electrical system 16-3 gear position switch removal ......................................................................................... 16-104 gear position switch installation ...................................................................................... 16-105 gear position switch in...

  • Page 620

    16-4 electrical system exploded view http://mototh.Com.

  • Page 621

    Electrical system 16-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 adjuster knob bracket screws 1.2 0.12 11 in·lb 2 aiming bracket screws 1.2 0.12 11 in·lb 3 front turn signal light mounting screws 1.2 0.12 11 in·lb 4 license plate light cover mounting screws 0.90 0.092 8 in·lb 5 lic...

  • Page 622

    16-6 electrical system exploded view http://mototh.Com.

  • Page 623

    Electrical system 16-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 alternator cover bolts 9.8 1.0 87 in·lb 2 alternator lead holding plate bolts 8.3 0.85 73 in·lb l 3 alternator rotor bolt 110 11.2 81.1 s 4 crankshaft sensor bolts 5.9 0.60 52 in·lb l 5 crankshaft sensor cover bolts 9...

  • Page 624

    16-8 electrical system exploded view http://mototh.Com.

  • Page 625

    Electrical system 16-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front brake light switch screw 1.2 0.12 11 in·lb 2 left switch housing screws 3.5 0.36 31 in·lb 3 right switch housing screws 3.5 0.36 31 in·lb 4 sidestand switch bolt 8.8 0.90 78 in·lb l 5 speed sensor bolt 9.8 1.0 8...

  • Page 626

    16-10 electrical system parts location http://mototh.Com.

  • Page 627

    Electrical system 16-11 parts location 1. Turn signal relay 2. Battery 12 v 14 ah 3. Frame ground 4. Water temperature sensor 5. Stick coils 6. Air switching valve 7. Kipass signal diode (in main harness) 8. Meter unit 9. Oil control solenoid valve 10. Rear brake light switch 11. Engine ground 12. C...

  • Page 628

    16-12 electrical system parts location http://mototh.Com.

  • Page 629

    Electrical system 16-13 parts location 24. Electric windshield motor 25. Steering lock unit 26. Headlight relays (hi and lo) 27. Kipass signal relay 28. Accessory relay 29. Electric windshield relays (up and down) 30. Fan motors 31. Exhaust camshaft position sensor 32. Turn signal relay 33. Fuse box...

  • Page 630

    16-14 electrical system wiring diagram (abs equipped models) http://mototh.Com.

  • Page 631

    Electrical system 16-15 wiring diagram (abs equipped models) http://mototh.Com.

  • Page 632

    16-16 electrical system wiring diagram (other than abs equipped models) http://mototh.Com.

  • Page 633

    Electrical system 16-17 wiring diagram (other than abs equipped models) http://mototh.Com.

  • Page 634

    16-18 electrical system specifications item standard service limit battery type sealed battery – – – model name ftz14-bs – – – capacity 12 v 14 ah – – – voltage 12.6 v or more – – – charging system type three-phase ac – – – alternator output voltage 56 v or more @4 000 r/min (rpm) – – – stator coil ...

  • Page 635

    Electrical system 16-19 special tools and sealant hand tester: 57001-1394 flywheel puller assembly, m38 × 1.5/m35 × 1.5: 57001-1405 peak voltage adapter: 57001-1415 lead wire - peak voltage adapter: 57001-1449 needle adapter set: 57001-1457 harness adapter: 57001-1562 grip: 57001-1591 flywheel & pul...

  • Page 636

    16-20 electrical system special tools and sealant kawasaki bond (silicone sealant): 92104-0004 http://mototh.Com.

  • Page 637

    Electrical system 16-21 precautions there are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○ always check battery con...

  • Page 638

    16-22 electrical system electrical wiring wiring inspection • visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clea...

  • Page 639

    Electrical system 16-23 battery battery removal • turn the key knob to off. • remove: bolt [a] right cover [b] ○ pull out the projection [c] of the cover from the rubber grommet. • remove: bolts [a] battery compartment cover [b] ○ clear the front part [c] of the cover from the rear middle cover. • r...

  • Page 640

    16-24 electrical system battery • disconnect the negative (–) cable [a]. • remove the battery [b] from the battery tray. Battery installation • place the battery in the battery tray [a]. • connect the negative (–) cable [b] to the battery. • put a light coat of grease on the (–) terminal to prevent ...

  • Page 641

    Electrical system 16-25 battery • install the bracket [a]. ○ insert the projections on the battery tray into the holes [b] of the bracket. • tighten the bracket bolts. • connect the connector [c]. • install the negative cable (–) terminal [a] to the frame so that the flat surface faces to frame and ...

  • Page 642

    16-26 electrical system battery caution do not remove the aluminum sealing sheet [a] from the filler ports [b] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. • place the battery on a level surface. • check to see that the sealing sheet has...

  • Page 643

    Electrical system 16-27 battery • gently remove the container from the battery. • let the battery sit for 60 minutes prior to charging to allow the electrolyte to permeate into the plates for optimum performance. Note ○ charging the battery immediately after filling can shorten service life. Let the...

  • Page 644

    16-28 electrical system battery note ○ to ensure maximum battery life and customer satisfac- tion, it is recommended the battery be load tested at three times its amp-hour rating for 15 seconds. Re-check voltage and if less than 12.6 volts repeat the charging cycle and load test. If still below 12.6...

  • Page 645

    Electrical system 16-29 battery charging condition inspection ○ battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter [a]. • remove: battery (see battery removal) • measure the battery terminal voltage. Note ○ measure with a digital voltmeter which ...

