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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 er-6n abs 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 er-6n abs motorcycle service manual all rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of quality assuran...

  • Page 6

    List of abbreviations a ampere(s) kds kawasaki diagnostic system abdc after bottom dead center km/h kilometers per hour ac alternating current l liter(s) ah ampere hour lb pound(s) atdc after top dead center lcd liquid crystal display bbdc before bottom dead center led light emission diode bdc botto...

  • Page 7

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

  • Page 8

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

  • Page 9: Foreword

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

  • Page 11: General Information

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

  • Page 12

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

  • Page 13

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

  • Page 14

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

  • Page 15

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

  • Page 16

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

  • Page 17

    General information 1-7 model identification er650ec left side view er650ec right side view.

  • Page 18

    1-8 general information model identification er650fc left side view er650fc right side view frame number engine number.

  • Page 19

    General information 1-9 general specifications items er650ec/fc dimensions overall length 2 110 mm (83.07 in.) overall width 770 mm (30.3 in.) overall height 1 110 mm (43.70 in.) wheelbase 1 410 mm (55.51 in.) road clearance 130 mm (5.12 in.) seat height 805 mm (31.7 in.) curb mass: er650e: 204 kg (...

  • Page 20

    1-10 general information general specifications items er650ec/fc exhaust: open 50° bbdc close 30° atdc duration 260° lubrication system forced lubrication (semi-dry sump) engine oil: grade api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity sae 10w-40 capacity 2.3 l (2.4 us qt) drive train p...

  • Page 21

    General information 1-11 general specifications items er650ec/fc rear suspension: type swingarm wheel travel 130 mm (5.12 in.) brake type: front dual discs rear single disc electrical equipment battery 12 v 10 ah headlight: type semi-sealed beam bulb: high 12 v 55 w + 55 w (quartz-halogen) low 12 v ...

  • Page 22

    1-12 general information unit conversion table prefixes for units: prefix symbol power mega m × 1 000 000 kilo k × 1 000 centi c × 0.01 milli m × 0.001 micro µ × 0.000001 units of mass: kg × 2.205 = lb g × 0.03527 = oz units of volume: l × 0.2642 = gal (us) l × 0.2200 = gal (imp) l × 1.057 = qt (us)...

  • 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 headlight aiming inspection ............................................................................................. 2-41 sidestand switch operation inspection ............................................................................ 2-42 engine stop switch operation...

  • 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) item every 1 (0.6) 6 (3.75) 12 (7.5) 18 (11.25) 24 (15) 30 (18.75) 36 (22.5) see page final drive drive chain lubrication condition - inspect # every 600 km (400 mile) 2-2...

  • Page 27

    Periodic maintenance 2-5 periodic maintenance chart periodic replacement parts frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) item every 1 (0.6) 12 (7.5) 24 (15) 36 (22.5) 48 (30) see page air cleaner element # - replace every 18 000 km (11 250 mile) 2-46 engine oil # -...

  • 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 silicone sealant etc. Letters used in the “remarks” column mean: al: tighten the two clamp bolts alternately two times to ensure...

  • Page 29

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks rear camshaft chain guide bolt 20 2.0 15 l throttle body assy holder bolts 12 1.2 106 in·lb cylinder bolt (m8) 27.5 2.8 20 mo, s cylinder nut 49 5.0 36 mo, s cylinder bolts (m6) 12 1.2 106 in·lb l, s exhaust pi...

  • Page 30

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks engine ground lead terminal bolt 9.8 1.0 87 in·lb crankshaft/transmission breather plate bolts 9.8 1.0 87 in·lb l race holder screw 4.9 0.50 43 in·lb l connecting rod big end nuts see text ← ← mo crankcase bolt...

  • Page 31

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks engine sprocket cover bolts 9.8 1.0 87 in·lb brakes caliper bleed valves 7.8 0.80 69 in·lb brake hose banjo bolts 25 2.5 18 brake lever pivot bolt 1.0 0.10 9 in·lb si brake lever pivot bolt locknut 5.9 0.60 52 ...

  • Page 32

    2-10 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks sidestand switch bolt 8.8 0.90 78 in·lb l electrical system license plate light mounting screws 1.2 0.12 11 in·lb alternator cover bolts 9.8 1.0 87 in·lb alternator lead holding plate bolt 9.8 1.0 87 in·lb l a...

  • Page 33

    Periodic maintenance 2-11 torque and locking agent the table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cl...

  • Page 34

    2-12 periodic maintenance specifications item standard service limit fuel system (dfi) throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 1 300 ±50 r/min (rpm) – – – bypass screws (turn out) 0 ∼ 2 1/2 (for reference) – – – engine vacuum 35.3 ±1.3 kpa (265 ±10 mmhg) – – – air cleaner...

  • Page 35

    Periodic maintenance 2-13 specifications item standard service limit final drive drive chain slack 25 ∼ 35 mm (1.0 ∼ 1.4 in.) – – – chain 20-link length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) standard chain: make daido – – – type did 520vp2-t – – – link 114 links – – – brakes brake f...

  • Page 36

    2-14 periodic maintenance special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 jack: 57001-1238 oil filter wrench: 57001-1249 vacuum gauge: 57001-1369 throttle sensor setting adapter: 57001-1538 extension tube: 57001-1578 pilot screw adjuster, e: 57001-1603.

  • Page 37

    Periodic maintenance 2-15 periodic maintenance procedures fuel system (dfi) throttle control system inspection • check that the throttle grip [a] moves smoothly from full open to close, and the throttle closes quickly and com- pletely by the return spring in all steering positions. If the throttle g...

  • Page 38

    2-16 periodic maintenance periodic maintenance procedures • for sea-b1 and th models, remove the tubes [a] from the fittings on the throttle body. • connect a vacuum gauge (special tool) and hoses [a] to the fittings on the throttle body. Special tool - vacuum gauge: 57001-1369 • connect a highly ac...

  • Page 39

    Periodic maintenance 2-17 periodic maintenance procedures if any one vacuum is not within the specification, turn in the bypass screws until it seats fully but not tightly. Special tool - pilot screw adjuster, e [a]: 57001-1603 notice do not over tighten them. They could be damaged, requiring replac...

  • Page 40

    2-18 periodic maintenance periodic maintenance procedures • disconnect: fuel pump lead connector extension tube • remove the air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter), take off the vacuum gauge hoses and install the rubber caps onto the fittings on the th...

  • Page 41

    Periodic maintenance 2-19 periodic maintenance procedures fuel hose inspection (fuel leak, damage, installation condition) ○ if the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak [a] or the hose to burst. Remove the fuel tank (see fuel tank re- mo...

  • Page 42

    2-20 periodic maintenance periodic maintenance procedures evaporative emission control system inspection (sea-b1 and th models) • inspect the canister as follows. ○ remove: left frame cover (see frame cover removal in the frame chapter) canister bracket bolts [a] ○ unhook the band [b] to remove the ...

  • Page 43

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

  • Page 44

    2-22 periodic maintenance periodic maintenance procedures • using the thickness gauge [a], measure the valve clear- ance between cam and valve lifter. Valve clearance standard: exhaust 0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.) intake 0.15 ∼ 0.21 mm (0.0059 ∼ 0.0083 in.) ○ each piston has two intake and t...

  • Page 45

    Periodic maintenance 2-23 periodic maintenance procedures valve clearance adjustment chart intake 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 t...

  • 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 air suction system damage inspection • 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) • take the air switching valve hose end [...

  • Page 48

    2-26 periodic maintenance periodic maintenance procedures warning the engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch the engine or exhaust pipe during clutch adjustment. • turn the adjuster [a] so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) [b] of th...

  • Page 49

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

  • Page 50

    2-28 periodic maintenance periodic maintenance procedures wheel bearing damage inspection • raise the front wheel off the ground with the jack. Special tool - jack: 57001-1238 • turn the handlebar all the way to the right or left. • inspect the roughness of the front wheel bearing by push- ing and p...

  • Page 51

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

  • Page 52

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

  • Page 53

    Periodic maintenance 2-31 periodic maintenance procedures drive chain wear inspection • remove the 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 t...

  • Page 54

    2-32 periodic maintenance periodic maintenance procedures brake system brake fluid leak (brake hose and pipe) inspection • for models equipped with an abs, remove the right swingarm bracket (see abs hydraulic unit removal in the brakes chapter). • apply the brake lever or pedal, and inspect the brak...

  • Page 55

    Periodic maintenance 2-33 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 56

    2-34 periodic maintenance periodic maintenance procedures brake pad wear inspection • check the lining thickness [a] of the pads in each caliper. Pad lining thickness standard: front [c] 4.5 mm (0.18 in.) rear [d] 5.0 mm (0.20 in.) service limit: 1 mm (0.04 in.) if the lining thickness of either pad...

  • Page 57

    Periodic maintenance 2-35 periodic maintenance procedures if it does not go on, inspect or replace the following items. Battery (see charging condition inspection in the elec- trical system chapter) brake light (see tail/brake light (led) unit removal in the electrical system chapter) main fuse 30 a...

  • Page 58

    2-36 periodic maintenance periodic maintenance procedures rear shock absorber oil leak inspection • visually inspect the shock absorber [a] for oil leakage. If the oil leakage is found on it, replace the shock absorber with a new one. Steering system steering play inspection • raise the front wheel ...

  • Page 59

    Periodic maintenance 2-37 periodic maintenance procedures • loosen the upper front fork clamp bolts [a]. • remove: steering stem head bolt plug [b] steering stem head bolt [c] and washer steering stem head [d] • bend the claws [a] of the claw washer straighten. • remove the steering stem locknut [b]...

  • Page 60

    2-38 periodic maintenance periodic maintenance procedures steering stem bearing lubrication • remove the steering stem (see stem, stem bearing re- moval in the steering chapter). • using a high flash-point solvent, wash the upper and lower ball bearings [a] in the cages, and wipe the upper and lower...

  • Page 61

    Periodic maintenance 2-39 periodic maintenance procedures electrical system lights and switches operation inspection first step • set the gear position in the neutral position. • turn the ignition switch to on. • the following lights should go on according to the table below. City lights [a] goes on...

  • Page 62

    2-40 periodic maintenance periodic maintenance procedures • turn the ignition switch to off. • the all lights should go off. If any light does not go off, replace the ignition switch. Second step • turn the ignition switch to p (park) position. • the city light, taillight and license plate light sho...

  • Page 63

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

  • Page 64

    2-42 periodic maintenance periodic maintenance procedures headlight beam vertical adjustment • turn the vertical adjuster [a] on the headlight in or out to adjust the headlight vertically. Note ○ on high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels...

  • Page 65

    Periodic maintenance 2-43 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 66

    2-44 periodic maintenance 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 67

    Periodic maintenance 2-45 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 68

    2-46 periodic maintenance periodic maintenance procedures replacement parts air cleaner element replacement note ○ in dusty areas, the element should be replaced more frequently than the recommended interval. Warning if dirt or dust is allowed to pass through into the throttle body assy, the throttl...

  • Page 69

    Periodic maintenance 2-47 periodic maintenance procedures • remove: screws [a] air cleaner housing cover [b] • loosen the screw [a] to remove the air cleaner element [b]. • remove the screw from the element. • install a new element so that the screen side faces up- ward. Notice use only the recommen...

  • Page 70

    2-48 periodic maintenance periodic maintenance procedures fuel hose replacement • remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • be sure to place a piece of cloth [a] around the fuel hose joint. • insert a standard tip screwdriver [b] into the slit on the joint lock...

  • Page 71

    Periodic maintenance 2-49 periodic maintenance procedures coolant change warning coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it cool completely. Immediately wipe any spi...

  • Page 72

    2-50 periodic maintenance periodic maintenance procedures • take off the reserve tank from the frame. • remove the reserve tank cap, and pour the coolant into a suitable container. • hook the reserve tank to the frame again. • tighten the drain bolt with a new gasket. Torque - water pump drain bolt:...

  • Page 73

    Periodic maintenance 2-51 periodic maintenance procedures radiator hose and o-ring replacement • drain the coolant (see coolant change). • remove: thermostat housing [a] (see thermostat removal in the cooling system chapter) water pump cover [b] (see water pump removal in the cooling system chapter)...

  • Page 74

    2-52 periodic maintenance periodic maintenance procedures • pour in the specified type and amount of oil. Recommended engine oil type: api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity: sae 10w-40 capacity: 1.6 l (1.7 us qt) (when filter is not removed) 1.8 l (1.9 us qt) (when filter is re...

  • Page 75

    Periodic maintenance 2-53 periodic maintenance procedures brake hose and pipe replacement notice brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • remove the brake hose banjo bolts [a]. • remove the brake hoses [b], noting the follo...

  • Page 76

    2-54 periodic maintenance periodic maintenance procedures • install the brake hose, noting the following. ○ replace the washers [a] on each side of hose fitting [b] with new ones. ○ avoid sharp bending, kinking, flattening or twisting, and route the hoses according to cable, wire, and hose rout- ing...

  • Page 77

    Periodic maintenance 2-55 periodic maintenance procedures • change the brake fluid. ○ repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. 1. Open the bleed valve [a]. 2. Apply the brake and hold it [b]. 3. Close the bleed valve [c]. 4. Rel...

  • Page 78

    2-56 periodic maintenance periodic maintenance procedures rear master cylinder disassembly note ○ do not remove the push rod clevis for master cylinder disassembly since removal requires brake position ad- justment. • remove the rear master cylinder (see rear master cylin- der removal in the brakes ...

  • Page 79

    Periodic maintenance 2-57 periodic maintenance procedures • using compressed air, remove the pistons. ○ cover the piston area with a clean, thick cloth [a]. ○ blow compressed air [b] into the hole for the banjo bolt to remove the piston. Warning the piston in the brake caliper can crush hands and fi...

  • Page 80

    2-58 periodic maintenance periodic maintenance procedures • apply brake fluid to the outside of the pistons, and push them into each cylinder by hand. • check the friction boot [a] and the dust cover [b] replace them with new ones if they are damaged. • apply a thin coat of pbc (poly butyl cuprysil)...

  • Page 81

    Periodic maintenance 2-59 periodic maintenance procedures rear caliper assembly • clean the caliper parts except for the pads. Notice for cleaning of the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • install the bleed valve and rubber cap. Torque - caliper bleed valve: 7.8...

  • Page 82

    2-60 periodic maintenance periodic maintenance procedures • replace the spark plugs with new ones. Standard spark plug type: cr9eia-9 • insert the spark plug [a] into the plug wrench [b]. • install the spark plug into the plug hole, and hand-tighten it first. Notice the insulator of the spark plug m...

  • Page 83: Fuel System (Dfi)

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

  • Page 84

    3-2 fuel system (dfi) subthrottle sensor input voltage inspection..................................................................... 3-62 subthrottle sensor output voltage inspection .................................................................. 3-63 subthrottle sensor resistance inspection .....

  • Page 85

    Fuel system (dfi) 3-3 fuel injector resistance inspection .................................................................................. 3-96 fuel injector power source voltage inspection ................................................................ 3-97 fuel injector output voltage inspectio...

  • Page 86

    3-4 fuel system (dfi) exploded view.

  • Page 87

    Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air cleaner element screw 1.2 0.12 11 in·lb 2 air cleaner housing cover screws 1.2 0.12 11 in·lb 3 intake air temperature sensor screw 1.2 0.12 11 in·lb 4 air cleaner housing clamp bolt 2.0 0.20 18 in·lb 5 timing rotor...

  • Page 88

    3-6 fuel system (dfi) exploded view.

