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Kawasaki ER-6N - Service Manual

Other manuals for ER-6N -: Brochure, Brochure, Service Manual, Owner's Manual

Summary of ER-6N -

  • Page 1

    Er-6n 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: Er-6N

    Er-6n 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 quality division/consumer...

  • Page 6

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

  • Page 7: 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 8

    Note ○ this note symbol indicates points of par- ticular interest for more efficient and con- venient operation. • indicates a procedural step or work to be done. ○ indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a note. Indicates...

  • Page 9: General Information

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

  • Page 10

    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 11

    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 12

    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 13

    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 14

    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 15

    General information 1-7 model identification er650a6f/er650a6s left side view er650a6f/er650a6s right side view er650a6f: australia, malaysia er650a6s: europe.

  • Page 16

    1-8 general information general specifications items er650a6f/er650a6s dimensions overall length 2 100 mm (82.7 in.) overall width 760 mm (29.9 in.) overall height 1 095 mm (43.1 in.) wheelbase 1 405 mm (55.3 in.) road clearance 140 mm (5.5 in.) seat height 785 mm (30.9 in.) dry mass 174 kg (383.7 l...

  • Page 17

    General information 1-9 general specifications items er650a6f/er650a6s viscosity sae 10w-40 capacity 2.4 l (2.5 us qt) drive train primary reduction system: type gear reduction ratio 2.095 (88/42) clutch type wet multi disc transmission: type 6-speed, constant mesh, return shift gear ratios: 1st 2.4...

  • Page 18

    1-10 general information general specifications items er650a6f/er650a6s headlight: type semi-sealed beam bulb 12 v 55 w × 2/55 w (hi/lo) tail/brake light 12 v 5/21 w alternator: type three-phase ac rated output 24 a/14 v @5 000 r/min (rpm) specifications are subject to change without notice, and may...

  • Page 19

    General information 1-11 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 er650a enables transmission to be removed from the right side of engine as ...

  • Page 20

    1-12 general information technical information - inlet air pressure sensor atmospheric pressure sensor and camshaft position sensor are not equipped with the er650a. As a substitute of these sensors above, the er650a recognizes atmospheric pressure and intake stroke of #1 by the signal of inlet air ...

  • Page 21

    General information 1-13 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 23: Periodic Maintenance

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

  • Page 24

    2-2 periodic maintenance steering play inspection ................................................................................................... 2-35 steering play adjustment.................................................................................................. 2-35 steering stem bea...

  • Page 25

    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 26

    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 brake hose and pipe damage - inspect year • • • • • • • 2-31 brake hose installation condi...

  • Page 27

    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 engine oil # year • • • • • 2-45 ...

  • Page 28

    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 liquid gasket. Letters used in the “remarks” column mean: al: tighten the two clamp bolts alternately two times to ensure even t...

  • Page 29

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks clutch upper cap on clutch cover 3.9 0.40 35 in·lb lower cap on clutch cover – – – hand-tighten oil filler plug – – – hand-tighten clutch cover mounting bolts 9.8 1.0 87 in·lb clutch spring bolts 9.8 1.0 87 in·...

  • Page 30

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks oil pressure switch 15 1.5 11 ss oil passage plug 20 2.0 15 l gear positioning lever bolt 12 1.2 106 in·lb l shift shaft return spring pin 29 2.9 22 l shift drum cam bolt 12 1.2 106 in·lb l neutral switch 15 1....

  • Page 31

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks rear shock absorber nut 59 6.0 44 swingarm pivot shaft nut 108 11.0 80 steering front fork clamp bolts (lower) 20 2.0 15 al front fork clamp bolts (upper) 20 2.0 15 handlebar holder bolts 25 2.5 18 s left switc...

  • Page 32

    2-10 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks timing rotor bolt 40 4.1 30 water temperature sensor 12 1.2 106 in·lb the table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the ...

  • Page 33

    Periodic maintenance 2-11 specifications item standard service limit fuel system 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 ∼ 3 1/2 (for reference) – – – engine vacuum 35.3 ±1.3 kpa (265 ±10 mm hg) air cleaner element po...

  • Page 34

    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 35

    Periodic maintenance 2-13 special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 jack: 57001-1238 oil filter wrench: 57001-1249 extension tube: 57001-1578 pilot screw adjuster, e: 57001-1603 jack attachment: 57001-1608.

  • Page 36

    2-14 periodic maintenance periodic maintenance procedures fuel system (dfi) 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...

  • Page 37

    Periodic maintenance 2-15 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. • loosen the locknut [a] at the midd...

  • Page 38

    2-16 periodic maintenance periodic maintenance procedures 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. Warning if dirt or ...

  • Page 39

    Periodic maintenance 2-17 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 40

    2-18 periodic maintenance 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 41

    Periodic maintenance 2-19 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 42

    2-20 periodic maintenance periodic maintenance procedures radiator hose and pipe inspection (coolant leak, damage, installation condition) ○ 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 inspe...

  • Page 44

    2-22 periodic maintenance 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 45

    Periodic maintenance 2-23 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 46

    2-24 periodic maintenance 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 47

    Periodic maintenance 2-25 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 48

    2-26 periodic maintenance 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 49

    Periodic maintenance 2-27 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 50

    2-28 periodic maintenance 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 51

    Periodic maintenance 2-29 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 52

    2-30 periodic maintenance 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 53

    Periodic maintenance 2-31 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] and fittings [b]. If the brake fluid leaked from any position, inspect or re- place the ...

  • Page 54

    2-32 periodic maintenance periodic maintenance procedures brake fluid level inspection • check that the brake fluid level in the front brake reservoir [a] is above the lower level line [b]. Note ○ hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid le...

  • Page 55

    Periodic maintenance 2-33 periodic maintenance procedures brake pad wear inspection • check the lining thickness [a] of the pads in each caliper. If the lining thickness of either pad is less than the service limit [b], replace both pads in the caliper as a set. Pad lining thickness standard: front ...