  • Page 646

    16-30 electrical system battery • determine the battery condition after refresh charge. ○ determine the condition of the battery left for 30 minutes after completion of the charge by measuring the terminal voltage according to the table below. Criteria judgement 12.6 v or higher good 12.0 ∼ lower th...

  • Page 647

    Electrical system 16-31 charging system alternator cover removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) bolt [a] bracket [b] • disconnect: alternator lead connectors [a] • remove: bolts [a] cover [b] • pull the alternator lead out of between the engine and frame...

  • Page 648

    16-32 electrical system charging system stator coil installation • tighten the stator coil bolts to the specified torque. Torque - stator coil bolts: 12 n·m (1.2 kgf·m, 106 in·lb) • apply silicone sealant to the circumference of the alter- nator lead grommet, and fit the grommet into the notch of th...

  • Page 649

    Electrical system 16-33 charging system • using a cleaning fluid, clean off any oil or dirt on the washer [a] and dry if with a clean cloth. Note ○ confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque. • install the rotor bolt [b] and tighten it with 6...

  • Page 650

    16-34 electrical system charging system • to check the alternator output voltage, do the following procedures. ○ turn the key knob to off. ○ disconnect the alternator lead connector [a] from the reg- ulator/rectifier. ○ connect the hand tester [b] as shown in the table 1. Special tool - hand tester:...

  • Page 651

    Electrical system 16-35 charging system regulator/rectifier inspection • remove: regulator/rectifier bolts [a] • remove: connectors [a] regulator/rectifier [b] • set the hand tester to the × 1 k Ω range and make the measurements shown in the table. Special tool - hand tester: 57001-1394 • connect th...

  • Page 652

    16-36 electrical system charging system charging voltage inspection • check the battery condition (see charging condition in- spection). • warm up the engine to obtain actual alternator operating conditions. • remove the right cover. • check that the key knob is turned off, and connect the hand test...

  • Page 653

    Electrical system 16-37 charging system charging system circuit 1. Steering lock unit 2. Regulator/rectifier 3. Alternator 4. Load 5. Main fuse 30 a 6. Frame ground 7. Battery 12 v 14 ah 8. Frame ground 9. Engine ground http://mototh.Com.

  • Page 654

    16-38 electrical system ignition system http://mototh.Com.

  • Page 655

    Electrical system 16-39 ignition system warning the ignition system produces extremely high volt- age. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock. Caution do not disconnect the battery cables or any other electrical connect...

  • Page 656

    16-40 electrical system ignition system crankshaft sensor installation • apply a non-permanent locking agent to the threads of the crankshaft sensor bolts [a], and tighten them. Torque - crankshaft sensor bolts: 5.9 n·m (0.60 kgf·m, 52 in·lb) • apply silicone sealant to the circumference of the cran...

  • Page 657

    Electrical system 16-41 ignition system • set the hand tester [a] to the × 25 v dc range, and con- nect the peak voltage adapter [b]. Special tools - hand tester: 57001-1394 peak voltage adapter: 57001-1415 type: kek-54-9-b connections: crankshaft sensor connector [c] adapter hand tester black ← bla...

  • Page 658

    16-42 electrical system ignition system • remove: bolt [a] bracket and connector [b] • disconnect the stick coil connectors [c]. • pull the stick coils [d] off the spark plugs. Caution do not pry the connector part of the coil while re- moving the coil. Stick coil installation • apply grease [a] to ...

  • Page 659

    Electrical system 16-43 ignition system stick coil inspection • remove the stick coils (see stick coil removal). • measure the primary winding resistance [a] as follows. ○ connect the hand tester between the coil terminals. ○ set the tester to the × 1 Ω range, and read the tester. • measure the seco...

  • Page 660

    16-44 electrical system ignition system warning to avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • turn the ignition switch and engine stop switch on. • pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measure th...

  • Page 661

    Electrical system 16-45 ignition system • disconnect the camshaft position sensor lead connector [a]. • remove: quick rivets [a] cover [b] camshaft position sensor bolt [c] camshaft position sensor [d] (inlet side) • loosen the clamps of the throttle body assy and remove the throttle body assy from ...

  • Page 662

    16-46 electrical system ignition system camshaft position sensor installation • replace the o-rings of the camshaft position sensors. • apply grease to the new o-rings. • tighten: torque - camshaft position sensor bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • route the camshaft position sensor lead correct...

  • Page 663

    Electrical system 16-47 ignition system • turn the key knob and engine stop switch on. • pushing the starter button, run the engine with the trans- mission gear in neutral to measure the camshaft position sensor peak voltage. • repeat the measurement 5 or more times. Camshaft position sensor peak vo...

  • Page 664

    16-48 electrical system ignition system ic igniter inspection ○ the ic igniter is built in the ecu [a]. • refer to the following items. Interlock operation inspection (see interlock operation inspection) ignition system troubleshooting (see ignition system section) ecu power supply inspection (see e...

  • Page 665

    Electrical system 16-49 ignition system ignition system circuit 1. Sidestand switch 2. Water temperature sen- sor 3. Inlet camshaft position sensor 4. Exhaust camshaft posi- tion sensor 5. Meter unit 6. Speed sensor 7. Gear position switch 8. Water-proof joint 1 9. Atmospheric pressure sensor 10. Ve...

  • Page 666

    16-50 electrical system electric starter system starter motor removal • remove: left rear middle fairing (see middle fairing removal in the frame chapter) clamp bolts [a] • remove: speed sensor (see speed sensor removal) starter motor mounting bolts [a] • pull out the starter motor [b]. • slide out ...