  • Page 89

    Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 switch housing screws 3.5 0.36 31 in·lb 2 fuel pump bolts 9.8 1.0 87 in·lb l, s 3. Other than sea-b1 and th models 4. Sea-b1 and th models 5. Au lams model 6. Throttle cable (accelerator) 7. Throttle cable (decelerator...

  • Page 90

    3-8 fuel system (dfi) exploded view sea-b1 and th models.

  • Page 91

    Fuel system (dfi) 3-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 purge valve mounting nut 7.0 0.71 62 in·lb 2. Canister 3. Purge valve.

  • Page 92

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

  • Page 93

    Fuel system (dfi) 3-11 dfi system 1. Ecu (electronic control unit) 2. Battery 3. Fuel tank 4. Fuel pump 5. Pressure regulator 6. Delivery pipe 7. Intake air temperature sensor 8. Subthrottle valve 9. Air cleaner housing 10. Subthrottle sensor 11. Main throttle valve 12. Air switching valve 13. Fuel ...

  • Page 94

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

  • Page 95

    Fuel system (dfi) 3-13 dfi system part name 1. Ecu 2. Joint connector b 3. Kawasaki diagnostic system connector 4. Fuel pump 5. Frame ground 1 6. Frame ground 2 7. Battery 12 v 10 ah 8. Main fuse 30 a 9. Relay box 10. Fuel pump relay 11. Ecu main relay 12. Radiator fan relay 13. Fuse box 1 14. Fi fu...

  • Page 96

    3-14 fuel system (dfi) dfi system terminal numbers of ecu connectors terminal names 1. Subthrottle valve actuator: bk/o 2. Subthrottle valve actuator: g/y 3. Unused 4. Oxygen sensor (equipped models): bl/y 5. Speed sensor: lg/r 6. Main throttle sensor: y/r 7. Intake air pressure sensor: y/bl 8. Powe...

  • Page 97

    Fuel system (dfi) 3-15 dfi parts location ignition switch [a] relay box [b] (ecu main relay, radiator fan relay, fuel pump relay) ecu [c] intake air temperature sensor [d] vehicle-down sensor [e] fuse box [f] (oxygen sensor heater fuse 10 a, radia- tor fan fuse 15 a, ecu fuse 15 a, ignition fuse 10 ...

  • Page 98

    3-16 fuel system (dfi) dfi parts location battery 12 v 10 ah [a] kawasaki diagnostic system connector [b] crankshaft sensor [a] speed sensor [a] neutral switch [b] oxygen sensor [a] (equipped models) purge valve [a] (sea-b1 and th models).

  • Page 99

    Fuel system (dfi) 3-17 specifications item standard digital fuel injection system idle speed 1 300 ±50 r/min (rpm) throttle body assy: throttle valve dual throttle valve bore 38 mm (1.5 in.) bypass screws (turn out) 0 ∼ 2 1/2 (for reference) ecu (electronic control unit): make denso type digital mem...

  • Page 100

    3-18 fuel system (dfi) specifications item standard output voltage with the sensor tilted 60 ∼ 70° or more: 0.65 ∼ 1.35 v with the sensor arrow mark pointed up: 3.55 ∼ 4.45 v subthrottle sensor: non-adjustable and non-removable input voltage dc 4.75 ∼ 5.25 v output voltage dc 0.6 ∼ 0.8 v at idle thr...

  • Page 101

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

  • Page 102

    3-20 fuel system (dfi) special tools and sealant oxygen sensor measuring adapter: 57001-1682 measuring adapter: 57001-1700 liquid gasket, tb1211: 56019-120

  • Page 103

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

  • Page 104

    3-22 fuel system (dfi) dfi servicing precautions ○ if the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see fuel tank removal) and check the fuel hose [a]. Replace the fuel hose if any fraying, cracks o...

  • Page 105

    Fuel system (dfi) 3-23 troubleshooting the dfi system outline when a problem occurs with dfi system, the yellow en- gine warning indicator light (led) [a] goes on or blinks to alert the rider. In addition, the condition of the problem is stored in the memory of the ecu. With the engine stopped and t...

  • Page 106

    3-24 fuel system (dfi) troubleshooting the dfi system even when the dfi system is operating normally, the yel- low engine warning indicator light (led) may go on under strong electrical interference. Additional measures are not required. Turn the ignition switch to off to stop the indica- tor light....

  • Page 107

    Fuel system (dfi) 3-25 troubleshooting the dfi system ○ after measurement, remove the needle adapters and ap- ply silicone sealant to the seals [a] of the connector [b] for waterproofing. Sealant - liquid gasket, tb1211: 56019-120 • always check battery condition before replacing the dfi parts. A fu...

  • Page 108

    3-26 fuel system (dfi) troubleshooting the dfi system ○ when checking a harness [a] for short circuit, open one end [b] and check the continuity between the other end [c] and ground [d]. If there is continuity, the harness has a short circuit to ground, and it must be repaired or re- placed. • narro...

  • Page 109

    Fuel system (dfi) 3-27 troubleshooting the dfi system inquiries to rider ○ each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ try to find out exactly what problem occurred under exactly what conditions by asking the rider...

  • Page 110

    3-28 fuel system (dfi) troubleshooting the dfi system □ very low idle speed, □ very high idle speed, □ rough idle speed □ battery voltage is low (charge the battery) □ spark plug loose (tighten it) □ spark plug dirty, broken, or gap maladjusted (remedy it) □ backfiring □ afterfiring □ hesitation whe...

  • Page 111

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

  • Page 112

    3-30 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions fuel pressure regulator trouble inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged inspect and repair (see chapter 3). Intake air pressure sensor trouble inspect (see chapter 3). W...

  • Page 113

    Fuel system (dfi) 3-31 dfi system troubleshooting guide symptoms or possible causes actions water temperature sensor trouble inspect (see chapter 3). Intake air temperature sensor trouble inspect (see chapter 3). Spark plug dirty, broken or gap maladjusted inspect and replace (see chapter 2). Stick ...

  • Page 114

    3-32 fuel system (dfi) dfi system troubleshooting guide poor running or no power at high speed symptoms or possible causes actions firing incorrect: stick coil shorted or not in good contact inspect or reinstall (see chapter 16). Stick coil trouble inspect (see chapter 16). Spark plug dirty, broken ...

  • Page 115

    Fuel system (dfi) 3-33 dfi system troubleshooting guide symptoms or possible causes actions engine overheating - water temperature sensor, crankshaft sensor or speed sensor trouble (see overheating of troubleshooting guide in chapter 17) air switching valve trouble inspect and replace (see chapter 1...

  • Page 116

    3-34 fuel system (dfi) self-diagnosis self-diagnosis outline the self-diagnosis system has 2 modes and can be switched to another mode by operating the meter unit. User mode the ecu notifies the rider of troubles in dfi system and ignition system by lighting the yellow engine warning indi- cator lig...

  • Page 117

    Fuel system (dfi) 3-35 self-diagnosis • turn the ignition switch to on. • press the left button [a] to display the odometer [b]. • press the left button [a] for more than 2 seconds. • the service code [b] is displayed on the lcd by the num- ber of two digits. • any of the following procedures ends s...

  • Page 118

    3-36 fuel system (dfi) self-diagnosis.

  • Page 119

    Fuel system (dfi) 3-37 self-diagnosis service code reading ○ the service code(s) is displayed on the lcd by the number of two digits. ○ when there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical or...

  • Page 120

    3-38 fuel system (dfi) self-diagnosis service code table service code problems 11 main throttle sensor malfunction, wiring open or short 12 intake air pressure sensor malfunction, wiring open or short 13 intake air temperature sensor malfunction, wiring open or short 14 water temperature sensor malf...

  • Page 121

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

  • Page 122

    3-40 fuel system (dfi) self-diagnosis service codes parts output signal usable range or criteria backups by ecu 39 ecu the ecu sends the data (for service code) to the meter unit. — 51 stick coil #1* the ecu must send signals continuously to the stick coil primary winding. If the stick coil #1 prima...

  • Page 123

    Fuel system (dfi) 3-41 main throttle sensor (service code 11) main throttle sensor removal/adjustment notice do not remove or adjust the main throttle sensor [a] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface. Such a ...

  • Page 124

    3-42 fuel system (dfi) main throttle sensor (service code 11) main throttle sensor output voltage inspection • measure the output voltage at the main throttle sensor in the same way as input voltage inspection, noting the following. ○ disconnect the main throttle sensor connector and con- nect the h...

  • Page 125

    Fuel system (dfi) 3-43 main throttle sensor (service code 11) if the output voltage is normal, check the wiring for conti- nuity. ○ disconnect the ecu and sensor connectors. Wiring continuity inspection ecu connector [a] ←→ main throttle sensor connector [b] y/r lead (ecu terminal 6) [c] br/bk lead ...

  • Page 126

    3-44 fuel system (dfi) intake air pressure sensor (service code 12) intake air pressure sensor removal notice never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. • remove the fuel tank (see fuel tank removal). • pull the intake air pressure sensor [a] rearwar...

  • Page 127

    Fuel system (dfi) 3-45 intake air pressure sensor (service code 12) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main harness connectors. Special tool - hand tester: 57001-1394 ○ disconnect the ecu and sensor connectors. Wiring continuity inspecti...

  • Page 128

    3-46 fuel system (dfi) intake air pressure sensor (service code 12) if the reading is within the usable range, remove the ecu and check the wiring for continuity between main harness connector. Special tool - hand tester: 57001-1394 ○ disconnect the ecu and sensor connectors. Wiring continuity inspe...

  • Page 129

    Fuel system (dfi) 3-47 intake air pressure sensor (service code 12) suppose: pg: vacuum pressure (gauge) to sensor pl: local atmospheric pressure (absolute) measured by a barometer pv: vacuum pressure (absolute) to sensor vv: sensor output voltage (v) then pv = pl – pg for example, suppose the follo...

  • Page 130

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

  • Page 131

    Fuel system (dfi) 3-49 intake air pressure sensor (service code 12) intake air pressure sensor circuit 1. Ecu 2. Intake air pressure sensor 3. Joint connector c.

  • Page 132

    3-50 fuel system (dfi) intake air temperature sensor (service code 13) intake air temperature sensor removal/instal- lation notice 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...

  • Page 133

    Fuel system (dfi) 3-51 intake air temperature sensor (service code 13) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main harness side connectors. Special tool - hand tester: 57001-1394 ○ disconnect the ecu and sensor connectors. Wiring continuity ...

  • Page 134

    3-52 fuel system (dfi) intake air temperature sensor (service code 13) intake air temperature sensor circuit 1. Ecu 2. Intake air temperature sensor 3. Joint connector d.

  • Page 135

    Fuel system (dfi) 3-53 water temperature sensor (service code 14) water temperature sensor removal/installation notice 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). • discon...

  • Page 136

    3-54 fuel system (dfi) water temperature sensor (service code 14) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main harness connectors. Special tool - hand tester: 57001-1394 ○ disconnect the ecu and sensor connectors. Wiring continuity inspection...

  • Page 137

    Fuel system (dfi) 3-55 crankshaft sensor (service code 21) the crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no sig- nals. Crankshaft sensor removal/installation • refer to the crankshaft sensor removal/installation in the electrical system chapter...

  • Page 138

    3-56 fuel system (dfi) speed sensor (service code 24, 25) speed sensor removal/installation • refer to the speed sensor removal/installation in the electrical system chapter. Speed sensor inspection • refer to the speed sensor inspection in the electrical system chapter. Speed sensor input voltage i...

  • Page 139

    Fuel system (dfi) 3-57 speed sensor (service code 24, 25) speed sensor output voltage inspection • before this inspection, inspect the input voltage (see speed sensor input voltage inspection). Note ○ be sure the battery is fully charged. • turn the ignition switch to off. • disconnect the speed sen...

  • Page 140

    3-58 fuel system (dfi) speed sensor (service code 24, 25) speed sensor circuit 1. Ecu 2. Joint connector d 3. Joint connector c 4. Speed sensor 5. Meter unit.

  • Page 141

    Fuel system (dfi) 3-59 vehicle-down sensor (service code 31) vehicle-down sensor removal/installation notice never drop the vehicle-down sensor especially on a hard surface. Such a shock to the sensor can damage it. • remove: fuel tank (see fuel tank removal) fuel tank bracket (see air cleaner eleme...

  • Page 142

    3-60 fuel system (dfi) vehicle-down sensor (service code 31) • remove the vehicle-down sensor (see vehicle-down sensor removal/installation). ○ do not disconnect the sensor connector. • connect a digital meter [a] to the connector with needle adapter set [b]. Special tool - needle adapter set: 57001...

  • Page 143

    Fuel system (dfi) 3-61 vehicle-down sensor (service code 31) vehicle-down sensor circuit 1. Ecu 2. Vehicle-down sensor 3. Joint connector c.

  • Page 144

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

  • Page 145

    Fuel system (dfi) 3-63 subthrottle sensor (service code 32) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main harness connectors. Special tool - hand tester: 57001-1394 ○ disconnect the ecu and sensor connectors. Wiring continuity inspection ecu c...

  • Page 146

    3-64 fuel system (dfi) subthrottle sensor (service code 32) subthrottle sensor output voltage connections to adapter: digital meter (+) → y/w (sensor br) lead digital meter (–) → bk/bl (sensor br/bk) lead • turn the ignition switch to on. • measure the output voltage when the subthrottle valve is fu...

  • Page 147

    Fuel system (dfi) 3-65 subthrottle sensor (service code 32) subthrottle sensor resistance inspection • turn the ignition switch to off. • disconnect the subthrottle sensor connector. • connect a digital meter [a] to the subthrottle sensor con- nector [b]. • measure the subthrottle sensor resistance....

  • Page 148

    3-66 fuel system (dfi) oxygen sensor-not activated (service code 33) (equipped models) oxygen sensor removal/installation • refer to the oxygen sensor removal/installation in the electrical system chapter. Oxygen sensor inspection • turn the ignition switch to off. • remove the engine sprocket cover...

  • Page 149

    Fuel system (dfi) 3-67 oxygen sensor-not activated (service code 33) (equipped models) if the reading is out of the standard (with plug: dc 0.7 v or more, without plug: dc 0.2 v or less), remove the ecu and check the wiring for continuity between main harness connectors. Special tool - hand tester: ...

  • Page 150

    3-68 fuel system (dfi) oxygen sensor-not activated (service code 33) (equipped models) oxygen sensor circuit 1. Ignition switch 2. Oxygen sensor 3. Ecu 4. Frame ground 2 5. Battery 12 v 10 ah 6. Main fuse 30 a 7. Relay box 8. Ecu main relay 9. Fuse box 1 10. Fi fuse 15 a 11. Ignition fuse 10 a.

  • Page 151

    Fuel system (dfi) 3-69 stick coils #1, #2: (service code 51, 52) stick coil #1: service code 51 stick coil #2: service code 52 stick coil removal/installation • refer to the stick coil removal/installation in the electri- cal system chapter. Stick coil primary winding resistance inspection • refer t...

  • Page 152

    3-70 fuel system (dfi) stick coils #1, #2: (service code 51, 52) stick coil circuit 1. Ignition switch 2. Engine stop switch 3. Stick coils 4. Ecu 5. Frame ground 6. Battery 12 v 10 ah 7. Main fuse 30 a 8. Fuse box 1 9. Ignition fuse 10 a.

  • Page 153

    Fuel system (dfi) 3-71 radiator fan relay (service code 56) radiator fan relay removal/installation ○ the radiator fan relay is built in the relay box [a]. • refer to the relay box removal in the electrical system chapter. Radiator fan relay inspection • refer to the relay circuit inspection in the ...