  • Page 56

    2-34 periodic maintenance 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 57

    Periodic maintenance 2-35 periodic maintenance procedures steering system steering play inspection • raise the front wheel off the ground with jack. Special tools - jack: 57001-1238 jack attachment: 57001-1608 • with the front wheel pointing straight ahead, alternately tap each end of the handlebar....

  • Page 58

    2-36 periodic maintenance periodic maintenance procedures • adjust the steering. Special tool - steering stem nut wrench [a]: 57001-1100 if the steering is too tight, loosen the stem nut [b] a fraction of a turn. If the steering is too loose, tighten the stem nut a fraction of a turn. Note ○ turn th...

  • Page 59

    Periodic maintenance 2-37 periodic maintenance procedures electrical system spark plug condition inspection • remove the spark plugs (see spark plug replacement). • visually inspect the spark plugs. If the spark plug center electrode [a] and/or side elec- trode [b] are corroded or damaged, or if the...

  • Page 60

    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 61

    Periodic maintenance 2-39 periodic maintenance procedures third step • turn on the turn signal switch [a] (left or right position). • the left or right turn signal lights [b] (front and rear) ac- cording to the switch position should flash. • the turn signal indicator light (led) [c] in the meter un...

  • Page 62

    2-40 periodic maintenance periodic maintenance procedures • set the dimmer switch to high beam position. • the low beam [a] and high beam [b] headlights should go on. • the high beam indicator light (led) [c] should go on. If the high beam headlight and/or high beam indicator light (led) does not go...

  • Page 63

    Periodic maintenance 2-41 periodic maintenance procedures note ○ on high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper an- gle according to local regulations. Low beam [a] height of headlight ...

  • Page 64

    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 65

    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 66

    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 67

    Periodic maintenance 2-45 periodic maintenance procedures replacement parts air cleaner element replacement • refer to the air cleaner element cleaning. 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 pa...

  • Page 68

    2-46 periodic maintenance periodic maintenance procedures oil filter replacement • drain the engine oil (see engine oil change). • remove the oil filter [a] with the oil filter wrench [b]. Special tool - oil filter wrench: 57001-1249 • replace the filter with a new one. • apply engine oil to the gas...

  • Page 69

    Periodic maintenance 2-47 periodic maintenance procedures • install the new fuel hose. • insert [a] the fuel hose joint [b] straight onto the delivery pipe until the hose joint clicks. • push [c] the joint lock [d]. • push and pull [a] the fuel hose joint [b] back and forth more than two times and m...

  • Page 70

    2-48 periodic maintenance periodic maintenance procedures • put [a] the projection [b] on the reserve tank into the hole [c] on the frame bracket, and place the reserve tank on the right side of frame. • place a container under the water pump drain bolt [a], then remove the drain bolt. • remove the ...

  • Page 71

    Periodic maintenance 2-49 periodic maintenance procedures • when filling the coolant, choose a suitable mixture ratio by referring to the coolant manufacturer’s directions. Caution soft or distilled water must be used with the an- tifreeze in the cooling system. If hard water is used in the system, ...

  • Page 72

    2-50 periodic maintenance periodic maintenance procedures radiator hose and o-ring replacement • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: thermostat housing [a] (see water pump removal in the cooling system chapter) water pump cover [b] (see water pump re...

  • Page 73

    Periodic maintenance 2-51 periodic maintenance procedures brake hose and pipe replacement caution brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • remove the banjo bolts [a]. • when removing the brake hose, take care not to spill t...

  • Page 74

    2-52 periodic maintenance periodic maintenance procedures • level the brake fluid reservoir. • remove the reservoir cap and diaphragm. • remove the rubber cap from the bleed valve [a] on the caliper. • attach a clear plastic hose [b] to the bleed valve, and run the other end of the hose into a conta...

  • Page 75

    Periodic maintenance 2-53 periodic maintenance procedures master cylinder rubber parts replacement front master cylinder disassembly • remove the front master cylinder (see front master cylin- der removal in the brakes chapter). • remove the reservoir cap and diaphragm, and pour the brake fluid into...

  • Page 76

    2-54 periodic maintenance periodic maintenance procedures • apply brake fluid to the new parts and to the inner wall of the cylinder. • take care not to scratch the piston or the inner wall of the cylinder. • tighten the brake lever pivot bolt and locknut. • apply silicone grease. Brake lever pivot ...

  • Page 77

    Periodic maintenance 2-55 periodic maintenance procedures • replace the fluid seals [a] with new ones. ○ apply brake fluid to the fluid seals, and install them into the cylinders by hand. • replace the dust seals [b] with new ones if they are dam- aged. ○ apply brake fluid to the dust seals, and ins...

  • Page 78

    2-56 periodic maintenance periodic maintenance procedures rear caliper assembly • clean the caliper parts except for the pads. Caution for cleaning of the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • install the bleed valve and rubber cap. Torque - bleed valve: 7.8 n·m (0...

  • Page 79

    Periodic maintenance 2-57 periodic maintenance procedures • insert the spark plug vertically into the plug hole with the spark plug installed in the plug wrench [a]. Owner’s tool - spark plug wrench, 16 mm: 92110-1132 • tighten: torque - spark plugs: 15 n·m (1.5 kgf·m, 11 ft·lb) • install: stick coi...

  • Page 81: Fuel System (Dfi)

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

  • Page 82

    3-2 fuel system (dfi) sensor resistance inspection .......................................................................................... 3-53 crankshaft sensor (service code 21).................................................................................... 3-54 crankshaft sensor removal/in...

  • Page 83

    Fuel system (dfi) 3-3 pump screen, fuel filter cleaning ................................................................................... 3-86 fuel injectors .......................................................................................................................... 3-88 removal/inst...

  • Page 84

    3-4 fuel system (dfi) exploded view.