  • Page 667

    Electrical system 16-51 electric starter system • install the starter motor cable [a] side by side with starter motor [b]. • tighten: torque - starter motor cable terminal nut: 5.9 n·m (0.60 kgf·m, 52 in·lb) • slide back the rubber cap [c] to the original position. Starter motor disassembly • remove...

  • Page 668

    16-52 electrical system electric starter system • install the brush plate assembly [a] into the right-hand end cover [b]. • replace the o-ring [c] with a new one. • install: insulators [d] washer [e] • tighten: torque - starter motor terminal locknut [f]: 6.9 n·m (0.70 kgf·m, 61 in·lb) • install the...

  • Page 669

    Electrical system 16-53 electric starter system brush inspection • measure the length [a] of each brush [b]. If any is worn down to the service limit, replace the brush holder assembly. Starter motor brush length standard: 10 mm (0.39 in.) service limit: 5 mm (0.20 in.) commutator cleaning and inspe...

  • Page 670

    16-54 electrical system electric starter system brush lead inspection • using the × 1 Ω hand tester range, measure the resis- tance as shown. Terminal bolt and positive brush [a] right-hand end cover and negative brush [b] special tool - hand tester: 57001-1394 if there is not close to zero ohms, th...

  • Page 671

    Electrical system 16-55 electric starter system electric starter circuit 1. Sidestand switch 2. Engine stop switch 3. Starter button 4. Fuse box 2 5. Ignition fuse 10 a 6. Steering lock unit 7. Joint connector 1 8. Joint connector 8 9. Gear position switch 10. Starter lockout switch 11. Starter circ...

  • Page 672

    16-56 electrical system lighting system this motorcycle adopts the daylight system and has a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays o...

  • Page 673

    Electrical system 16-57 lighting system • install the hook [a]. • fit the dust cover [a] onto the bulb [b] firmly as shown in the figure. Good [c] bad [d] • connect the headlight connector. • after installation, adjust the headlight aim (see headlight aiming inspection in the periodic maintenance ch...

  • Page 674

    16-58 electrical system lighting system • insert the socket [a] so that the round side [b] fits the wall [c]. Headlight removal/installation • remove: upper fairing (see upper fairing removal in the frame chapter) upper fairing damper bracket screws [a] (tapping screws) headlight mounting screws [b]...

  • Page 675

    Electrical system 16-59 lighting system tail/brake light (led) removal • remove: seat (see seat removal in the frame chapter) ecu (see ecu removal in the fuel system (dfi) chapter tail/brake light lead connector [a] • open the clamp [b]. • remove: bolts [a] carrier plate [b] • remove: bolts [a] • mo...

  • Page 676

    16-60 electrical system lighting system • remove: tail light cover bracket bolts [a] upper cover [b] lower cover [c] • remove: bolts [a] bracket [b] • remove: tail light screws [a] tail light bracket [b] tail/brake light (led) installation • installation is basically the reverse of removal. • tighte...

  • Page 677

    Electrical system 16-61 lighting system • push and turn the bulb [a] counterclockwise wise and re- move it. • replace the bulb with a new one. • insert the new bulb [a] by aligning its upper and lower pins [b] with the upper and lower grooves [c] in the socket, and turn the bulb clockwise. ○ turn th...

  • Page 678

    16-62 electrical system lighting system headlight/tail light circuit 1. Fuse box 1 2. Taillight fuse 10 a 3. Headlight fuse 10 a 4. Headlight fuse (lo) 15 a 5. Headlight fuse (hi) 15 a 6. Steering lock unit 7. Joint connector 8 8. Joint connector 1 9. Joint connector 2 10. High beam indicator light ...

  • Page 679

    Electrical system 16-63 lighting system turn signal light bulb replacement front turn signal light • remove: front middle fairings (see middle fairing removal in the frame chapter) • turn the socket [a] counterclockwise and pull out the socket together with the bulb. • push and turn the front turn s...

  • Page 680

    16-64 electrical system lighting system • push and turn the rear turn signal light bulb [a] counter- clockwise and remove it. • insert the new bulb [a] by aligning its upper and lower pins [b] with the upper and lower grooves [c] in the socket, and turn the bulb clockwise. ○ turn the bulb about 15°....

  • Page 681

    Electrical system 16-65 lighting system • connect one 12 v battery and turn signal lights as indi- cated in the figure, and count how may times the lights flash for one minute. Turn signal relay [a] turn signal lights [b] (12 v 21 w × 2) 12 v battery [c] if the lights do not flash as specified, repl...

  • Page 682

    16-66 electrical system lighting system turn signal light circuit 1. Kipass signal diode 2. Kipass signal relay 3. Kipass ecu 4. Joint connector 9 5. Joint connector 8 6. Right turn signal indicator light (led) 7. Left turn signal indicator light (led) 8. Joint connector 1 9. Joint connector 2 10. F...

  • Page 683

    Electrical system 16-67 air switching valve air switching valve operation test • refer to the air suction system damage inspection in the periodic maintenance chapter. Air switching valve unit test • remove the air switching valve (see air switching valve removal in the engine top end chapter). • se...

  • Page 684

    16-68 electrical system air switching valve air switching valve circuit 1. Steering lock unit 2. Fuse box 2 3. Ignition fuse 10 a 4. Air switching valve 5. Ecu 6. Main fuse 30 a 7. Battery 12 v 14 ah 8. Frame ground 9. Joint connector 9 10. Joint connector 3 http://mototh.Com.

  • Page 685

    Electrical system 16-69 radiator fan system fan motor inspection • remove the front middle fairings (see middle fairing re- moval in the frame chapter). • disconnect the connectors. Right fan motor lead connector [a] left fan motor lead connector [b] • using an auxiliary leads, supply battery power ...

