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Kawasaki 2005 ER-6f Service Manual

Summary of 2005 ER-6f

  • Page 1

    Ninja 650r er-6f abs er-6f motorcycle service manual.

  • 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 5: Ninja 650R

    Ninja 650r er-6f er-6f abs 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 permission of qual...

  • Page 6

    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 7

    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 8: 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 9

    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 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 ex650a6f (united states and canada) left side view ex650a6f (united states and canada) right side view.

  • Page 18

    1-8 general information model identification ex650a6f (europe) left side view ex650a6f (europe) right side view.

  • Page 19

    General information 1-9 model identification ex650b6f left side view ex650b6f right side view frame number engine number.

  • Page 20

    1-10 general information general specifications items ex650a6f, ex650b6f dimensions overall length 2 105 mm (82.9 in.) overall width 760 mm (29.9 in.) overall height 1 210 mm (47.6 in.) wheelbase 1 410 mm (55.5 in.) road clearance 145 mm (5.7 in.) seat height 790 mm (31.1 in.) dry mass: ex650a6f 178...

  • Page 21

    General information 1-11 general specifications items ex650a6f, ex650b6f exhaust: open 50° bbdc close 30° atdc duration 260° lubrication system forced lubrication (semi-dry sump) engine oil: type api se, sf or sg api sh, sj or sl with jaso ma viscosity sae 10w-40 capacity 2.4 l (2.5 us qt) drive tra...

  • Page 22

    1-12 general information general specifications items ex650a6f, ex650b6f type swingarm wheel travel 125 mm (4.9 in.) brake type: front dual discs rear single disc electrical equipment battery 12 v 10 ah headlight: type semi-sealed beam bulb 12 v 55 w × 2/55 w (hi/lo) tail/brake light 12 v 5/21 w alt...

  • Page 23

    General information 1-13 technical information - cassette type transmission cassette type transmission the transmission of the current model is unable to be removed without disassembling upper and lower crankcase halves. The ex650a/b enables transmission to be removed from the right side of engine a...

  • Page 24

    1-14 general information technical information - inlet air pressure sensor atmospheric pressure sensor and camshaft position sensor are not equipped with the ex650a/b. As a substitute of these sensors above, the ex650a/b recognizes atmospheric pressure and intake stroke of #1 by the signal of inlet ...

  • Page 25

    General information 1-15 technical information – abs (anti – lock brake system) outline abs controls the brake caliper fluid pressure by means of mechatronics - a combination of electronic and hydraulic control technology in order to keep the friction force between the tires and the road surfaces cl...

  • Page 26

    1-16 general information technical information – abs (anti – lock brake system) abs system block diagram 1. Power source 2. Ignition power source 3. Battery power source 4. Indicator light output 5. Abs indicator light (led) 6. Ecu 7. Abs solenoid valve relay 8. Output 9. Monitor input 10. Valve out...

  • Page 27

    General information 1-17 technical information – abs (anti – lock brake system) related parts and function 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 f...

  • Page 28

    1-18 general information technical information – abs (anti – lock brake system) abs hydraulic unit the outlet and inlet solenoid valves, reservoir, pump motor, solenoid valve relay, motor relay, and ecu are built in the abs hydraulic unit. 1. Brake lever 2. Brake pedal 3. Pump motor 4. Rear inlet so...

  • Page 29

    General information 1-19 technical information – abs (anti – lock brake system) inlet solenoid valve inlet solenoid valves control the brake pressure of each wheel by combining the operation of the outlet solenoid valve. The ecu changes the electric current in the solenoids of the inlet solenoid val...

  • Page 30

    1-20 general information technical information – abs (anti – lock brake system) reservoir when the passage opens between the caliper and the reservoir with the outlet solenoid valve in “decrease mode”, the brake fluid flows into the reservoir by pushing the piston, stays there temporar- ily, and the...

  • Page 31

    General information 1-21 technical information – abs (anti – lock brake system) abs solenoid valve relay abs solenoid valve relay supply or intercept the power to the inlet or outlet solenoid valves. Abs motor relay abs motor relay supply or intercept the power to the pump motor. Ecu ecu inputs the ...

  • Page 32

    1-22 general information technical information – abs (anti – lock brake system) abs operation the abs has two independent hydraulic lines, one for the front wheel and the other for the rear wheel. The front wheel system is explained here and is identical to the rear wheel system. Abs in action (incr...

  • Page 33

    General information 1-23 technical information – abs (anti – lock brake system) (hold mode) when the caliper fluid pressure is to be hold, the tappet of inlet solenoid valve closes, and the passage (master cylinder side) to the valve body is intercepted. No matter how hard the brake lever is pulled,...

  • Page 34

    1-24 general information technical information – abs (anti – lock brake system) (decrease mode) when the caliper fluid pressure is to be decreased, the tappet of inlet solenoid valve closes, and the passage to the valve body is intercepted. The valve of outlet solenoid valve is opened by the operati...

  • Page 35

    General information 1-25 technical information – abs (anti – lock brake system) abs disabled (conventional mode) during cruising (without braking) or in case of a malfunction with the abs, the ecu stops operating. This is “conventional mode”. When the caliper fluid pressure is to be increased, first...

  • Page 36

    1-26 general information technical information – abs (anti – lock brake system) riding characteristics of abs abs is designed to help prevent the wheels from locking up when hard brakes are applied while running straight. The abs automatically regulates brake force. Intermittently gaining gripping f...

  • Page 37

    General information 1-27 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)...

  • Page 39: Periodic Maintenance

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

  • Page 40

    2-2 periodic maintenance steering stem bearing lubrication ................................................................................... 2-37 electrical system ................................................................................................................. 2-37 spark plug cond...

  • Page 41

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

  • Page 42

    2-4 periodic maintenance periodic maintenance chart frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) 1 6 12 18 24 30 36 inspection every (0.6) (4) (7.5) (12) (15) (20) (24) see page drive chain guide wear - inspect • • • 2-31 brake system brake fluid leak (brake hose and ...

  • Page 43

    Periodic maintenance 2-5 periodic maintenance chart periodic replacement parts frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) 1 12 24 36 48 change/replace item every (0.6) (7.5) (15) (24) (30) see page air cleaner element # 2 years 2-45 fuel hose 4 years • 2-45 coolant ...

  • Page 44

    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 45

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks muffler body mounting bolt (rear) 20 2.0 15 baffle plate bolts 5.9 0.60 52 in·lb clutch upper cap on clutch cover 3.9 0.40 35 in·lb lower cap on clutch cover – – – hand-tighten oil filler plug – – – hand-tighte...

  • Page 46

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks shift drum bearing holder screw 4.9 0.50 43 in·lb l connecting rod big end nuts see text ← ← mo timing rotor bolt 40 4.1 30 oil pressure switch 15 1.5 11 ss oil passage plug 20 2.0 15 l gear positioning lever b...

  • Page 47

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks front fork clamp bolts (lower) 20 2.0 15 al front fork clamp bolts (upper) 20 2.0 15 front fork top plugs 25 2.5 18 rear shock absorber bolt 59 6.0 44 rear shock absorber nut 59 6.0 44 swingarm pivot shaft nut ...

  • Page 48

    2-10 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks starter motor cable terminal nut 6.0 0.60 53 in·lb starter motor clutch bolts 34 3.5 25 l starter motor mounting bolts 9.8 1.0 87 in·lb l starter motor terminal locknut 11 1.1 97 in·lb starter motor through bo...

  • Page 49

    Periodic maintenance 2-11 specifications item standard service limit fuel system (dfi) throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 1 300 ±50 r/min (rpm) – – – bypass screws (turn out) 0 ∼ 2 1/2 (for reference) – – – engine vacuum 35.3 ±1.3 kpa (265 ±10 mmhg) – – – air cleaner...

  • Page 50

    2-12 periodic maintenance specifications item standard service limit final drive drive chain slack 30 ∼ 40 mm (1.2 ∼ 1.6 in.) – – – drive chain wear (20-link length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) standard chain: make enuma – – – type ek520mvxl1 – – – link 114 links – – – bra...

  • Page 51

    Periodic maintenance 2-13 special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 oil filter wrench: 57001-1249 extension tube: 57001-1578 pilot screw adjuster, e: 57001-1603.

  • Page 52

    2-14 periodic maintenance periodic maintenance procedures fuel system (dfi) air cleaner element cleaning note ○ in dusty areas, the element should be cleaned more frequently than the recommended interval. ○ after riding through rain or on muddily roads, the ele- ment should be cleaned immediately. W...

  • Page 53

    Periodic maintenance 2-15 periodic maintenance procedures warning clean the element in a well-ventilated area, and make sure that there are no sparks or flame any- where near the working area. Because of the danger of highly flammable liquids, do not use gasoline or a low-flash point solvent to clea...

  • Page 54

    2-16 periodic maintenance periodic maintenance procedures if necessary, adjust the throttle cable as follows. • loosen the locknut [a] at the upper end of the accelerator cable. • turn the adjuster [b] in completely so as to give the throttle grip plenty of play. • remove the right center fairing (s...

  • Page 55

    Periodic maintenance 2-17 periodic maintenance procedures • start the engine and warm it up thoroughly. • check the idle speed. Tachometer [a] • open and close the throttle. If the idle speed is out of the specified range, adjust it. Caution do not measure the idle speed by the tachometer of the met...

  • Page 56

    2-18 periodic maintenance periodic maintenance procedures • repeat the same procedure for other bypass screws. • repeat the synchronization. If the vacuums are correct, check the output voltage of the main throttle sensor (see main throttle sensor output voltage inspection in the fuel system (dfi) c...

  • Page 57

    Periodic maintenance 2-19 periodic maintenance procedures fuel hose inspection (fuel leak, damage, installation condition) ○ the fuel hose is designed to be used throughout the mo- torcycle’s life without any maintenance. However, if the motorcycle is not properly handled, the high pressure in- side...

  • Page 58

    2-20 periodic maintenance periodic maintenance procedures • check the liquid/vapor separator as follows. ○ remove: left center fairing (see center fairing removal in the frame chapter) ○ disconnect the hoses from the separator, and remove the separator [a] from the motorcycle left side. ○ visually i...

  • Page 59

    Periodic maintenance 2-21 periodic maintenance procedures radiator hose damage and installation condition inspection ○ the high pressure inside the radiator hose and pipe can cause coolant to leak [a] or the hose to burst if the line is not properly maintained. • visually inspect the hoses for signs...

  • Page 60

    2-22 periodic maintenance periodic maintenance procedures • check the valve clearance when the pistons are at tdc. ○ the pistons are numbered beginning with the engine left side. • using a wrench [a] on the crankshaft rotation bolt, turn the crankshaft clockwise until the "1/t" mark on the timing ro...

  • Page 61

    Periodic maintenance 2-23 periodic maintenance procedures valve clearance measuring position #2 piston tdc at end of compression stroke → inlet valve clearances of #2 piston, and exhaust valve clearances of #2 piston if the valve clearance is not with in the specified range, first record the clearan...

  • Page 62

    2-24 periodic maintenance periodic maintenance procedures valve clearance adjustment chart inlet valve 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where th...

  • Page 63

    Periodic maintenance 2-25 periodic maintenance procedures valve clearance adjustment chart exhaust valve 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where ...

  • Page 64

    2-26 periodic maintenance periodic maintenance procedures clutch clutch operation inspection • pull the clutch lever just enough to take up the free play [a]. • measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow,...

  • Page 65

    Periodic maintenance 2-27 periodic maintenance procedures wheel/tire damage inspection • remove any imbedded stones [a] or other foreign parti- cles [b] from tread. • visually inspect the tire for cracks and cuts, and replace the tire if necessary. Swelling or high spots indicate inter- nal damage, ...

  • Page 66

    2-28 periodic maintenance periodic maintenance procedures wheel bearing damage inspection • raise the front wheel off the ground with jack (see front wheel removal in the wheels/tires chapter). • turn the handlebar all the way to the right or left. • inspect the roughness of the front wheel bearing ...

  • Page 67

    Periodic maintenance 2-29 periodic maintenance procedures • apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the o-rings so that the o-rings will be coated with oil. • wipe off any excess oil. Oil applied areas [a] o-rings [b] drive chain...

  • Page 68

    2-30 periodic maintenance periodic maintenance procedures • insert a new cotter pin [a]. Note ○ when inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [b] up to next alignment. ○ it should be within 30°. ○ loosen once and t...

  • Page 69

    Periodic maintenance 2-31 periodic maintenance procedures drive chain wear inspection • remove: chain cover (see swingarm removal in the suspension chapter) • rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the d...

  • Page 70

    2-32 periodic maintenance periodic maintenance procedures 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], fittings [b] and pipes [c]. If the brake fluid leaked from any position, inspect or re-...

  • Page 71

    Periodic maintenance 2-33 periodic maintenance procedures brake operation inspection • inspect the operation of the front and rear brake by run- ning the vehicle on the dry road. If the brake operation is insufficiency, inspect the brake system. Warning when inspecting by running the vehicle, note a...

  • Page 72

    2-34 periodic maintenance periodic maintenance procedures • follow the procedure below to install the rear brake fluid reservoir cap correctly. ○ first, tighten the rear brake fluid reservoir cap [b] clock- wise [c] by hand until slight resistance is felt indicating that the cap is seated on the res...

  • Page 73

    Periodic maintenance 2-35 periodic maintenance procedures suspensions front forks/rear shock absorber operation inspection • pump the forks down and up [a] 4 or 5 times, and inspect the smooth stroke. If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see fron...

  • Page 74

    2-36 periodic maintenance periodic maintenance procedures steering system steering play inspection • raise the front wheel off the ground with jack (see front wheel removal in the wheels/tires chapter). • with the front wheel pointing straight ahead, alternately tap each end of the handlebar. The fr...

  • Page 75

    Periodic maintenance 2-37 periodic maintenance procedures • install the claw washer [a] so that its bent side [b] faces upward, and engage the bent claws with the grooves of stem locknut [c]. • hand tighten the stem locknut until it touches the claw washer. • tighten the stem locknut clockwise until...

  • Page 76

    2-38 periodic maintenance periodic maintenance procedures lights and switches operation inspection first step • turn on the ignition switch. • 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 panel lcd [d] ...

  • Page 77

    Periodic maintenance 2-39 periodic maintenance procedures • turn off the ignition switch. • the all lights should go off. If the light does not go off, replace the ignition switch. Second step • turn the ignition switch to p (park) position. • the city light, taillight and license plate light should...

  • Page 78

    2-40 periodic maintenance periodic maintenance procedures fourth step • set the dimmer switch [a] to low beam position. • start the engine. • the low beam headlight should go on. If the low beam headlight does not go on, inspect or re- place the following item. Headlight low beam bulb (see headlight...

  • Page 79

    Periodic maintenance 2-41 periodic maintenance procedures headlight beam vertical adjustment • turn the vertical adjuster [a] on the headlight with the screwdriver in or out to adjust the headlight vertically. Note ○ on high beam, the brightest points should be slightly below horizontal with the mot...

  • Page 80

    2-42 periodic maintenance periodic maintenance procedures if the sidestand switch operation does not work, inspect or replace the following item. Battery (see charging condition inspection in the elec- trical system chapter) main fuse 30 a (see fuse inspection in the electrical system chapter) ignit...

  • Page 81

    Periodic maintenance 2-43 periodic maintenance procedures others chassis parts lubrication • before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • lubricate the points listed below with indicated lubricant. Note ○ whenever the vehic...

  • Page 82

    2-44 periodic maintenance periodic maintenance procedures bolts, nuts and fasteners tightness inspection • check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. Note ○ for the engine fasteners, check the tightness of them wh...

  • Page 83

    Periodic maintenance 2-45 periodic maintenance procedures replacement parts air cleaner element replacement • refer to the air cleaner element cleaning. Fuel hose replacement caution when removing and installing the fuel hose joint, do not apply strong force to the outlet pipe on the fuel pump and d...

  • Page 84

    2-46 periodic maintenance periodic maintenance procedures coolant change warning to avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury. Immediat...

  • Page 85

    Periodic maintenance 2-47 periodic maintenance procedures • remove the radiator cap [a] in two steps. First turn the cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap. ○ the coolant will drain from the radiator and engine. • turn over [a] ...

  • Page 86

    2-48 periodic maintenance periodic maintenance procedures • temporarily install the reserve tank to the frame with two bolts. • fill the reserve tank up to the “f” (full) level line [a] with coolant and install the cap [b]. • start the engine, warm it up thoroughly until the radiator fan turns on an...

  • Page 87

    Periodic maintenance 2-49 periodic maintenance procedures engine oil change • situate the motorcycle so that it is vertical after warming up the engine. • unscrew the oil filler plug [a]. • place on oil pan beneath the engine. • remove the engine oil drain bolt [a] to drain the oil. ○ the oil in the...