  • Page 85

    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 led light 3. Throttle cable (accelerator) 4. Throttle cable (decelerator) 5. Throttle body assy 6. Injectors cl: apply cable lubricant. Eo: apply engine oil. G: app...

  • Page 86

    3-6 fuel system (dfi) exploded view.

  • Page 87

    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 66 in·lb l 3 oxygen sensor (europe model) 44.1 4.50 32.5 4. Inlet air pressure sensor 5. Air switching valve 6. Inlet air temperature sensor 7. Cra...

  • Page 88

    3-8 fuel system (dfi) dfi system dfi system.

  • Page 89

    Fuel system (dfi) 3-9 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 valve...

  • Page 90

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

  • Page 91

    Fuel system (dfi) 3-11 dfi system part name 1. Oxygen sensor (europe model) 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. Sub...

  • Page 92

    3-12 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 6. Speed sensor signal 7. Main throttle sensor signal 8. Inlet air pressure sensor si...

  • Page 93

    Fuel system (dfi) 3-13 dfi parts location dfi: digital fuel injection parts 1. Fi indicator light led (dfi) 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...

  • Page 94

    3-14 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 95

    Fuel system (dfi) 3-15 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 96

    3-16 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 97

    Fuel system (dfi) 3-17 special tools and sealant kawasaki bond (silicone sealant): 56019-120

  • Page 98

    3-18 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 99

    Fuel system (dfi) 3-19 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 100

    3-20 fuel system (dfi) troubleshooting the dfi system outline outline when an abnormality in the system occurs, the fi indica- tor led (light emitting diode) light 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 ...

  • Page 101

    Fuel system (dfi) 3-21 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 102

    3-22 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 103

    Fuel system (dfi) 3-23 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 104

    3-24 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 105

    Fuel system (dfi) 3-25 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 106

    3-26 fuel system (dfi) troubleshooting the dfi system □ clutch slipping □ 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...

  • Page 107

    Fuel system (dfi) 3-27 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 108

    3-28 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 109

    Fuel system (dfi) 3-29 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 110

    3-30 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 111

    Fuel system (dfi) 3-31 dfi system troubleshooting guide symptoms or possible causes actions (chapter) loose terminal of battery (–) lead 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 accelera...

  • Page 112

    3-32 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 113

    Fuel system (dfi) 3-33 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 114

    3-34 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 115

    Fuel system (dfi) 3-35 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 116

    3-36 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 117

    Fuel system (dfi) 3-37 self-diagnosis.

  • Page 118

    3-38 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 119

    Fuel system (dfi) 3-39 self-diagnosis service code table service code table service code fi indicator led light 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 o...

  • Page 120

    3-40 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 121

    Fuel system (dfi) 3-41 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 122

    3-42 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 sensor, especially on a hard surface. Such a shock to th...

  • Page 123

    Fuel system (dfi) 3-43 main throttle sensor (service code 11) 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 harness adapter [a] betw...

  • Page 124

    3-44 fuel system (dfi) main throttle sensor (service code 11) 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 resistance. Main throttle s...

  • Page 125

    Fuel system (dfi) 3-45 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. Removal • remove: left center fairing (see center fairing removal in the frame chapter) • disconnect the inlet air pressure sensor c...

  • Page 126

    3-46 fuel system (dfi) inlet air pressure sensor (service code 12) 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 following. Inlet air pressure se...

  • Page 127

    Fuel system (dfi) 3-47 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 cmhg...

  • Page 128

    3-48 fuel system (dfi) inlet air pressure sensor (service code 12) pv = 55 ∼ 86 cmhg vv: inlet air pressure sensor output voltage (v) (digital meter reading) pv: throttle vacuum pressure (absolute) ps: standard atmospheric pressure (absolute) id: idling to: throttle full open st: standard of sensor ...

  • Page 129

    Fuel system (dfi) 3-49 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 130

    3-50 fuel system (dfi) inlet air temperature sensor (service code 13) 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] from the inlet air tempera-...

  • Page 131

    Fuel system (dfi) 3-51 inlet air temperature sensor (service code 13) sensor resistance inspection • remove the inlet air temperature sensor. • suspend the sensor [a] in a container of machine oil so that the heat-sensitive portion is submerged. • suspend a thermometer [b] with the heat-sensitive po...

  • Page 132

    3-52 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). • disco...

  • Page 133

    Fuel system (dfi) 3-53 water temperature sensor (service code 14) water temperature sensor circuit 1. Ecu 2. Water temperature sensor 3. Water-proof joint e 4. Meter unit sensor resistance inspection • remove the water temperature sensor (see water tem- perature sensor removal/installation). • refer...

  • Page 134

    3-54 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 135

    Fuel system (dfi) 3-55 speed sensor (service code 24, 25) speed sensor removal/installation • see the switches and sensors section in the electrical system chapter. Speed sensor inspection • see speed sensor inspection section in the electrical system chapter. Speed sensor input voltage inspection n...

  • Page 136

    3-56 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 137

    Fuel system (dfi) 3-57 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] connection and vehicle-down sensor [b] vehicle-down sensor installation • the up ma...

  • Page 138

    3-58 fuel system (dfi) vehicle-down sensor (service code 31) • remove the sensor. • 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 sensor meter (+) → y/g lead [e] meter (...

  • Page 139

    Fuel system (dfi) 3-59 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 140

    3-60 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 sensor, especially on a hard surface. Such a shock to the sens...

  • Page 141

    Fuel system (dfi) 3-61 subthrottle sensor (service code 32) subthrottle sensor output voltage inspection • remove the fuel tank (see fuel tank removal). • measure the output voltage at the subthrottle sensor in the same way as input voltage inspection. Note the fol- lowing. • disconnect the subthrot...

  • Page 142

    3-62 fuel system (dfi) subthrottle sensor (service code 32) subthrottle sensor resistance inspection • turn the ignition switch off. • disconnect the subthrottle sensor connector. • connect a digital meter [a] to the subthrottle sensor con- nector [b]. • measure the subthrottle sensor resistance. Th...