  • Page 686

    16-70 electrical system oil control solenoid valve oil control solenoid valve inspection • remove: right rear middle fairing (see middle fairing removal in the frame chapter) • disconnect the oil control solenoid valve lead connector [a]. • set the hand tester [a] to ×1 Ω range and connect the teste...

  • Page 687

    Electrical system 16-71 electric windshield electric windshield assembly removal • remove: upper fairing (see upper fairing removal in the frame chapter) • position the windshield bracket [a] as shown. • remove: clamp [b] bolts [c] • disconnect the electric windshield motor lead connector [a]. ○ pus...

  • Page 688

    16-72 electrical system electric windshield electric windshield assembly lubrication • remove: windshield (see windshield removal in the frame chapter) quick rivets [a] screws [b] electric windshield actuator cover [c] • apply silicon grease to the right rail [a]. • apply silicon grease to the left ...

  • Page 689

    Electrical system 16-73 electric windshield • connect the hand tester [a] and 12 v battery [b] to the electric windshield relay [c] as shown. Special tool - hand tester: 57001-1394 if the relay does not work as specified, replace the relay. Testing relay hand tester range: × 1 Ω criteria: when batte...

  • Page 690

    16-74 electrical system electric windshield electric windshield circuit 1. Electric windshield motor 2. Steering lock unit 3. Main fuse 30 a 4. Fuse box 3 5. Electric windshield fuse 30 a 6. Electric windshield switch 7. Electric windshield relay (down) 8. Electric windshield relay (up) 9. Joint con...

  • Page 691

    Electrical system 16-75 meter, gauge, indicator unit meter unit removal • remove: windshield (see windshield removal in the frame chapter) quick rivets [a] screws [b] electric windshield actuator cover [c] • remove: meter lead connector [a] meter unit mounting nuts [b] and washers meter unit [c] dam...

  • Page 692

    16-76 electrical system meter, gauge, indicator unit meter unit disassembly • remove: meter unit (see meter unit removal) screws [a] lower meter cover [b] • separate: upper meter cover [a] middle meter cover [b] meter assembly [c] meter operation inspection • push the key knob [a]. • check that the ...

  • Page 693

    Electrical system 16-77 meter, gauge, indicator unit ○ after the k kawasaki mark appeared, the ordinary indica- tion [a] (example: n, average --.- km/l), odometer [b] or trip meter, clock [c], water temperature gauge [d], and fuel level gauge [e] appear in the display. If the meter does not work and...

  • Page 694

    16-78 electrical system meter, gauge, indicator unit • check that the display changes to the language setting mode [a]. ○ this display is system menu indication. • by pushing the lower button each time, check that the cursor [b] changes on the languages. If the display function does not work, replac...

  • Page 695

    Electrical system 16-79 meter, gauge, indicator unit • select the mileage indication. • push the upper button [a] for more than two seconds. • check that the unit [b] flashes. • by pushing the lower button each time, check that the display changes as follows. • check that the unit setting menu is de...

  • Page 696

    16-80 electrical system meter, gauge, indicator unit • by pushing the lower button, check that the hour and minute display [a] starts flashing. • by pushing the upper button, check that the hour and minute display is decided. • when both hour and minute display flashing, by pushing the lower button,...

  • Page 697

    Electrical system 16-81 meter, gauge, indicator unit check 1: can communication line resistance inspec- tion • set the hand tester [a] to the ×1 Ω range and connect it to the terminal [17] and [18] in the meter unit. Special tool - hand tester: 57001-1394 can communication line resistance (at meter ...

  • Page 698

    16-82 electrical system meter, gauge, indicator unit check 3: kipass flashing mode inspection • connect the leads in the same circuit as check 2. • disconnect the terminal [9]. • check that the warning light (led) [a] starts flashing (kipass warning light flashing mode). • push the upper [b] and low...

  • Page 699

    Electrical system 16-83 meter, gauge, indicator unit • check that the high beam indicator light (led) [a] goes on. If the indicator light does not go on, replace the meter assembly. Check 5: right turn signal indicator light (led) in- spection • connect the leads in the same circuit as check 2. • co...

  • Page 700

    16-84 electrical system meter, gauge, indicator unit check 7: oil pressure warning indicator light (led) inspection • connect the leads in the same circuit as check 2. • connect the terminal [2] to the battery (–) terminal. • check that the oil pressure warning indicator light (led) [a] goes on. If ...

  • Page 701

    Electrical system 16-85 meter, gauge, indicator unit • connect the terminal [6] to the battery (–) terminal. • check that the abs indicator light (led) goes off. If the indicator light does not work, replace the meter as- sembly. Check 10: speed sensor supply voltage inspection • connect the leads i...

  • Page 702

    16-86 electrical system meter, gauge, indicator unit • push and turn the key knob to on. • check that the symbol [a] appears in the water tempera- ture gauge and the three segments [b] for fuel level gauge start flashing. • turn the key knob to off. • check that the three segments [a] for the water ...

  • Page 703

    Electrical system 16-87 meter, gauge, indicator unit check 12: battery voltage inspection • connect the leads in the same circuit as check 11. • push and turn the key knob to on. • 1st, set the battery display [a]. • check that the display indicates the battery voltage. • 2nd, disconnect the termina...

  • Page 704

    16-88 electrical system meter, gauge, indicator unit check 13: fi error inspection • connect the leads in the same circuit as check 11. • for example, disconnect the atmospheric pressure sen- sor connector under the seat. • push and turn the key knob to on. • check that the warning light (led) [a] g...