  • Page 154

    3-72 fuel system (dfi) subthrottle valve actuator (service code 62) subthrottle valve actuator removal notice do not remove the subthrottle valve actuator [a] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface. Such a sho...

  • Page 155

    Fuel system (dfi) 3-73 subthrottle valve actuator (service code 62) subthrottle valve actuator input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch to off. • disconnect the subthrottle valve actuator connector and connect the harness adapter [a] between th...

  • Page 156

    3-74 fuel system (dfi) subthrottle valve actuator (service code 62) subthrottle valve actuator circuit 1. Ecu 2. Subthrottle valve actuator.

  • Page 157

    Fuel system (dfi) 3-75 air switching valve (service code 64) air switching valve removal/installation • refer to the air switching valve removal/installation in the engine top end chapter. Air switching valve inspection • refer to the air switching valve operation test/unit test in the electrical sy...

  • Page 158

    3-76 fuel system (dfi) oxygen sensor heater (service code 67) (equipped models) 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 ch...

  • Page 159

    Fuel system (dfi) 3-77 oxygen sensor heater (service code 67) (equipped models) oxygen sensor heater power source voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch to off. • disconnect the oxygen sensor lead connector and con- nect the oxygen sensor measuring...

  • Page 160

    3-78 fuel system (dfi) oxygen sensor heater (service code 67) (equipped models) oxygen sensor circuit 1. Ignition switch 2. Oxygen sensor 3. Ecu 4. Frame ground 2 5. Battery 12 v 10 ah 6. Main fuse 30 a 7. Relay box 8. Ecu main relay 9. Fuse box 1 10. Fi fuse 15 a 11. Ignition fuse 10 a.

  • Page 161

    Fuel system (dfi) 3-79 oxygen sensor-incorrect output voltage (service code 94) (equipped models) oxygen sensor removal/installation • refer to the oxygen sensor removal/installation in the electrical system chapter. Oxygen sensor inspection • turn the ignition switch to off. • remove the engine spr...

  • Page 162

    3-80 fuel system (dfi) oxygen sensor-incorrect output voltage (service code 94) (equipped models) • next, remove the plug from the fitting [a] with idling. Warning the engine gets extremely hot during normal oper- ation and can cause serious burns. Never touch a hot engine. • measure the output volt...

  • Page 163

    Fuel system (dfi) 3-81 oxygen sensor-incorrect output voltage (service code 94) (equipped models) oxygen sensor circuit 1. Ignition switch 2. Oxygen sensor 3. Ecu 4. Frame ground 2 5. Battery 12 v 10 ah 6. Main fuse 30 a 7. Relay box 8. Ecu main relay 9. Fuse box 1 10. Fi fuse 15 a 11. Ignition fuse...

  • Page 164

    3-82 fuel system (dfi) purge valve (service code 3a) (sea-b1 and th models) purge valve removal/installation • remove: left frame cover (see frame cover removal in the frame chapter) purge valve connector [a] (disconnect) tubes [b] (disconnect) purge valve mounting nut [c] purge valve [d] • installa...

  • Page 165

    Fuel system (dfi) 3-83 purge valve (service code 3a) (sea-b1 and th models) • disconnect the 12 v battery. • blow the air to the intake air duct [a] again, and make sure that the air does not flow from the outlet air duct [b]. If the purge valve dose not operate as described, replace it with a new o...

  • Page 166

    3-84 fuel system (dfi) yellow engine warning indicator light (led) yellow engine warning indicator light (led) inspection • refer to the electronic combination meter unit inspection in the electrical system chapter. Yellow engine warning indicator light (led) circuit for dfi system 1. Ecu 2. Meter u...

  • Page 167

    Fuel system (dfi) 3-85 ecu ecu identification ○ most countries have their own regulations, so each ecu has different characteristic. So, do not confuse ecu with each other and use only the ecu for your model. Other- wise, the motorcycle can not clear the regulation. Ecu identification part number [a...

  • Page 168

    3-86 fuel system (dfi) ecu • turn the ignition switch to off. • disconnect the ecu connectors [a]. • set the hand tester [b] to the × 1 Ω range and check the following wiring for continuity. Special tool - hand tester: 57001-1394 ecu grounding continuity inspection connections: (i) bk lead (ecu term...

  • Page 169

    Fuel system (dfi) 3-87 ecu ecu power source circuit 1. Ecu 2. Frame ground 1 3. Frame ground 2 4. Battery 12 v 10 ah 5. Main fuse 30 a 6. Relay box 7. Ecu main relay 8. Fuse box 1 9. Fi fuse 15 a 10. Ignition fuse 10 a 11. Ignition switch.

  • Page 170

    3-88 fuel system (dfi) dfi power source ecu fuse removal • refer to the 15 a ecu fuse removal in the electrical system chapter. Ecu fuse installation if a fuse fails during operation, inspect the dfi system to determine the cause, and then replace it with a new fuse of proper amperage. • refer to th...

  • Page 171

    Fuel system (dfi) 3-89 fuel line fuel pressure inspection note ○ be sure the battery is fully charged. • remove: fuel tank (see fuel tank removal) fuel hose (see fuel hose replacement in the periodic maintenance chapter) ○ be sure to place a piece of cloth around the fuel supply pipes of the fuel pu...

  • Page 172

    3-90 fuel system (dfi) fuel line note ○ the gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. • turn the ignition switch to off. If the fuel pressure is much higher than specified, the fuel pressure regulator in the fuel pump have been clogged or s...

  • Page 173

    Fuel system (dfi) 3-91 fuel line • open the fuel tank cap [a] to lower the pressure in the tank. • remove the fuel hose from the fuel pump (see fuel tank removal). ○ be sure to place a piece of cloth around the fuel supply pipe of the fuel pump. Warning fuel is flammable and explosive under certain ...

  • Page 174

    3-92 fuel system (dfi) fuel pump fuel pump removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a ...

  • Page 175

    Fuel system (dfi) 3-93 fuel pump • replace the fuel pump gasket [a] with a new one and apply grease to it. • apply a non-permanent locking agent to the threads of the fuel pump bolts. • tighten the fuel pump bolts to a snug fit, and tighten them alternating diagonally. Torque - fuel pump bolts: 9.8 ...

  • Page 176

    3-94 fuel system (dfi) fuel pump fuel pump operating voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch to off. • remove the left side cover (see side cover removal in the frame chapter). • disconnect the fuel pump lead connector and connect the harness adapte...

  • Page 177

    Fuel system (dfi) 3-95 fuel pump pressure regulator removal ○ the pressure regulator [a] is built into the fuel pump [b] and cannot be removed. Fuel filter cleaning ○ the fuel filter [a] is built into the pump and cannot be cleaned or checked. If the pump screen or fuel filter is suspected of cloggi...

  • Page 178

    3-96 fuel system (dfi) fuel injectors fuel injector removal/installation • refer to the throttle body assy disassembly/assembly. Fuel injector audible inspection • start the engine, and let it to idle. • apply the tip of a screwdriver [a] to the fuel injector [b]. Put the grip end onto your ear, and...

  • Page 179

    Fuel system (dfi) 3-97 fuel injectors fuel injector power source voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch to off. • disconnect the injector connector and connect the har- ness adapter [a] between these connectors as shown in the figure. Main harness ...

  • Page 180

    3-98 fuel system (dfi) fuel injectors fuel injector output voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch to off. • remove the ecu (see ecu removal). ○ do not disconnect the ecu connector. • connect a digital meter [a] to the connector [b] with the needle ...

  • Page 181

    Fuel system (dfi) 3-99 fuel injectors fuel injector fuel line inspection • remove: fuel tank (see fuel tank removal) fuel hose (see fuel hose replacement in the periodic maintenance chapter) ○ be sure to place a piece of cloth around the fuel supply pipes of the fuel pump and the throttle body assy....

  • Page 182

    3-100 fuel system (dfi) fuel injectors fuel injector circuit 1. Ignition switch 2. Engine stop switch 3. Fuel injectors 4. Ecu 5. Frame ground 1 6. Frame ground 2 7. Battery 12 v 10 ah 8. Main fuse 30 a 9. Relay box 10. Ecu main relay 11. Fuel pump relay 12. Fuse box 1 13. Fi fuse 15 a 14. Ignition ...

  • Page 183

    Fuel system (dfi) 3-101 throttle grip and cables throttle grip free play inspection • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Throttle grip free play adjustment • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Thr...

  • Page 184

    3-102 fuel system (dfi) throttle body assy idle speed inspection/adjustment • refer to the idle speed inspection/adjustment in the pe- riodic maintenance chapter. Synchronization inspection/adjustment • refer to the engine vacuum synchronization inspection in the periodic maintenance chapter. Thrott...

  • Page 185

    Fuel system (dfi) 3-103 throttle body assy • pull the throttle body assy [a] out of the holder. • disconnect the subthrottle sensor connector [b]. • loosen the locknut [a] and screw the adjuster [b] to give the throttle grip plenty of play. • remove the clamp [c]. • pull the throttle cables out of t...

  • Page 186

    3-104 fuel system (dfi) throttle body assy • install the throttle body assy holder clamp bolts [a] so that their bolt heads [b] face outward. • install the throttle body assy onto the holder securely. • tighten: torque - throttle body assy holder clamp bolts: 2.0 n·m (0.20 kgf·m, 18 in·lb) • turn th...

  • Page 187

    Fuel system (dfi) 3-105 throttle body assy • remove: throttle body assy (see throttle body assy removal) screws [a] • pull out the fuel injectors [b] from the throttle body assy together with the delivery pipe [c]. • pull out the fuel injectors from the delivery pipe. Throttle body assy assembly • r...

  • Page 188

    3-106 fuel system (dfi) air cleaner air cleaner element removal/installation • refer to the air cleaner element replacement in the pe- riodic maintenance chapter. Air cleaner element inspection • remove the air cleaner element (see air cleaner element replacement in the periodic maintenance chapter)...

  • Page 189

    Fuel system (dfi) 3-107 air cleaner • pull out the air cleaner housing [a] from the throttle body assy. • disconnect the air switching valve hose [b] from the hous- ing. Air cleaner housing installation • installation is the reverse of removal. ○ install the air cleaner housing onto the throttle bod...

  • Page 190

    3-108 fuel system (dfi) fuel tank fuel tank removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a...

  • Page 191

    Fuel system (dfi) 3-109 fuel tank • remove the fuel tank bolts [a] and washers. • draw the fuel out from the fuel tank with a commercially available pump [a]. ○ use a soft plastic hose [b] as a pump intake hose in order to insert the hose smoothly. ○ put the hose through the fill opening [c] into th...

  • Page 192

    3-110 fuel system (dfi) fuel tank • turn the driver [a] to disconnect the joint lock [b]. • pull the fuel hose joint [c] out of the outlet pipe [d]. Warning fuel is flammable and explosive under certain con- ditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be ...

  • Page 193

    Fuel system (dfi) 3-111 fuel tank • push and pull [a] the hose joint [b] back and forth more than 2 times and make sure it is locked and does not come off. Warning leaking fuel can cause a fire or explosion resulting in serious burns. Make sure the hose joint is in- stalled correctly on the delivery...

  • Page 194

    3-112 fuel system (dfi) fuel tank fuel tank cleaning warning gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the tank in a well-ventilated area, and take care that there are no sparks or flame any- where near the working area. Do not use gasoline...

  • Page 195

    Fuel system (dfi) 3-113 evaporative emission control system (sea-b1 and th models) the evaporative emission control system routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorou...

  • Page 197: Cooling System

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

  • Page 198

    4-2 cooling system exploded view.

  • Page 199

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 radiator bolt 7.9 0.81 70 in·lb 2 coolant reserve tank mounting bolts 7.9 0.81 70 in·lb 3 water temperature sensor 12 1.2 106 in·lb 4 water hose clamp screws 3.0 0.31 27 in·lb 5 thermostat housing bolts 9.8 1.0 87 in·lb 6...

  • Page 200

    4-4 cooling system coolant flow chart.

  • Page 201

    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 202

    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 203

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

  • Page 204

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

  • Page 205

    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 206

    4-10 cooling system water pump water pump removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: water hose [a] water pump cover bolts [b] water pump cover [c] • shift the transmission into 1st gear. • while applying the rear brake, remove the water pump impe...

  • Page 207

    Cooling system 4-11 water pump • be sure that the dowel pins [a] are in position. • install the water pump cover and the bolts. [a] l = 40 mm (1.6 in.) [b] l = 30 mm (1.2 in.) • tighten: torque - water pump cover bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • when installing the water hose, align the white ...

  • Page 208

    4-12 cooling system water pump water pump housing disassembly notice be careful not to damage the sealing surface of the mechanical seal. • remove the water pump housing (see water pump re- moval). • take the oil seal [a] out of the housing [b] with a hook [c]. • press the mechanical seal [a] out of...

  • Page 209

    Cooling system 4-13 radiator radiator and radiator fan removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove the left center fairing (see center fairing re- moval in the frame chapter). • disconnect the radiator fan lead connector [a]. • remove the water hose...

  • Page 210

    4-14 cooling system radiator radiator and radiator fan installation • install the radiator fan [a] and tighten the bolts. • install the rubber dampers [b] and collar [c] to the radiator and frame. • install the radiator so that the projections [d] on the frame fit into the holes [e] on the dampers. ...

  • Page 211

    Cooling system 4-15 radiator radiator inspection • remove the radiator (see radiator and radiator fan re- moval). • inspect the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [a] are deformed, carefully straighten them. If the air passages of the radiator c...

  • Page 212

    4-16 cooling system radiator radiator filler neck inspection • remove the radiator cap (see coolant change in the pe- riodic maintenance chapter). • inspect the radiator filler neck for signs of damage. • inspect the condition of the top and bottom sealing seats [a] in the filler neck. They must be ...

  • Page 213

    Cooling system 4-17 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) water hose [a] thermostat housing bolts [b] thermostat housing [c] • pull the thermostat [a]...

  • Page 214

    4-18 cooling system thermostat thermostat inspection • remove the thermostat (see thermostat removal), and inspect the thermostat valve [a] at room temperature. If the valve is open, replace the thermostat with a new one. • to check valve opening temperature, suspend the ther- mostat [a] in a contai...

  • Page 215

    Cooling system 4-19 hose and pipes hose installation • install the hoses, being careful to follow bending direction. Avoid sharp bending, kinking, flattening or twisting. • run the hoses correctly (see cable, wire, and hose rout- ing section in the appendix chapter). • install the clamp [a] as near ...

  • Page 216

    4-20 cooling system water temperature sensor water temperature sensor removal/installation • refer to the water temperature sensor removal/instal- lation in the fuel system (dfi) chapter. Water temperature sensor inspection • refer to the water temperature sensor inspection in the electrical system ...

  • Page 217: Engine Top End

    Engine top end 5-1 5 engine top end table of contents exploded view................................... 5-2 exhaust system identification ........... 5-6 specifications .................................... 5-7 special tools and sealant ................. 5-9 clean air system..............................

  • Page 218

    5-2 engine top end exploded view.

  • Page 219

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 baffle plate bolts 5.9 0.60 52 in·lb 2 air suction valve cover bolts 9.8 1.0 87 in·lb 3 cylinder head cover bolts 9.8 1.0 87 in·lb 4 camshaft cap bolts 12 1.2 106 in·lb s 5 throttle body assy holder clamp bolts 2.0 0.20 1...

  • Page 220

    5-4 engine top end exploded view.

  • Page 221

    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 bolts (m6) 12 1.2 106 in·lb l, s 3 cylinder nut 49 5.0 36 mo, s 4 exhaust pipe manifold holder nuts 17 1.7 13 5 muffler body mounting bolts 20 2.0 15 l: apply a non-permanent...