  • Page 143

    Fuel system (dfi) 3-63 oxygen sensor-not activated (service code 33) - europe model oxygen sensor removal/installation • refer to switches and sensors section in the electrical system chapter. Oxygen sensor inspection • warm up the engine thoroughly until the radiator fan starts. • turn the ignition...

  • Page 144

    3-64 fuel system (dfi) oxygen sensor-not activated (service code 33) - europe model • 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: 0...

  • Page 145

    Fuel system (dfi) 3-65 stick coils (#1, #2: service code 51, 52) stick coil #1: ignition coil (service code 51) stick coil #2: ignition coil (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...

  • Page 146

    3-66 fuel system (dfi) 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 147

    Fuel system (dfi) 3-67 radiator fan relay (service code 56) radiator fan relay removal/installation • radiator fan relay is bult in the relay box. • remove the relay box (see relay box removal in the electrical system chapter). Radiator fan relay inspection • see relay circuit inspection in the elec...

  • Page 148

    3-68 fuel system (dfi) subthrottle valve actuator (service code 62) subthrottle valve actuator removal caution do not remove the subthrottle valve actuator [a] since it has been adjusted and set with precision at the factory. Never drop the actuator , especially on a hard sur- face. Such a shock to ...

  • Page 149

    Fuel system (dfi) 3-69 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 150

    3-70 fuel system (dfi) air switching valve (service code 64) air switching valve removal/installation • refer to clean air system section in the engine top end chapter. Air switching valve inspection • refer to air switching valve section in the electrical sys- tem chapter. • remove the fuel tank an...

  • Page 151

    Fuel system (dfi) 3-71 oxygen sensor heater (service code 67) - europe model oxygen sensor heater removal/installation the oxygen sensor heater is bult 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 chapt...

  • Page 152

    3-72 fuel system (dfi) oxygen sensor heater (service code 67) - europe model 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 153

    Fuel system (dfi) 3-73 oxygen sensor-incorrect output voltage (service code 94) - europe model oxygen sensor removal/installation • refer to oxygen sensor removal/installation in the elec- trical system chapter. Oxygen sensor inspection • warm up the engine thoroughly until the radiator fan starts. ...

  • Page 154

    3-74 fuel system (dfi) oxygen sensor-incorrect output voltage (service code 94) - europe model • 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, witho...

  • Page 155

    Fuel system (dfi) 3-75 fi indicator light (led) inspection flow chart.

  • Page 156

    3-76 fuel system (dfi) 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 157

    Fuel system (dfi) 3-77 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 covers removal in the frame chapter) center seat cover [b] (see seat covers section ...

  • Page 158

    3-78 fuel system (dfi) 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 159

    Fuel system (dfi) 3-79 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 160

    3-80 fuel system (dfi) 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 161

    Fuel system (dfi) 3-81 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 162

    3-82 fuel system (dfi) 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 163

    Fuel system (dfi) 3-83 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 164

    3-84 fuel system (dfi) 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 165

    Fuel system (dfi) 3-85 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 166

    3-86 fuel system (dfi) 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 167

    Fuel system (dfi) 3-87 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 168

    3-88 fuel system (dfi) 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 [c]. Put the grip end onto your ear, and listen whether the injector is clicking or not. ○ a ...

  • Page 169

    Fuel system (dfi) 3-89 fuel injectors fuel injector output voltage inspection • turn the ignition switch off. • remove the ecu (see ecu power supply inspection). • connect a digital voltmeter [a] to the ecu connector [b] with the needle adapter set [c]. Special tool - needle adapter set: 57001-1457 ...

  • Page 170

    3-90 fuel system (dfi) 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 171

    Fuel system (dfi) 3-91 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 172

    3-92 fuel system (dfi) fuel injectors fuel injector circuit 1. Ecu 2. Fuel injectors 3. Water-proof joint c 4. Engine stop switch 5. Ignition switch 6. Ignition fuse 10 a 7. Fuel pump relay (for fuel pump and injec- tors) 8. Relay box 9. Main fuse 30 a 10. Battery 11. Frame ground 12. Joint connecto...

  • Page 173

    Fuel system (dfi) 3-93 throttle grip and cables throttle grip free play inspection • refer to throttle control system inspection in the peri- odic maintenance chapter. Throttle grip free play adjustment • refer to throttle control system inspection in the peri- odic maintenance chapter. Throttle cab...

  • Page 174

    3-94 fuel system (dfi) throttle body assy idle speed inspection • refer to idle speed inspection in the periodic mainte- nance chapter. Engine vacuum synchronization inspection/adjust- ment • refer to engine vacuum synchronization inspection in the periodic maintenance chapter. High altitude perform...

  • Page 175

    Fuel system (dfi) 3-95 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 176

    3-96 fuel system (dfi) 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 177

    Fuel system (dfi) 3-97 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 178

    3-98 fuel system (dfi) air cleaner air cleaner element removal/installation • refer to air cleaner element replacement in the periodic maintenance chapter. Air cleaner element inspection • remove the air cleaner element (see air cleaner element replacement in the periodic maintenance chapter). • vis...

  • Page 179

    Fuel system (dfi) 3-99 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 180

    3-100 fuel system (dfi) fuel tank fuel tank removal warning gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignit...

  • Page 181

    Fuel system (dfi) 3-101 fuel tank • be sure to place a piece of cloth [a] around the fuel hose joint. • insert a minus screw driver [b] into the slit [c]on the joint lock. • turn [a] the driver to disconnect the joint lock [b]. • pull [c] the fuel hose joint out [d] of the outlet pipe. Caution when ...

  • Page 182

    3-102 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] • insert [a] the fuel hose joint [b] straight onto the delivery pipe until the hose joint clicks. Caution when installing the fu...

  • Page 183

    Fuel system (dfi) 3-103 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 185: Cooling System

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

  • Page 186

    4-2 cooling system exploded view.