  • Page 705

    Electrical system 16-89 meter, gauge, indicator unit • push the upper and lower buttons for more than two sec- onds, check that the error code [a] and numbers ap- pear in the display. ○ the warning indicator light (led) goes on. • again, push the upper and lower buttons for more than two seconds, ch...

  • Page 706

    16-90 electrical system meter, gauge, indicator unit • after about 5 seconds, check that one segment [a] in the fuel gauge starts flashing. • check that the fuel low [b] and fuel symbol [c] appear alternately in the display. ○ this display is the warning message indication. If the display function d...

  • Page 707

    Electrical system 16-91 meter, gauge, indicator unit check 16: speedometer inspection • connect the leads in the same circuit as check 11. • the speed equivalent to the input frequency is indicated in the oscillator [a], if the square wave is input into terminal [13]. • push and turn the key knob to...

  • Page 708

    16-92 electrical system meter, gauge, indicator unit check 19: tachometer inspection • connect the leads in the same circuit as check 11. • start the engine. • check that the needle in the tachometer moves. If the needle does not move, go to the check 1 and in- spect the following items. Wiring (see...

  • Page 709

    Electrical system 16-93 meter, gauge, indicator unit • push and turn the key knob to on. • set the low gear position, check that the display changes to 1 mark [a]. • for the other gear position indication; • using the center stand, raise the rear wheel off the ground. • start the engine, and change ...

  • Page 710

    16-94 electrical system meter, gauge, indicator unit meter unit circuit 1. Abs hydraulic unit 2. Oil pressure switch 3. Gear position switch 4. Speed sensor 5. Fuel level sensor 6. Joint connector 9 7. Fuel reserve switch 8. Joint connector 2 9. Water-proof joint 2 10. Water temperature sensor 11. C...

  • Page 711

    Electrical system 16-95 kipass this motorcycle is equipped with the kipass (kawasaki’s intelligent proximity activation start sys- tem) to protect the motorcycle from theft. Refer to the technical information-kipass (kawasaki’s intelligent proximity activation start system) section in the general in...

  • Page 712

    16-96 electrical system kipass • check the kipass ecu power source voltage with the hand tester [a]. ○ position the terminal in accordance with terminal numbers of kipass ecu connector [b] in the figure. Kipass ecu power source inspection tester connections: between 7 (lg) terminal and frame ground ...

  • Page 713

    Electrical system 16-97 kipass • remove: steering stem head (see stem, stem bearing removal in the steering chapter) • using a small chisel or punch, turn out the torx bolts [a]. • remove the steering lock unit [b]. • tighten a new torx bolt [a] until the bolt head [b] is broken. [c] broken head of ...

  • Page 714

    16-98 electrical system kipass • remove: middle fairings (see middle fairing removal in the frame chapter) kipass signal relay connector [a] • connect the hand tester [b] to the blue lead terminal [c] of the kipass signal relay connector and front turn signal light lead connector as shown. Front lef...

  • Page 715

    Electrical system 16-99 kipass kipass circuit 1. Steering lock unit 2. Joint connector 8 3. Joint connector 9 4. Kipass signal relay 5. Kipass signal diode 6. Front left turn signal light 12 v 21 w 7. Rear left turn signal light 12 v 21 w 8. Front right turn signal light 12 v 21 w 9. Rear right turn...

  • Page 716

    16-100 electrical system switches and sensors brake light timing inspection • refer to the brake light switch operation inspection in the periodic maintenance chapter. Brake light timing adjustment • refer to the brake light switch operation inspection in the periodic maintenance chapter. Switch ins...

  • Page 717

    Electrical system 16-101 switches and sensors water temperature sensor inspection • remove the water temperature sensor (see removal/in- stallation in the water temperature sensor (service code 14) section in the fuel system (dfi) chapter). • suspend the sensor [a] in a container of coolant so that ...

  • Page 718

    16-102 electrical system switches and sensors speed sensor inspection • remove the speed sensor (see speed sensor removal). • connect the speed sensor lead connector [a] with the bat- tery [b], 10 k Ω resistor [c] and hand tester [d] as shown. • set the tester to the dc 25 v range. Special tool - ha...

  • Page 719

    Electrical system 16-103 switches and sensors • install a new gasket [a] on the fuel level sensor as shown. Hollows [b] front [c] • apply a non-permanent locking agent to the threads of the level sensor bolts and tighten it. Torque - fuel level sensor bolts: 6.9 n·m (0.70 kgf·m, 61 in·lb) fuel reser...

  • Page 720

    16-104 electrical system switches and sensors gear position switch removal • remove the lower fairings (see lower fairing removal in the frame chapter). • slide out the rubber boot [a]. • loosen the oil pressure switch terminal bolt [b], and re- move the switch lead [c]. • open the clamp [a]. • disc...

  • Page 721

    Electrical system 16-105 switches and sensors gear position switch installation • securely place the springs [a] and pins [b] into the holes of the shift drum [c]. • apply grease to the new o-ring [d]. • install the gear position switch [e] so that the switch sticks to the engine. • apply a non-perm...

  • Page 722

    16-106 electrical system switches and sensors oxygen sensor removal (equipped models) note ○ the oxygen sensor itself is the same for #1 [a] and #2 [b], but wiring of the main harness side is different. • remove the right front middle fairing (see middle fairing removal in the frame chapter). • disc...

  • Page 723

    Electrical system 16-107 relay box and accessory relay relay box removal • remove: seat (see seat removal in the frame chapter) tool kit box (see ecu removal in the fuel system (dfi) chapter) • take out the relay box [a] and disconnect the connectors [b]. Note ○ the relay box has relays and diodes. ...