  • Page 88

    2-50 periodic maintenance periodic maintenance procedures • replace the filter with a new one. • apply engine oil to the gasket [a] before installation. • tighten the filter with the oil filter wrench. Torque - oil filter: 17.2 n·m (1.75 kgf·m, 13 ft·lb) note ○ hand tightening of the oil filter can ...

  • Page 89

    Periodic maintenance 2-51 periodic maintenance procedures • remove: rear fender front (see rear fender front removal in the frame chapter) (ex650b models) right center fairing (see center fairing removal in the frame chapter) (ex650b models) air cleaner housing (see air cleaner housing removal in th...

  • Page 90

    2-52 periodic maintenance periodic maintenance procedures • change the brake fluid. ○ repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. 1. Open the bleed valve [a]. 2. Apply the brake and hold it [b]. 3. Close the bleed valve [c]. 4. Rel...

  • Page 91

    Periodic maintenance 2-53 periodic maintenance procedures rear master cylinder disassembly note ○ do not remove the push rod clevis for master cylinder disassembly since removal reguires brake position ad- justment. • remove the rear master cylinder (see rear master cylin- der removal in the brakes ...

  • Page 92

    2-54 periodic maintenance periodic maintenance procedures caliper rubber parts replacement front caliper disassembly • remove: front caliper (see front caliper removal in the brakes chapter) brake pads (see front brake pad removal in the brakes chapter) • using compressed air, remove the pistons. ○ ...

  • Page 93

    Periodic maintenance 2-55 periodic maintenance procedures • apply brake fluid to the outside of the pistons, and push them into each cylinder by hand. • check the shaft rubber friction boot [a] and the dust cover [b] replace them with new ones if they are damaged. • apply a thin coat of pbc (poly bu...

  • Page 94

    2-56 periodic maintenance periodic maintenance procedures • replace the fluid seal [a] with a new one. ○ apply brake fluid to the fluid seal, and install it into the cylinder by hand. • replace the dust seal [b] with a new one if it is damaged. ○ apply brake fluid to the dust seal, and install it in...

  • Page 95: Fuel System (Dfi)

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

  • Page 96

    3-2 fuel system (dfi) speed sensor (service code 24, 25)..................................................................................... 3-57 speed sensor removal/installation.................................................................................. 3-57 speed sensor inspection............

  • Page 97

    Fuel system (dfi) 3-3 fuel injector power source voltage inspection ................................................................ 3-91 fuel injector output voltage inspection ............................................................................ 3-92 injector signal test.......................

  • Page 98

    3-4 fuel system (dfi) exploded view.

  • Page 99

    Fuel system (dfi) 3-5 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. Fi indicator light (led) 3. Throttle cable (accelerator) 4. Throttle cable (decelerator) 5. Throttle body assy 6. Injectors 7. Meter unit (ex650b models) cl: apply cable lubrica...

  • Page 100

    3-6 fuel system (dfi) exploded view.

  • Page 101

    Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 water temperature sensor 12 1.2 106 in·lb 2 speed sensor bolt 7.8 0.80 69 in·lb l 3 oxygen sensor (europe models) 44.1 4.50 32.5 4. Inlet air pressure sensor 5. Air switching valve 6. Inlet air temperature sensor 7. Cr...

  • Page 102

    3-8 fuel system (dfi) exploded view california model.

  • Page 103

    Fuel system (dfi) 3-9 exploded view 1. Tube (green) 2. Tube (blue) 3. Tube (white) 4. Tube (blue) 5. Tube (red).

  • Page 104

    3-10 fuel system (dfi) dfi system dfi system.

  • Page 105

    Fuel system (dfi) 3-11 dfi system 1. Ignition switch 2. Starter lockout switch 3. Starter relay 4. Tachometer 5. Fi indicator light (led) 6. Inlet air pressure sensor 7. Spark plug 8. Crankshaft sensor 9. Injector 10. Main throttle sensor 11. Delivery pipe 12. Subthrottle sensor 13. Subthrottle valv...

  • Page 106

    3-12 fuel system (dfi) dfi system dfi system wiring diagram.

  • Page 107

    Fuel system (dfi) 3-13 dfi system part name 1. Oxygen sensor (europe models) 2. Crankshaft sensor 3. Inlet air temperature sensor 4. Water temperature sensor 5. Water-proof joint e 6. Injectors 7. Vehicle-down sensor 8. Water-proof joint d 9. Inlet air pressure sensor 10. Main throttle sensor 11. Su...

  • Page 108

    3-14 fuel system (dfi) dfi system terminal names 1. Subthrottle valve actuator drive signal 2 2. Subthrottle valve actuator drive signal 1 3. Water temperature warning light signal 4. Unused 5. Oxygen sensor signal (europe models) 6. Speed sensor signal 7. Main throttle sensor signal 8. Inlet air pr...

  • Page 109

    Fuel system (dfi) 3-15 dfi parts location dfi: digital fuel injection parts 1. Fi indicator light (led) 2. Ignition switch 3. Throttle body assy 4. Inlet air temperature sensor 5. Injectors 6. Fuel pump 7. Relay box (ecu main relay, fuel pump relay, radiator fan relay) 8. Fuse box (ecu fuse 15 a, ox...

  • Page 110

    3-16 fuel system (dfi) specifications item standard digital fuel injection system idle speed 1 300 ±50 r/min (rpm) throttle assy: type two barrel type bore 38 mm (1.50 in.) ecu (electronic control unit): make denso type digital memory type, with built in ic igniter, sealed with resin usable engine s...

  • Page 111

    Fuel system (dfi) 3-17 specifications item standard output voltage with the sensor tilted 60 ∼ 70° or more: 0.65 ∼ 1.35 v with sensor arrow mark pointed up: 3.55 ∼ 4.45 v subthrottle sensor: non-adjustable and non-removal input voltage 4.75 ∼ 5.25 v dc between bl and br/bk leads output voltage at id...

  • Page 112

    3-18 fuel system (dfi) special tools and sealant oil pressure gauge, 5 kgf/cm²: 57001-125 fork oil level gauge: 57001-1290 hand tester: 57001-1394 throttle sensor setting adapter #1: 57001-1400 peak voltage adapter: 57001-1415 needle adapter set: 57001-1457 throttle sensor setting adapter: 57001-153...

  • Page 113

    Fuel system (dfi) 3-19 special tools and sealant kawasaki bond (silicone sealant): 56019-120

  • Page 114

    3-20 fuel system (dfi) dfi servicing precautions dfi servicing precautions there are a number of important precautions that should be followed servicing the dfi system. ○ this dfi system is designed to be used with a 12 v sealed battery as its power source. Do not use any other battery except for a ...

  • Page 115

    Fuel system (dfi) 3-21 dfi servicing precautions ○ to maintain the correct fuel/air mixture (f/a), there must be no inlet air leaks in the dfi system. Be sure to install the oil filler plug [a] after filling the engine oil. Clutch cover [b] torque - oil filler plug: hand-tighten.

  • Page 116

    3-22 fuel system (dfi) troubleshooting the dfi system outline outline when an abnormality in the system occurs, the fi indi- cator light (led) goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ecu (electronic control unit). With t...

  • Page 117

    Fuel system (dfi) 3-23 troubleshooting the dfi system ○ the dfi part connectors [a] have seals [b], including the ecu. • join the connector and insert the needle adapters [c] inside the seals [b] from behind the connector until the adapter reaches the terminal. Special tool - needle adapter set: 570...

  • Page 118

    3-24 fuel system (dfi) troubleshooting the dfi system • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. • check the wiring for continuity. ○ use the...

  • Page 119

    Fuel system (dfi) 3-25 troubleshooting the dfi system ○ there are two ways to inspect the dfi system. One is voltage check method and the other is resistance check method. (voltage check method) ○ this method is conducted by measuring the input voltage [b] to a sensor [a] first, and then the output ...

  • Page 120

    3-26 fuel system (dfi) troubleshooting the dfi system dfi diagnosis flow chart inquiries to rider 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...

  • Page 121

    Fuel system (dfi) 3-27 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 122

    3-28 fuel system (dfi) troubleshooting the dfi system □ other □ spark plug loose (tighten it) □ spark plug dirty, broken, or gap maladjusted (remedy it) poor running or no power at high speed □ spark plug incorrect (replace it) □ knocking (fuel poor quality or incorrect, → use high-octane gasoline) ...

  • Page 123

    Fuel system (dfi) 3-29 dfi system troubleshooting guide note ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. ○ the ecu may be involved in the dfi electri...

  • Page 124

    3-30 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) clutch lever not pulled in and gear not in neutral whether sidestand up or not pull the lever in and shift the gear in neutral. Though clutch lever pulled in, sidestand up and gear not in neutral si...

  • Page 125

    Fuel system (dfi) 3-31 dfi system troubleshooting guide symptoms or possible causes actions (chapter) no valve clearance adjust (see chapter 2). Valve guide worn inspect and replace (see chapter 5). Valve spring broken or weak inspect and replace (see chapter 5). Valve not seating properly (valve be...

  • Page 126

    3-32 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) engine stalls easily: fuel pump trouble inspect (see chapter 3). Fuel injector trouble inspect (see chapter 3). Main throttle sensor trouble inspect (see chapter 3). Fuel pressure too low or too hig...

  • Page 127

    Fuel system (dfi) 3-33 dfi system troubleshooting guide symptoms or possible causes actions (chapter) loose terminal of battery (–) cable or engine ground lead inspect and repair (see chapter 16). Delay of ignition timing inspect crankshaft sensor and ic igniter in ecu (see chapter 16). Poor acceler...

  • Page 128

    3-34 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) inlet air temperature sensor trouble inspect (see chapter 3). Water temperature sensor trouble inspect (see chapter 3). Inlet air pressure sensor trouble inspect (see chapter 3). Fuel injector troub...

  • Page 129

    Fuel system (dfi) 3-35 dfi system troubleshooting guide symptoms or possible causes actions (chapter) throttle body assy o-ring damaged replace (see chapter 3). Fuel tank air vent obstructed inspect and repair (see chapter 3). Fuel line clogged inspect and repair (see chapter 3). Fuel pump operates ...

  • Page 130

    3-36 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) drive train trouble inspect drive chain (see chapter 2) and sprockets (see chapter 11). Camshaft cam worn inspect and replace (see chapter 5). Air switching valve trouble inspect and replace (see ch...

  • Page 131

    Fuel system (dfi) 3-37 self-diagnosis self-diagnosis outline self-diagnosis outline the self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User mode the ecu notifies the rider of troubles in dfi system and ignition system by lighting t...

  • Page 132

    3-38 fuel system (dfi) self-diagnosis • to enter the self-diagnosis dealer mode 2, open [b] and ground [a] the lead more than five times [f] within 2 sec- onds [c] after the lead is first grounded, and then keep it grounded continuously [d] for more than 2 seconds. ○ count the blinks of the light (l...

  • Page 133

    Fuel system (dfi) 3-39 self-diagnosis.

  • Page 134

    3-40 fuel system (dfi) self-diagnosis how to read service codes how to read service codes ○ service codes are shown by a series of long and short blinks of the fi indicator light (led) as shown below. ○ read 10th digit and unit digit as the fi indicator light (led) blinks. ○ when there are a number ...

  • Page 135

    Fuel system (dfi) 3-41 self-diagnosis service code table service code table service code fi indicator light (led) 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...

  • Page 136

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

  • Page 137

    Fuel system (dfi) 3-43 self-diagnosis service codes parts output signal usable range or criteria backups by ecu 51 stick coil #1 (ignition coil)* the stick coil primary winding must send signals (output voltage) continuously to the ecu. If the ignition primary winding #1 has failures (no signal, wir...

  • Page 138

    3-44 fuel system (dfi) main throttle sensor (service code 11) main throttle sensor removal/adjustment caution do not remove or adjust the main throttle sensor [a] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface. Such a...

  • Page 139

    Fuel system (dfi) 3-45 main throttle sensor (service code 11) main throttle sensor output voltage inspection • measure the output voltage at the main throttle sensor in the same way as input voltage inspection, note the following. • disconnect the main throttle sensor connector and con- nect the har...

  • Page 140

    3-46 fuel system (dfi) main throttle sensor (service code 11) main throttle sensor resistance inspection • turn the ignition switch off. • disconnect the main throttle sensor connector. • connect a digital meter [a] to the main throttle sensor connector [b]. • measure the main throttle sensor resist...

  • Page 141

    Fuel system (dfi) 3-47 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 upper inner fairing (see upper inner fairing re- moval in the frame chapter) • disc...

  • Page 142

    3-48 fuel system (dfi) inlet air pressure sensor (service code 12) inlet air pressure sensor output voltage inspection note ○ the output voltage changes according to the local at- mospheric pressure. • measure the output voltage at the ecu in the same way as input voltage inspection. Note the follow...

  • Page 143

    Fuel system (dfi) 3-49 inlet air pressure sensor (service code 12) then pv = pl – pg for example, suppose the following data is obtained: pg = 8 cmhg (vacuum gauge reading) pl = 70 cmhg (varometer reading) vv = 3.2 v (digital volt meter reading) then pv = 70 – 8 = 62 cmhg (abs.) plot this pv (62 cmh...

  • Page 144

    3-50 fuel system (dfi) inlet air pressure sensor (service code 12) pv = 55 ∼ 86 cmhg id: idling ps: standard atmospheric pressure (absolute) pv: throttle vacuum pressure (absolute) st: standard of sensor output voltage (v) to: throttle full open ur: usable range of sensor output voltage (v) vv: inle...

  • Page 145

    Fuel system (dfi) 3-51 inlet air pressure sensor (service code 12) inlet air pressure sensor circuit 1. Ecu 2. Water-proof joint e 3. Water-proof joint d 4. Inlet air pressure sensor.

  • Page 146

    3-52 fuel system (dfi) inlet air temperature sensor (service code 13) inlet air temperature sensor removal/installation 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). • disconnect the connector [a...

  • Page 147

    Fuel system (dfi) 3-53 inlet air temperature sensor (service code 13) inlet air temperature sensor resistance inspection • remove the inlet air temperature sensor (see inlet air temperature sensor removal/installation). • suspend the sensor [a] in a container of machine oil so that the heat-sensitiv...

  • Page 148

    3-54 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 149

    Fuel system (dfi) 3-55 water temperature sensor (service code 14) water temperature sensor circuit 1. Ecu 2. Water temperature sensor 3. Water-proof joint e 4. Meter unit water temperature sensor resistance inspection • remove the water temperature sensor (see water tem- perature sensor removal/inst...

  • Page 150

    3-56 fuel system (dfi) crankshaft sensor (service code 21) start the engine and switch the diagnosis mode to dealer 1 mode to know all the problem that the dfi system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of ...

  • Page 151

    Fuel system (dfi) 3-57 speed sensor (service code 24, 25) speed sensor removal/installation • refer to the speed sensor removal/installation in the electrical system chapter. Speed sensor inspection • refer to the speed sensor inspection in the electrical system chapter. Speed sensor input voltage i...

  • Page 152

    3-58 fuel system (dfi) speed sensor (service code 24, 25) • disconnect the speed sensor connector and connect the harness adapter [a] between the harness connector and speed sensor connector. • connect a digital meter to the harness adapter leads. Special tool - throttle sensor setting adapter #1: 5...

  • Page 153

    Fuel system (dfi) 3-59 vehicle-down sensor (service code 31) vehicle-down sensor removal caution never drop the down-sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove: bolts [a] connector and vehicle-down sensor [b] vehicle-down sensor installation • the up mar...

  • Page 154

    3-60 fuel system (dfi) vehicle-down sensor (service code 31) • remove the sensor (see vehicle-down sensor removal). • connect a digital volt meter [a] to the connector with nee- dle adapter set [b]. Special tool - needle adapter set: 57001-1457 vehicle-down sensor output voltage connections to senso...

  • Page 155

    Fuel system (dfi) 3-61 vehicle-down sensor (service code 31) vehicle-down sensor circuit 1. Ecu 2. Water-proof joint e 3. Vehicle-down sensor 4. Water-proof joint d.

  • Page 156

    3-62 fuel system (dfi) subthrottle sensor (service code 32) subthrottle sensor removal/adjustment caution do not remove or adjust the subthrottle sensor [a] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface. Such a shock...

  • Page 157

    Fuel system (dfi) 3-63 subthrottle sensor (service code 32) • turn the ignition switch off. If the input voltage is normal, check the sensor output voltage. If the input voltage is less than the standard, remove the ecu and check the wiring between these connectors. ○ disconnect the ecu and sensor c...

  • Page 158

    3-64 fuel system (dfi) subthrottle sensor (service code 32) if the output voltage is out of the standard, inspect the subthrottle sensor resistance. If the output voltage is normal, check the wiring for conti- nuity. Wiring connection ecu connector [a] ←→ subthrottle sensor connector [b] bl/w lead (...