  • Page 222

    5-6 engine top end exhaust system identification exhaust system muffler mark position [a] honeycomb type catalyst position [a] muffler with hole [a] for oxygen sensor [b].

  • Page 223

    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 (1.407 in.) intake 36.543 ∼ 36.657 mm (1.4387 ∼ 1.4432 in.) 36.44 mm (1.435 in.) camshaft journal, camshaft cap clearance 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in...

  • Page 224

    5-8 engine top end specifications item standard service limit valve spring free length: exhaust 41.91 mm (1.650 in.) 40.3 mm (1.59 in.) intake 41.91 mm (1.650 in.) 40.3 mm (1.59 in.) cylinder, pistons cylinder inside diameter 82.994 ∼ 83.006 mm (3.2675 ∼ 3.2679 in.) 83.09 mm (3.271 in.) piston diame...

  • Page 225

    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 226

    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 filler cap driver: 57001-1454 piston pin puller: 57001-1568 piston pin puller adapter, 12: 5...

  • Page 227

    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 (see air switching valve removal) air suction valve c...

  • Page 228

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

  • Page 229

    Engine top end 5-13 clean air system clean air system hose inspection • be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the air cleaner housing, air switching valve and air suction valve cover. If they are not, correct them. Replace them i...

  • Page 230

    5-14 engine top end cylinder head cover cylinder head cover removal • remove the right center fairing (see center fairing re- moval in the frame chapter). • remove the radiator bolt [a] and lower the radiator [b] for extra clearance. • for models equipped with an abs, remove the bolt [a] and damper ...

  • Page 231

    Engine top end 5-15 cylinder head cover cylinder head cover installation • replace the head cover gasket [a] with a new one. • clean off any oil or dirt and apply liquid gasket to the areas [b] on the cylinder. Sealant - liquid gasket, tb1216b: 92104-1064 • replace the plug hole gaskets [a] with new...

  • Page 232

    5-16 engine top end cylinder head cover • be sure that the dampers [a] of the baffle plate are in position. • tighten: torque - baffle plate bolts: 5.9 n·m (0.60 kgf·m, 52 in·lb) • install the other removed parts (see appropriate chap- ters)..

  • Page 233

    Engine top end 5-17 camshaft chain tensioner camshaft chain tensioner removal notice 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 tens...

  • Page 234

    5-18 engine top end camshaft chain tensioner • install the tensioner body so that the stopper [a] faces upward. • apply a non-permanent locking agent to the camshaft chain tensioner mounting bolts and tighten them. Torque - camshaft chain tensioner mounting bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • ins...

  • Page 235

    Engine top end 5-19 camshaft, camshaft chain camshaft removal • remove: cylinder head cover (see cylinder head cover re- moval) timing inspection cap [a] timing rotor bolt cap [b] special tool - filler cap driver [c]: 57001-1454 • using a wrench on the timing rotor bolt [a], turn the crank- shaft cl...

  • Page 236

    5-20 engine top end camshaft, camshaft chain • remove the camshaft chain tensioner (see camshaft chain tensioner removal). • loosen the camshaft cap bolts following the sequence [1 ∼ 12 ] shown in the figure, and remove them. • remove: camshaft caps [a] camshafts [b] notice the crankshaft may be tur...

  • Page 237

    Engine top end 5-21 camshaft, camshaft chain camshaft installation • replace the plug hole gaskets [a] with new ones. • be sure to install the following parts. Dowel pins [b] plug hole gaskets • install the camshaft sprockets so that the marked (“in" and “ex”) side faces outward. ○ the intake [a] an...

  • Page 238

    5-22 engine top end camshaft, camshaft chain • using a wrench on the timing rotor bolt [a], turn the crank- shaft clockwise until the 2/t mark line [b] on the timing rotor is aligned with the notch [c] in the edge of the timing inspection hole in the clutch cover. Notice the crankshaft may be turned...

  • Page 239

    Engine top end 5-23 camshaft, camshaft chain • before installing the camshaft caps, install the camshaft chain tensioner body temporarily (see camshaft chain tensioner installation). • install the camshaft caps as shown. Note ○ the exhaust cap has an “ex” mark [a] and the intake cap has an “in” mark...

  • Page 240

    5-24 engine top end camshaft, camshaft chain camshaft, camshaft cap wear inspection • remove the camshaft caps (see camshaft removal). • cut strips of plastigage (press gauge) to journal width. Place a strip on each journal parallel to the camshaft in- stalled in the correct position. • tighten the ...

  • Page 241

    Engine top end 5-25 camshaft, camshaft chain camshaft chain removal • split the crankcase (see crankcase splitting in the crank- shaft/transmission chapter). • remove the camshaft chain [a] from the crankshaft sprocket..

  • Page 242

    5-26 engine top end cylinder head cylinder compression measurement note ○ be sure the battery is fully charged. • warm up the engine thoroughly. • stop the engine. • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) air cleaner housing (see air cleaner housing removal in the...

  • Page 243

    Engine top end 5-27 cylinder head cylinder head removal • drain: engine oil (see engine oil change in the periodic main- tenance chapter) coolant (see coolant change in the periodic mainte- nance chapter) • remove: muffler (see muffler removal) cylinder head cover (see cylinder head cover re- moval)...

  • Page 244

    5-28 engine top end cylinder head • apply molybdenum disulfide oil solution [a] to both sides of washers and the threads of bolts and nut. M10 cylinder head bolts [b] m10 cylinder nut [c] m8 cylinder bolt [d] • tighten the all bolts and nut following the tightening se- quence [1 ∼ 8]. Torque - cylin...

  • Page 245

    Engine top end 5-29 cylinder head • install the front camshaft chain guide [a]. ○ insert the end [b] of front camshaft chain guide into the hollow on the lower crankcase half. • install the other removed parts (see appropriate chap- ters). Cylinder head warp inspection • remove the cylinder head (se...

  • Page 246

    5-30 engine top end valves valve clearance inspection • refer to the valve clearance inspection in the periodic maintenance chapter. Valve clearance adjustment • refer to the valve clearance adjustment in the periodic maintenance chapter. Valve removal • remove cylinder head (see cylinder head remov...

  • Page 247

    Engine top end 5-31 valves valve guide installation • apply engine oil to the valve guide outer surface before installation. • heat the area around the valve guide hole to about 120 ∼ 150°c (248 ∼ 302°f). • drive the valve guide in from the top of the head using the valve guide arbor. The flange sto...

  • Page 248

    5-32 engine top end valves valve seat inspection • remove the valve (see valve removal). • check the valve seating surface [a] between the valve [b] and valve seat [c]. ○ measure the outside diameter [d] of the seating pattern on the valve seat. If the outside diameter is too large or too small, rep...

  • Page 249

    Engine top end 5-33 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 250

    5-34 engine top end valves • measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range. Widened width [a] of engagement by machining with 45° cutter ...

  • Page 251

    Engine top end 5-35 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 252

    5-36 engine top end valves.

  • Page 253

    Engine top end 5-37 cylinder, pistons cylinder removal • remove: cylinder head (see cylinder head removal) front engine mounting bolts [a] and nuts (left and right) collar [b] cylinder [c] cylinder installation note ○ if a new cylinder is used, use new piston ring. • be sure that the dowel pins [a] ...

  • Page 254

    5-38 engine top end cylinder, pistons piston removal • remove the cylinder (see cylinder removal). • place a clean cloth under the pistons. • remove the piston pin snap ring [a] by using the pliers [b] from the outside of each piston. • remove the piston pins. Special tools - piston pin puller [a]: ...

  • Page 255

    Engine top end 5-39 cylinder, pistons • apply molybdenum disulfide oil solution to the top and second rings. • do not mix up the top and second ring. • install the top ring [a] so that the "r" mark [b] faces up. • install the second ring [c] so that the "rn" mark [d] faces up. Note ○ if a new piston...

  • Page 256

    5-40 engine top end cylinder, pistons piston wear inspection • measure the outside diameter [a] of each piston 18 mm (0.7087 in.) [b] up from the bottom of the piston at a right angle to the direction of the piston pin. If the measurement is under service limit, replace the pis- ton. Piston diameter...

  • Page 257

    Engine top end 5-41 cylinder, pistons piston ring thickness inspection • measure the piston ring thickness. ○ use the micrometer to measure at several points around the ring. Piston ring thickness standard: top [a] 0.87 ∼ 0.89 mm (0.0343 ∼ 0.0350 in.) second [b] 0.97 ∼ 0.99 mm (0.0382 ∼ 0.0390 in.) ...

  • Page 258

    5-42 engine top end throttle body assy holder throttle body assy holder removal • remove: throttle body assy (see throttle body assy removal in the fuel system (dfi) chapter) clamps [a] bolts [b] throttle body assy holders [c] throttle body assy holder installation • replace the o-rings [a] with new...

  • Page 259

    Engine top end 5-43 muffler muffler removal warning the muffler can become extremely hot during nor- mal operation and cause severe burns. Do not re- move the muffler while it is hot. • remove: frame covers (see frame cover removal in the frame chapter) right footpeg stay (see footpeg stay removal i...

  • Page 260

    5-44 engine top end muffler muffler installation • installation is the reverse of removal. ○ replace the exhaust pipe gaskets [a] with new ones. ○ tighten: torque - exhaust pipe manifold holder nuts: 17 n·m (1.7 kgf·m, 13 ft·lb) muffler body mounting bolts [b]: 20 n·m (2.0 kgf·m, 15 ft·lb) ○ for oxy...

  • Page 261: Clutch

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

  • Page 262

    6-2 clutch exploded view.

  • Page 263

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 clutch cable clamp bracket bolt 9.8 1.0 87 in·lb 2 clutch cable holder bolts 9.8 1.0 87 in·lb l 3 clutch cover bolts 9.8 1.0 87 in·lb 4 clutch hub nut 130 13.3 96 r 5 clutch spring bolts 9.8 1.0 87 in·lb 6 timing inspection cap 3...

  • Page 264

    6-4 clutch specifications item standard service limit clutch lever 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.) 2.7 mm (0.106 in.) friction plate warp 0.15 mm (0.059 in.) or less 0.3 mm (0.012 in.) steel plate warp 0.2 mm ...

  • Page 265

    Clutch 6-5 special tools and sealant clutch holder: 57001-1243 filler cap driver: 57001-1454 liquid gasket, tb1211f: 92104-0004.

  • Page 266

    6-6 clutch clutch lever and cable clutch lever free play inspection • refer to the clutch operation inspection in the periodic maintenance chapter. Clutch lever free play adjustment • refer to the clutch operation inspection in the periodic maintenance chapter. Clutch cable removal • open the clamp ...

  • Page 267

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

  • Page 268

    6-8 clutch clutch cover clutch cover removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: right frame cover (see frame cover removal in the frame chapter) lower fairing (see lower fairing removal in the frame chapter) clutch cable holder bolts [a] c...

  • Page 269

    Clutch 6-9 clutch cover release shaft removal notice 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 [a] stra...

  • Page 270

    6-10 clutch clutch cover clutch cover assembly • replace the needle bearings [a] and oil seal [b] with new ones. Note ○ install the needle bearings so that the manufacture’s mark face out. • install the needle bearings and oil seal as shown. ○ press [c] the bearings so that the bearing surface [d] a...

  • Page 271

    Clutch 6-11 clutch clutch removal • remove: clutch cover (see clutch cover removal) clutch spring bolts and washers [a] clutch springs clutch spring plate [b] (with bearing) pusher [c] friction plates steel plates • hold the clutch hub [a] steady with the clutch holder [b], and remove the clutch hub...

  • Page 272

    6-12 clutch clutch clutch installation • install the oil pump chain guide [a]. • apply a non-permanent locking agent to the upper chain guide bolts [b]. • tighten: torque - oil pump chain guide bolts: 12 n·m (1.2 kgf·m, 106 in·lb) • install the spacer [c] onto the drive shaft. • put the oil pump cha...

  • Page 273

    Clutch 6-13 clutch • install the washer so that the out side mark [a] faces outward. • replace the clutch hub nut [a] with a new one. • hold the clutch hub [b] steady with the clutch holder [c], and tighten the clutch hub nut. Special tool - clutch holder: 57001-1243 torque - clutch hub nut: 130 n·m...

  • Page 274

    6-14 clutch clutch clutch plate, wear, damage inspection • visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. • measure the thickness of each friction plate [a] at several points. If any plates show signs of damage, or if they have worn ...

  • Page 275

    Clutch 6-15 clutch clutch housing spline inspection • visually inspect where the teeth [a] on the steel plates wear against the clutch hub splines [b]. If there are notches worn into the splines, replace the clutch hub. Also, replace the steel plates if their teeth are damaged..

  • Page 277: Engine Lubrication System

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

  • Page 278

    7-2 engine lubrication system exploded view.

  • Page 279

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oil filter 17.5 1.8 13 eo, r 2 holder mounting bolt 25 2.5 18 l 3 oil passage plug (m6) 3.5 0.36 31 in·lb 4 oil passage plug 20 2.0 15 l 5 oil pressure switch 15 1.5 11 lg 6 oil plate bolts 9.8 1.0 87 in·lb l 7...

  • Page 280

    7-4 engine lubrication system engine oil flow chart.

  • Page 281

    Engine lubrication system 7-5 engine oil flow chart.

  • Page 282

    7-6 engine lubrication system specifications item standard engine oil type api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity sae 10w-40 capacity: 1.6 l (1.7 us gt) (when filter is not removed) 1.8 l (1.9 us gt) (when filter is removed) 2.3 l (2.4 us gt) (when engine is completely dry) leve...

  • Page 283

    Engine lubrication system 7-7 special tools and sealant oil pressure gauge, 10 kgf/cm²: 57001-164 oil pressure gauge adapter, pt3/8: 57001-1233 liquid gasket, tb1211: 56019-120

  • Page 284

    7-8 engine lubrication system engine oil and oil filter warning vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter accordin...

  • Page 285

    Engine lubrication system 7-9 oil pan oil pan removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: lower fairing (see lower fairing removal in the frame chapter) lower fairing brackets (see lower fairing bracket re- moval in the frame chapter) muffl...

  • Page 286

    7-10 engine lubrication system oil pan oil pan installation if the following parts were removed, install them in the following procedure. Oil pipes oil pipe plate dampers oil screen filter filter plate ○ replace the o-rings with new ones. ○ apply grease to the o-rings on the oil pipes [a]. ○ install...

  • Page 287

    Engine lubrication system 7-11 oil pan • tighten the oil pan bolts following the specified tightening sequence. Torque - oil pan bolts: 12 n·m (1.2 kgf·m, 106 in·lb).

  • Page 288

    7-12 engine lubrication system oil pressure relief valve oil pressure relief valve removal • remove: oil pan (see oil pan removal) oil pressure relief valve [a] oil pressure relief valve installation • apply a non-permanent locking agent to the threads of the oil pressure relief valve, and tighten i...

  • Page 289

    Engine lubrication system 7-13 oil pump oil pump removal • remove: clutch (see clutch removal in the clutch chapter) oil pump cover bolts [a] • temporarily install the oil pump sprocket bolt [a]. Note ○ the oil pump sprocket bolt has a left-hand threads. • using the oil pump sprocket bolt, pull out ...

  • Page 290

    7-14 engine lubrication system oil pump • remove the pin [a]. • remove: pin [a] inner rotor for feed pump [b] oil pump shaft [c] oil pump installation • apply molybdenum disulfide oil solution to the portion [a] of the oil pump shaft as shown in the figure. • assemble the following parts. Oil pump s...