  • Page 187

    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 188

    4-4 cooling system coolant flow chart.

  • Page 189

    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 190

    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 191

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

  • Page 192

    4-8 cooling system coolant coolant deterioration inspection • remove the right center fairing cover (see center fairing removal 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....

  • Page 193

    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 194

    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 195

    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 196

    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 197

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

  • Page 198

    4-14 cooling system radiator radiator and radiator fan installation • install the grommet [a] so that its large side faces the front. • install the radiator [b] to the frame. ○ align [c] the projection on the radiator with the hole on the frame. ○ align [d] the projection on the frame with the hole ...

  • Page 199

    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 200

    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 201

    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 202

    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 203

    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 water temperature sensor removal/installation in...

  • Page 205: Engine Top End

    Engine top end 5-1 5 engine top end table of contents exploded view................................... 5-2 specifications .................................... 5-7 special tools and sealant ................. 5-9 clean air system............................... 5-11 air suction valve removal..............

  • Page 206

    5-2 engine top end exploded view.

  • Page 207

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air suction valve cover bolts 9.8 1.0 87 in·lb 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 208

    5-4 engine top end exploded view.

  • Page 209

    Engine top end 5-5 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 210

    5-6 engine top end exploded view silencer [c] with hole [a] for oxygen sensor [b].

  • Page 211

    Engine top end 5-7 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 i...

  • Page 212

    5-8 engine top end 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 dia...

  • Page 213

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

  • Page 214

    5-10 engine top end 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 215

    Engine top end 5-11 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 216

    5-12 engine top end clean air system air switching valve installation • install the vacuum switch valve so that the vacuum fitting [a] faces left side. • route the hoses correctly (see cable, wire, and hose routing section in the appendix chapter). Air switching valve operation test • refer to air s...

  • Page 217

    Engine top end 5-13 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 218

    5-14 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 219

    Engine top end 5-15 camshaft, camshaft chain camshaft removal • remove: cylinder head cover (see cylinder head cover re- moval) • position the crankshaft as follows. ○ remove the upper [a] and lower [b] caps on the clutch cover. ○ using a wrench on the crankshaft rotation bolt, turn the crankshaft c...

  • Page 220

    5-16 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 221

    Engine top end 5-17 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 222

    5-18 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 223

    Engine top end 5-19 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 224

    5-20 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: seat (see seat removal in the frame chapter) fuel tank (see fuel tank removal in the fuel system (dfi) chapter) air cleaner ...

  • Page 225

    Engine top end 5-21 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 pisto...

  • Page 226

    5-22 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 227

    Engine top end 5-23 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] • torque the all the bolts and nut following the tightening sequence [1 ∼ 8]. Torque - cyli...

  • Page 228

    5-24 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 229

    Engine top end 5-25 valves valve clearance inspection • refer to valve clearance inspection in the periodic main- tenance chapter. Valve clearance adjustment • refer to valve clearance adjustment in the periodic maintenance chapter. Valve removal • remove cylinder head (see cylinder head removal). •...

  • Page 230

    5-26 engine top end valves valve guide installation • apply oil to the valve guide outer surface before installa- tion. • 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 stops th...

  • Page 231

    Engine top end 5-27 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 232

    5-28 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 233

    Engine top end 5-29 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 234

    5-30 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 235

    Engine top end 5-31 valves.

  • Page 236

    5-32 engine top end cylinder, pistons cylinder removal • remove: cylinder head (see cylinder head removal) horn • remove: 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 eng...

  • Page 237

    Engine top end 5-33 cylinder, pistons • remove the piston pins. Special tool - piston pin puller: 57001-1568 [a] piston pin puller adapter c: 57001-1657 [d] center bolt [b] shall of piston [c] • remove the pistons. • carefully spread the ring opening with your thumbs and then push up on the opposite...

  • Page 238

    5-34 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 239

    Engine top end 5-35 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 240

    5-36 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 241

    Engine top end 5-37 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 242

    5-38 engine top end muffler warning to avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. Muffler body removal • remove: right frame cover (see frame cover removal in the frame chapter) • remove the bolts and lift up the right footpeg stay...

  • Page 243

    Engine top end 5-39 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 245: Clutch

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

  • Page 246

    6-2 clutch exploded view.

  • Page 247

    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 – – – hard-tighten 3 oil filler plug – – – hard-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 248

    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 249

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

  • Page 250

    6-6 clutch clutch lever and cable clutch lever free play inspection • refer to clutch operation inspection in the periodic main- tenance chapter. Clutch lever free play adjustment • refer to clutch operation inspection in the periodic main- tenance chapter. Clutch cable removal • remove the right fr...

  • Page 251

    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 252

    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) clutch cable lower end [a] clutch cover mounting bolts [b] • turn the release lever [a] toward the rea...

  • Page 253

    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 254

    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 255

    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 256

    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. • install the following parts on the drive shaft. Spacer [a...

  • Page 257

    Clutch 6-13 clutch • install the friction plates and steel plates, starting with a friction plate and alternating them. Caution if new dry friction plates and steel plates are in- stalled, apply engine oil to the surfaces of each plate to avoid clutch plate seizure. ○ for the first steel plate [a], ...

  • Page 258

    6-14 clutch clutch clutch spring free length measurement • measure the free length of the clutch springs [a]. If any spring is shorter than the service limit, it must be replaced. Clutch spring free length standard: 33.6 mm (1.32 in.) service limit: 32.6 mm (1.28 in.) clutch housing finger inspectio...

  • Page 259: Engine Lubrication System

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

  • Page 260

    7-2 engine lubrication system exploded view.

  • Page 261

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine oil drain bolt 20 2.0 15 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 262

    7-4 engine lubrication system engine oil flow chart.

  • Page 263

    Engine lubrication system 7-5 engine oil flow chart.