  • Page 724

    16-108 electrical system relay box and accessory relay diode circuit inspection • remove the relay box (see relay box removal). • check conductivity of the following pairs of terminals (see relay box internal circuit). Diode circuit inspection tester connection 1-11, 2-11, 12-13, 12-15, 12-16, 13-14...

  • Page 725

    Electrical system 16-109 fuse 30 a main fuse removal • remove: battery (see battery removal) bolts and cable terminals [a] • take out the starter relay assembly [a]. • disconnect the 30 a main fuse connector [b]. • pull out the 30 a main fuse [c] from the starter relay as- sembly. Fuse box fuse remo...

  • Page 726

    16-110 electrical system fuse • pull the fuses [a] straight out of the fuse box with needle nose pliers. Fuse installation if a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage. • install the fuse box fuses on...

  • Page 727: Appendix

    Appendix 17-1 17 appendix table of contents cable, wire, and hose routing .............................................................................................. 17-2 troubleshooting guide ...........................................................................................................

  • Page 728

    17-2 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 729

    Appendix 17-3 cable, wire, and hose routing 1. Grommet 2. Insert the air switching valve hose into the air cleaner until white paint mark on it is hidden a half. 3. About 41 mm (1.61 in.) 4. Air switching valve hose 5. Clamp 6. Breather hose 7. Clamp 8. Breather cover 9. Align the white paint mark w...

  • Page 730

    17-4 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 731

    Appendix 17-5 cable, wire, and hose routing 1. Run the air cleaner drain hose and idle adjusting screw cable through to the outside of the main harness. 2. Air cleaner drain hose 3. Main harness 4. Idle adjusting screw 5. Run the air cleaner drain hose through the front of the clamp. 6. Clamp 7. Pos...

  • Page 732

    17-6 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 733

    Appendix 17-7 cable, wire, and hose routing 1. Run the reserve tank hose between the air suction valve and bracket. 2. Run the air switching valve lead which is connected to the water temperature sensor lead be- tween the throttle body #3 and #4. 3. Run the reserve tank hose over the air bleeder hos...

  • Page 734

    17-8 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 735

    Appendix 17-9 cable, wire, and hose routing 1. Run the oil control solenoid valve lead between the cylinder head cover and throttle body assy, and connect it. 2. Hold the crankshaft sensor lead with the clamps. 3. Run the oxygen sensor leads, and close the clamp. 4. Engine subharness connector (blac...

  • Page 736

    17-10 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 737

    Appendix 17-11 cable, wire, and hose routing 1. Radiator 2. Water hose 3. Water hose 4. Left side view 5. Inlet hose 6. Outlet hose 7. Oil cooler 8. Water hose 9. Air bleeder hose for water pump 10. Water pump 11. Air bleeder hose for thermostat housing 12. Thermostat housing 13. Right side view 14....

  • Page 738

    17-12 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 739

    Appendix 17-13 cable, wire, and hose routing 1. Install the clamp so that knob of the clamp faces right side of the frame as shown in the figure. 2. Reserve tank 3. Clamp 4. Clamp 5. About 20 mm (0.79 in.) 6. Insert the hose until it hit the projection of the cylinder fitting. 7. Inlet hose 8. Insta...

  • Page 740

    17-14 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 741

    Appendix 17-15 cable, wire, and hose routing 1. Main harness 2. Fuel hose 3. 4-pin connector (unused) 4. Run the regulator/rectifier lead under the cross bracket. 5. Alternator lead 6. Alternator connectors (1-pin × 3) 7. Alternator lead 8. Put the alternator lead between the frames when the lead re...

  • Page 742

    17-16 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 743

    Appendix 17-17 cable, wire, and hose routing 1. Idle adjusting screw 2. Run the speed sensor lead to the outside of the fuel tank drain hose, alternator lead, and fuel tank breather hose and to the inside of the air cleaner drain hose, idle adjuster screw, and clutch hose. 3. Fuel tank breather hose...

  • Page 744

    17-18 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 745

    Appendix 17-19 cable, wire, and hose routing 1. Insert the clamp on the main harness to the bracket. 2. Front 3. Run the headlight lead between the resonator and the headlight. 4. Run the headlight lead to the inside of the fairing stay. 5. Headlight lead 6. Left turn signal light lead connector 7. ...

  • Page 746

    17-20 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 747

    Appendix 17-21 cable, wire, and hose routing 1. Headlight connector 2. Headlight lead 3. City light lead 4. Runt he right switch housing lead, horn lead and front wheel rotation sensor lead (abs models only) into the clamp. 5. Runt he right switch housing lead, horn lead and front wheel rotation sen...

  • Page 748

    17-22 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 749

    Appendix 17-23 cable, wire, and hose routing 1. Run the right switch housing lead, horn lead and front wheel rotation sensor lead (abs models only) into the clamp. 2. Run the main harness to the outside of the fairing stay. 3. Fix the clamp on the main harness to the fairing stay. 4. Right turn sign...

  • Page 750

    17-24 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 751

    Appendix 17-25 cable, wire, and hose routing 1. Fuel pump lead connector 2. Fuel level sensor lead connector 3. Clamp 4. Fuse box 1 5. Run the fuse box 1 lead under the cross bracket. 6. Front 7. Turn signal relay 8. After fixing the rear brake light switch lead connector to the bracket, put the con...