  • Page 159

    Fuel system (dfi) 3-65 subthrottle sensor (service code 32) subthrottle sensor circuit 1. Ecu 2. Water-proof joint e 3. Water-proof joint d 4. Subthrottle sensor.

  • Page 160

    3-66 fuel system (dfi) oxygen sensor-not activated (service code 33) (europe models) oxygen sensor removal/installation • refer to the oxygen sensor removal/installation in the electrical system chapter. Oxygen sensor inspection • warm up the engine thoroughly until the radiator fan starts. • turn t...

  • Page 161

    Fuel system (dfi) 3-67 oxygen sensor-not activated (service code 33) (europe models) • measure the output voltage of the sensor with the con- nector joined. Oxygen sensor output voltage (without plugs) standard: 0.2 v or less if the reading is within range (with plugs: 0.7 v or more, without plugs: ...

  • Page 162

    3-68 fuel system (dfi) stick coils #1, #2: (service code 51, 52) stick coil #1: service code 51 stick coil #2: service code 52 stick coil removal/installation caution never drop the stick coils, especially on a hard sur- face. Such a shock to the stick coil can damage it. • refer to the stick coil (...

  • Page 163

    Fuel system (dfi) 3-69 stick coils #1, #2: (service code 51, 52) stick coil circuit 1. Ecu 2. Water-proof joint c 3. Stick coils 4. Engine stop switch 5. Ignition switch 6. Ignition fuse 10 a 7. Main fuse 30 a 8. Battery 9. Frame ground 10. Joint connector.

  • Page 164

    3-70 fuel system (dfi) radiator fan relay (service code 56) radiator fan relay removal/installation • radiator fan relay is built in the relay box. • remove the relay box (see relay box removal in the electrical system chapter). Radiator fan relay inspection • refer to the relay circuit inspection i...

  • Page 165

    Fuel system (dfi) 3-71 subthrottle valve actuator (service code 62) subthrottle valve actuator removal caution do not remove the subthrottle valve actuator [a] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface. Such a sh...

  • Page 166

    3-72 fuel system (dfi) subthrottle valve actuator (service code 62) subthrottle valve actuator input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • connect the peak voltage adapter [a] and a digital meter [b] to the connector [c], using the needle a...

  • Page 167

    Fuel system (dfi) 3-73 air switching valve (service code 64) air switching valve removal/installation • refer to the air switching valve removal/installation in the engine top end chapter. Air switching valve inspection • refer to the air switching valve operation test/unit test in the electrical sy...

  • Page 168

    3-74 fuel system (dfi) oxygen sensor heater (service code 67) (europe models) oxygen sensor heater removal/installation the oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see oxygen sensor removal in the electrical system cha...

  • Page 169

    Fuel system (dfi) 3-75 oxygen sensor heater (service code 67) (europe models) oxygen sensor circuit 1. Ecu 2. Oxygen sensor 3. Water-proof joint e 4. Water-proof joint d 5. Oxygen sensor heater fuse 10 a 6. Main fuse 30 a 7. Battery 8. Frame ground 9. Joint connector.

  • Page 170

    3-76 fuel system (dfi) oxygen sensor-incorrect output voltage (service code 94) (europe models) oxygen sensor removal/installation • refer to the oxygen sensor removal/installation in the electrical system chapter. Oxygen sensor inspection • warm up the engine thoroughly until the radiator fan start...

  • Page 171

    Fuel system (dfi) 3-77 oxygen sensor-incorrect output voltage (service code 94) (europe models) • measure the output voltage of the sensor with the con- nector joined. Oxygen sensor output voltage (without plugs) standard: 0.2 v or less if the reading is within range (with plugs: 0.7 v or more, with...

  • Page 172

    3-78 fuel system (dfi) fi indicator light (led) inspection flow chart.

  • Page 173

    Fuel system (dfi) 3-79 fi indicator light (led) fi indicator light (led) inspection • remove the meter unit (see meter unit removal in the electrical system chapter). • using two auxiliary leads, supply battery power to the fi indicator light (led) [a]. 12 v battery [b] fi indicator light (led) chec...

  • Page 174

    3-80 fuel system (dfi) ecu caution never drop the ecu, especially on a hard surface. Such a shock to the ecu can damage it. Ecu removal • remove: seat (see seat removal in the frame chapter) grab rails [a] (see seat cover removal in the frame chapter) center seat cover [b] (see seat cover removal in...

  • Page 175

    Fuel system (dfi) 3-81 ecu ecu power supply inspection • visually inspect the terminals [a] of the ecu connectors. If the connector is clogged with mud or dust, blow it off with compressed air. Replace the main harness if the terminals of the main harness connectors are cracked, bent, or otherwise d...

  • Page 176

    3-82 fuel system (dfi) ecu ecu power source circuit 1. Ecu 2. Water-proof joint c 3. Ignition switch 4. Water-proof joint a 5. Ecu main fuse 15 a 6. Ecu main relay 7. Relay box 8. Main fuse 30 a 9. Battery 10. Frame ground 11. Joint connector.

  • Page 177

    Fuel system (dfi) 3-83 fuel line fuel pressure inspection note ○ this inspection can determine which trouble the dfi system has, mechanical or electrical trouble. ○ it is preferable to measure the fuel pressure while run- ning the motorcycle just when trouble occurred in order to know symptom well. ...

  • Page 178

    3-84 fuel system (dfi) fuel line • turn the ignition switch on. The fuel pump will turn for 3 seconds, and then stop. Caution do not drive the fuel pump without the fuel in the fuel tank. • measure the fuel pressure with the engine stopped. Fuel pressure right after ignition switch on, with pump run...

  • Page 179

    Fuel system (dfi) 3-85 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 applia...

  • Page 180

    3-86 fuel system (dfi) fuel line caution do not drive the fuel pump without the fuel in the fuel tank. • measure the discharge for 3 seconds with the plastic hose filled with fuel. ○ repeat this operation several times. Amount of fuel flow standard: 60 ml or more for 3 seconds if the fuel flow is mu...

  • Page 181

    Fuel system (dfi) 3-87 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 an...

  • Page 182

    3-88 fuel system (dfi) fuel pump • replace the fuel pump gasket [a] with a new one. • apply a non-permanent locking agent to the threads of the fuel pump bolts. • tighten the fuel pump bolts to a snug fit, tighten them alternating diagonally. Torque - fuel pump bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) •...

  • Page 183

    Fuel system (dfi) 3-89 fuel pump • connect the hand tester (25 v dc) to the fuel pump con- nector [a] with needle adapter set. Special tools - hand tester: 57001-1394 needle adapter set: 57001-1457 ○ measure the operating voltage with the engine stopped, and with the connector joined. • turn the ign...

  • Page 184

    3-90 fuel system (dfi) fuel pump fuel pump circuit 1. Ecu 2. Water-proof joint c 3. Engine stop switch 4. Ignition switch 5. Ignition fuse 10 a 6. Fuel pump relay 7. Relay box 8. Main fuse 30 a 9. Battery 10. Frame ground 11. Fuel pump.

  • Page 185

    Fuel system (dfi) 3-91 fuel injectors removal/installation • refer to the throttle body assy disassembly/assembly. Audible inspection • start the engine. • apply the tip of a screwdriver [a] to the injector [b]. Put the grip end onto your ear, and listen whether the injector is clicking or not. ○ a ...

  • Page 186

    3-92 fuel system (dfi) fuel injectors fuel injector output voltage inspection • turn the ignition switch off. • remove the ecu (see ecu removal). • connect a digital voltmeter [a] to the ecu connector [b] with the needle adapter set [c]. Special tool - needle adapter set: 57001-1457 injector output ...

  • Page 187

    Fuel system (dfi) 3-93 fuel injectors • remove the fuel tank (see fuel tank removal). • remove the air cleaner housing (see air cleaner housing removal) • remove connectors for injector [a]. • connect each test light set [b] to the injector sub harness connector [c]. • turn the ignition switch on. •...

  • Page 188

    3-94 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 battery [d] caution be sure to connect the bulb in series. The bulb works as a current limiter to protect the solenoi...

  • Page 189

    Fuel system (dfi) 3-95 fuel injectors • watch the gauge for at least 6 seconds. If the pressure holds steady, the system is good. If the pressure drops at once or if bubbles are found in the area, the line is leaking. Replace the delivery pipe, injectors and related parts. ○ repeat the leak test, an...

  • Page 190

    3-96 fuel system (dfi) throttle grip and cables throttle grip free play inspection • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Throttle grip free play adjustment • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Thro...

  • Page 191

    Fuel system (dfi) 3-97 throttle body assy idle speed inspection • refer to the idle speed inspection in the periodic main- tenance chapter. Engine vacuum synchronization inspection/ad- justment • refer to the engine vacuum synchronization inspection in the periodic maintenance chapter. High altitude...

  • Page 192

    3-98 fuel system (dfi) throttle body assy • loosen the locknut and screw in the throttle cable adjuster fully to give the cables plenty of play. • remove the right switch housing and take out the acceler- ator cable upper end [a] and the decelerator cable upper end [b]. • remove the throttle cable l...

  • Page 193

    Fuel system (dfi) 3-99 throttle body assy • fit the accelerator cable end [a] and the decelerator cable end [b] into the throttle pulley. • check fuel leakage from the throttle body assy. Warning fuel spilled from the carburetors is hazardous. • apply a thin coating of grease to the throttle cable u...

  • Page 194

    3-100 fuel system (dfi) throttle body assy • remove: screws [a] delivery pipe [b] fuel injectors [c] throttle body assy assembly ○ replace the o-rings [a] and seals [b] with the new ones. • before assembling, blow away dirt or dust from the throttle body and delivery pipe by applying compressed air....

  • Page 195

    Fuel system (dfi) 3-101 air cleaner air cleaner element removal/installation • refer to the air cleaner element replacement in the pe- riodic maintenance chapter. Air cleaner element inspection • remove the air cleaner element (see air cleaner element replacement in the periodic maintenance chapter)...

  • Page 196

    3-102 fuel system (dfi) air cleaner • unscrew the bolts [a] and remove the air cleaner housing [b]. Air cleaner housing installation • install the clamp on the hose [a] so that its pinch heads [b] face the right. • install the clamp on the breather hose [c] so that its pinch heads [d] face the front...

  • Page 197

    Fuel system (dfi) 3-103 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 198

    3-104 fuel system (dfi) fuel tank • disconnect the fuel pump lead connector [a] and the tube [b]. • remove: fuel return hose [c] (red, california model) fuel tank breather hose [d] (blue, california model) • be sure to place a piece of cloth [a] around the fuel hose joint. • insert a minus screw dri...

  • Page 199

    Fuel system (dfi) 3-105 fuel tank • close the fuel tank cap. • remove the fuel tank, and place it on a flat surface. ○ do not apply the load to the fuel pump outlet portion [a] especially the outlet pipe made from resin. • for california model, note the following. Caution for california model, if ga...

  • Page 200

    3-106 fuel system (dfi) fuel tank • be sure that the trim seal [a] is on the fuel tank. Reverse side of fuel tank [b] side cover [c] approx. 17 mm (0.67 in.) [d] front [e] • for california model, note the following. ○ to prevent the gasoline from flowing into or out of the canister, hold the separat...

  • Page 201

    Fuel system (dfi) 3-107 fuel tank fuel tank cleaning warning clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger or highly flammable liquids, do not use gasoline or low-flash point solvents to clean the tank....

  • Page 202

    3-108 fuel system (dfi) evaporative emission control system (california model) 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 v...

  • Page 203

    Fuel system (dfi) 3-109 evaporative emission control system (california model) 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 ...

  • Page 205: Cooling System

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

  • Page 206

    4-2 cooling system exploded view.

  • Page 207

    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 17 in·lb 2 water pump impeller bolt 9.8 1.0 87 in·lb 3 water pump cover bolts 9.8 1.0 87 in·lb 4 water pump drain bolt 7.0 0.70 62 in·lb 5 thermostat housing bolts 9.8 1.0 87 in·lb 6 wa...

  • Page 208

    4-4 cooling system coolant flow chart.

  • Page 209

    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 210

    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 211

    Cooling system 4-7 special tools bearing driver set: 57001-1129 oil seal driver: 57001-1660

  • Page 212

    4-8 cooling system coolant coolant deterioration inspection • remove the right center fairing (see center fairing re- moval in the frame chapter). • visually inspect the coolant [a] in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If ...

  • Page 213

    Cooling system 4-9 coolant cooling system flushing over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water...

  • Page 214

    4-10 cooling system water pump water pump removal • drain the coolant (see coolant change in the periodic maintenance chapter). • loosen the clamp and remove the radiator hose [a] from the water pump cover [b]. • remove the water pump cover bolts [c]. • shift the transmission into 1st gear. • while ...

  • Page 215

    Cooling system 4-11 water pump • install the water pump cover, being careful of the two dowel pins [a]. Torque - water pump cover bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) mechanical seal inspection • visually inspect the mechanical seal. If any one of the parts is damaged, replace the mechani- cal seal ...

  • Page 216

    4-12 cooling system water pump impeller assembly • clean the sliding surface of the mechanical seal with a high-flash point solvent, and apply a little coolant to the sliding surface to give the mechanical seal initial lubrica- tion. • apply coolant to the surfaces of the rubber seal [a] and sealing...

  • Page 217

    Cooling system 4-13 radiator radiator and radiator fan removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: center fairings (see center fairing in the frame chap- ter) reserve tank (see coolant change in the periodic main- tenance chapter) radiator fan moto...

  • Page 218

    4-14 cooling system radiator radiator and radiator fan installation • install the radiator [a] to the frame. ○ align [b] the projection on the frame with the hole on the radiator. ○ tighten the radiator bolt [c]. ○ note the baffle plate on the cylinder head cover when installing the radiator. ○ posi...

  • Page 219

    Cooling system 4-15 radiator • install the cap [a] on a cooling system pressure tester [b]. Note ○ wet the cap sealing surfaces with water or coolant to prevent pressure leaks. • watching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gauge ne...

  • Page 220

    4-16 cooling system thermostat thermostat removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: left center fairing (see center fairing removal in the frame chapter) thermostat hosing bolts [a] thermostat hosing [b] • pull the thermostat [a] out of the cylin...

  • Page 221

    Cooling system 4-17 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 222

    4-18 cooling system hose and pipes hose installation • install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • run the hoses (see cable, wire, and hose routing sec- tion in the appendix chapter). • install the clamp [a] as nea...

  • Page 223

    Cooling system 4-19 water temperature sensor caution the water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it. Water temperature sensor removal/installation • refer to the water temperature sensor removal/instal- lat...

  • Page 225: Engine Top End

    Engine top end 5-1 5 engine top end table of contents exploded view........................................................................................................................ 5-3 exhaust system.................................................................................................

  • Page 226

    5-2 engine top end piston ring groove width................................................................................................. 5-39 piston ring thickness ...................................................................................................... 5-39 piston ring end gap .......

  • Page 227

    Engine top end 5-3 exploded view dummy page.

  • Page 228

    5-4 engine top end exploded view.

  • Page 229

    Engine top end 5-5 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 2 cylinder head cover bolts 9.8 1.0 87 in·lb 3 camshaft cap bolts 12 1.2 106 in·lb s cylinder head bolts (m10 new bolts) 54 5.5 40 mo, s 4 cylinder head bolts (m10 used bolts...

  • Page 230

    5-6 engine top end exploded view.

  • Page 231

    Engine top end 5-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 cylinder bolt (m8) 27.5 2.8 20 mo,s 2 cylinder nut (m10) 49 5.0 36 mo,s 3 cylinder bolts (m6) 12 1.2 106 in·lb s 4 exhaust pipe manifold holder nuts 17 1.7 12 5 muffler body mounting bolt (front) 20 2.0 15 6 muffler body ...

  • Page 232

    5-8 engine top end exhaust system exhaust system ex650a6f/ex650b6f full: full power h: honeycomb type catalyst silencer [a] with hole [b] for oxygen sensor [c].

  • Page 233

    Engine top end 5-9 exhaust system manifold mark position [a] silencer mark position [a].

  • Page 234

    5-10 engine top end specifications item standard service limit camshafts cam height: exhaust 35.843 ∼ 35.957 mm (1.4111 ∼ 1.4156 in.) 35.74 mm (1.4071 in.) inlet 36.543 ∼ 36.657 mm (1.4387 ∼ 1.4432 in.) 36.44 mm (1.4346 in.) camshaft journal, camshaft cap clearance 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 ...