  • Page 291

    Engine lubrication system 7-15 oil pump • be sure that the dowel pin [a] is in position. • fit the dowel pin into the hole [b] on the oil pump cover [c]. • apply a non-permanent locking agent to the oil pump cover bolts and tighten them. Torque - oil pump cover bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) •...

  • Page 292

    7-16 engine lubrication system oil pressure measurement oil pressure measurement • remove: lower fairing (see lower fairing removal in the frame chapter) right lower fairing bracket (see lower fairing bracket removal in the frame chapter) oil passage plug [a] note ○ place a suitable container under ...

  • Page 293

    Engine lubrication system 7-17 oil pressure switch oil pressure switch removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: lower fairing (see lower fairing removal in the frame chapter) right lower fairing bracket (see lower fairing bracket removal...

  • Page 295: Engine Removal/installation

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

  • Page 296

    8-2 engine removal/installation exploded view.

  • Page 297

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front engine bracket bolts (left) 25 2.5 18 s 2 front engine bracket bolts (right) 30 3.1 22 s 3 front engine mounting bolt (right) 49 5.0 36 s 4 front engine mounting bolt (left) 44 4.5 32 s 5 rear engine mo...

  • Page 298

    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 motorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to hold the front b...

  • Page 299

    Engine removal/installation 8-5 engine removal/installation • disconnect: crankshaft sensor lead connector [a] starter motor cable terminal [b] engine ground lead terminal [c] water temperature sensor lead connector [d] • disconnect the alternator lead connector [a]. • disconnect the neutral switch ...

  • Page 300

    8-6 engine removal/installation engine removal/installation • remove: front engine mounting bolt [a] and nut (right) front engine bracket bolts (right) [b] front engine bracket (right) [c] guard [d] • remove the rear engine mounting bolt and nut (upper) [a]. • remove: rear engine mounting bolt and n...

  • Page 301

    Engine removal/installation 8-7 engine removal/installation • install the following temporarily: front engine bracket (right) [a] guard [b] front engine bracket bolts (right) [c] • replace the front engine mounting nut (right) [d] with a new one. • install the following temporarily: front engine mou...

  • Page 302

    8-8 engine removal/installation engine removal/installation ○ tighten: torque - front engine bracket bolts (left) [g]: 25 n·m (2.5 kgf·m, 18 ft·lb) front engine mounting bolt [h] (left): 44 n·m (4.5 kgf·m, 32 ft·lb) • run the leads, cables, and hoses correctly (see cable, wire, and hose routing sect...

  • Page 303: Crankshaft/transmission

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

  • Page 304

    9-2 crankshaft/transmission exploded view.

  • Page 305

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

  • Page 306

    9-4 crankshaft/transmission exploded view.

  • Page 307

    Crankshaft/transmission 9-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 transmission case bolts 20 2.0 15 2 gear positioning lever bolt 12 1.2 106 in·lb l 3 trasnmission case oil nozzle 2.9 0.30 26 in·lb l 4 shift drum cam bolt 12 1.2 106 in·lb l 5 shift drum bearing holder screws 4....

  • Page 308

    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 309

    Crankshaft/transmission 9-7 specifications item standard service limit crankshaft runout tir 0.02 mm (0.0008 in.) or less tir 0.05 mm (0.002 in.) crankshaft main bearing insert/journal clearance 0.017 ∼ 0.041 mm (0.0007 ∼ 0.0016 in.) 0.07 mm (0.003 in.) crankshaft main journal diameter: 37.984 ∼ 38....

  • Page 310

    9-8 crankshaft/transmission specifications item standard service limit crankcase bearing bore diameter: 31.000 ∼ 31.016 mm (1.2205 ∼ 1.2211 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 311

    Crankshaft/transmission 9-9 special tools and sealants outside circlip pliers: 57001-144 bearing driver set: 57001-1129 liquid gasket, tb1211f: 92104-0004 liquid gasket, tb1216b: 92104-1064 liquid gasket, tb1207b: 92104-2068.

  • Page 312

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

  • Page 313

    Crankshaft/transmission 9-11 crankcase splitting • remove the upper crankcase bolts [a] and the copper plated washers. • remove: oil pan (see oil pan removal in the engine lubrication system chapter) oil screen (see oil pan removal in the engine lubrica- tion system chapter) oil pipes (see oil pan r...

  • Page 314

    9-12 crankshaft/transmission crankcase splitting ○ prepare a 5 mm rod [a], and insert it to the hole of the upper crankcase half. ○ remove the oil pipe [b], tapping [c] the rod as shown. If the breather plate [a] is to be removed, follow the next procedure. ○ remove the oil pipe (see above). ○ cut t...

  • Page 315

    Crankshaft/transmission 9-13 crankcase splitting • when the new needle bearing [a] for the shift drum is installed in the lower crankcase half [b], press and insert [c] the new needle bearing until it is bottomed. Special tool - bearing driver set: 57001-1129 • when the new needle bearing [d] for th...

  • Page 316

    9-14 crankshaft/transmission crankcase splitting ○ apply a non-permanent locking agent to the threads of the breather plate bolts [a] and tighten them. Torque - breather plate bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) ○ install the breather pipe [a]. ○ align the white mark [b] on the pipe with the white ...

  • Page 317

    Crankshaft/transmission 9-15 crankcase splitting • install the crankshaft and the balancer shaft on the upper crankcase half. ○ apply molybdenum disulfide oil solution to the following items. Crankshaft main bearing insert balancer shaft bearing insert ○ align [a] the timing mark on the balancer gea...

  • Page 318

    9-16 crankshaft/transmission crankcase splitting • with a high flash-point solvent, clean off the mating sur- faces of the crankcases halves and wipe dry. • using compressed air, blow out the oil passages in the crankcase halves. • apply liquid gasket [a] to the mating surface of the lower crankcase...

  • Page 319

    Crankshaft/transmission 9-17 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 320

    9-18 crankshaft/transmission crankcase splitting • the upper crankcase bolts [a] have copper plated wash- ers, replace them with new ones. • tighten the upper crankcase bolts with copper plated washers. Torque - upper crankcase bolts: 27.5 n·m (2.8 kgf·m, 20 ft·lb) • wipe up the liquid gasket that s...

  • Page 321

    Crankshaft/transmission 9-19 crankshaft and connecting rods crankshaft removal • split the crankcase (see crankcase splitting). • remove: camshaft chain [a] crankshaft [b] crankshaft installation note ○ if the crankshaft is replaced with a new one, refer to the connecting rod big end bearing/cranksh...

  • Page 322

    9-20 crankshaft/transmission crankshaft and connecting rods connecting rod installation notice 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 notice if the connecting rods, ...

  • Page 323

    Crankshaft/transmission 9-21 crankshaft and connecting rods ○ the connecting rod big end is bolted using the “plastic region fastening method”. ○ this method precisely achieves the needed clamping force without exceeding it unnecessarily, allowing the use of thinner, lighter bolts further decreasing...

  • Page 324

    9-22 crankshaft/transmission crankshaft and connecting rods • install new bolts in reused connecting rods. • dent both bolt head and bolt tip with a punch as shown. • before tightening, use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt st...

  • Page 325

    Crankshaft/transmission 9-23 crankshaft and connecting rods • install new bolts in reused connecting rods. • apply a small amount of molybdenum disulfide oil solution to the following. Threads [a] of nuts and bolts seating surfaces [b] of nuts and connecting rods • first, tighten the nuts to the spe...

  • Page 326

    9-24 crankshaft/transmission crankshaft and connecting rods connecting rod twist inspection • with the big-end arbor [a] still on v block [c], hold the connecting rod horizontally and measure the amount that the arbor [b] varies from being paralleled with the surface plate over a 100 mm (3.94 in.) l...

  • Page 327

    Crankshaft/transmission 9-25 crankshaft and connecting rods if the clearance is within the standard, no bearing replace- ment is required. If the clearance is between 0.042 mm (0.00165 in.) and the service limit (0.08 mm, 0.003 in.), replace the bear- ing inserts [a] with inserts painted blue [b]. C...

  • Page 328

    9-26 crankshaft/transmission crankshaft and connecting rods • select the proper bearing insert [a] in accordance with the combination of the connecting rod and crankshaft coding. Size color [b] bearing insert connecting rod big end inside diameter marking crankpin diameter marking size color part nu...

  • Page 329

    Crankshaft/transmission 9-27 crankshaft and connecting rods crankshaft main bearing insert/journal wear inspection • using a plastigage (press gauge) [a], measure the bear- ing insert/journal [b] clearance. Note ○ tighten the crankcase bolts to the specified torque (see crankcase assembly). ○ do not...

  • Page 330

    9-28 crankshaft/transmission crankshaft and connecting rods • measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. Crankcase main bearing inside diameter marks: “ ○ ” or no mark. • tighten the crankcase bolts to the specified torque (s...

  • Page 331

    Crankshaft/transmission 9-29 balancer balancer removal • split the crankcase (see crankcase splitting). • pull the balancer shaft [a] with the balancer gear out of the crankcase. Balancer installation • apply molybdenum disulfide oil solution to the inside of the balancer shaft bearing insert. • ali...

  • Page 332

    9-30 crankshaft/transmission balancer note ○ do not turn the balancer shaft during clearance mea- surement. ○ remove the lower crankcase half and measure the plas- tigage width [a] to determine the bearing insert/journal [b] clearance. Balancer shaft bearing insert/journal clearance standard: 0.011 ...

  • Page 333

    Crankshaft/transmission 9-31 balancer • put the lower crankcase half on the upper crankcase half without bearing inserts, and tighten the case bolts to the specified torque and sequence (see crankcase assem- bly). • measure the crankcase bearing bore diameter for the bal- ancer shaft, and mark the u...

  • Page 334

    9-32 crankshaft/transmission external shift mechanism shift pedal removal • remove: shift pedal bolt [a] shift pedal [b] shift pedal installation • install the shift pedal [a] to the shift shaft. ○ align the punch mark [b] on the shift shaft with the punch mark [c] on the shift pedal. • tighten: tor...

  • Page 335

    Crankshaft/transmission 9-33 external shift mechanism • remove: clutch (see clutch removal in the clutch chapter) gear positioning lever bolt [a] spacer [b] gear positioning lever [c] washer and spring external shift mechanism installation • install the gear positioning lever [a] as shown in the fig...

  • Page 336

    9-34 crankshaft/transmission external shift mechanism • replace the shift shaft cover gasket with a new one. • install the shift shaft cover. • apply a non-permanent locking agent to the shift shaft cover screw [a]. • apply a non-permanent locking agent to the shift shaft cover bolts [b, c]. [b] l =...

  • Page 337

    Crankshaft/transmission 9-35 transmission transmission assy removal • remove: shift shaft assembly (see external shift mechanism re- moval) neutral switch holder screw [a] neutral switch holder [b] and pin shift drum holder [c] and pin • remove the collar [a] and the o-ring [b] from the output shaft...

  • Page 338

    9-36 crankshaft/transmission transmission • install: pin [a] shift drum holder [b] pin [c] neutral switch holder [d] • apply a non-permanent locking agent to the neutral switch holder screw [e] and tighten it. Torque - neutral switch holder screw: 4.9 n·m (0.50 kgf·m, 43 in·lb) • apply grease to the...

  • Page 339

    Crankshaft/transmission 9-37 transmission • remove the following from the transmission case as nec- essary. Shift drum bearing holder screws [a] shift drum bearing holder [b] • remove the following from the transmission case as nec- essary. Drive shaft bearing holder screw [a] drive shaft bearing ho...

  • Page 340

    9-38 crankshaft/transmission transmission if the drive shaft bearing holder [a] is to be removed, fol- low the next procedure. ○ apply a non-permanent locking agent to the threads of the drive shaft bearing holder screw [b] and tighten it. Torque - drive shaft bearing holder screw: 4.9 n·m (0.50 kgf...

  • Page 341

    Crankshaft/transmission 9-39 transmission • apply engine oil to the shift drum groove. • 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...

  • Page 342

    9-40 crankshaft/transmission transmission transmission shaft disassembly • remove the transmission shafts (see transmission assy disassembly). • remove the circlips, disassemble the transmission shafts. Special tool - outside circlip pliers: 57001-144 • the 5th gear [a] on the output shaft has three...

  • Page 343

    Crankshaft/transmission 9-41 transmission • fit the steel balls into the 5th gear holes in the output shaft, aligning oil hole as shown in the figure. 5th gear [a] output shaft [b] steel balls [c] oil holes [d] notice do not apply grease to the balls to hold them in place. This will cause the positi...

  • Page 344

    9-42 crankshaft/transmission transmission 1. Drive shaft 2. 1st gear 3. 2nd gear 4. 3rd gear 5. 4th gear 6. 5th gear 7. 6th (top) gear 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. Output shaft 16. Spacer...

  • Page 345

    Crankshaft/transmission 9-43 transmission shift drum and fork removal • refer to the transmission assy disassembly. Shift drum and fork installation • refer to the transmission assy assembly. Shift drum disassembly • refer to the transmission assy disassembly. Shift drum assembly • refer to the tran...

  • Page 346

    9-44 crankshaft/transmission transmission gear dog and gear dog hole damage inspection • visually inspect the gear dogs [a] and gear dog holes [b]. Replace any damaged gears or gears with excessively worn dogs or dog holes..

  • Page 347

    Crankshaft/transmission 9-45 ball bearing, needle bearing, and oil seal ball and needle bearing replacement notice 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 absen...

  • Page 349: Wheels/tires

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

  • Page 350

    10-2 wheels/tires exploded view.

  • Page 351

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front axle 108 11.0 80 2 front axle clamp bolt 34 3.5 25 3 rear axle nut 108 11.0 80 4. Er650f model g: apply grease. Hg: apply high-temperature grease. R: replacement parts wl: apply soap and water solution or rubber lubr...

  • Page 352

    10-4 wheels/tires specifications item standard service limit wheels (rims) rim runout: axial tir 0.5 mm (0.02 in.) or less tir 1.0 mm (0.04 in.) radial tir 0.8 mm (0.03 in.) or less tir 1.0 mm (0.04 in.) axle runout/100 mm (3.94 in.) tir 0.03 mm (0.001 in.) or less tir 0.2 mm (0.008 in.) wheel balan...

  • Page 353

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

  • Page 354

    10-6 wheels/tires wheels (rims) front wheel removal • remove: front caliper mounting bolts [a] (both sides) front calipers [b] (both sides) • loosen: front axle clamp bolt [a] front axle [b] • remove: lower fairing (see lower fairing removal in the frame chapter) lower fairing bracket (see lower fai...

  • Page 355

    Wheels/tires 10-7 wheels (rims) • apply high-temperature grease to the grease seal lips. • fit the collars [a] on the both sides of the hub. ○ the collars are identical. • insert the front axle. • remove the jack. • tighten: torque - front axle: 108 n·m (11.0 kgf·m, 80 ft·lb) • before tightening the...

  • Page 356

    10-8 wheels/tires wheels (rims) • remove: cotter pin [a] rear axle nut [b] washer [c] rear axle [d] (from right side) • remove the drive chain [a] from the rear sprocket toward the left. • move the rear wheel back and remove it. Notice do not lay the wheel on the ground with the disc facing down. Th...

  • Page 357

    Wheels/tires 10-9 wheels (rims) • bend the cotter pin [a] over the nut [b]. Warning a loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper torque and install a new cotter pin. • install the rear caliper (see rear caliper installation in the ...

  • Page 358

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

  • Page 359

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

  • Page 360

    10-12 wheels/tires wheels (rims) balance weight part number weight 41075-0007 10 g (0.35 oz.) 41075-0008 20 g (0.71 oz.) 41075-0009 30 g (1.06 oz.) note ○ balance weights are available from kawasaki dealers in 10, 20 and 30 grams (0.35, 0.71 and 1.06 oz.) sizes. An imbalance of less than 10 grams (0...