  • Page 752

    17-26 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 753

    Appendix 17-27 cable, wire, and hose routing 1. Kipass ecu 2. Front 3. Run the fuse box 3 lead to the outside of the atmospheric pressure sensor. 4. Fuse box 3 5. Atmospheric pressure sensor 6. Tool connector (unsed) 7. Kawasaki diagnostic system connector 8. Abs kawasaki self-diagnostic system conn...

  • Page 754

    17-28 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 755

    Appendix 17-29 cable, wire, and hose routing 1. Tail/brake light lead connector 2. Vehicle-down sensor lead 3. Run the tail/brake light lead and vehicle-down sensor lead into the clamp. 4. Rear right turn signal light lead 5. Clamp the tail/brake light lead. 6. After connecting connectors for the ta...

  • Page 756

    17-30 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 757

    Appendix 17-31 cable, wire, and hose routing 1. Inlet air temperature sensor lead 2. Run the inlet air temperature sensor lead through the upper hole of the cover. 3. Abs hydraulic unit lead (abs models only) 4. Run the abs hydraulic unit lead (abs models only) through the lower hole of the cover. 5...

  • Page 758

    17-32 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 759

    Appendix 17-33 cable, wire, and hose routing 1. Main harness 2. Alternator lead 3. Fuel hose 4. Right switch lead and speed sensor lead 5. Run the alternator leads to the upper side of the main harness. 6. The lead from the battery box 7. Inlet air temperature sensor 8. Inlet air temperature sensor ...

  • Page 760

    17-34 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 761

    Appendix 17-35 cable, wire, and hose routing 1. Fuel tank breather hose 2. Fuel tank drain hose 3. Run the fuel tank breather and drain hoses to the upper side of the cross bracket. 4. Run the fuel tank drain hose to the backside of the clamp. 5. Run the fuel tank breather and drain hoses under the ...

  • Page 762

    17-36 appendix cable, wire, and hose routing california model http://mototh.Com.

  • Page 763

    Appendix 17-37 cable, wire, and hose routing 1. Evaporative hoses 2. Fuel tank drain hose 3. Run the fuel tank drain and evaporative hoses to the upper side of the cross bracket. 4. Run the fuel tank drain hose to the backside of the clamp. 5. Run the fuel tank drain hose under the fuel hose. 6. Run...

  • Page 764

    17-38 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 765

    Appendix 17-39 cable, wire, and hose routing 1. Seat lock cable 2. Run the seat lock cable to the upper side of the saddlebag hook. 3. Run the seat lock cable through the middle hole on the rear frame. 4. Seat lock cable http://mototh.Com.

  • Page 766

    17-40 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 767

    Appendix 17-41 cable, wire, and hose routing 1. Run the air cleaner drain hose and idle adjusting screw to the outside of the main harness. 2. Air cleaner drain hose 3. Idle adjusting screw 4. Fuel tank breather hose 5. Alternator lead 6. Sidestand switch lead 7. Clamp the fuel tank breather hose an...

  • Page 768

    17-42 appendix cable, wire, and hose routing abs equipped models http://mototh.Com.

  • Page 769

    Appendix 17-43 cable, wire, and hose routing 1. Throttle cables 2. Run the throttle cables between the front fork and the brake hose. 3. Run the throttle cables to the upper side of the right switch housing lead. 4. Run the throttle cables and the right switch housing lead into the clamp. Http://mot...

  • Page 770

    17-44 appendix cable, wire, and hose routing non abs equipped models http://mototh.Com.

  • Page 771

    Appendix 17-45 cable, wire, and hose routing 1. Throttle cables 2. Run the throttle cables between the front fork and the brake hose. 3. Run the throttle cables to the upper side of the right switch housing lead. 4. Run the throttle cables and the right switch housing lead into the clamp. Http://mot...

  • Page 772

    17-46 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 773

    Appendix 17-47 cable, wire, and hose routing 1. Throttle cables 2. Run the throttle cables into the clamp. Http://mototh.Com.

  • Page 774

    17-48 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 775

    Appendix 17-49 cable, wire, and hose routing 1. Clutch hose 2. Run the clutch hose to the inside of the coolant reserver tank. 3. Run the clutch hose to the outside of the sidestand switch lead. 4. Run the clutch hose to the inside of the subframe. 5. Idle adjusting screw 6. Air cleaner drain hose 7...

  • Page 776

    17-50 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 777

    Appendix 17-51 cable, wire, and hose routing 1. Clutch hose 2. Fix the clutch hose to the clamp on the subrame. 3. Run the clutch hose to the inside of the engine harness. 4. Run the clutch hose to the inside of the subframe. 5. Run the clutch hose into the clamp. 6. Run the steering lock unit leads...

  • Page 778

    17-52 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 779

    Appendix 17-53 cable, wire, and hose routing 1. Clutch hose 2. Install the clutch hose joint as shown in the figure (face the projection of the clutch hose joint backward.) http://mototh.Com.

  • Page 780

    17-54 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 781

    Appendix 17-55 cable, wire, and hose routing 1. Brake hose 2. Brake hose 3. Brake hose 4. Front view 5. Clamps (insert the clamps into the front fender.) 6. Brake hose http://mototh.Com.

  • Page 782

    17-56 appendix cable, wire, and hose routing abs equipped models http://mototh.Com.

  • Page 783

    Appendix 17-57 cable, wire, and hose routing 1. Clamp (hold the front wheel rotation sensor lead.) 2. Clamp (hold the brake hose and front wheel rotation sensor lead, and align the clamp with white mark of the front wheel rotation sensor lead.) 3. Clamps (insert the clamps into the front fender.) 4....

  • Page 784

    17-58 appendix cable, wire, and hose routing abs equipped models http://mototh.Com.