  • Page 235

    Engine top end 5-11 specifications item standard service limit valve spring free length: exhaust 41.91 mm (1.650 in.) 40.3 mm (1.587 in.) inlet 41.91 mm (1.650 in.) 40.3 mm (1.587 in.) cylinder, pistons cylinder inside diameter 82.994 ∼ 83.006 mm (3.2675 ∼ 3.2679 in.) 83.10 mm (3.2716 in.) piston di...

  • Page 236

    5-12 engine top end 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 sea...

  • Page 237

    Engine top end 5-13 special tools and sealant compression gauge adapter, m10 × 1.0: 57001-1317 valve seat cutter holder, 4.5: 57001-1330 valve guide arbor, 4.5: 57001-1331 valve guide reamer, 4.5: 57001-1333 piston pin puller: 57001-1568 piston pin puller adapter c: 57001-1657 kawasaki bond (silicon...

  • Page 238

    5-14 engine top end clean air system air suction valve removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter) air switching valve with hoses (see air switching valve removal) air suct...

  • Page 239

    Engine top end 5-15 clean air system air switching valve operation test • refer to the air switching valve operation test in the electrical system chapter. Air switching valve unit test • refer to the air switching valve unit test in the electrical system chapter. Clean air system hose inspection • ...

  • Page 240

    5-16 engine top end cylinder head cover cylinder head cover removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter) air suction valve cover [a] with hose [b] stick coils [c] baffle pla...

  • Page 241

    Engine top end 5-17 cylinder head cover • install the baffle plate [a]. • tighten: torque - baffle plate bolts [b]: 5.9 n·m (0.60 kgf·m, 52 in·lb).

  • Page 242

    5-18 engine top end camshaft chain tensioner camshaft chain tensioner removal caution this is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: when removing the ten...

  • Page 243

    Engine top end 5-19 camshaft, camshaft chain camshaft removal • remove: cylinder head cover (see cylinder head cover re- moval) right lower fairing (see lower fairing removal in the frame chapter) • position the crankshaft as follows. ○ remove the upper [a] and lower [b] caps on the clutch cover. ○ ...

  • Page 244

    5-20 engine top end camshaft, camshaft chain • apply molybdenum disulfide oil solution to all cams [a] journals [b] and thrust blocks [c] with × marks. • if a new camshaft is to be used, apply a thin coat of molyb- denum disulfide grease to the cam surfaces. Note ○ the exhaust camshaft has a 2 412 e...

  • Page 245

    Engine top end 5-21 camshaft, camshaft chain ○ the timing marks must be aligned with the cylinder head upper surface [c]. Ex mark [d] (between #1 pin and #2 pin) in mark [e] (between #31 pin and #32 pin) #1 pin [f] #2 pin [g] #31 pin [h] #32 pin [j] • install the camshaft cap, while pushing the cams...

  • Page 246

    5-22 engine top end camshaft, camshaft chain camshaft and sprocket assembly ○ the inlet and exhaust sprockets are identical. • install the sprockets so that the marked (“in” and “ex”) side faces to the right side. Caution inlet sprocket must use “in” marked bolts holes [a]. Exhaust sprocket must use...

  • Page 247

    Engine top end 5-23 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 248

    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: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) air cleaner housing (see air cleaner housing removal in t...

  • Page 249

    Engine top end 5-25 cylinder head ○ the following table should be consulted if the obtainable compression reading is not within the us- able range. Problem diagnosis remedy (action) carbon accumulation on piston and in combustion chamber possibly due to damaged valve stem oil seal and/or damaged pis...

  • Page 250

    5-26 engine top end cylinder head • firstly remove the m6 cylinder head bolts and m6 cylinder bolts [a]. • secondly, remove the m8 bolts [b]. • thirdly, remove the m10 nut [c]. • fourthly, remove the m10 bolts [d]. Cylinder head installation note ○ the camshaft cap is machined with the cylinder head...

  • Page 251

    Engine top end 5-27 cylinder head • apply molybdenum disulfide oil solution [a] to both sides of washers and the threads of bolts and nut. M10 cylinder head bolts [b] m10 cylinder nut [c] m8 cylinder bolt [d] • tighten the all the bolts and nut following the tightening sequence [1 ∼ 8]. Torque - cyl...

  • Page 252

    5-28 engine top end cylinder head • tighten the m6 cylinder head bolts and m6 cylinder bolts [a]. Torque - cylinder head bolts (m6): 12 n·m (1.2 kgf·m, 106 in·lb) cylinder bolts (m6): 12 n·m (1.2 kgf·m, 106 in·lb) • install the front camshaft chain guide [a]. ○ insert the end [b] of front camshaft c...

  • Page 253

    Engine top end 5-29 valves valve clearance inspection • refer to the valve clearance inspection in the periodic maintenance chapter. Valve clearance adjustment • refer to the valve clearance adjustment in the periodic maintenance chapter. Valve removal • remove cylinder head (see cylinder head remov...

  • Page 254

    5-30 engine top end valves valve guide installation • apply engine oil to the valve guide outer surface before installation. • heat the area around the valve guide hole to about 120 ∼ 150°c (248 ∼ 302°f). • drive the valve guide in from the top of the head using the valve guide arbor. The flange sto...

  • Page 255

    Engine top end 5-31 valves valve seat inspection • remove the valve (see valve removal). • check the valve seating surface [a] between the valve [b] and valve seat [c]. ○ measure the outside diameter [d] of the seating pattern on the valve seat. If the outside diameter is too large or too small, rep...

  • Page 256

    5-32 engine top end valves seat cutter operation care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. 3. Do not fai...

  • Page 257

    Engine top end 5-33 valves • measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range. Widened width [a] of engagement by machining with 45° cutter ...

  • Page 258

    5-34 engine top end valves if the seat width is too wide, make the 60° or 55° [a] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. • grind the seat at a 60° or 55° angle until the seat width is within the specified range. ○ to make...

  • Page 259

    Engine top end 5-35 valves.

  • Page 260

    5-36 engine top end cylinder, pistons cylinder removal • remove: cylinder head (see cylinder head removal) front engine mounting bolts (both side) [a] (see engine removal in the engine removal/installation chapter) front engine brackets (both side) [b] (see engine re- moval in the engine removal/ins...

  • Page 261

    Engine top end 5-37 cylinder, pistons • remove the piston pins. Special tools - piston pin puller [a]: 57001-1568 piston pin puller adapter c [d]: 57001-1657 center bolt [b] shall of piston [c] • remove the pistons. • carefully spread the ring opening with your thumbs and then push up on the opposit...

  • Page 262

    5-38 engine top end cylinder, pistons note ○ if a new piston is used, use new piston ring. • install the piston with its marking hollow facing forward. • fit a new piston pin snap ring into the side of the piston so that the ring opening [a] does not coincide with the slit [b] of the piston pin hole...

  • Page 263

    Engine top end 5-39 cylinder, pistons piston ring, piston ring groove wear • check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. • with the piston rings in their grooves, make ...

  • Page 264

    5-40 engine top end cylinder, pistons piston ring end gap • place the piston ring [a] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. • measure the gap [b] between the ends of the ring with a thickn...

  • Page 265

    Engine top end 5-41 throttle body holder throttle body holder installation • be sure to install the o-rings [a]. • install the clamps [b] as shown and so that their projec- tions fit [c] on the holes of the holders. ○ be sure that the clamp bolt heads [d] face outwards. • tighten: torque - throttle ...

  • Page 266

    5-42 engine top end muffler muffler body removal warning to avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. • remove: right frame cover (see frame cover removal in the frame chapter) • remove the bolts and lift up the right footpeg stay...

  • Page 267

    Engine top end 5-43 muffler muffler body and exhaust pipe installation • replace the exhaust pipe gaskets [a] and muffler body connection gasket [b] with new ones and install them. ○ install the muffler body connection gasket until it is bot- tomed so that the chamfer side [c] feces muffler body [d]...

  • Page 269: Clutch

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

  • Page 270

    6-2 clutch exploded view.

  • Page 271

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper cap on clutch cover 3.9 0.40 35 in·lb 2 lower cap on clutch cover – – – hand-tighten 3 oil filler plug – – – hand-tighten 4 clutch cover mounting bolts 9.8 1.0 87 in·lb 5 clutch spring bolts 9.8 1.0 87 in·lb 6 clutch hub nu...

  • Page 272

    6-4 clutch specifications item standard service limit clutch lever free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – clutch friction plate thickness 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) 2.8 mm (0.110 in.) friction plate warp 0.15 mm (0.16 in.) or less 0.3 mm (0.012 in.) steel plate warp 0.2 mm (0.008 in.) or...

  • Page 273

    Clutch 6-5 special tool and sealant clutch holder: 57001-1243 kawasaki bond (silicone sealant): 92104-0004.

  • Page 274

    6-6 clutch clutch lever and cable clutch lever free play inspection • refer to the clutch operation inspection in the periodic maintenance chapter. Clutch lever free play adjustment • refer to the clutch operation inspection in the periodic maintenance chapter. Clutch cable removal • remove: right f...

  • Page 275

    Clutch 6-7 clutch lever and cable clutch lever installation • install the clutch lever so that the mating surface [b] of the clutch lever clamp is aligned with the punch mark [a]. • tighten the upper clamp bolt first, and then the lower clamp bolt. There will be a gap at the lower part of the clamp ...

  • Page 276

    6-8 clutch clutch cover clutch cover removal • remove: engine oil (drain, see engine oil change in the periodic maintenance chapter) right frame cover (see frame cover removal in the frame chapter) right center fairing (see center fairing removal in the frame chapter) clutch cable lower end [a] clut...

  • Page 277

    Clutch 6-9 clutch cover release shaft removal caution do not remove the clutch release lever and shaft assembly unless it is absolutely necessary. If re- moved, the oil seal replacement may be required. • remove the clutch cover (see clutch cover removal). • pull the lever and shaft assembly straigh...

  • Page 278

    6-10 clutch clutch cover • remove the oil level gauge [a]. Clutch cover assembly • replace the needle bearings and oil seal with new ones. Note ○ install the needle bearings so that the manufacture’s mark face out. • install the needle bearings [a] and oil seal [b] position as shown. Press [c] the b...

  • Page 279

    Clutch 6-11 clutch clutch removal • remove: engine oil (drain, see engine oil change in the periodic maintenance chapter) clutch cover (see clutch cover removal) clutch spring bolts [a] clutch springs clutch spring plate [b] (with thrust bearing and pusher [c]) • remove: friction plates, steel plate...

  • Page 280

    6-12 clutch clutch • be sure that the spacer [a] is in position. • insert the following on the drive shaft. Clutch housing [a] with chain [b] and sprocket [c] sleeve [d] • align [e] the hole on the oil pump sprocket with the oil pump shaft. Note ○ insert the sleeve into the clutch housing, noting it...

  • Page 281

    Clutch 6-13 clutch ○ replace the clutch hub nut with a new one. ○ holding the clutch hub, tighten the clutch hub nut. Special tool - clutch holder: 57001-1243 torque - clutch hub nut: 132 n·m (13.5 kgf·m, 98 ft·lb) • install the friction plates and steel plates, starting with a friction plate and al...

  • Page 282

    6-14 clutch clutch clutch plate warp inspection • place each friction plate or steel plate on a surface plate and measure the gap between the surface plate [a] and each friction plate or steel plate [b] with a thickness gauge [c]. The gap is the amount of friction or steel plate warp. If any plate i...

  • Page 283: Engine Lubrication System

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

  • Page 284

    7-2 engine lubrication system exploded view.

  • Page 285

    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 filter plate bolts 9.8 1.0 87 in·lb l 3 oil filter 17.2 1.75 13 eo, r 4 holder mounting bolt 25 2.5 18 l 5 oil pan bolts 12 1.2 106 in·lb 6 oil pipe plate bolt 9.8 1.0 87 in·lb...

  • Page 286

    7-4 engine lubrication system engine oil flow chart.

  • Page 287

    Engine lubrication system 7-5 engine oil flow chart.

  • Page 288

    7-6 engine lubrication system specifications item standard engine oil type api se, sf or sg api sh, sj or sl with jaso ma viscosity sae 10w-40 capacity: 1.7 l (1.8 us gt) (when filter is not removed) 1.9 l (2.0 us gt) (when filter is removed) 2.4 l (2.5 us gt) (when engine is completely dry) level b...

  • Page 289

    Engine lubrication system 7-7 special tools and sealant oil pressure gauge, 10 kgf/cm²: 57001-164 oil pressure gauge adapter, pt3/8: 57001-1233 oil filter wrench: 57001-1249 kawasaki bond (silicone sealant): 56019-120

  • Page 290

    7-8 engine lubrication system engine oil and oil filter warning motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil level inspection • check that the engine oil le...

  • Page 291

    Engine lubrication system 7-9 oil pan oil pan removal • remove: engine oil (drain, see engine oil change in the periodic maintenance chapter) exhaust pipe (see exhaust pipe removal in the engine top end chapter) muffler body (see muffler body removal in the engine top end chapter) oil pan bolts [a] ...

  • Page 292

    7-10 engine lubrication system oil pan oil pan installation • apply grease to the o-rings on the oil pipes [a]. • install the oil pipe plate [b] so that its guide portion [c] fits the breather pipe [d] as shown. • apply a non-permanent locking agent to the oil pipe plate bolt. Torque - oil pipe plat...

  • Page 293

    Engine lubrication system 7-11 oil pressure relief valve oil pressure relief valve removal • refer to the oil pan removal. Oil pressure relief valve installation • refer to the oil pan installation. Oil pressure relief valve inspection • check to see if the valve [a] slides smoothly when push- ing i...

  • Page 294

    7-12 engine lubrication system 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] • remove: inner rotor [a] for scavenge pump outer rotor [...

  • Page 295

    Engine lubrication system 7-13 oil pump oil pump installation • apply molybdenum disulfide grease to the portion [a] of the oil pump shaft as shown. • install: outer rotor [b] for feed pump inner rotor [c] for feed pump oil pump shaft [d] and pin [e] dowel pin [f] oil pump body [g] pin [h] and inner...

  • Page 296

    7-14 engine lubrication system oil pressure measurement oil pressure measurement • remove the right lower fairing (see lower fairing re- moval 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/c...

  • Page 297

    Engine lubrication system 7-15 oil pressure switch oil pressure switch 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) switch cover [a] switch terminal bolt [b] oil pressure switch [c...

  • Page 299: Engine Removal/installation

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

  • Page 300

    8-2 engine removal/installation exploded view.

  • Page 301

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear engine mounting nuts 44 4.5 32 s 2 front engine mounting bolts 44 4.5 32 s 3 engine mounting bracket bolts 25 2.5 18 s 4. Engine mounting brackets 5. Collar s: follow the specified tightening sequence..

  • Page 302

    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 303

    Engine removal/installation 8-5 engine removal/installation • disconnect the crankshaft sensor lead connector [a]. • remove: exhaust pipe (see exhaust pipe removal in the engine top end chapter) muffler body (see muffler body removal in the engine top end chapter) fuel tank (see fuel tank removal in...

  • Page 304

    8-6 engine removal/installation engine removal/installation • remove the engine sprocket cover (see engine sprocket removal in the final drive chapter). • remove the shift pedal [a] (see shift pedal removal in the crankshaft/transmission chapter). • disconnect: oxygen sensor lead connector [b] (euro...

  • Page 305

    Engine removal/installation 8-7 engine removal/installation engine installation • firstly, insert the rear engine mounting bolts [a] from the left side of the engine. • secondly, temporally tighten the right engine mounting bracket bolts [b] and then the right front engine mounting bolt [c]. ○ posit...

  • Page 307: Crankshaft/transmission

    Crankshaft/transmission 9-1 9 crankshaft/transmission table of contents exploded view........................................................................................................................ 9-2 specifications ..............................................................................

  • Page 308

    9-2 crankshaft/transmission exploded view.

  • Page 309

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 connecting rod big end nuts see text ← ← mo 2 timing rotor bolt 40 4.1 30 3 oil plate bolts 9.8 1.0 87 in·lb l 4 breather plate bolts 9.8 1.0 87 in·lb l 5 shift shaft return spring pin 29 2.9 22 l 6 oil pipe bolt...

  • Page 310

    9-4 crankshaft/transmission exploded view.

  • Page 311

    Crankshaft/transmission 9-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 gear positioning lever bolt 12 1.2 106 in·lb l 2 transmission case bolts 20 2.0 15 3 shift drum cam bolt 12 1.2 106 in·lb l 4 shift drum bearing holder screw 4.9 0.50 43 in·lb l 5 shift rod plate bolt 9.8 1.0 87 ...

  • Page 312

    9-6 crankshaft/transmission specifications item standard service limit crankshaft, connecting rods connecting rod bend – – – tir 0.2/100 mm (0.008/3.94 in.) connecting rod twist – – – tir 0.2/100 mm (0.008/3.94 in.) connecting rod big end side clearance 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.) 0.58 mm (...