  • Page 264

    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 265

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

  • Page 266

    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 267

    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 268

    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 269

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

  • Page 270

    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 271

    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 inne...

  • Page 272

    7-14 engine lubrication system oil pressure measurement oil pressure measurement • remove the lower fairing (see lower fairing removal in the frame chapter). • remove the oil passage plug, and attach the adapter [a] and gauge [b] to the plug hole. Special tools - oil pressure gauge, 10 kgf/cm²: 5700...

  • Page 273

    Engine lubrication system 7-15 oil pressure switch oil pressure switch removal • remove or drain: engine oil (see engine oil change in the periodic main- tenance chapter) switch cover [a] switch terminal bolt [b] oil pressure switch [c] oil pressure switch installation • apply silicone sealant to th...

  • Page 275: Engine Removal/installation

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

  • Page 276

    8-2 engine removal/installation exploded view.

  • Page 277

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

  • Page 278

    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 279

    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 280

    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] neutr...

  • Page 281

    Engine removal/installation 8-7 engine removal/installation • tighten: torque - rear engine mounting nuts: 44 n·m (4.5 kgf·m, 32 ft·lb) font engine mounting bolts: 44 n·m (4.5 kgf·m, 32 ft·lb) engine mounting bracket bolts: 25 n·m (2.5 kgf·m, 18 ft·lb) • install the engine sprocket (see engine sproc...

  • Page 283: Crankshaft/transmission

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

  • Page 284

    9-2 crankshaft/transmission exploded view.

  • Page 285

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 connecting rod big end nuts see text ← ← ← 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 bolts...

  • Page 286

    9-4 crankshaft/transmission exploded view.

  • Page 287

    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 288

    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 289

    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 290

    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 291

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

  • Page 292

    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 293

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

  • Page 294

    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 295

    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 296

    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 297

    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 298

    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 299

    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 300

    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 301

    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 302

    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 303

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

  • Page 304

    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 305

    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 306

    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 307

    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 308

    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 309

    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 310

    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 311

    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 312

    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 313

    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 314

    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 315

    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 316

    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 and torque it. Torque - shift drum cam bolt:...

  • Page 317

    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 318

    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 319

    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 320

    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 321

    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 transmission assy assembly and inst...

  • Page 322

    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 323

    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 325: Wheels/tires

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

  • Page 326

    10-2 wheels/tires exploded view.

  • Page 327

    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 g: apply grease. Hg: apply high-temperature grease. R: replacement parts wl: apply soap and water solution or rubber lubricant..

  • Page 328

    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 329

    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 330

    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 fairing (see lower fairing removal in the frame chapter). • raise the front wheel off the ground with ...

  • Page 331

    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 332

    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: cotter pin [a] axle nut [b] washer [c] axle [d] with washer • remove the drive chain [a] from the rear sprocket toward ...

  • Page 333

    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 334

    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 335

    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 336

    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 337

    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 338

    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 339

    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 340

    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 341

    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 343: Final Drive

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

  • Page 344

    11-2 final drive exploded view.

  • Page 345

    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 346

    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 347

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

  • Page 348

    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 349

    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 350

    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 351

    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 352

    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 353

    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 354

    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 355

    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 356

    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 357: Brakes

    Brakes 12-1 12 brakes table of contents exploded view................................... 12-2 specifications .................................... 12-6 special tools ..................................... 12-7 brake lever, brake pedal.................. 12-8 brake lever position adjustment. 12-8 brake ...

  • Page 358

    12-2 brakes exploded view.

  • Page 359

    Brakes 12-3 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 360

    12-4 brakes exploded view.

  • Page 361

    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 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 362

    12-6 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 linin...

  • Page 363

    Brakes 12-7 special tools inside circlip pliers: 57001-143 jack: 57001-1238 jack attachment: 57001-1608.

  • Page 364

    12-8 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 hold...

  • Page 365

    Brakes 12-9 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 b...

  • Page 366

    12-10 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 367

    Brakes 12-11 calipers front caliper removal • loosen the banjo bolt [a] at the brake hose lower end, and tighten it loosely. • unscrew the caliper mounting bolts [b], and detach the caliper [c] from the disc. • unscrew the banjo bolt and remove the brake hoses [d] from the caliper (see brake hose re...

  • Page 368

    12-12 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 369

    Brakes 12-13 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 370

    12-14 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 371

    Brakes 12-15 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 372

    12-16 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 373

    Brakes 12-17 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 374

    12-18 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 375

    Brakes 12-19 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 376

    12-20 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 377

    Brakes 12-21 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 378

    12-22 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 379: Suspension

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

  • Page 380

    13-2 suspension exploded view.

  • Page 381

    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 al: tighten the two clamp ...

  • Page 382

    13-4 suspension exploded view.

  • Page 383

    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 384

    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 approx...

  • Page 385

    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 386

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

  • Page 387

    Suspension 13-9 front fork front fork removal • remove: front wheel (see front wheel removal in the wheels/tires chapter) front fender (see front fender removal in the frame chapter) loosen the upper fork clamp bolt [a] and fork top plug [b] beforehand if the fork leg is to be disassembled. Note ○ l...

  • Page 388

    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: approx. 390 ml (13.2 us oz.) after disassembly and ...

  • Page 389

    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 390

    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 391

    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 392

    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 393

    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 3rd position. Spring preload setting ...

  • Page 394

    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 395

    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 396

    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 397

    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 398

    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 399: Steering

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

  • Page 400

    14-2 steering exploded view.

  • Page 401

    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 402

    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 403

    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 404

    14-6 steering steering stem stem, stem bearing removal • remove: front wheel (see front wheel removal in the wheels/tires chapter) headlight assy (see headlight removal/installation in the electrical system chapter) handlebar (see handlebar removal) steering stem head bolt plug [a] steering stem hea...

  • Page 405

    Steering 14-7 steering stem • remove the lower bearing inner race [a] which is pressed onto the steering stem with a suitable commercially avail- able chisel [b]. Stem, stem bearing installation • replace the bearing outer races with new ones. • apply grease to the outer races, and drive them into t...