  • Page 785

    Appendix 17-59 cable, wire, and hose routing 1. About 48° 2. Brake pipe (white paint mark) 3. Brake pipe (blue paint mark) 4. Clamp 5. Damper 6. Front 7. Brake hose 8. Brake hose 9. Front view 10. Brake hose 11. Clamp (hold the front wheel rotation sensor lead.) 12. Clamp (hold the brake hose and fr...

  • Page 786

    17-60 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 787

    Appendix 17-61 cable, wire, and hose routing 1. Brake hose 2. Clamp (hold the brake hose.) 3. Rear brake light switch lead 4. Clamp (hold the rear brake light switch lead.) 5. Upper view 6. Clamp (hold the brake hose.) 7. Brake hose 8. Clamp (hold the brake hose.) 9. Rear view http://mototh.Com.

  • Page 788

    17-62 appendix cable, wire, and hose routing abs equipped models http://mototh.Com.

  • Page 789

    Appendix 17-63 cable, wire, and hose routing 1. Brake pipe (blue paint marks) 2. Brake pipe (blue paint marks (both sides)) 3. About 38.5° 4. Abs hydraulic unit 5. Brake pipe (white paint mark) 6. Brake pipe (white paint marks (both sides)) 7. Rear wheel rotation sensor lead 8. Rear brake light swit...

  • Page 790

    17-64 appendix cable, wire, and hose routing abs equipped models http://mototh.Com.

  • Page 791

    Appendix 17-65 cable, wire, and hose routing 1. Brake hose 2. Clamp the brake hose and the front wheel rotation sensor lead at the mark (white tape) on the lead. 3. Run the brake hose only into the clamp (right side only). 4. Bracket (the au, ca and us models have the bracket (11054-1227).) 5. Front...

  • Page 792

    17-66 appendix cable, wire, and hose routing abs equipped models http://mototh.Com.

  • Page 793

    Appendix 17-67 cable, wire, and hose routing 1. Install the brake hose joint as shown in the figure (face the projection of the brake hose joint backward). 2. Brake hoses 3. Brake pipes 4. Bracket http://mototh.Com.

  • Page 794

    17-68 appendix cable, wire, and hose routing abs equipped models http://mototh.Com.

  • Page 795

    Appendix 17-69 cable, wire, and hose routing 1. Bracket (push the joint portions of the brake pipe, and clamp them.) 2. Align the brake pipes with groove of the frame. 3. Brake pipe (one white paint mark, abs hydraulic unit side) 4. Brake pipe (one blue paint mark, abs hydraulic unit side) 5. Brake ...

  • Page 796

    17-70 appendix cable, wire, and hose routing abs equipped models http://mototh.Com.

  • Page 797

    Appendix 17-71 cable, wire, and hose routing 1. Insert the brake pipes to the holes of damper, and fit the projection on the damper into the hole of the bracket. 2. Run the brake pipes under the hoses and leads. 3. Brake pipe (43060-0040) 4. Brake pipe (two white paint marks) 5. Brake hose 6. Bracke...

  • Page 798

    17-72 appendix cable, wire, and hose routing abs equipped models http://mototh.Com.

  • Page 799

    Appendix 17-73 cable, wire, and hose routing 1. Clamps 2. Rear wheel rotation sensor leads 3. Brake hose 4. Clamp the brake hose and rear wheel rotation sensor lead, and align the clamps with white tape of the rear wheel rotation sensor lead. 5. Run the rear wheel rotation sensor lead through the cl...

  • Page 800

    17-74 appendix cable, wire, and hose routing california model http://mototh.Com.

  • Page 801

    Appendix 17-75 cable, wire, and hose routing 1. Fuel tank 2. Clamp 3. Canister 4. Throttle body assy 5. To the fitting of the throttle body #3. 6. To the fitting of the throttle body #4. 7. Hose (green) 8. Hose (white) 9. Hose (blue) 10. Hose (red) 11. Fitting 12. Separator 13. Hose (blue) 14. Hose ...

  • Page 802

    17-76 appendix troubleshooting guide note ○ refer to the fuel system chapter for most of dfi trouble shooting guide. ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common di...

  • Page 803

    Appendix 17-77 troubleshooting guide cylinder head not sufficiently tightened down no valve clearance cylinder, piston worn piston ring bad (worn, weak, broken, or sticking) piston ring/groove clearance excessive cylinder head gasket damaged cylinder head warped valve spring broken or weak valve not...

  • Page 804

    17-78 appendix troubleshooting guide air cleaner poorly sealed, or missing air cleaner clogged compression high: carbon built up in combustion chamber engine load faulty: clutch slipping engine oil level too high engine oil viscosity too high drive train trouble brake dragging lubrication inadequate...

  • Page 805

    Appendix 17-79 troubleshooting guide piston ring/groove clearance excessive piston ring worn, broken, or stuck piston ring groove worn piston seizure, damage cylinder head gasket leaking exhaust pipe leaking at cylinder head con- nection crankshaft runout excessive engine mount loose crankshaft bear...

  • Page 806

    17-80 appendix troubleshooting guide right and left front fork oil level uneven shock absorption unsatisfactory: (too hard) front fork oil excessive front fork oil viscosity too high rear shock absorber adjustment too hard tire air pressure too high front fork bent (too soft) tire air pressure too l...

  • Page 807

    Model application year model beginning frame no. 2008 zg1400a8f jkbzgna1 □ 8a005001 jkbzgt40aaa005001 zgt40a-005001 2008 zg1400b8f jkbzgnb1 □ 8a005001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1379-01 printed in japan http://mototh.Com.