  • Page 361

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

  • Page 362

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

  • Page 363

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

  • Page 364

    10-16 wheels/tires hub bearing hub bearing removal • remove the wheels (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]. Notice do not lay the wheel on the ground with the disc facing ...

  • Page 365

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

  • Page 367: Final Drive

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

  • Page 368

    11-2 final drive exploded view.

  • Page 369

    Final drive 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 speed sensor bracket bolts 9.8 1.0 87 in·lb 2 speed sensor bolt 7.8 0.80 69 in·lb l 3 engine sprocket nut 125 12.7 92 mo 4 engine sprocket cover bolts 9.8 1.0 87 in·lb 5 rear sprocket nuts 59 6.0 44 r 6 rear axle nut 108 11...

  • Page 370

    11-4 final drive specifications item standard service limit drive chain drive chain slack 25 ∼ 35 mm (1.0 ∼ 1.4 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 daido – – – type did 520vp2-t – – – link 114 links – – – sprockets ...

  • Page 371

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

  • Page 372

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

  • Page 373

    Final drive 11-7 drive chain • grind [a] the heads of the link pin to make it flat. • set the cutting and riveting pin [c] in the pin holder [b] as shown in the figure. • set the “u” holder and body, align the positioning pin [a] with the “a” mark [b]. • tighten the pin holder by hand until the cutt...

  • Page 374

    11-8 final drive drive chain • set the “u” holder and body, align the positioning pin [a] with the “a” mark [b]. • hold the body with a wrench [c]. • turn the pin holder clockwise [d] with another wrench and press in the link plate on the link pin. • remove the “u” holder and body. • set the cutting...

  • Page 375

    Final drive 11-9 drive chain • after riveting, check the ends of the riveted pins for cracks. • measure the outside diameter [a] and the length [b] of the link pin. Link pin outside diameter standard: 5.5 ∼ 5.8 mm (0.22 ∼ 0.23 in.) link pin length standard: 20.20 mm (0.795 in.) or less if the readin...

  • Page 376

    11-10 final drive sprocket, coupling engine sprocket removal • remove: left frame cover (see frame cover removal in the frame chapter) 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]. • re...

  • Page 377

    Final drive 11-11 sprocket, coupling • be sure that the dowel pins [a] are in position. • install the speed sensor bracket and tighten the bolts. Torque - speed sensor bracket bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • run the leads and hoses correctly (see cable, wire, and hose routing section in the a...

  • Page 378

    11-12 final drive sprocket, coupling • replace the o-ring [a] with a new one and apply grease to it. • install: o-ring collar [b] coupling coupling bearing removal • remove: coupling grease seal circlip [a] special tool - inside circlip pliers: 57001-143 • remove the bearing [a] by tapping from the ...

  • Page 379

    Final drive 11-13 sprocket, coupling coupling bearing inspection since the coupling bearing is made to extremely close tolerances, the clearance can not normally be measured. Note ○ it is not necessary to remove the coupling bearing for inspection. If the bearing is removed, it will need to be repla...

  • Page 380

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

  • Page 381: Brakes

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

  • Page 382

    12-2 brakes abs servicing precautions ............................................................................................... 12-35 abs troubleshooting outline............................................................................................ 12-37 inquiries to rider...................

  • Page 383

    Brakes 12-3 exploded view this page intentionally left blank..

  • Page 384

    12-4 brakes exploded view er650e model.

  • Page 385

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front brake reservoir cap screws 1.5 0.15 13 in·lb 2 brake lever pivot bolt 1.0 0.10 9 in·lb si 3 brake lever pivot bolt locknut 5.9 0.60 52 in·lb r 4 front master cylinder clamp bolts 11 1.1 97 in·lb s 5 front brake light switc...

  • Page 386

    12-6 brakes exploded view er650e model.

  • Page 387

    Brakes 12-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake hose banjo bolts 25 2.5 18 2 rear master cylinder mounting bolts 25 2.5 18 3 rear master cylinder push rod locknut 17 1.7 13 4 brake pedal bolt 8.8 0.90 78 in·lb 5 caliper bleed valve 7.8 0.80 69 in·lb 6 rear caliper mount...

  • Page 388

    12-8 brakes exploded view er650f model.

  • Page 389

    Brakes 12-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front brake reservoir cap screws 1.5 0.15 13 in·lb 2 brake lever pivot bolt 1.0 0.10 9 in·lb si 3 brake lever pivot bolt locknut 5.9 0.60 52 in·lb r 4 front master cylinder clamp bolts 11 1.1 97 in·lb s 5 front brake light switc...

  • Page 390

    12-10 brakes exploded view er650f model.

  • Page 391

    Brakes 12-11 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake hose banjo bolts 25 2.5 18 2 rear master cylinder mounting bolts 25 2.5 18 3 rear master cylinder push rod locknut 17 1.7 13 4 brake pipe joint nuts 18 1.8 13 5 caliper bleed valve 7.8 0.80 69 in·lb 6 rear caliper mountin...

  • Page 392

    12-12 brakes specifications item standard service limit brake lever, brake pedal lever position 5-way adjustable (to suit rider) – – – lever free play non-adjustable – – – pedal position about 50 mm (2.0 in.) below top of footpeg – – – pedal free play non-adjustable – – – brake pads lining thickness...

  • Page 393

    Brakes 12-13 special tools jack: 57001-1238 hand tester: 57001-1394 needle adapter set: 57001-1457.

  • Page 394

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

  • Page 395

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

  • Page 396

    12-16 brakes calipers front caliper removal • loosen the banjo bolt [a], being careful not to spill brake fluid. • remove the caliper mounting bolts [b]. • remove the banjo bolt and take off the brake hoses from the caliper. Notice immediately wipe up any brake fluid that spilled. Note ○ if the cali...

  • Page 397

    Brakes 12-17 calipers • bleed the brake line (see brake line bleeding). • check the fluid level in the brake reservoirs (see brake fluid level inspection in the periodic maintenance chap- ter). • check the brake for good braking power, no brake drag, and no fluid leakage. Warning after servicing, it...

  • Page 398

    12-18 brakes calipers caliper dust seal damage inspection • check that the dust seal(s) [a] are not cracked, worn, swollen, or otherwise damaged. If they show any damage, replace the dust seals with new ones. Piston(s) [b] fluid seal(s) [c] caliper dust boot and friction boot damage inspection • che...

  • Page 399

    Brakes 12-19 calipers caliper piston and cylinder damage inspection • visually inspect the piston(s) [a] and cylinder surface(s) [b]. Replace the caliper if the cylinder and piston are badly scores or rusty. Caliper holder shaft wear inspection the caliper body must slide smoothly on the caliper hol...

  • Page 400

    12-20 brakes brake pads front brake pad removal • remove the front caliper with the hose installed (see front caliper removal). • draw out the holder shaft pin [a], and take off the holder shaft [b]. • remove the pad [c] from the holder shaft [d]. • remove the other side pad [e]. Front brake pad ins...

  • Page 401

    Brakes 12-21 master cylinder front master cylinder removal • remove the right rear view mirror (see rear view mirror removal in the frame chapter). • disconnect the front brake light switch connectors [a]. • loosen the banjo bolt [b], being careful not to spill brake fluid. • remove the banjo bolt a...

  • Page 402

    12-22 brakes master cylinder • install the front master cylinder. ○ align the punch mark [a] on the handlebar with the mating surface [b] of the master cylinder clamp. • tighten the upper clamp bolt [a] first, and then the lower clamp bolt [b]. There will be a gap at the lower part of the clamp afte...

  • Page 403

    Brakes 12-23 master cylinder rear master cylinder removal • loosen the banjo bolt [a], being careful not to spill brake fluid. • remove the banjo bolt and take off the brake hose from the master cylinder [b]. Notice immediately wipe up any brake fluid that spilled. • loosen the rear master cylinder ...

  • Page 404

    12-24 brakes master cylinder • replace the washers [a] on each side of the hose fitting [b] with new ones. • install the brake hose lower end. • tighten: torque - brake hose banjo bolt: 25 n·m (2.5 kgf·m, 18 ft·lb) • install the rear master cylinder. Torque - rear master cylinder mounting bolts: 25 ...

  • Page 405

    Brakes 12-25 master cylinder master cylinder inspection • remove the master cylinders (see front/rear master cylinder removal). • disassemble the front and rear master cylinders (see master cylinder disassembly). • check that there are no scratches, rust or pitting on the inner wall [a] of each mast...

  • Page 406

    12-26 brakes brake disc brake disc removal • remove the wheel (see front/rear wheel removal in the wheels/tires chapter). • unscrew the mounting bolts [a], and take off the disc [b]. • for front brake disc, remove the gaskets. Brake disc installation • for front brake disc, replace the gaskets with ...

  • Page 407

    Brakes 12-27 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 408

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

  • Page 409

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

  • Page 410

    12-30 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 411

    Brakes 12-31 anti-lock brake system (equipped models) parts location front wheel rotation sensor [a] front wheel rotation sensor rotor [b] rear wheel rotation sensor [a] rear wheel rotation sensor rotor [b] yellow abs indicator light (led) [a] abs hydraulic unit [a] abs solenoid valve relay fuse 15 ...

  • Page 412

    12-32 brakes anti-lock brake system (equipped models) abs kawasaki diagnostic system connector [a] abs self-diagnosis terminal [b].

  • Page 413

    Brakes 12-33 anti-lock brake system (equipped models) abs system wiring diagram 1. Ignition switch 2. Front wheel rotation sensor 3. Front brake light switch 4. Rear wheel rotation sensor 5. Rear brake light switch 6. Frame ground 7. Battery 12 v 10 ah 8. Main fuse 30 a 9. Frame ground 10. Fuse box ...

  • Page 414

    12-34 brakes anti-lock brake system (equipped models) terminal names 1. Ground 2. Unused 3. Front wheel rotation sensor signal 4. Power supply 5. Abs kawasaki diagnostic system terminal 6. Front/rear brake light switch 7. Abs self-diagnosis terminal 8. Unused 9. Power supply to abs solenoid valve re...

  • Page 415

    Brakes 12-35 anti-lock brake system (equipped models) abs servicing precautions there are a number of important precautions that should be followed servicing the abs system. ○ this abs system is designed to be used with a 12 v sealed battery as its power source. Do not use any other battery except f...

  • Page 416

    12-36 brakes anti-lock brake system (equipped models) warning air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If any of the brake line fittings, including the abs hydraulic unit joint nuts, or the bleed valve is opened at any time, the air ...

  • Page 417

    Brakes 12-37 anti-lock brake system (equipped models) ○ the yellow abs indicator light (led) may go on if the engine is run with the motorcycle on its stand and the transmission in gear. If the warning indicator light goes on, just turn the ignition switch to off, then clear service code 42, which i...

  • Page 418

    12-38 brakes anti-lock brake system (equipped models) even when the abs is operating normally, the yellow abs indicator light (led) may go on under the conditions listed below. Turn the ignition switch to off to stop the yel- low abs indicator light (led). If the motorcycle runs with- out erasing th...

  • Page 419

    Brakes 12-39 anti-lock brake system (equipped models) abs diagnosis flow chart.

  • Page 420

    12-40 brakes anti-lock brake system (equipped models) inquiries to rider ○ each rider reacts to problems in different ways, so it is important to confirm what kind of condition the rider is dissatisfied with. ○ try to find out exactly what problem occurs under exactly what conditions by asking the r...

  • Page 421

    Brakes 12-41 anti-lock brake system (equipped models) pre-diagnosis inspection 1.

  • Page 422

    12-42 brakes anti-lock brake system (equipped models) pre-diagnosis inspection 2 self-diagnosis outline when the yellow abs indicator light (led) has blinked or goes on, the abs hydraulic unit memorizes and stores the service code (15 codes including “normal code”) for the service person to troubles...

  • Page 423

    Brakes 12-43 anti-lock brake system (equipped models) • remove the front seat (see front seat removal in the frame chapter). • ground the self-diagnosis terminal [a] (gray) to the bat- tery (–) terminal or battery (–) cable connector, using a lead. • turn the ignition switch to on. ○ count the blink...

  • Page 424

    12-44 brakes anti-lock brake system (equipped models) self-diagnosis flow chart.

  • Page 425

    Brakes 12-45 anti-lock brake system (equipped models) how to read service codes ○ service codes are shown by a series of long and short blinks of the yellow abs indicator light (led) as shown below. ○ read 10th digit and unit digit as the yellow abs indicator light (led) blinks. ○ when there are a n...

  • Page 426

    12-46 brakes anti-lock brake system (equipped models) service code table service code yellow abs indicator light (led) problems light state 12 start code (not fault) after starts, turn off 13 rear intake solenoid valve trouble (open, temperature abnormal) on 14 rear outlet solenoid valve trouble (op...

  • Page 427

    Brakes 12-47 anti-lock brake system (equipped models) yellow abs indicator light (led) inspection • turn the ignition switch to on. If the yellow abs indicator light (led) [a] goes on, it is normal. If the yellow abs indicator light (led) does not go on, go to step “yellow abs indicator light (led) ...

  • Page 428

    12-48 brakes anti-lock brake system (equipped models) • do the 3rd step test as follows. ○ disconnect the abs hydraulic unit connector (see abs hydraulic unit removal). ○ check for continuity between the black/white lead termi- nal of the main harness side connector (meter unit) [a] and black/white ...

  • Page 429

    Brakes 12-49 anti-lock brake system (equipped models) • do the 2nd step test as follows. ○ disconnect the abs hydraulic unit connector [a] (see abs hydraulic unit removal). ○ check for continuity between the red/black and black lead terminals of the abs hydraulic unit connector. If there is the cont...

  • Page 430

    12-50 brakes anti-lock brake system (equipped models) front, rear wheel rotation difference abnormal (service code 25) • do the 1st step test as follows. ○ check the following and correct the faulty part. Incorrect the tire pressure. Tires not recommended for the motorcycle were installed (incorrect...

  • Page 431

    Brakes 12-51 anti-lock brake system (equipped models) • do the 4th step test as follows. ○ check the battery terminal voltage between the red/white lead terminal of the fuse box [a] and ground. Special tool - hand tester: 57001-1394 battery terminal voltage standard: battery voltage if the battery t...

  • Page 432

    12-52 brakes anti-lock brake system (equipped models) • do the 2nd step test as follows. ○ check that there is iron or other magnetic deposits be- tween the sensor [a] and sensor rotor [b], and the sensor rotor slots for obstructions. ○ check the installation condition of the sensor for loose- ness....

  • Page 433

    Brakes 12-53 anti-lock brake system (equipped models) • do the 3rd step test as follows. ○ recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the yellow abs indicator light (led) [a] goes on, faulty ecu in the ...

  • Page 434

    12-54 brakes anti-lock brake system (equipped models) rear wheel rotation sensor wiring inspection (service code 45) • do the 1st step test as follows. ○ disconnect: abs hydraulic unit connector (see abs hydraulic unit removal) rear wheel rotation sensor connector (see rear wheel rotation sensor rem...

  • Page 435

    Brakes 12-55 anti-lock brake system (equipped models) • do the 2nd step test as follows. ○ connect the abs kawasaki diagnostic system connector and abs hydraulic unit connector. ○ check the battery terminal voltage, connect the hand tester to the brown/white terminal of abs kawasaki diagnostic syste...