  • Page 406

    14-8 steering steering stem • 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 torque first, and loosen it a fraction of a turn until it turns lightly. Afterward tighten it again with specified torque using a stem nut wrench [a] in the ...

  • Page 407

    Steering 14-9 steering stem 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. If the steering stem [a] is bent, replace the steering stem. Stem cap deterioration, damage replace the stem cap ...

  • Page 408

    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 409

    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 411: Frame

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

  • Page 412

    15-2 frame exploded view.

  • Page 413

    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 g: apply grease. L: apply a non-permanent locking agent. R: replacement parts.

  • Page 414

    15-4 frame exploded view.

  • Page 415

    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 l: apply a non-permanent locking agent..

  • Page 416

    15-6 frame exploded view.

  • Page 417

    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 lower fairing mounting bolts 8.8 0.90 78 in·lb.

  • Page 418

    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 419

    Frame 15-9 fairings lower fairing removal • remove the mounting bolts [a] and lower fairing [b]. Lower fairing installation • install the lower fairing, and tighten the mounting bolts. Torque - lower fairing, mounting bolts: 8.8 n·m (0.90 kgf·m, 78 in·lb) center fairing removal • remove the mounting...

  • Page 420

    15-10 frame fairings • connect the turn signal lead connector. • insert the projections [a] into the holes [b]. • install the mounting bolts. Upper fairing removal • remove: headlight assy (see headlight removal/installation in the electrical system chapter) mounting bolts [a] upper fairings upper f...

  • Page 421

    Frame 15-11 fairings inner fairing removal • remove: center fairings (see center fairing removal) mounting screws [a] inner fairing [b] inner fairing installation • tighten the mounting screws. • install the center fairings (see center fairing installation)..

  • Page 422

    15-12 frame 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 423

    Frame 15-13 seat covers seat cover removal • remove: seat (see seat removal) bolts [a] grab rails [b] 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 remove the seat covers. Seat cover installation ...

  • Page 424

    15-14 frame 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 425

    Frame 15-15 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 426

    15-16 frame 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 427

    Frame 15-17 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 428

    15-18 frame 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 429

    Frame 15-19 rear view mirrors rear view mirrors removal • loosen the lower hexagonal area [a] for tightening to re- move the rear view mirror from the holder. Caution do not force to tighten and/or loosen the upper hexagonal area (adapter) [b] with a pair of span- ners. Disassembly of this area is n...

  • Page 431: Electrical System

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

  • Page 432

    16-2 electrical system ic igniter inspection .......................................................................................................... 16-40 electric starter system ........................................................................................................... 16-43 star...

  • Page 433

    Electrical system 16-3 exploded view dummy page.

  • Page 434

    16-4 electrical system exploded view.

  • Page 435

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

  • Page 436

    16-6 electrical system exploded view.

  • Page 437

    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 438

    16-8 electrical system exploded view.

  • Page 439

    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 440

    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 441

    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 442

    16-12 electrical system parts location 1. Air switching valve 2. Alternator 3. Battery 12 v 10 ah 4. Crankshaft sensor 5. Ecu (electric control unit) 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 1...

  • Page 443

    Electrical system 16-13 parts location dummy page.

  • Page 444

    16-14 electrical system wiring diagram.

  • Page 445

    Electrical system 16-15 wiring diagram.

  • Page 446

    16-16 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 447

    Electrical system 16-17 precautions male connectors [b].

  • Page 448

    16-18 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 449

    Electrical system 16-19 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 450

    16-20 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 451

    Electrical system 16-21 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 452

    16-22 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 453

    Electrical system 16-23 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 454

    16-24 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 455

    Electrical system 16-25 charging system alternator cover removal • remove: lower fairing (see lower 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 outside. Al...

  • Page 456

    16-26 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 457

    Electrical system 16-27 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 458

    16-28 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 459

    Electrical system 16-29 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 460

    16-30 electrical system charging system regulator circuit check to test the regulator out of circuit, use three 12 v batteries and a test light (12 v 3 ∼ 6 w bulb in a socket with leads). Caution the test light works as an indicator and also a cur- rent limiter to protect the regulator/rectifier fro...

  • Page 461

    Electrical system 16-31 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 462

    16-32 electrical system 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 463

    Electrical system 16-33 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 464

    16-34 electrical system 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 465

    Electrical system 16-35 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 466

    16-36 electrical system 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 467

    Electrical system 16-37 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 468

    16-38 electrical system ignition system warning to avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • turn the ignition switch and the engine stop switch on. • pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measur...

  • Page 469

    Electrical system 16-39 ignition system interlock operation inspection • raise the rear wheel off the ground with stand. 1st check • start the engine to the following conditions. Condition transmission gear → 1st position clutch lever → release sidestand → down or up ○ turn the ignition switch on an...

  • Page 470

    16-40 electrical system ignition system ic igniter inspection ○ the ic igniter is built in the ecu [a]. • refer to the interlock operation inspection, ignition sys- tem troubleshooting chart and fuel system (dfi) chapter for ecu power supply inspection..

  • Page 471

    Electrical system 16-41 ignition system.

  • Page 472

    16-42 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 473

    Electrical system 16-43 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 the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • slide back the rubber cap [a]. • remove the s...

  • Page 474

    16-44 electrical system electric starter system • remove: terminal locknut and washers o-ring • remove the brush plate assy [a] from the yoke [b]. • remove the brush plate [a] from the plate cover [b]. Note ○ do not remove the negative carbon brushes form the brush plate. Starter motor assembly • in...

  • Page 475

    Electrical system 16-45 electric starter system • align the lines [a] on the yoke with the end cover lines [b]. • tighten the through bolts. Torque - starter motor through bolts: 4.9 n·m (0.50 kgf·m, 43 in·lb) brush inspection • measure the length of each brush [a]. If any is worn down to the servic...