  • Page 313

    Crankshaft/transmission 9-7 specifications item standard service limit crankshaft runout tir 0.02 mm (0.0008 in.) or less tir 0.05 mm (0.0020 in.) crankshaft main bearing insert/journal clearance 0.012 ∼ 0.036 mm (0.0005 ∼ 0.0014 in.) 0.07 mm (0.0028 in.) crankshaft main journal diameter: 37.984 ∼ 3...

  • Page 314

    9-8 crankshaft/transmission specifications item standard service limit crankcase bearing bore diameter: 31.000 ∼ 31.016 mm (1.2205 ∼ 1.2228 in.) – – – marking: ○ 31.000 ∼ 31.008 mm (1.2205 ∼ 1.2208 in.) – – – none 31.009 ∼ 31.016 mm (1.2208 ∼ 1.2211 in.) – – – balancer shaft bearing insert thickness...

  • Page 315

    Crankshaft/transmission 9-9 special tools and sealant outside circlip pliers: 57001-144 bearing driver set: 57001-1129 kawasaki bond: 92104-1064.

  • Page 316

    9-10 crankshaft/transmission crankcase splitting crankcase splitting • remove: engine (see engine removal in the engine removal/in- stallation chapter) cylinder (see cylinder removal in the engine top end chapter) pistons (see piston removal in the engine top end chapter) stater motor (see starter m...

  • Page 317

    Crankshaft/transmission 9-11 crankcase splitting if the oil pipe is to be removed, follow the next procedure. ○ unscrew the bolts [a] and remove the oil pipe [b]. ○ prepare a 5 mm rod [a], and insert it to the hole of the upper crankcase half. ○ remove the oil pipe [b], tapping [c] the rod as shown....

  • Page 318

    9-12 crankshaft/transmission crankcase splitting • press and insert [a] the new needle bearing [b] for the shift drum until it is bottomed. Special tool - bearing driver set: 57001-1129 • press and insert [c] the new needle bearing [d] for the shift shaft so that the bearing surface is flush with th...

  • Page 319

    Crankshaft/transmission 9-13 crankcase splitting • install the crankshaft assembly and the balancer shaft as- sembly on the upper crankcase half. ○ align [a] the timing mark on the balancer gear [b] with the timing mark on the balancer drive gear [c] of the crank- shaft. • be sure to hang the camsha...

  • Page 320

    9-14 crankshaft/transmission crankcase splitting • apply liquid gasket [a] to the mating surface of the lower crankcase half. Sealant - kawasaki bond: 92104-1064 note ○ especially, apply a liquid gasket carefully so that it shall be filled up on the grooves. Caution do not apply liquid gasket around...

  • Page 321

    Crankshaft/transmission 9-15 crankcase splitting • fit the lower crankcase half to the upper crankcase half. ○ insert [a] the breather pipe [b] on the upper crankcase half through the hole [c] on the lower crankcase half. Note ○ make the application finish within 20 minutes when the liquid gasket to...

  • Page 322

    9-16 crankshaft/transmission crankcase splitting • tighten the lower crankcase bolts using the following steps. ○ following the sequence numbers on the lower crankcase half, tighten the m9 bolts [1, 2] l= 113 mm (4.45 in.) with washers. Torque - crankcase bolts (m9): 44 n·m (4.5 kgf·m, 32 ft·lb) ○ t...

  • Page 323

    Crankshaft/transmission 9-17 crankshaft and connecting rods crankshaft removal • split the crankcase (see crankcase splitting). • remove the crankshaft [a]. Crankshaft installation caution if the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing insert...

  • Page 324

    9-18 crankshaft/transmission crankshaft and connecting rods connecting rod installation caution to minimize vibration, the connecting rods should have the same weight mark. Big end cap [a] connecting rod [b] weight mark, alphabet [c] diameter mark [d]: “ ○ ” or no mark caution if the connecting rods...

  • Page 325

    Crankshaft/transmission 9-19 crankshaft and connecting rods • install the crankshaft (see crankshaft installation). • install each connecting rod on its original crankpin. Note ○ install each connecting rod so that its oil jet [a] faces the exhaust side (the front [b]) (see engine oil flow chart in ...

  • Page 326

    9-20 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 [a] to measure the length of new connecting rod bolts and record the val- ues to find the b...

  • Page 327

    Crankshaft/transmission 9-21 crankshaft and connecting rods • install new bolts in reused connecting rods. • apply a small amount of molybdenum disulfide oil solution to the following. Threads [a] of nuts and bolts seating surfaces [b] of nuts and con-rods • first, tighten the nuts to the specified ...

  • Page 328

    9-22 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 329

    Crankshaft/transmission 9-23 crankshaft and connecting rods if any crankpin has worn past the service limit, replace the crankshaft with a new one. If the measured crankpin diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make ...

  • Page 330

    9-24 crankshaft/transmission crankshaft and connecting rods crankshaft side clearance • insert a thickness gauge [a] between the crankcase main bearing and the crank web at the no. 2 journal [b] to determine clearance. If the clearance exceeds the service limit, replace the crankcase halves as a set...

  • Page 331

    Crankshaft/transmission 9-25 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 332

    9-26 crankshaft/transmission crankshaft and connecting rods • install the new inserts in the crankcase halves and check insert/journal clearance with the plastigage..

  • Page 333

    Crankshaft/transmission 9-27 balancer balancer removal • split the crankcase (see crankcase splitting). • pull the balancer shaft with the balancer gear out of the crankcase. Balancer installation • apply molybdenum disulfide oil solution to the inside of the balancer shaft bearing insert. • align [...

  • Page 334

    9-28 crankshaft/transmission balancer if either journal has worn past the service limit, replace the balancer shaft with a new one. If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings on the balancer shaft, write new marks on...

  • Page 335

    Crankshaft/transmission 9-29 transmission shift pedal removal • remove: shift lever bolt [a] shift lever [b] shift pedal installation • align the mark [a] on the shift shaft with the slit [b] on the shift lever. • tighten the shift lever bolt securely. • be sure the shift pedal position is as shown....

  • Page 336

    9-30 crankshaft/transmission transmission • remove: clutch (see clutch removal in the clutch chapter) gear positioning lever bolt [a] gear positioning lever [b], spacer, washer and spring external shift mechanism installation • install the gear positioning lever [a] as shown. Spring [b] washer [c] s...

  • Page 337

    Crankshaft/transmission 9-31 transmission • when the new needle bearing [a] is installed in the shift shaft cover [b], press and insert the new needle bearing until it is bottomed. Special tool - bearing driver set: 57001-1129 • when the new oil seal [c] is installed in the shift cover, press and in...

  • Page 338

    9-32 crankshaft/transmission transmission • check the gear positioning lever [a] and its spring for breaks or distortion. If the lever or spring are damaged in any way, replace them. • visually inspect the shift drum cam [b]. If they are badly worn or if they show any damage, replace it. Transmissio...

  • Page 339

    Crankshaft/transmission 9-33 transmission transmission assy disassembly • remove the transmission assy (see transmission assy removal). • remove the following from the transmission case [a]. Shift rods [b] shift forks [c] drive shaft [d] output shaft [e] • remove: shift drum cam bolt [a] shift drum ...

  • Page 340

    9-34 crankshaft/transmission transmission • install the following on the transmission case [a]. Shift drum [b] pin [c] shift drum cam [d] ○ align the pin with the hole on the shift drum cam. • apply a non-permanent locking agent to the shift drum cam bolt [e] and tighten it. Torque - shift drum cam ...

  • Page 341

    Crankshaft/transmission 9-35 transmission • install the gear positioning lever (see external shift mech- anism installation). • install the shift rod plate. Torque - shift rod plate bolt: 9.8 n·m (1.0 kgf·m, 87 in·lb) • set the gear positioning lever to the neutral position [a]. • check that the dri...

  • Page 342

    9-36 crankshaft/transmission transmission • install the transmission assy on the crankcase (see trans- mission assy installation). • press in the oil seal [a] onto collar [b] so that the surface of the oil seal is flush with the surface [c] of the crankcase. ○ apply oil to the outer circumference [d...

  • Page 343

    Crankshaft/transmission 9-37 transmission • the drive shaft gears can be recognized by size: the gear with the smallest diameter is 1st gear, and the largest one is 6th gear. Be sure that all parts are put back in the cor- rect sequence and all circlips and washers are properly in place. • install t...

  • Page 344

    9-38 crankshaft/transmission transmission 1. 1st gear 2. 2nd gear 3. 3rd gear 4. 4th gear 5. 5th gear 6. 6th (top) gear 7. Ball bearing 8. Bushing 9. Toothed washer, 34 mm (1.34 in.) 10. Circlip 11. Bushing 12. Thrust washer, 30 mm (1.18 in.) 13. Needle bearing 14. Circlip 15. Oil seal 16. Collar 17...

  • Page 345

    Crankshaft/transmission 9-39 transmission shift drum and fork removal • remove the transmission assy (see transmission assy removal). • remove the shift forks [a] and shift drum [b] (see trans- mission assy disassembly). Shift drum and fork installation • refer to the transmission assy assembly and ...

  • Page 346

    9-40 crankshaft/transmission transmission shift fork guide pin/drum groove wear • measure the diameter of each shift fork guide pin [a], and measure the width [b] of each shift drum groove. If the guide pin on any shift fork is less than the service limit, the fork must be replaced. Shift fork guide...

  • Page 347

    Crankshaft/transmission 9-41 ball bearing, needle bearing, and oil seal ball and needle bearing replacement caution do not remove the ball or needle bearings unless it is necessary. Removal may damage them. • using a press or puller, remove the ball bearing and/or needle bearings. Note ○ in the abse...

  • Page 349: Wheels/tires

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

  • Page 350

    10-2 wheels/tires exploded view.

  • Page 351

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front axle 108 11.0 80 2 front axle clamp bolt 34 3.5 25 3 rear axle nut 108 11.0 80 4. Caliper bracket (ex650b models) g: apply grease. Hg: apply high-temperature grease. R: replacement parts wl: apply soap and water solu...

  • Page 352

    10-4 wheels/tires specifications item standard service limit wheels (rims) rim runout: axial tir 0.5 mm (0.02 in.) or less tir 1.0 mm (0.04 in.) radial tir 0.8 mm (0.03 in.) or less tir 1.0 mm (0.04 in.) axle runout/100 mm (3.94 in.) tir 0.03 mm (0.0012 in.) or less tir 0.2 mm (0.008 in.) wheel bala...

  • Page 353

    Wheels/tires 10-5 special tools bearing driver set: 57001-1129 jack: 57001-1238 bearing remover head, 20 × 22: 57001-1293 bearing remover shaft, 13: 57001-1377 jack attachment: 57001-1608.

  • Page 354

    10-6 wheels/tires wheels (rims) front wheel removal • remove: brake caliper mounting bolts [a] front brake calipers [b] • loosen: axle clamp bolt [a] • remove the front axle [b]. • remove the lower fairings (see lower fairing removal in the frame chapter). • raise the front wheel off the ground with...

  • Page 355

    Wheels/tires 10-7 wheels (rims) • apply high-temperature grease to the grease seal lips. • fit the collars [a] on the both sides of the hub. • insert the front axle, and tighten the axle. Torque - front axle: 108 n·m (11.0 kgf·m, 80 ft·lb) • before tightening the axle clamp bolt on the right front f...

  • Page 356

    10-8 wheels/tires wheels (rims) rear wheel removal • raise the rear wheel off the ground with stand [a]. • remove: brake caliper mounting bolts [a] rear brake caliper [b] • remove the rear wheel rotation sensor from the caliper bracket (see rear wheel rotation sensor removal in the brakes chapter) (...

  • Page 357

    Wheels/tires 10-9 wheels (rims) • engage the drive chain with the rear sprocket. • install the caliper bracket [a] onto the swingarm stop [b]. • insert the axle from the right side of the wheel, and tighten the axle nut. Torque - rear axle nut: 108 n·m (11.0 kgf·m, 80 ft·lb) • insert a new cotter pi...

  • Page 358

    10-10 wheels/tires wheels (rims) wheel inspection • raise the front/rear wheel off the ground with jack. Special tools - jack: 57001-1238 jack attachment: 57001-1608 • spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings. • inspect th...

  • Page 359

    Wheels/tires 10-11 wheels (rims) balance inspection • remove the front and rear wheels (see front/rear wheel removal). • support the wheel so that it can be spun freely. • spin the wheel lightly, and mark [a] the wheel at the top when the wheel stops. ○ repeat this procedure several times. If the wh...

  • Page 360

    10-12 wheels/tires wheels (rims) balance weight part number weight 41075-0007 10 g (0.35 oz.) 41075-0008 20 g (0.71 oz.) 41075-0009 30 g (1.06 oz.) note ○ balance weights are available from kawasaki dealers in 10, 20, and 30 grams (0.35, 0.71, and 1.06 oz.) sizes. An imbalance of less than 10 grams ...

  • Page 361

    Wheels/tires 10-13 tires air pressure inspection/adjustment • refer to the air pressure inspection in the periodic main- tenance chapter. Tire inspection • refer to the wheel/tire damage inspection in the peri- odic maintenance chapter. Tire removal • remove: wheel (see front/rear wheel removal) val...

  • Page 362

    10-14 wheels/tires tires • install a new valve in the rim. ○ remove the valve cap, lubricate the stem seal [a] with a soap and water solution or rubber lubricant, and pull [b] the valve stem through the rim from the inside out until it snaps into place. Caution do not use engine oil or petroleum dis...

  • Page 363

    Wheels/tires 10-15 tires • check to see that the rim lines [a] on both sides of the tire sidewalls are parallel with the rim flanges. If the rim flanges and tire sidewall rim lines are not parallel, remove the valve core. • lubricate the rim flanges and tire beads. • install the valve core and infla...

  • Page 364

    10-16 wheels/tires 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 bearings [a]. Caution do not lay the wheel on the ground with the disc facing ...

  • Page 365

    Wheels/tires 10-17 hub bearing hub bearing lubrication note ○ since the hub bearings are packed with grease and sealed, lubrication is not required..

  • Page 367: Final Drive

    Final drive 11-1 11 final drive table of contents exploded view........................................................................................................................ 11-2 specifications ...................................................................................................

  • Page 368

    11-2 final drive exploded view.

  • Page 369

    Final drive 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine sprocket nut 125 12.7 92 mo 2 rear axle nut 108 11.0 80 3 rear sprocket nuts 59 6.0 44 4 speed sensor bolt 7.8 0.80 69 in·lb l 5 speed sensor bracket bolts 9.8 1.0 87 in·lb g: apply grease. Hg: apply high-temperature...

  • Page 370

    11-4 final drive specifications item standard service limit drive chain drive chain slack 30 ∼ 40 mm (1.2 ∼ 1.6 in.) – – – drive chain wear (20-link length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) standard chain: make enuma – – – type ek520mvxl1 – – – link 114 links – – – sprockets re...

  • Page 371

    Final drive 11-5 special tools inside circlip pliers: 57001-143 bearing driver set: 57001-1129.

  • Page 372

    11-6 final drive drive chain drive chain slack inspection • refer to the drive chain slack inspection in the periodic maintenance chapter. Drive chain slack adjustment • refer to the drive chain slack adjustment in the periodic maintenance chapter. Wheel alignment inspection/adjustment • refer to th...

  • Page 373

    Final drive 11-7 drive chain • screw the pin holder until it touches chain pin. • be sure that the cutting pin hits center of chain pin. • screw the handlebar [a] into body. • turn the pin holder with wrench [b] clockwise to extract chain pin. Drive chain installation • engage the new drive chain to...

  • Page 374

    11-8 final drive drive chain • fit the plate holder (a) to link plate. • turn the pin holder by hand until plate holder (b) touches the other link plate. • turn the pin holder by wrench clockwise until two pins of link come into groove of plate holder (a). • take off the plate holder (a). • set the ...

  • Page 375

    Final drive 11-9 drive chain • after staking, check the staked area of the link pin for cracks. • measure the outside diameter [a] of the link pin and link plates width [b]. Link pin outside diameter standard: 5.7 ∼ 6.0 mm (0.22 ∼ 0.24 in.) link plates outside width standard: 17.25 ∼ 17.45 mm (0.679...

  • Page 376

    11-10 final drive sprocket, coupling engine sprocket removal • remove: engine sprocket cover bolts [a] engine sprocket cover [b] • remove: speed sensor bracket bolts [a] speed sensor bracket [b] • flatten out the bended washer [a]. • remove the engine sprocket nut [b] and washer. Note ○ when looseni...

  • Page 377

    Final drive 11-11 sprocket, coupling engine sprocket installation • replace the sprocket washer and axle cotter pin. • install the engine sprocket [a] so that “outside” letters face outward. • apply molybdenum disulfide oil solution to the threads of the output shaft and seating surface of the engin...