  • Page 436

    12-56 brakes anti-lock brake system (equipped models) • do the 2nd step test as follows. ○ connect the abs kawasaki diagnostic system connector and abs hydraulic unit connector. ○ check the battery terminal voltage, connect the hand tester to the brown/white terminal of abs kawasaki diagnostic syste...

  • Page 437

    Brakes 12-57 anti-lock brake system (equipped models) abs hydraulic unit removal notice the abs hydraulic unit has been adjusted and set with precision at the factory. Therefore, it should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface. Be careful ...

  • Page 438

    12-58 brakes anti-lock brake system (equipped models) • remove the brake pipe joint nuts [a] with the flare nut wrench. Note ○ remove the brake hoses and pipes according to each assembly of the exploded view. • tape the brake line opening to prevent brake fluid leakage or contamination by foreign ma...

  • Page 439

    Brakes 12-59 anti-lock brake system (equipped models) abs hydraulic unit installation • install the bracket to the abs hydraulic unit. Notice brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • install the abs hydraulic unit to the fr...

  • Page 440

    12-60 brakes anti-lock brake system (equipped models) • remove the headlight unit (see headlight unit removal in the electrical system chapter). • disconnect the front wheel rotation sensor connector [a]. • free the front wheel rotation sensor lead [a] from the clamps [b]. • remove: front wheel rota...

  • Page 441

    Brakes 12-61 anti-lock brake system (equipped models) • remove: right frame cover (see frame cover removal in the frame chapter) • disconnect the connector [a]. • remove: rear wheel rotation sensor bolt [a] rear wheel rotation sensor [b] • free the sensor lead from the clamps. Rear wheel rotation se...

  • Page 442

    12-62 brakes anti-lock brake system (equipped models) wheel rotation sensor air gap inspection • raise the front/rear wheel off the ground (see front/rear wheel removal in the wheels/tires chapter). • measure the air gap between the sensor and sensor rotor at several points by turning the wheel slow...

  • Page 443

    Brakes 12-63 anti-lock brake system (equipped models) abs motor relay fuse 25 a removal • remove the left frame cover (see frame cover removal in the frame chapter). • unlock the hook, and open the lid [a]. • pull out the relay fuse [b] from the fuse box with needle nose pliers. Fuse installation • ...

  • Page 445: Suspension

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

  • Page 446

    13-2 suspension exploded view.

  • Page 447

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fork top plugs 22.5 2.3 17 2 front fork clamp bolts (upper) 20 2.0 15 3 front fork clamp bolts (lower) 20.5 2.1 15 al 4 front axle clamp bolt 34 3.5 25 5 front fork bottom allen bolts 30 3.1 22 l al: tighten the two cl...

  • Page 448

    13-4 suspension exploded view.

  • Page 449

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear shock absorber mounting bolts 59 6.0 44 2 swingarm bracket bolts 44 4.5 32 s 3 swingarm bracket bolt (lower left) 59 6.0 44 s 4 swingarm pivot shaft nut 108 11.0 80 g: apply grease. R: replacement parts.

  • Page 450

    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: recommended oil kayaba khl34-g10 or equivalent amount ...

  • Page 451

    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 front fork oil seal driver: 57001-1219 fork oil level gauge: 57001-129...

  • Page 452

    13-8 suspension front fork front fork removal • remove: upper fairing (see upper fairing removal in the frame chapter) front fender (see front fender removal in the frame chapter) front wheel (see front wheel removal in the wheels/tires chapter) front wheel rotation sensor lower end (abs equipped mo...

  • Page 453

    Suspension 13-9 front fork front fork oil change • remove: front fork (see front fork removal) top plug [a] with o-ring spacer [b] fork spring seat [c] fork spring [d] • compress [a] the fork [b] upside down to draw out the oil into the suitable container [c]. • hold the fork tube upright, pour in t...

  • Page 454

    13-10 suspension front fork • hold the outer tube vertically in a vise and compress the fork completely. • wait until the oil level stabilizes. • use the fork oil level gauge [a] to measure the distance from the top of the inner tube to the oil level. Special tool - fork oil level gauge: 57001-1290 ...

  • Page 455

    Suspension 13-11 front fork • remove the cylinder unit [a], washer [b], and the spring [c] from the inner tube. • remove the following from the top of the outer tube. Dust seal [a] retaining ring [b] • separate the inner tube [a] from the outer tube [b]. Note ○ from the compressed state, firmly pull...

  • Page 456

    13-12 suspension front fork front fork assembly • replace the following parts with new ones. Top plug o-ring retaining ring [a] dust seal [b] oil seal [c] inner guide bushing [d] outer guide bushing [e] fork bottom allen bolt gasket [f] • install the following on the end of the inner tube. Outer gui...

  • Page 457

    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. Special tools - fork c...

  • Page 458

    13-14 suspension front fork spring tension inspection • since a spring becomes shorter as it weakens, check its free length [a] to determine its condition. If the spring of either fork leg is shorter than the service limit, replace it with a new one. If the length of a replace- ment spring and that ...

  • Page 459

    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 is 4th position. Spring preload setting standard position: 4th position adjustable range: 1st to 7th position • if the ...

  • Page 460

    13-16 suspension rear shock absorber • remove: right stay cover [a] • remove: rear shock absorber mounting bolt (upper) [a], washer and o-ring rear shock absorber mounting bolt (lower) [b], nut, collar and washer • remove the rear shock absorber [c] backward. Rear shock absorber installation • insta...

  • Page 461

    Suspension 13-17 swingarm swingarm removal • remove: chain cover bolts [a] chain cover [b] • remove: frame covers (see frame cover removal in the frame chapter) engine sprocket cover (see engine sprocket cover re- moval in the final drive chapter) footpeg stays (see footpeg stay removal in the frame...

  • Page 462

    13-18 suspension swingarm • support the frame using the jack. Special tool - jack: 57001-1238 • remove the following parts, and remove the swingarm. Rear shock absorber mounting bolt (lower), nut, collar and washer swingarm pivot shaft nut swingarm pivot shaft swingarm installation • installation is...

  • Page 463

    Suspension 13-19 swingarm • remove the ball bearing and needle bearings with oil seal & bearing remover [a]. Special tool - oil seal & bearing remover: 57001-1058 swingarm bearing installation • replace the ball and needle bearings [a] with new ones. • install the ball and needle bearings so that th...

  • Page 464

    13-20 suspension swingarm swingarm bearing, sleeve inspection notice do not remove the bearings for inspection. Re- moval may damage them. • inspect the needle bearings [a] and ball bearing installed in the swingarm. ○ the rollers and ball in a bearing normally wear very little, and wear is difficul...

  • Page 465: Steering

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

  • Page 466

    14-2 steering exploded view.

  • Page 467

    Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 switch housing screws 3.5 0.36 31 in·lb 2 handlebar holder bolts 25 2.5 18 s 3 steering stem head bolt 108 11.0 80 4 front fork clamp bolts (upper) 20 2.0 15 5 handlebar holder mounting nuts 34 3.5 25 r 6 steering stem nut 20 ...

  • Page 468

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

  • Page 469

    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 470

    14-6 steering steering stem stem, stem bearing removal • remove: meter unit (see meter unit removal in the electrical sys- tem chapter) handlebar (see handlebar removal) headlight unit (see headlight unit removal in the elec- trical system chapter) front wheel (see front wheel removal in the wheels/...

  • Page 471

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

  • Page 472

    14-8 steering steering stem • install the lower ball bearing [a] onto the stem. • apply grease to the following. Inner and outer races lower ball bearing • install the steering stem [a] through the head pipe, and install the upper ball bearing [b] and upper ball bearing inner race [c] on it. • apply...

  • Page 473

    Steering 14-9 steering stem note ○ tighten the upper front fork clamp bolts first, next the stem head bolt, last the lower front fork clamp bolts. ○ tighten the two lower front fork clamp bolts alternately two times to ensure even tightening torque. Torque - front fork clamp bolts (upper): 20 n·m (2...

  • Page 474

    14-10 steering handlebar handlebar removal • remove: meter unit (see meter unit removal in the electrical sys- tem chapter) clutch lever clamp bolts [a] and washers clutch lever assembly [b] left switch housing [c] handlebar weight [d] • remove: front master cylinder [a] (see front master cylinder r...

  • Page 475

    Steering 14-11 handlebar • set the handlebar onto the lower handlebar holders. ○ align the punch mark [a] on the handlebar with the corner edge [b] of the lower handlebar holder. • install the upper handlebar holder [a]. • tighten the front handlebar holder bolts [b] first, and then the rear handleb...

  • Page 476

    14-12 steering handlebar • install: throttle grip throttle cable tips [a] right switch housing ○ fit the projection [b] into a hole [c] on the handlebar. ○ the lower switch housing screw is longer than the upper one. • tighten: torque - switch housing screws: 3.5 n·m (0.36 kgf·m, 31 in·lb) • install...

  • Page 477: Frame

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

  • Page 478

    15-2 frame exploded view.

  • Page 479

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 footpeg stay bolts 25 2.5 18 s 2 sidestand bolt 44 4.5 32 3 sidestand switch bolt 8.8 0.90 78 in·lb l 4. Ca and au models 5. Au model g: apply grease. L: apply a non-permanent locking agent. R: replacement parts s: follow the spe...

  • Page 480

    15-4 frame exploded view.

  • Page 481

    Frame 15-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front turn signal light mounting bolts 4.2 0.43 37 in·lb 2. Au model 3. Ca model.

  • Page 482

    15-6 frame exploded view.

  • Page 483

    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 bracket bolts 12 1.2 106 in·lb l 3 lower fairing mounting bolts 8.8 0.90 78 in·lb l 4 seat lock mounting screws 0.4 0.04 4 in·lb l: apply a non-permanent locking agent..

  • Page 484

    15-8 frame seats rear seat removal • insert the ignition switch key [a] into the seat lock. • turn the key clockwise, and pull up the front part of the seat [b]. • remove the seat forward. Rear seat installation • insert the seat hook [a] into the bracket hole [b]. • push down the front part of the ...

  • Page 485

    Frame 15-9 fairings lower fairing removal • remove the mounting bolts [a] on both sides, and take off the lower fairing [b]. Lower fairing installation • install the lower fairing. • apply a non-permanent locking agent to the threads of the lower fairing mounting bolts and tighten them. Torque - low...

  • Page 486

    15-10 frame fairings center fairing removal • remove: bolt [a] and washer bolt [b] • pull out the center fairing [c] outward to clear the stop- pers. Center fairing installation • installation is the reverse of removal. ○ install the center fairing so that the projections [a] fit into the grommets [...

  • Page 487

    Frame 15-11 seat covers front seat cover removal • remove: front seat (see front seat removal) screws [a] front seat covers [b] front seat cover installation • installation is the reverse of removal. Rear seat cover removal • remove: front seat (see front seat removal) bolts [a] and washers (left an...

  • Page 488

    15-12 frame seat covers rear seat cover installation • installation is the reverse of removal. ○ install the rear seat cover [a] so that the ribs [b] fit inside the rear fender [c]. ○ install the center seat cover [a] so that the projections [b] fit into the slots [c]. ○ install the grab rails and t...

  • Page 489

    Frame 15-13 fenders front fender removal • remove: bolts [a] and washers (left and right) bolts [b] (left and right) front fender [c] front fender installation • install the front fender [a] together with the brake hose clamps [b] on both sides. Flap removal • remove the rear seat (see rear seat rem...

  • Page 490

    15-14 frame fenders rear fender removal • remove: flap (with reinforce installed, see flap removal) bolts [a] and washers (left and right) rear brake fluid reservoir mounting bolt [b] and washer • clear the hook [a] from the frame to remove the rear fender [b]. Rear fender installation • installatio...

  • Page 491

    Frame 15-15 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 resulting in injury or death. If the frame is bent, dented, cracked, or warped, ...

  • Page 492

    15-16 frame battery case battery case removal • remove: battery (see battery removal in the electrical system chapter) fuel tank (see fuel tank removal in the fuel system (dfi) chapter) screw [a] and connector holder [b] (abs equipped models) starter relay [c] dust cover [d] • clear the leads from t...

  • Page 493

    Frame 15-17 footpeg stay footpeg stay removal • remove: frame cover (see frame cover removal) footpeg stay mounting bolts [a] footpeg stay [b] rear master cylinder (right side, see rear master cylinder removal in the brakes chapter) brake pedal (right side, see brake pedal removal in the brakes chap...

  • Page 494

    15-18 frame sidestand sidestand removal • raise the rear wheel off the ground using a stand [a]. • remove: sidestand switch bolt [a] clamp [b] sidestand switch [c] • remove: spring [a] sidestand nut [b] sidestand bolt [c] sidestand [d] sidestand installation • apply grease to the sliding area [a] of...

  • Page 495

    Frame 15-19 frame cover frame cover removal • remove the bolt [a] and collar. • pull the frame cover [b] outward to clear the stoppers. Frame cover installation • installation is the reverse of removal. ○ fit the rib [a] to the inside of the footpeg stay. ○ insert the projections [b] into the gromme...

  • Page 496

    15-20 frame rear view mirrors rear view mirror removal • slide out the dust cover [a]. • loosen the lower hexagonal area [b], and remove the rear view mirror [c] from the holder. ○ the upper hexagonal area has left-hand threads. Rear view mirror installation • screw the lower hexagonal area [a] of t...

  • Page 497: Electrical System

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

  • Page 498

    16-2 electrical system starter motor installation................................................................................................... 16-47 starter motor disassembly................................................................................................ 16-48 starter motor ass...

  • Page 499

    Electrical system 16-3 this page intentionally left blank..

  • Page 500

    16-4 electrical system exploded view.

  • Page 501

    Electrical system 16-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front turn signal light mounting bolts 4.2 0.43 37 in·lb 2 license plate light mounting screws 1.2 0.12 10 in·lb.

  • Page 502

    16-6 electrical system exploded view.

  • Page 503

    Electrical system 16-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 switch housing screws 3.5 0.36 31 in·lb 2 front brake light switch screw 1.2 0.12 11 in·lb 3 engine ground lead terminal bolt 9.8 1.0 87 in·lb 4 starter relay terminal bolts 3.6 0.36 31 in·lb 5 starter motor cable ter...

  • Page 504

    16-8 electrical system exploded view.

  • Page 505

    Electrical system 16-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 regulator/rectifier bolts 9.8 1.0 87 in·lb 2 fuel pump bolts 9.8 1.0 87 in·lb l, s 3 sidestand switch bolt 8.8 0.90 78 in·lb l 4 spark plugs 15 1.5 11 5 water temperature sensor 12 1.2 106 in·lb 6 alternator cover bol...

  • Page 506

    16-10 electrical system specifications item standard battery type sealed battery model name yt12a-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 ∼ 0.26 Ω at 20°c (68°f) charging...

  • Page 507

    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 rotor holder: 57001-1567 extension tube: ...

  • Page 508

    16-12 electrical system special tools and sealants liquid gasket, tb1211: 56019-120 liquid gasket, tb1211f: 92104-0004.

  • Page 509

    Electrical system 16-13 parts location this page intentionally left blank..

  • Page 510

    16-14 electrical system parts location.

  • Page 511

    Electrical system 16-15 parts location 1. Regulator/rectifier 2. Water temperature sensor 3. Starter relay with main fuse 4. Battery 12 v 10 ah 5. Speed sensor 6. Sidestand switch 7. Neutral switch 8. Oxygen sensor (equipped models) 9. Alternator 10. Turn signal relay 11. Radiator fan motor 12. Ecu ...

  • Page 512

    16-16 electrical system wiring diagram (er650e model).

  • Page 513

    Electrical system 16-17 wiring diagram (er650e model).

  • Page 514

    16-18 electrical system wiring diagram (er650f model).