  • Page 476

    16-46 electrical system electric starter system note ○ even if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with the hand tester. If all other starter motor and starter motor circuit components check good, but the starter motor still do...

  • Page 477

    Electrical system 16-47 electric starter system • 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 is connected directly to the battery positive (+) termi- ...

  • Page 478

    16-48 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 479

    Electrical system 16-49 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 480

    16-50 electrical system lighting system • fit the dust cover [a] with the “top” mark upward onto the bulb [b] firmly as shown. Good [c] bad [d] top mark [e] • after installation, adjust the headlight aim (see headlight aiming inspection in the periodic maintenance chapter). City light bulb replaceme...

  • Page 481

    Electrical system 16-51 lighting system headlight removal/installation • remove: mounting bolts [a] • disconnect the headlight connectors [a] and city light con- nector [b]. • remove the headlight assy. • remove the upper fairings (see upper fairing removal in the frame chapter). • installation is t...

  • Page 482

    16-52 electrical system 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 483

    Electrical system 16-53 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 484

    16-54 electrical system 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 485

    Electrical system 16-55 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 486

    16-56 electrical system 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 487

    Electrical system 16-57 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 488

    16-58 electrical system 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 489

    Electrical system 16-59 meter, gauge, indicator unit meter unit removal • remove: headlight assy (see headlight removal/installation) screws [a] and cover [b] • slide the dust cover [a] and remove the connector [b]. • remove the meter unit by taking off the mounting screws [c] with the washers. Caut...

  • Page 490

    16-60 electrical system meter, gauge, indicator unit electronic combination meter unit inspection • remove the meter unit [a] (see meter unit removal). [1] battery (+) [2] ignition [3] ground (–) [4] unused [5] speed sensor signal [6] tachometer signal [7] water temperature sensor (–) [8] oil pressu...

  • Page 491

    Electrical system 16-61 meter, gauge, indicator unit ○ when the terminals are connected, all the lcd segments [a] and led warning lights [b] appear (fi warning light appear for two seconds). If the lcd segments and led warning lights will not ap- pear, replace the meter assembly. • disconnect the te...

  • Page 492

    16-62 electrical system 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 493

    Electrical system 16-63 meter, gauge, indicator unit • if the oscillator is not available, the speedometer can be checked as follows. ○ install the meter unit. ○ raise the rear wheel off the ground with stand. ○ turn on the ignition switch. ○ rotate the rear wheel by hand. ○ check that the speedomet...

  • Page 494

    16-64 electrical system meter, gauge, indicator unit • if the oscillator is not available, the tachometer can be checked as follows. ○ connect the 12 v battery and terminals in the same man- ner as specified in the “liquid crystal display (lcd) seg- ments check”. ○ using an auxiliary wire, quick ope...

  • Page 495

    Electrical system 16-65 meter, gauge, indicator unit fuel level warning indictor light (led) battery negative (–) terminal to terminal [9] high beam indicator light (led) battery positive (+) terminal to terminal [11] neutral indicator light (led) battery negative (–) terminal to terminal [12] right...

  • Page 496

    16-66 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 497

    Electrical system 16-67 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 498

    16-68 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 499

    Electrical system 16-69 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 500

    16-70 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 501

    Electrical system 16-71 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 502

    16-72 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 503

    Electrical system 16-73 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 504

    16-74 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 505

    Electrical system 16-75 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 507: Appendix

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

  • Page 508

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

  • Page 509

    Appendix 17-3 cable, wire, and hose routing 1. Clamp (from the on sequentially, through the left switch housing lead, ignition switch 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 510

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

  • Page 511

    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 512

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

  • Page 513

    Appendix 17-7 cable, wire, and hose routing 1. Inlet pressure sensor 2. Turn signal relay 3. Clamp (insert the clamp in the frame.) 4. Horn lead 5. To the water temperature sensor 6. Oxygen sensor lead connector 7. Clamp (through the sidestand switch lead and oxygen sensor lead in the clamp.) 8. Oxy...

  • Page 514

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

  • Page 515

    Appendix 17-9 cable, wire, and hose routing 1. Radiator fan connector 2. Clamp (through the main harness and radiator fan lead, and insert the clamp in the frame.) 3. Through the horn lead between water pipe and frame. 4. To front left turn signal light 5. Clamp (insert the clamp in the bracket.) 6....

  • Page 516

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

  • Page 517

    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 (insert the clamp in the bracket.) 7. Clamp (insert the clamp in the frame.) 8. About 45...

  • Page 518

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

  • Page 519

    Appendix 17-13 cable, wire, and hose routing 1. Crankshaft sensor lead connector 2. Clamp (insert the clamp in the bracket.).

  • Page 520

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

  • Page 521

    Appendix 17-15 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 522

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

  • Page 523

    Appendix 17-17 cable, wire, and hose routing 1. Right switch housing lead 2. Throttle cables 3. Headlight (lo) connector 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. City light connector 12. Clamp (insert ...

  • Page 524

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

  • Page 525

    Appendix 17-19 cable, wire, and hose routing 1. Clamp 2. Clamp 3. Clamp 4. Clamp (clamp the main harness, 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. Cl...

  • Page 526

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

  • Page 527

    Appendix 17-21 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 528

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

  • Page 529

    Appendix 17-23 cable, wire, and hose routing 1. Clamp (insert the clamp in the front fender.) 2. Brake hose 3. Clamp.

  • Page 530

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

  • Page 531

    Appendix 17-25 cable, wire, and hose routing 1. Brake hose 2. Clamp 3. Clamp.

  • Page 532

    17-26 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 533

    Appendix 17-27 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 534

    17-28 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 535

    Appendix 17-29 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 536

    17-30 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 537

    Model application year model beginning frame no. 2006 er650a6f jkaerea1 □ 6a000001 er650a-000001 2006 er650a6s jkaer650aaa000001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1360-01 printed in japan.