  • Page 378

    11-12 final drive sprocket, coupling coupling installation • apply high-temperature grease to the coupling grease seal lips [a]. • apply grease to the coupling internal surface [b]. • grease the following. Wheel flange portion [a] o-ring [b] • install the collar [c]. Coupling bearing removal • remov...

  • Page 379

    Final drive 11-13 sprocket, coupling • replace the grease seal with a new one. • press in the grease seal so that the seal surface is flush with the end of the hole. ○ apply high-temperature grease to the grease seal lips. Special tool - bearing driver set: 57001-1129 coupling bearing inspection sin...

  • Page 380

    11-14 final drive sprocket, coupling rear sprocket warp inspection • raise the rear wheel off the ground with stand so that it will turn freely. • set a dial gauge [a] against the rear sprocket [b] near the teeth as shown, and rotate [c] the rear wheel to measure the sprocket runout (warp). The diff...

  • Page 381: Brakes

    Brakes 12-1 12 brakes table of contents exploded view................................... 12-3 specifications .................................... 12-12 special tools ..................................... 12-13 brake lever, brake pedal.................. 12-14 brake lever position adjustment. 12-14 br...

  • Page 382

    12-2 brakes front wheel rotation sensor removal .................................... 12-55 front wheel rotation sensor installation ................................. 12-56 rear wheel rotation sensor removal .................................... 12-56 rear wheel rotation sensor installation .............

  • Page 383

    Brakes 12-3 exploded view dummy page.

  • Page 384

    12-4 brakes exploded view.

  • Page 385

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bleed valve 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 front brake disc mounting bolts 27 2.8 20 l 6 front brake light s...

  • Page 386

    12-6 brakes exploded view.

  • Page 387

    Brakes 12-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bleed valve 7.8 0.80 69 in·lb 2 brake hose banjo bolts 25 2.5 18 3 brake pedal bolt 8.8 0.90 78 in·lb 4 rear brake disc mounting bolts 27 2.8 20 l 5 rear caliper mounting bolts 25 2.5 18 6 rear master cylinder mounting bolts 25 ...

  • Page 388

    12-8 brakes exploded view ex650b models.

  • Page 389

    Brakes 12-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bleed valve 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 l 5 brake pipe joint nuts 18 1.8 13 6 front brake disc mounting bol...

  • Page 390

    12-10 brakes exploded view.

  • Page 391

    Brakes 12-11 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bleed valve 7.8 0.80 69 in·lb 2 brake hose banjo bolts 25 2.5 18 3 brake pedal bolt 8.8 0.90 78 in·lb 4 brake pipe joint nuts 18 1.8 13 5 rear brake disc mounting bolts 27 2.8 20 l 6 rear caliper mounting bolts 25 2.5 18 7 rear...

  • Page 392

    12-12 brakes specifications item standard service limit brake lever, brake pedal brake lever position 5-way adjustable (to suit rider) – – – brake lever free play non-adjustable – – – pedal free play non-adjustable – – – pedal position about 40 mm (1.6 in.) below top of footpeg – – – brake pads lini...

  • Page 393

    Brakes 12-13 special tools inside circlip pliers: 57001-143 jack: 57001-1238 hand tester: 57001-1394 jack attachment: 57001-1608.

  • Page 394

    12-14 brakes brake lever, brake pedal brake lever position adjustment the brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator’s hand. • push the lever forward and turn the adjuster [a] to align the number with the arrow mark [b] on the lever hol...

  • Page 395

    Brakes 12-15 brake lever, brake pedal brake pedal removal • remove: frame cover (see frame cover removal in the frame chapter) bolts [a] right footpeg stay [b] • remove: cotter pin [a] joint pin [b] rear brake light switch spring [c] return spring [d] • remove the mounting bolt [e] and take out the ...

  • Page 396

    12-16 brakes brake lever, brake pedal • install the right footpeg stay, and tighten the bolts. Torque - footpeg stay bolts: 34 n·m (3.5 kgf·m, 25 ft·lb) ○ depress the brake pedal [a] and then align the bolts holes of the master cylinder [b]. Torque - rear master cylinder mounting bolts: 25 n·m (2.5 ...

  • Page 397

    Brakes 12-17 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. • unscrew the banjo bolt and remove the brake hoses [d] from the caliper (see brake hose re...

  • Page 398

    12-18 brakes calipers front caliper disassembly • refer to the caliper rubber parts replacement in the pe- riodic maintenance chapter. Front caliper assembly • refer to the caliper rubber parts replacement in the pe- riodic maintenance chapter. Rear caliper disassembly • refer to the caliper rubber ...

  • Page 399

    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. Rear caliper holder shaft wear the caliper body must slide smoothly on the caliper holder shafts [a]. If th...

  • Page 400

    12-20 brakes brake pads front brake pad removal • remove the front caliper with the hose installed (see front caliper removal). • draw out the holder shaft pin [a], and take off the holder shaft [b]. • remove the pad [c] on the piston side. • push the holder [d] towards the piston, and remove the pa...

  • Page 401

    Brakes 12-21 master cylinder front master cylinder removal • remove the banjo bolt [a] to disconnect the brake hose from the master cylinder [b] (see brake hose removal/in- stallation). • disconnect the front brake light switch connectors [a]. • unscrew the clamp bolts [b], and take off the master c...

  • Page 402

    12-22 brakes master cylinder rear master cylinder removal • unscrew the brake hose banjo bolt [a] on the master cylin- der (see brake hose removal/installation). • unscrew the master cylinder mounting bolts [a]. • remove the cotter pin [b]. Note ○ pull off the joint pin while pressing down the brake...

  • Page 403

    Brakes 12-23 master cylinder master cylinder inspection • remove the master cylinders (see front/rear master cylinder removal). • disassemble the front and rear master cylinders. • check that there are no scratches, rust or pitting on the inner wall [a] of each master cylinder and on the outside of ...

  • Page 404

    12-24 brakes brake disc brake disc removal • remove the wheel (see front/rear wheel removal in the wheels/tires chapter). • unscrew the mounting bolts, and take off the disc. • remove the gaskets. Brake disc installation • replace the gaskets with new ones. • install the brake disc on the wheel so t...

  • Page 405

    Brakes 12-25 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 406

    12-26 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 407

    Brakes 12-27 brake fluid warning when working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types and brands of fluid for use in th...

  • Page 408

    12-28 brakes brake hose brake hose removal/installation • refer to the brake hose and pipe replacement in the periodic maintenance chapter. Brake hose inspection • refer to the brake hose damage and installation condi- tion inspection in the periodic maintenance chapter..

  • Page 409

    Brakes 12-29 anti-lock brake system 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 system connector.

  • Page 410

    12-30 brakes anti-lock brake system abs system wiring diagram 1. Ignition switch 2. Abs hydraulic unit 3. Abs self-diagnosis terminal 4. Abs kawasaki self-diagnosis system connector 5. Front wheel rotation sensor 6. Rear wheel rotation sensor 7. Abs solenoid valve relay 8. Abs motor relay 9. Frame g...

  • Page 411

    Brakes 12-31 anti-lock brake system terminal names 1. Ground to motor 2. Power supply to abs motor relay 3. Power supply to abs solenoid valve relay 4. Ground 5. Front wheel rotation sensor signal 6. Unused 7. Power supply to rear wheel rotation sensor 8. Unused 9. Unused 10. Unused 11. Abs kawasaki...

  • Page 412

    12-32 brakes anti-lock brake system abs servicing precautions there are a number of important precautions that should be followed servicing the abs system. ○ this abs system is designed to be used with a 12 v sealed battery as its power source. Do not use any other battery except for a 12 v sealed b...

  • Page 413

    Brakes 12-33 anti-lock brake system ○ 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-recommended tires may...

  • Page 414

    12-34 brakes anti-lock brake system 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-diagnosis mode, the ser-...

  • Page 415

    Brakes 12-35 anti-lock brake system • 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 carefully. If it is dam...

  • Page 416

    12-36 brakes anti-lock brake system abs diagnosis flow chart.

  • Page 417

    Brakes 12-37 anti-lock brake system inquiries to rider ○ each rider reacts to problems in different ways, so it is important to confirm what kind of condition the rider is dissatisfied with. ○ try to find out exactly what problem occurs under exactly what conditions by asking the rider; know- ing th...

  • Page 418

    12-38 brakes anti-lock brake system pre-diagnosis inspection 1.

  • Page 419

    Brakes 12-39 anti-lock brake system 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 (15 codes including “normal code”) for the service person to troubleshoot easily. The service code memor...

  • Page 420

    12-40 brakes anti-lock brake system • remove the seat (see seat removal in the frame chap- ter). • ground the self-diagnosis terminal [a] (gray) to the bat- tery (–) terminal or battery (–) lead connector, using a lead. • turn on the ignition switch. ○ count the blinks of the light to read the servi...

  • Page 421

    Brakes 12-41 anti-lock brake system self-diagnosis flow chart.

  • Page 422

    12-42 brakes anti-lock brake system 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 faults, a maximum of si...

  • Page 423

    Brakes 12-43 anti-lock brake system service code table service code abs indicator light (led) problems light state 12 start code (not fault) after starts, turn off 13 rear inlet solenoid valve trouble (open, temperature abnormal) on 14 rear outlet solenoid valve trouble (open, temperature abnormal) ...

  • Page 424

    12-44 brakes anti-lock brake system abs indicator light (led) inspection • turn the ignition switch 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 ignition switch turned to on)”....

  • Page 425

    Brakes 12-45 anti-lock brake system abs indicator light (led) lights (when the motorcycle is running, - no service code) • do the 1st step test. ○ check the terminal voltage between the orange/black and black/yellow lead terminals of the meter connector [a]. Special tool - hand tester: 57001-1394 te...

  • Page 426

    12-46 brakes anti-lock brake system • do the 2nd step test. ○ disconnect the abs hydraulic unit connector [a]. ○ check for continuity between the white/red and black/yel- low lead terminals of the abs hydraulic unit connector. If there is the continuity in the lead, replace the abs hy- draulic unit....

  • Page 427

    Brakes 12-47 anti-lock brake system 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). Deformation of t...

  • Page 428

    12-48 brakes anti-lock brake system • do the 4th step test. ○ check the battery terminal voltage between the red/white lead terminal of the fuse box [a] and ground. Special tool - hand tester: 57001-1394 battery terminal voltage standard: battery voltage if the battery terminal voltage is not within...

  • Page 429

    Brakes 12-49 anti-lock brake system • 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 the sensor and senso...

  • Page 430

    12-50 brakes anti-lock brake system • 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. Replace the abs hydr...

  • Page 431

    Brakes 12-51 anti-lock brake system 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 red and green lead terminals of the main har- ness side connector [a] with a ...

  • Page 432

    12-52 brakes anti-lock brake system • do the 2nd step test. ○ connect the abs kawasaki self-diagnosis system con- nector and abs hydraulic unit connector. ○ check the battery terminal voltage, connect the hand tester to the brown terminal of abs kawasaki self-diagnosis system connector [a] and groun...

  • Page 433

    Brakes 12-53 anti-lock brake system • 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. Replace the abs hydr...

  • Page 434

    12-54 brakes anti-lock brake system • remove: bolts [a] • remove: brake pipe joint nuts [a] [b] [c] [d] • tape the brake line opening to prevent brake fluid leakage or contamination by foreign matter. Caution brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely ...

  • Page 435

    Brakes 12-55 anti-lock brake system 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 connector terminals [...

  • Page 436

    12-56 brakes anti-lock brake system • remove: clamp [a] bolt [b] front wheel rotation sensor [c] front wheel rotation sensor installation • installation is the reverse of removal. ○ route the lead correctly (see cable, wire, and hose routing section in the appendix chapter). Rear wheel rotation sens...

  • Page 437

    Brakes 12-57 anti-lock brake system wheel rotation sensor inspection • remove the front wheel rotation sensor [a] from the front fork. • remove the rear wheel rotation sensor [b] from the caliper bracket. • visually inspect the wheel rotation sensors. Replace the wheel rotation sensor if it is crack...

  • Page 438

    12-58 brakes anti-lock brake system brake hose and pipe inspection • refer to the brake hose and pipe damage and instal- lation condition inspection in the periodic maintenance chapter. Abs solenoid valve relay fuse removal • remove the seat (see seat removal in the frame chap- ter). • unlock the ho...

  • Page 439

    Brakes 12-59 anti-lock brake system fuse inspection • remove the fuse (see abs solenoid valve relay/abs motor relay fuse removal). • inspect the fuse element. If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is eq...

  • Page 441: Suspension

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

  • Page 442

    13-2 suspension exploded view.

  • Page 443

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front axle clamp bolt 34 3.5 25 2 front fork bottom allen bolts 30 3.1 22 l 3 front fork clamp bolts (lower) 20 2.0 15 al 4 front fork clamp bolts (upper) 20 2.0 15 5 front fork top plugs 25 2.5 18 6. Outer tube (ex650b mode...

  • Page 444

    13-4 suspension exploded view.

  • Page 445

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear shock absorber bolt 59 6.0 44 2 rear shock absorber nut 59 6.0 44 3 swingarm pivot shaft nut 108 11.0 80 g: apply grease. R: replacement parts.

  • Page 446

    13-6 suspension specifications item standard front fork (per one unit) fork inner tube outside diameter 41 mm (1.6 in.) air pressure atmospheric pressure (non-adjustable) fork spring setting non-adjustable damper setting non-adjustable fork oil: viscosity kayaba khl34-g10 or equivalent amount: ex650...

  • Page 447

    Suspension 13-7 special tools inside circlip pliers: 57001-143 fork cylinder holder handle: 57001-183 fork cylinder holder adapter: 57001-1057 oil seal & bearing remover: 57001-1058 bearing driver set: 57001-1129 jack: 57001-1238 fork oil seal driver, 41: 57001-1288 fork oil level gauge: 57001-1290 ...

  • Page 448

    13-8 suspension special tools spacer, 28: 57001-1663.

  • Page 449

    Suspension 13-9 front fork front fork removal • remove: upper inner fairing (see upper inner fairing removal in the frame chapter) front wheel (see front wheel removal in the wheels/tires chapter) front fender (see front fender removal in the frame chapter) front wheel rotation sensor (see front whe...

  • Page 450

    13-10 suspension front fork • compress [a] the fork [b] upside down to draw out the oil into the suitable container [c]. • pour in the specified amount of oil. Fork oil viscosity: kayaba khl34-g10 or equivalent amount (per side): when changing oil: ex650a models approx. 415 ml (14.0 us oz.) ex650b m...

  • Page 451

    Suspension 13-11 front fork front fork disassembly • remove the front fork (see front fork removal). • remove the top plug [a] with o-ring, take out the collar [b], fork spring seat [c], and fork spring [d]. • drain the fork oil (see front fork oil change). • remove the allen bolt [a] from the botto...

  • Page 452

    13-12 suspension front fork • remove the following from the inner tube. Inner guide bushing [a] outer guide bushing [b] washer [c] oil seal [d] • remove the cylinder base [a] from the bottom of the outer tube. Front fork assembly • check the top plug o-ring and replace it with a new one. • replace t...

  • Page 453

    Suspension 13-13 front fork • apply non-permanent locking agent to the threads of the bottom allen bolt [a]. • hold the front fork horizontally in a vise [b]. • hold the cylinder unit [c] with the special tools and tighten the bottom allen bolt to secure the cylinder in place. Torque - front fork bo...

  • Page 454

    13-14 suspension front fork fork spring inspection • measure the free length [a] of the fork spring [b]. If the measured length is shorter than the service limit, the spring must be replaced. If the free length of the replace- ment spring and that of the remaining spring vary greatly, the remaining ...

  • Page 455

    Suspension 13-15 rear shock absorber spring preload adjustment • using the hook wrench [a], turn the adjusting nut [b] to adjust the spring preload. ○ the standard adjuster setting for average-build rider of 68 kg (150 ib) with no passenger and no accessories is 2nd position. Spring preload setting ...

  • Page 456

    13-16 suspension rear shock absorber • remove: upper shock absorber bolt [a] lower shock absorber nut and washer lower shock absorber bolt [b] • remove the shock absorber [c] from backward. Rear shock absorber installation • installation is the reverse of removal. • apply grease to the lip of oil se...

  • Page 457

    Suspension 13-17 swingarm swingarm removal • remove: chain cover bolts [a] and cover [b] • remove: right side cover (see side cover removal in the frame chapter) frame covers (see frame cover removal in the frame chapter) • remove the brake hose banjo bolt from the rear caliper, free the brake hose ...

  • Page 458

    13-18 suspension swingarm swingarm bearing removal • remove: swingarm (see swingarm removal) collar [a] oil seals [b] sleeve [c] circlip [d] special tool - inside circlip pliers: 57001-143 • remove the ball bearing and needle bearings. Special tool - oil seal & bearing remover [a]: 57001-1058 swinga...

  • Page 459

    Suspension 13-19 swingarm • install the needle bearings [a], ball bearing [b] and oil seals [c] position as shown. Circlip [d] 25 mm (0.98 in.) [e] 17 mm (0.67 in.) [f] 1 mm (0.04 in.) [g] 0.5 mm (0.02 in.) [h] 1 mm (0.04 in.) [i] 23.5 mm (0.93 in.) [j] 6 mm (0.24 in.) [k] swingarm bearing, sleeve i...

  • Page 460

    13-20 suspension swingarm • turn the bearing in the swingarm back and forth [a] while checking for plays, roughness, or binding. If the 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 t...

  • Page 461: Steering

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

  • Page 462

    14-2 steering exploded view.

  • Page 463

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

  • Page 464

    14-4 steering special tools 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.

  • Page 465

    Steering 14-5 steering steering inspection • refer to the steering play inspection in the periodic main- tenance chapter. Steering adjustment • refer to the steering play adjustment in the periodic maintenance chapter..

  • Page 466

    14-6 steering steering stem stem, stem bearing removal • remove: upper fairing (see upper fairing removal in the frame chapter) under bracket [a] (see upper fairing bracket removal in the frame chapter) • remove: upper fairing bracket [a] (see upper fairing bracket removal in the frame chapter) • re...

  • Page 467

    Steering 14-7 steering stem • to remove the bearing outer races [a] pressed into the head pipe [b], insert a bar [c] into the recesses of head pipe, and applying it to both recess alternately hammer it to drive the race out. Note ○ if either steering stem bearing is damaged, it is recom- mended that...

  • Page 468

    14-8 steering steering stem • install the stem [a] through the head pipe and install the ball bearing [b] and inner race [c] on it. • install the stem cap [d] and steering stem nut [e]. • settle the inner races in place as follows. ○ tighten the steering stem nut with 39 n·m (4.0 kgf·m, 29 ft·lb) of...

  • Page 469

    Steering 14-9 steering stem stem bearing lubrication • refer to the steering stem bearing lubrication in the pe- riodic maintenance chapter. Steering stem warp • whenever the steering stem is removed, or if the steering cannot be adjusted for smooth action, check the steering stem for straightness. ...

  • Page 470

    14-10 steering handlebar handlebar removal • remove: clutch lever assembly [a] left switch housing [b] left handlebar weight [c] • remove: front brake master cylinder [a] (see front master cylin- der removal in the brakes chapter) right switch housing [b] right handlebar weight [c] throttle grip [d]...

  • Page 471

    Steering 14-11 handlebar • install the clutch lever (see clutch lever installation in the clutch chapter). • apply adhesive cement to the inside of the left handlebar grip. • apply a non-permanent locking agent to the left handlebar weight bolt. • install the left switch housing. ○ fit the projectio...

  • Page 473: Frame

    Frame 15-1 15 frame table of contents exploded view........................................................................................................................ 15-2 seat .........................................................................................................................

  • Page 474

    15-2 frame exploded view.

  • Page 475

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 footpeg stay bolts 34 3.5 25 2 sidestand bolt 44 4.5 33 3 sidestand switch bolt 8.8 0.90 78 in·lb l 4. Ex650b models 5. Ex650a models g: apply grease. L: apply a non-permanent locking agent. R: replacement parts.

  • Page 476

    15-4 frame exploded view.

  • Page 477

    Frame 15-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fender bolts 3.9 0.40 35 in·lb 2 front fender bracket bolts 8.8 0.90 78 in·lb l 3 front turn signal light mounting screws 1.2 0.12 11 in·lb l: apply a non-permanent locking agent..

  • Page 478

    15-6 frame exploded view.

  • Page 479

    Frame 15-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 grab rail mounting bolts 25 2.5 18 2 seat lock mounting screws 1.2 0.12 11 in·lb 3. Seat (united states and canada models) 4. Seat lock bracket (ex650b models) 5. Ex650b models 6. Grab rails (other than united states and canada m...

  • Page 480

    15-8 frame seat seat removal • insert the ignition switch key [a] into the seat lock, turning the key clockwise, pulling up on the rear of the seat [b], and pulling the seat backward. Seat installation • slip the seat hook [a] under the brace [b] on the fuel tank bracket. • insert the seat latch [a]...

  • Page 481

    Frame 15-9 fairings lower fairing removal • pull up the core by the thin blade driver. • remove the quick rivets [a]. • remove the bolts [b] with collar and washers. • clear the hook portions from the slots. • separate the left lower fairing from the right lower fairing. Lower fairing installation •...

  • Page 482

    15-10 frame fairings • insert the hook [a] into the slot [b]. • insert the projection [a] into the hole [b]. • connect the turn signal lead connector. • install the bolt and screws. Windshield removal • remove: bolts [a] with washers windshield [b] dampers windshield installation • install the dampe...

  • Page 483

    Frame 15-11 fairings upper fairing disassembly • remove: headlight [a] (see headlight removal/installation in the electrical system chapter) upper fairing assembly • install the headlight (see headlight removal/installation in the electrical system chapter). Upper fairing installation • installation...

  • Page 484

    15-12 frame fairings • remove: bolts [a] clamps [b] upper fairing bracket [c] inner fairing removal • remove: center fairings (see center fairing removal) mounting screws [a] inner fairing [b] inner fairing installation • tighten the mounting screws. Torque - front turn signal light mounting screws:...

  • Page 485

    Frame 15-13 side covers side cover removal • remove the seat (see seat removal). • remove the bolt [a]. • pull the side cover [b] evenly outward to clear the stop- pers. Side cover installation • insert the tabs [a] into the holes [b]. • tighten the bolt. • install the seat (see seat installation)..

  • Page 486

    15-14 frame seat covers seat cover removal • remove: seat (see seat removal) bolts [a] grab rails [b] (other than united states and canada models) screw rivets [c] • push the central pin, and then remove the quick rivets [a]. • pull the front and rear portions of the seat cover outside, and then rem...

  • Page 487

    Frame 15-15 fenders front fender removal • remove: brake hose clamps [a] bolts [b] with collar (both side) • remove the front fender [c]. Front fender installation • tighten: torque - front fender bolts: 3.9 n·m (0.40 kgf·m, 35 in·lb) • install the brake hose clamps to the front fender holes. Flap a...

  • Page 488

    15-16 frame fenders rear fender front removal • remove: rear fender rear (see flap and rear fender rear re- moval) battery (see battery removal in the electrical system chapter) relay box (see relay box removal in the electrical sys- tem chapter) starter relay (see starter relay inspection in the el...

  • Page 489

    Frame 15-17 frame frame inspection • visually inspect the frame for cracks, dents, bending or warp. ○ if there is any damage to the frame, replace it. Warning a repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it..

  • Page 490

    15-18 frame sidestand sidestand removal • raise the rear wheel off the ground with stand. • remove: frame cover (see frame cover removal) bolts [a] footpeg stay [b] • remove: sidestand switch bolt [a] with clamp sidestand switch [b] • remove: spring [a] sidestand nut [b] sidestand bolt [c] sidestand...

  • Page 491

    Frame 15-19 frame cover frame cover removal • remove the bolt [a]. • pull the frame cover [b] outward to clear the stoppers. Frame cover installation • insert the projections [a] into the holes [b]. • tighten the bolt..

  • Page 493: Electrical System

    Electrical system 16-1 16 electrical system table of contents exploded view........................................................................................................................ 16-3 specifications .......................................................................................

  • Page 494

    16-2 electrical system electric starter system ........................................................................................................... 16-49 starter motor removal...................................................................................................... 16-49 starter m...

  • Page 495

    Electrical system 16-3 exploded view dummy page.

  • Page 496

    16-4 electrical system exploded view.

  • Page 497

    Electrical system 16-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front turn signal light mounting screws 1.2 0.12 11 in·lb 2 license plate light cover screws 0.90 0.090 8 in·lb 3 license plate light mounting screws 1.2 0.12 11 in·lb 4 meter screws 1.2 0.12 11 in·lb 5. Meter unit (e...

  • Page 498

    16-6 electrical system exploded view.

  • Page 499

    Electrical system 16-7 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 starter motor cable terminal nut 6.0 0.60 53 in·lb 5 starter motor moun...

  • Page 500

    16-8 electrical system exploded view.

  • Page 501

    Electrical system 16-9 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 bolt 9.8 1.0 87 in·lb l 3 alternator rotor bolt 155 15.8 114 mo 4 crankshaft sensor bolts 6.0 0.60 53 in·lb 5 neutral switch 15 1.5 11 6 oil pres...

  • Page 502

    16-10 electrical system specifications item standard battery type sealed battery model name ytx12-bs capacity 12 v 10 ah voltage 12.8 v or more charging system type three-phase ac alternator output voltage 42 v or more at 4 000 r/min (rpm) stator coil resistance 0.18 ∼ 0.27 Ω charging voltage 14.2 ∼...

  • Page 503

    Electrical system 16-11 special tools and sealants 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 grip: 57001-1591 flywheel & pulley holder: 57001-1605 roto...

  • Page 504

    16-12 electrical system parts location 1. Air switching valve 2. Alternator 3. Battery 12 v 10 ah 4. Crankshaft sensor 5. Ecu 6. Fan motor 7. Front brake light switch 8. Fuse box with ecu main fuse 9. Ignition switch 10. Meter unit 11. Neutral switch 12. Oil pressure switch 13. Rear brake light swit...

  • Page 505

    Electrical system 16-13 parts location dummy page.

  • Page 506

    16-14 electrical system wiring diagram (europe, korea, hong kong and kuwait).

  • Page 507

    Electrical system 16-15 wiring diagram (europe, korea, hong kong and kuwait).

  • Page 508

    16-16 electrical system wiring diagram (united states, canada, new zealand and malaysia).

  • Page 509

    Electrical system 16-17 wiring diagram (united states, canada, new zealand and malaysia).

  • Page 510

    16-18 electrical system wiring diagram (australia and south africa).

  • Page 511

    Electrical system 16-19 wiring diagram (australia and south africa).

  • Page 512

    16-20 electrical system wiring diagram (ex650b models).

  • Page 513

    Electrical system 16-21 wiring diagram (ex650b models).

  • Page 514

    16-22 electrical system precautions there are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○ always check battery con...

  • Page 515

    Electrical system 16-23 precautions male connectors [b].

  • Page 516

    16-24 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 517

    Electrical system 16-25 battery battery removal • remove: seat (see seat removal in the frame chapter) • disconnect the negative (–) cable [a]. • slide out the positive (+) terminal cap [b] and then discon- nect the positive (+) cable. Caution be sure to disconnect the negative (–) cable first. • re...

  • Page 518

    16-26 electrical system battery • remove the electrolyte container from the vinyl bag. • detach the strip of caps [a] from the container and set aside, these will be used later to seal the battery. Note ○ do not pierce or otherwise open the sealed cells [b] of the electrolyte container. Do not attem...

  • Page 519

    Electrical system 16-27 battery initial charge • place the strip [a] of caps loosely over the filler ports. • newly activated sealed batteries require an initial charge. Standard charge: 1.2 a × 5 ∼ 10 hours if using a recommended battery charger, follow the charger’s instructions for newly activate...

  • Page 520

    16-28 electrical system battery precautions 1) no need of topping-up no topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that. 2) refreshing charge. If an engine will not start, a horn sounds we...

  • Page 521

    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: seat (see seat removal in the frame chapter) battery cable cap (see battery removal) • disconnect the battery termin...

  • Page 522

    16-30 electrical system battery terminal voltage: 11.5 ∼ less than 12.8 v standard charge 1.2 a × 5 ∼ 10 h (see following chart) quick charge 5 a × 1 h caution if possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on. Terminal voltage: less than 11.5 v charg...

  • Page 523

    Electrical system 16-31 charging system alternator cover removal • remove: left center fairing (see center fairing removal in the frame chapter) alternator lead connector [a] • place a suitable container under the alternator cover [a], and remove the cover bolts [b]. • pull the alternator cover outs...

  • Page 524

    16-32 electrical system charging system stator coil installation • apply a non-permanent locking agent to the threads of the stator coil bolts and tighten them. Torque - stator coil bolts: 12 n·m (1.2 kgf·m, 106 in·lb) • secure the alternator lead with a holding plate, and tighten the bolt. ○ apply ...

  • Page 525

    Electrical system 16-33 charging system • install the starter gear [a] and washer [b]. • again, clean the crankshaft tapered portion [c] and dry there. • install the alternator rotor [a] while turning [b] it counter- clockwise. • install the washer [a]. Note ○ confirm the alternator rotor fit or not...

  • Page 526

    16-34 electrical system charging system • apply a thin coat of molybdenum disulfide grease to the shafts [a], and install them. • install the torque limiter [b] and starter idle gear [c]. • install the alternator cover (see alternator cover installa- tion). Alternator inspection there are three type...

  • Page 527

    Electrical system 16-35 charging system if there is more resistance than shown in the table, or no hand tester reading (infinity) for any two leads, the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced. • using the highest...

  • Page 528

    16-36 electrical system charging system rectifier circuit check • check conductivity of the following pair of terminals. Rectifier circuit inspection w/bl-bk1, w/bl-bk2, w/bl-bk3 tester connection bk/y-bk1, bk/y-bk2, bk/y-bk3 the resistance should be low in one direction and more than ten times as m...

  • Page 529

    Electrical system 16-37 charging system • do the 3rd step regulator circuit test. ○ connect the test light and the 12 v battery in the same manner as specified in the “regulator circuit test-1st step”. ○ momentarily apply 24 v to the voltage br terminal by adding a 12 v battery. ○ check the bk1, bk2...

  • Page 530

    16-38 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 seat (see seat removal in the frame chap- ter). • check that the ignition switc...

  • Page 531

    Electrical system 16-39 charging system charging system circuit 1. Ignition switch 2. Alternator 3. Regulator/rectifier 4. Water-proof joint c 5. Main fuse 30 a 6. Battery 12 v 10 ah 7. Load.

  • Page 532

    16-40 electrical system starter motor clutch starter motor clutch removal/installation • refer to the alternator rotor removal/installation. Starter motor clutch inspection • remove: alternator cover (see alternator cover removal) starter idle gear and torque limiter shafts • turn the starter motor ...

  • Page 533

    Electrical system 16-41 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 534

    16-42 electrical system ignition system crankshaft sensor installation • route the crankshaft sensor lead correctly (see cable, wire, and hose routing section in the appendix chapter). • tighten: torque - crankshaft sensor bolts: 6.0 n·m (0.60 kgf·m, 53 in·lb) • apply silicone sealant [a] to the cra...

  • Page 535

    Electrical system 16-43 ignition system • pushing the starter button, turn the engine 4 ∼ 5 sec- onds with the transmission gear in neutral to measure the crankshaft sensor peak voltage. • repeat the measurement 5 or more times. Crankshaft sensor peak voltage standard: 1.9 v or more special tools - ...

  • Page 536

    16-44 electrical system ignition system stick coil (ignition coil together with spark plug cap) inspection • remove the stick coils (see stick coil (ignition coil to- gether with spark plug cap) removal). • measure the primary winding resistance [a] as follows. ○ connect the hand tester between the ...

  • Page 537

    Electrical system 16-45 ignition system warning to avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • turn the ignition switch and the engine stop switch on. • pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measur...

  • Page 538

    16-46 electrical system ignition system 2nd check • start the engine to the following conditions. Condition transmission gear → 1st position clutch lever → pulled in sidestand → up ○ turn the ignition switch on and push the starter button. ○ then the starter motor should turn when the starter sys- t...

  • Page 539

    Electrical system 16-47 ignition system.

  • Page 540

    16-48 electrical system ignition system ignition system circuit 1. Ignition switch 2. Engine stop switch 3. Spark plugs 4. Stick coils 5. Water-proof joint c 6. Speed sensor 7. Subthrottle sensor 8. Main throttle sensor 9. Water-proof joint d 10. Vehicle-down sensor 11. Water-proof joint e 12. Water...

  • Page 541

    Electrical system 16-49 electric starter system starter motor removal caution do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) right center fairing (see center fairing removal in...

  • Page 542

    16-50 electrical system electric starter system starter motor disassembly • remove the starter motor (see starter motor removal). • take off the starter motor through bolts [a] and remove the both end covers [b] and pull the armature out of the yoke [c]. • remove: terminal locknut and washers o-ring...

  • Page 543

    Electrical system 16-51 electric starter system • install the new o-ring [a] as shown. • install: washers [b] and terminal locknut [c] • tighten: torque - starter motor terminal locknut: 11 n·m (1.1 kgf·m, 97 in·lb) • align the lines [a] on the yoke with the end cover lines [b]. • tighten the throug...

  • Page 544

    16-52 electrical system electric starter system armature inspection • using the × 1 Ω hand tester range, measure the resis- tance between any two commutator segments [a]. Special tool - hand tester: 57001-1394 if there is a high resistance or no reading (∞) between any two segments, a winding is ope...

  • Page 545

    Electrical system 16-53 electric starter system starter relay inspection • remove: bolt [a] and cover [b] • disconnect the connector [a]. • disconnect the starter motor cable [b] and battery positive (+) cable [c] from the starter relay [d]. Caution the battery positive (+) cable with the rubber cap...

  • Page 546

    16-54 electrical system electric starter system electric starter circuit 1. Ignition switch 2. Water-proof joint b 3. Starter lockout switch 4. Ignition fuse 10 a 5. Fuse box 6. Starter circuit relay 7. Relay box 8. Starter motor 9. Starter relay 10. Main fuse 30 a 11. Battery 12 v 10 ah 12. Sidesta...

  • Page 547

    Electrical system 16-55 lighting system this motorcycle adopt the daylight system and have a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays o...

  • Page 548

    16-56 electrical system lighting system • fit the dust cover [a] onto the bulb [b] firmly as shown. Good [c] bad [d] • after installation, adjust the headlight aim (see headlight aiming inspection in the periodic maintenance chapter). City light bulb replacement (europe models) • remove the meter co...

  • Page 549

    Electrical system 16-57 lighting system license plate light bulb replacement • remove: screws [a] license plate light cover [b] • push and turn the bulb counterclockwise 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 sock...

  • Page 550

    16-58 electrical system lighting system headlight/tail light circuit 1. Ignition switch 2. Water-proof joint a 3. Water-proof joint b 4. Position light 5. Headlight (high beam) 6. Headlight (low beam) 7. Dimmer switch 8. Passing switch 9. Headlight relay 10. Relay box 11. Starter relay 12. Main fuse...

  • Page 551

    Electrical system 16-59 lighting system • push and turn the bulb [a] counterclockwise 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°. • install the projection...

  • Page 552

    16-60 electrical system lighting system turn signal light circuit 1. Meter unit 2. Water-proof joint a 3. Water-proof joint b 4. Front right turn signal light 5. Front left turn signal light 6. Turn signal relay 7. Hazard button 8. Turn signal switch 9. Fuse box 10. Turn signal relay fuse 10 a 11. M...

  • Page 553

    Electrical system 16-61 air switching valve air switching valve operation test • remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • pull the air switching valve hose [a] out of the air cleaner base. • take the air switching valve hose end outside of the frame. • reinsta...

  • Page 554

    16-62 electrical system air switching valve • blow the air to the inlet air duct [a], and make sure does not flow the blown air from the outlet air duct [b]. • disconnect the 12 v battery. • blow the air to the inlet air duct [a], and make sure does not flow the blown air from the outlet air duct [b...

  • Page 555

    Electrical system 16-63 radiator fan system fan motor inspection • disconnect the connector [a]. • using an auxiliary leads, supply battery power to the fan motor. If the fan does not rotate, the fan motor is defective and must be replaced. Radiator fan circuit 1. Relay box 2. Radiator fan relay 3. ...

  • Page 556

    16-64 electrical system meter, gauge, indicator unit meter unit removal/installation • remove: windshield (see windshield removal in the frame chapter) upper inner fairings (see upper inner fairing removal in the frame chapter) screws [a] (both side) and meter cover [b] • slide the dust cover [a] an...

  • Page 557

    Electrical system 16-65 meter, gauge, indicator unit electronic combination meter unit inspection • remove the meter unit [a] (see meter unit removal/in- stallation). [1] ignition [2] fuel level warning indicator light (led) (–) [3] unused (ex650a models) abs indicator light (led)(–)(ex650b models) ...

  • Page 558

    16-66 electrical system meter, gauge, indicator unit ○ when the terminals are connected, the lcd segment [a] and led warning lights [b] appear. If the lcd segment and led warning lights will not ap- pear, replace the meter assembly. • disconnect the terminal [1]. ○ the lcd segment and led warning li...

  • Page 559

    Electrical system 16-67 meter, gauge, indicator unit • in the hour/minute setting mode, press the reset button again to effect the hour setting mode. ○ the hour display flashes on the display. • press the mode button to set the hour. • in the hour setting mode, press the reset button to effect the m...

  • Page 560

    16-68 electrical system meter, gauge, indicator unit speed sensor electric source check • connect the 12 v battery and terminals in the same man- ner as specified in the “liquid crystal display (lcd) seg- ments check”. • set the hand tester to the dc 25 v range and connect it to the terminals [12] a...

  • Page 561

    Electrical system 16-69 meter, gauge, indicator unit indicator lights inspection • connect the 12 v battery and terminals in the same man- ner as specified in the “liquid crystal display (lcd) seg- ments check”. Neutral indicator light (led) [a] fi indicator light (led) [b] oil pressure warning indi...

  • Page 562

    16-70 electrical system meter, gauge, indicator unit high beam indicator light (led) battery positive (+) terminal to terminal [15] neutral indicator light (led) battery negative (–) terminal to terminal [5] right and left turn signal indicator light (led) for right turn signal indicator light (led)...

  • Page 563

    Electrical system 16-71 meter, gauge, indicator unit ex650b models abs indicator light (led) battery negative (–) terminal to terminal [3] • if the light (led) keeps going on, replace the meter as- sembly..

  • Page 564

    16-72 electrical system meter, gauge, indicator unit meter circuit 1. Ignition switch 2. Frame ground 3. Meter unit 4. Water-proof joint b 5. Ecu fuse 15 a 6. Ignition fuse 10 a 7. Fuse box 8. Main fuse 30 a 9. Battery 12 v 10 ah 10. Frame ground 11. Fuel reserve switch 12. Joint connector 13. Ecu 1...

  • Page 565

    Electrical system 16-73 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 insp...

  • Page 566

    16-74 electrical system switches and sensors water temperature sensor inspection • remove the water temperature sensor (see removal/in- stallation in the fuel system (dfi) chapter). • suspend the sensor [a] in a container of coolant so that the temperature-sensing projection [c] and threaded por- ti...

  • Page 567

    Electrical system 16-75 switches and sensors speed sensor inspection • remove the speed sensor (see speed sensor removal). • connect the speed sensor connector [a] with the battery [b], 10 kΩ resistor [c] and hand tester [d] as shown. • set the tester to the dc 25 v range. Special tool - hand tester...

  • Page 568

    16-76 electrical system switches and sensors oxygen sensor inspection (europe models) • refer to the oxygen sensor inspection in the fuel system (dfi) chapter. Fuel reserve switch inspection • fill the fuel tank with fuel. • close the fuel tank cap surely. • remove the fuel tank (see fuel tank remov...

  • Page 569

    Electrical system 16-77 relay box the relay box [a] has relays and diodes. The relays and diodes can not be removed. Relay box removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) • take out the relay box [a] and disconnect the connectors [b]. Relay circuit inspection...

  • Page 570

    16-78 electrical system relay box relay circuit inspection (with the battery connected) battery connection (+) (–) tester connection tester reading (Ω) 2-11 1-3 0 ecu main relay 4-5 7-6 0 fuel pump relay 9-10 7-8 0 fan relay 18-19 17-20 0 battery connection (+) (–) tester connection dc 25 v range te...

  • Page 571

    Electrical system 16-79 relay box relay box internal circuit a: headlight relay b: ecu main relay c: fuel pump relay d: starter circuit relay e: fan relay.

  • Page 572

    16-80 electrical system fuse 30 a main fuse removal • remove: left side cover (see side cover removal in the frame chapter) cover (see starter relay inspection) connector [a] • pull out the main fuse [b] from the starter relay with needle nose pliers. Fuse box fuse removal • remove the seat (see sea...

  • Page 573

    Electrical system 16-81 fuse 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 the original position as spec- ified on the lid. Fuse inspection • remove...

  • Page 575: Appendix

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

  • Page 576

    17-2 appendix cable, wire, and hose routing.

  • Page 577

    Appendix 17-3 cable, wire, and hose routing 1. Clamp (from the on sequentially, through the ignition switch lead, left switch housing lead and main harness.) 2. Left switch housing lead connector 3. Clamp (insert the clamp from air cleaner side.) 4. Air switching valve lead connector 5. Main harness...

  • Page 578

    17-4 appendix cable, wire, and hose routing.

  • Page 579

    Appendix 17-5 cable, wire, and hose routing 1. Relay box 2. Main harness 3. Clamp (insert the clamp in the bracket.) 4. Battery negative cable 5. Battery positive cable 6. Ecu connectors 7. Clamp 8. Clamp 9. Tail light connector 10. License plate light connector 11. Rear left turn signal light conne...

  • Page 580

    17-6 appendix cable, wire, and hose routing ex650b models.

  • Page 581

    Appendix 17-7 cable, wire, and hose routing 1. To main harness 2. Battery positive cable 3. Abs kawasaki self-diagnosis system connector (insert the connector to the bracket.) 4. Abs motor relay fuse 5. Abs solenoid valve relay fuse.

  • Page 582

    17-8 appendix cable, wire, and hose routing.

  • Page 583

    Appendix 17-9 cable, wire, and hose routing 1. Inlet pressure sensor 2. Turn signal relay 3. Air cleaner drain tube 4. From this side, through the fuel tank drain tube, corrugated tube and air cleaner drain tube between chain guide and engine. 5. To the water temperature sensor 6. Oxygen sensor lead...

  • Page 584

    17-10 appendix cable, wire, and hose routing.

  • Page 585

    Appendix 17-11 cable, wire, and hose routing 1. Clamp (through the right switch housing lead, and insert the clamp in the frame.) 2. Clutch cable 3. Throttle cables 4. Clamp 5. Right switch housing lead 6. Clamp (through the clutch cable in the clamp.) 7. Frame (through the coolant hose in the frame...

  • Page 586

    17-12 appendix cable, wire, and hose routing ex650b models.

  • Page 587

    Appendix 17-13 cable, wire, and hose routing 1. Brake hose 2. Clutch cable 3. Throttle cables 4. Clamp 5. Right switch housing lead 6. Clamp (through the clutch cable in the clamp.) 7. Frame (through the coolant hose in the frame.) 8. Coolant hose 9. Clamp 10. Clamp (clamp the right switch housing l...

  • Page 588

    17-14 appendix cable, wire, and hose routing ex650b models.

  • Page 589

    Appendix 17-15 cable, wire, and hose routing 1. Right switch housing lead 2. Throttle cable (decelerator) 3. Throttle cable (accelerator) 4. Through the brake hose at the right side of the throttle cables..

  • Page 590

    17-16 appendix cable, wire, and hose routing.

  • Page 591

    Appendix 17-17 cable, wire, and hose routing 1. Crankshaft sensor lead connector 2. Clamp (insert the clamp in the bracket.).

  • Page 592

    17-18 appendix cable, wire, and hose routing.

  • Page 593

    Appendix 17-19 cable, wire, and hose routing 1. Tail light connector 2. License plate light connector 3. Rear right turn signal light connector 4. Rear left turn signal light connector 5. Clamp (insert the clamp in the rear fender rear.) 6. Clamp (insert the clamp in the rear fender rear.) 7. Diagno...

  • Page 594

    17-20 appendix cable, wire, and hose routing.

  • Page 595

    Appendix 17-21 cable, wire, and hose routing 1. Right switch housing lead 2. Throttle cables 3. Headlight (lo) connector (green tape) 4. Headlight (hi) connector 5. Brake hose 6. Clamp 7. Ignition switch lead 8. Main harness 9. Left switch housing lead 10. Clutch cable 11. Clamp (insert the clamp to...

  • Page 596

    17-22 appendix cable, wire, and hose routing ex650b models.

  • Page 597

    Appendix 17-23 cable, wire, and hose routing 1. Right switch housing lead 2. Throttle cables 3. Headlight (lo) connector (green tape) 4. Headlight (hi) connector 5. Brake hose (through the brake hose at the right side of the throttle cables.) 6. Clamp 7. Ignition switch lead 8. Main harness 9. Left ...

  • Page 598

    17-24 appendix cable, wire, and hose routing.

  • Page 599

    Appendix 17-25 cable, wire, and hose routing 1. Clamp 2. Clamp 3. Clamp 4. Clamp (clamp the subthrottle sensor lead and subthrottle valve actuator lead to the delivery pipe.) 5. Ground lead 6. Clamp 7. Subthrottle sensor lead connector 8. Subthrottle valve actuator lead connector 9. Clamp (clamp the...

  • Page 600

    17-26 appendix cable, wire, and hose routing.

  • Page 601

    Appendix 17-27 cable, wire, and hose routing 1. Regulator/rectifier lead 2. Clamp (insert the clamp in the frame.) 3. Rear brake light switch lead connector 4. Through the rear brake light switch lead and vehicle-down sensor lead from the front side of the rear shockabsorber installation part. 5. Th...

  • Page 602

    17-28 appendix cable, wire, and hose routing ex650b models.

  • Page 603

    Appendix 17-29 cable, wire, and hose routing 1. Abs hydraulic unit lead (ecu) (through the lead to the forward of frame cross pipe.) 2. Abs hydraulic unit 3. Through the rear wheel rotation sensor lead upper the starter motor cable and engine ground cable. 4. Through the regulator/rectifier lead in ...

  • Page 604

    17-30 appendix cable, wire, and hose routing ex650b models.

  • Page 605

    Appendix 17-31 cable, wire, and hose routing 1. Front wheel rotation sensor lead 2. Ignition switch lead 3. Left switch housing lead 4. Clamp (clamp the front wheel rotation sensor lead.) 5. Main harness 6. Clamp (clamp the front wheel rotation sensor lead.).

  • Page 606

    17-32 appendix cable, wire, and hose routing.

  • Page 607

    Appendix 17-33 cable, wire, and hose routing 1. To meter unit 2. Clamp 3. To front right turn signal light lead 4. Left switch housing lead 5. Ignition switch lead 6. Main harness 7. To front left turn signal light lead.

  • Page 608

    17-34 appendix cable, wire, and hose routing.

  • Page 609

    Appendix 17-35 cable, wire, and hose routing 1. Clamp 2. Clamp (insert the clamp to the inner fairing.) 3. Clamp (insert the clamp to the upper fairing bracket.).

  • Page 610

    17-36 appendix cable, wire, and hose routing california model.

  • Page 611

    Appendix 17-37 cable, wire, and hose routing 1. Through the hose between main harness and air cleaner housing. 2. To fuel tank (red) 3. To fuel tank (blue) 4. Left side view 5. Through the hose between main harness and air cleaner housing. 6. Front 7. Lower side view.

  • Page 612

    17-38 appendix cable, wire, and hose routing.

  • Page 613

    Appendix 17-39 cable, wire, and hose routing 1. Clamp (insert the clamp in the front fender.) 2. Brake hose 3. Clamp 4. Clamp.

  • Page 614

    17-40 appendix cable, wire, and hose routing ex650b models.

  • Page 615

    Appendix 17-41 cable, wire, and hose routing 1. Clamp (insert the clamp in the front fender.) 2. Brake hose.

  • Page 616

    17-42 appendix cable, wire, and hose routing.

  • Page 617

    Appendix 17-43 cable, wire, and hose routing 1. Brake hose 2. Clamp 3. Clamp.

  • Page 618

    17-44 appendix cable, wire, and hose routing ex650b models.

  • Page 619

    Appendix 17-45 cable, wire, and hose routing 1. Brake hose 2. Clamp 3. Clamp 4. Clamp.

  • Page 620

    17-46 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 621

    Appendix 17-47 troubleshooting guide compression low: spark plug loose 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 warped cylinder head gasket damaged val...

  • Page 622

    17-48 appendix troubleshooting guide engine oil viscosity too high drive train trouble brake dragging lubrication inadequate: engine oil level too low engine oil poor quality or incorrect gauge incorrect: water temperature gauge broken water temperature sensor broken coolant incorrect: coolant level...

  • Page 623

    Appendix 17-49 troubleshooting guide engine mount loose crankshaft bearing worn primary gear worn or chipped camshaft chain tensioner trouble camshaft chain, sprocket, guide worn air suction valve damaged air switching valve damaged alternator rotor loose catalytic converter melt down due to muffler...

  • Page 624

    17-50 appendix troubleshooting guide rear shock adjustment too soft front fork, rear shock absorber spring weak rear shock absorber oil leaking brake doesn’t hold: air in the brake line pad or disc worn brake fluid leakage disc warped contaminated pad brake fluid deteriorated primary or secondary cu...

  • Page 625

    Model application year model beginning frame no. 2006 ex650a6f jkaexea1 □ 6a000001 jkaex650aaa000001 2006 ex650b6f jkaex650aba000001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1361-01 printed in japan.