  • Page 515

    Electrical system 16-19 wiring diagram (er650f model).

  • Page 516

    16-20 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 517

    Electrical system 16-21 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 518

    16-22 electrical system battery battery removal • turn the ignition switch to off. • remove the front seat (see front seat removal in the frame chapter) • remove: front seat bracket bolts [a] front seat bracket [b] • disconnect the negative (–) cable [a]. Notice be sure to disconnect the negative (–...

  • Page 519

    Electrical system 16-23 battery battery activation electrolyte filling • make sure that the model name [a] of the electrolyte con- tainer matches the model name [b] of the battery. These names must be the same. Battery model name er650e/f: yt12a-bs notice each battery comes with its own specific ele...

  • Page 520

    16-24 electrical system battery • place the electrolyte container upside down with the six sealed cells into the filler ports of the battery. Hold the container level, push down to break the seals of all six cells. You will see air bubbles rising into each cell as the ports fill. Note ○ do not tilt ...

  • Page 521

    Electrical system 16-25 battery initial charge • 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 activated sealed battery. Kawasaki-recommended chargers: battery mate...

  • Page 522

    16-26 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 wea...

  • Page 523

    Electrical system 16-27 battery charging condition inspection battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter [a]. • remove the battery (see battery removal). Notice be sure to disconnect the negative (−) lead first. • measure the battery term...

  • Page 524

    16-28 electrical system battery note ○ increase the charging voltage to a maximum voltage of 25 v if the battery will not accept current initially. Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current. If the battery will accept current decrease the...

  • Page 525

    Electrical system 16-29 charging system alternator cover removal • remove: lower fairing (see lower fairing removal in the frame chapter) frame cover (see frame cover removal in the frame chapter) engine oil (drain, see engine oil change in the periodic maintenance chapter) engine sprocket cover (se...

  • Page 526

    16-30 electrical system charging system stator coil removal • remove: alternator cover (see alternator cover removal) alternator lead holding plate bolt [a] and holding plate [b] alternator lead grommet [c] stator coil bolts [d] • take off the stator coil [e] from the alternator cover. Stator coil i...

  • Page 527

    Electrical system 16-31 charging system • using the flywheel puller assembly [a], remove the alter- nator rotor from the crankshaft. Special tool - flywheel puller assembly, m38 × 1.5/m35 × 1.5: 57001-1405 notice do not strike the alternator rotor. Striking the rotor can cause the magnets to lose th...

  • Page 528

    16-32 electrical system charging system • install the washer [a]. Note ○ confirm that the alternator rotor fits onto the crankshaft before tightening it with specified torque. • apply molybdenum disulfide oil solution to the threads and seating surface of the rotor bolt. • install the rotor bolt [b]...

  • Page 529

    Electrical system 16-33 charging system • to check the alternator output voltage, do the following procedures. ○ turn the ignition switch to off. ○ remove the left frame cover (see frame cover removal in the frame chapter). ○ pull out the alternator lead connector [a] from the bracket and disconnect...

  • Page 530

    16-34 electrical system charging system regulator/rectifier inspection • remove: radiator (see radiator and radiator fan removal in the cooling system chapter) baffle plate bolts [a] baffle plate [b] • remove the regulator/rectifier bolts [a]. • disconnect the connector [a]. • remove the regulator/r...

  • Page 531

    Electrical system 16-35 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). Notice the test light works as an indicator and also a cur- rent limiter to protect the regulator/rectifier from...

  • Page 532

    16-36 electrical system charging system • installation is the reverse of removal. ○ tighten: torque - regulator/rectifier bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) baffle plate bolts: 5.9 n·m (0.60 kgf·m, 52 in·lb) charging voltage inspection • check the battery condition (see charging condition in- spec...

  • Page 533

    Electrical system 16-37 charging system charging system circuit 1. Ignition switch 2. Load 3. Alternator 4. Regulator/rectifier 5. Frame ground 6. Battery 12 v 10 ah 7. Main fuse 30 a.

  • Page 534

    16-38 electrical system starter motor clutch starter motor clutch removal/installation • refer to the alternator rotor removal/installation. Starter motor clutch inspection • remove: alternator cover (see alternator cover removal) starter idle gear and shaft (see alternator rotor re- moval) torque l...

  • Page 535

    Electrical system 16-39 ignition system warning the ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. Notice do not disconnect the battery cables or any ot...

  • Page 536

    16-40 electrical system ignition system crankshaft sensor inspection • remove the right frame cover (see frame cover removal in the frame chapter). • disconnect the crankshaft sensor lead connector [a]. • set the hand tester to the × 10 Ω range and connect (+) lead to the yellow lead and (–) lead to...

  • Page 537

    Electrical system 16-41 ignition system timing rotor removal • remove: clutch cover (see clutch cover removal in the clutch chapter) crankshaft sensor (see crankshaft sensor removal) • hold the timing rotor [a] steady with the flywheel & pulley holder [b]. Special tool - flywheel & pulley holder: 57...

  • Page 538

    16-42 electrical system ignition system stick coil inspection • remove the stick coils (see stick coil removal). • measure the primary winding resistance [a] as follows. ○ connect the hand tester between the coil terminals. ○ set the tester to the × 1 Ω range, and read the tester. • measure the seco...

  • Page 539

    Electrical system 16-43 ignition system warning to avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • turn the ignition switch to on and the engine stop switch to run position. • pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission i...

  • Page 540

    16-44 electrical system ignition system interlock operation inspection • raise the rear wheel off the ground with a stand. 1st check • start the engine in the following conditions. Condition transmission gear → 1st position clutch lever → release sidestand → down or up ○ turn the ignition switch to ...

  • Page 541

    Electrical system 16-45 ignition system.

  • Page 542

    16-46 electrical system ignition system ignition system circuit 1. Ignition switch 2. Engine stop switch 3. Spark plugs 4. Stick coils 5. Speed sensor 6. Subthrottle sensor 7. Main throttle sensor 8. Joint connector d 9. Vehicle-down sensor 10. Water temperature sensor 11. Neutral switch 12. Cranksh...

  • Page 543

    Electrical system 16-47 electric starter system starter motor removal notice do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) air cleaner housing (see air cleaner housing removal...

  • Page 544

    16-48 electrical system electric starter system starter motor disassembly • remove the starter motor (see starter motor removal). • take off the starter motor through bolts [a] and remove the both end covers [b]. • pull out the armature [a] out of the yoke [b]. Note ○ do not remove the circlip [c] f...

  • Page 545

    Electrical system 16-49 electric starter system • align the stoppers [a] on the negative brush assembly [b] with the grooves [c] on the brush holder [d]. • tighten the screw securely. • align the stoppers [a] on the positive brush assembly [b] with the grooves [c] on the brush holder [d]. • install ...

  • Page 546

    16-50 electrical system electric starter system • apply thin coat of grease to the oil seal [a]. • replace the o-rings [a] with new ones. • insert the armature [b] so that commutator side [c] faces hollow side [d] of the yoke [e]. • align the marks [a] to assembly the yoke and the end covers [b]. • ...

  • Page 547

    Electrical system 16-51 electric starter system commutator cleaning and inspection • clean the metallic debris off the between commutator segments [a]. Note ○ do not use emery or sand paper on the commutator. • check the commutator for damage or abnormal wear. Replace the starter motor with a new on...

  • Page 548

    16-52 electrical system electric starter system right-hand end cover inspection • using the highest tester range, measure the resistance as shown. Terminal bolt and right-hand end cover [a] terminal bolt and negative brushes [b] special tool - hand tester: 57001-1394 if there is any reading, the bru...

  • Page 549

    Electrical system 16-53 electric starter system electric starter circuit 1. Ignition switch 2. Engine stop switch 3. Starter button 4. Neutral switch 5. Sidestand switch 6. Frame ground 7. Battery 12 v 10 ah 8. Main fuse 30 a 9. Starter relay 10. Starter motor 11. Relay box 12. Starter circuit relay...

  • Page 550

    16-54 electrical system lighting system this motorcycle adopt the daylight system and have a headlight circuit 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...

  • Page 551

    Electrical system 16-55 lighting system • fit the dust cover [a] onto the bulb [b] firmly as shown. Good [c] bad [d] • install the headlight unit (see headlight unit installation). • after installation, adjust the headlight aim (see headlight aiming inspection in the periodic maintenance chapter). C...

  • Page 552

    16-56 electrical system lighting system tail/brake light (led) unit removal • remove: front seat (see front seat removal in the frame chap- ter) rear seat covers (see rear seat cover removal in the frame chapter) • remove the tool bag. • disconnect the tail/brake light lead connector [a] • free the ...

  • Page 553

    Electrical system 16-57 lighting system headlight/tail light circuit 1. Ignition switch 2. Alternator 3. License plate light 12 v 5 w 4. Tail/brake light (led) 13.5 v 0.3/3.4 w 5. Frame ground 6. Battery 12 v 10 ah 7. Main fuse 30 a 8. Starter relay 9. Relay box 10. Headlight circuit relay 11. Fuse ...

  • Page 554

    16-58 electrical system lighting system turn signal light bulb replacement • unscrew the screw [a] and remove the lens [b]. • remove the bulb [a]. ○ push and turn the bulb counterclockwise. • replace the bulb [a] with a new one. • insert the bulb by aligning its pins [b] with the grooves [c] in the ...

  • Page 555

    Electrical system 16-59 lighting system • connect one 12 v battery and turn signal lights as indi- cated in the figure, and count how may times the lights blink for one minute. Turn signal relay [a] turn signal lights [b] 12 v battery [c] testing turn signal relay load the number of turn signal ligh...

  • Page 556

    16-60 electrical system lighting system turn signal light circuit 1. Ignition switch 2. Meter unit 3. Joint connector a 4. Front right turn signal light 12 v 10 w 5. Front left turn signal light 12 v 10 w 6. Joint connector b 7. Rear right turn signal light 12 v 10 w 8. Rear left turn signal light 1...

  • Page 557

    Electrical system 16-61 air switching valve air switching valve operation test • 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) • take the air switching valve hose end [a] outside of th...

  • Page 558

    16-62 electrical system air switching valve air switching valve unit test • remove the air switching valve (see air switching valve removal in the engine top end chapter). • set the hand tester [a] to the × Ω range and connect it to the air switching valve terminals as shown. Special tool - hand tes...

  • Page 559

    Electrical system 16-63 air switching valve air switching valve circuit 1. Ignition switch 2. Air switching valve 3. Ecu 4. Frame ground 2 5. Battery 12 v 10 ah 6. Main fuse 30 a 7. Relay box 8. Ecu main relay 9. Fuse box 1 10. Fi fuse 15 a 11. Ignition fuse 10 a.

  • Page 560

    16-64 electrical system radiator fan system fan motor inspection • remove the left center fairing (see center fairing re- moval in the frame chapter). • disconnect the connector [a]. • using an auxiliary leads, supply the battery power to the fan motor. If the fan does not rotate, the fan motor is d...

  • Page 561

    Electrical system 16-65 meter, gauge, indicator unit meter unit removal • remove: bolts [a] and washers upper meter cover [b] • remove: wellnuts [a] lower meter cover [b] • slide out the dust cover [a], and disconnect the connector [b]. • remove the meter unit mounting bolts [c] and washers, and tak...

  • Page 562

    16-66 electrical system meter, gauge, indicator unit • separate the meter assembly [a] and upper meter case [b]. Electronic combination meter unit inspection • remove the meter unit (see meter unit removal). [1] green left turn signal indicator light (led) [2] green neutral indicator light (led) (–)...

  • Page 563

    Electrical system 16-67 meter, gauge, indicator unit ○ then the tachometer needle [a] sweeps to the maximum reading [b], then sweeps back to the minimum reading [c]. • connect the terminal [15] to the terminal [16]. ○ then the tachometer needle [a] sweeps to the maximum reading, then sweeps back to ...

  • Page 564

    16-68 electrical system meter, gauge, indicator unit left and right button operation check • connect the 12 v battery and terminals in the same man- ner as specified in the “liquid crystal display (lcd) seg- ments check”. • check that the multifunction meter displays shift as shown when the left but...

  • Page 565

    Electrical system 16-69 meter, gauge, indicator unit • in the hour setting mode, press the right button to effect the minute setting mode. ○ the minute display blinks on the display. • press the left button to set the minute. • in the minute setting mode, press the right button to return the hour/mi...

  • Page 566

    16-70 electrical system meter, gauge, indicator unit speedometer check • connect the 12 v battery and terminals in the same man- ner as specified in the “liquid crystal display (lcd) seg- ments check”. • the speed equivalent to the input frequency is indicated in the oscillator [a], if the square wa...

  • Page 567

    Electrical system 16-71 meter, gauge, indicator unit tachometer check • connect the 12 v battery and terminals in the same man- ner as specified in the “liquid crystal display (lcd) seg- ments check”. • the revolutions per minute (rpm) equivalent to the input frequency is indicated in the oscillator...

  • Page 568

    16-72 electrical system meter, gauge, indicator unit fuel level warning check • connect the 12 v battery and terminals in the same man- ner as specified in the “liquid crystal display (lcd) seg- ments check”. • connect the variable rheostat [a] to the terminal [5]. • adjust the resistance value to t...

  • Page 569

    Electrical system 16-73 meter, gauge, indicator unit yellow engine warning indicator light (led) battery negative (–) terminal to terminal [11] green left and right turn signal indicator light (led) for green left turn signal indicator light (led) battery positive (+) terminal to terminal [1] for gr...

  • Page 570

    16-74 electrical system meter, gauge, indicator unit meter circuit 1. Ignition switch 2. Speed sensor 3. Joint connector c 4. Joint connector d 5. Water temperature sensor 6. Neutral switch 7. Oil pressure switch 8. Ecu 9. Fuel level gauge 10. Frame ground 11. Battery 12 v 10 ah 12. Main fuse 30 a 1...

  • Page 571

    Electrical system 16-75 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 572

    16-76 electrical system switches and sensors water temperature sensor inspection • remove the water temperature sensor (see water tem- perature sensor removal/installation in the fuel system (dfi) chapter). • suspend the sensor [a] in a container of coolant so that the temperature-sensing projection...

  • Page 573

    Electrical system 16-77 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 574

    16-78 electrical system switches and sensors oxygen sensor removal (equipped models) notice never drop the sensor especially on a hard surface. Such a shock to the sensor can damage it. Notice do not pull strongly, twist, or bend the oxygen sen- sor lead. This may cause the wiring open. • remove the...

  • Page 575

    Electrical system 16-79 relay box note ○ 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) air cleaner element (see air cleaner element replace- ment in the periodic mainte...

  • Page 576

    16-80 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 577

    Electrical system 16-81 relay box relay box internal circuit a: headlight circuit relay b: ecu main relay c: fuel pump relay d: starter circuit relay e: radiator fan relay.

  • Page 578

    16-82 electrical system fuse 30 a main fuse removal • remove the starter relay (see starter relay inspection). • slide out the cap [a]. • open the cover [b], and pull out the main fuse [c] straight out of the fuse box with needle nose pliers. Fuse box fuse removal • remove the fuel tank (see fuel ta...

  • Page 579: Appendix

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

  • Page 580

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

  • Page 581

    Appendix 17-3 cable, wire, and hose routing 1. Run the main harness inside the ribs on the air cleaner housing cover. 2. Clamp (hold the main harness.) 3. Fix the clamp to the bracket. 4. Run the rear (smaller) ecu connecter lead above the other one. 5. Right switch housing lead connector 6. Air swi...

  • Page 582

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

  • Page 583

    Appendix 17-5 cable, wire, and hose routing 1. Guide (hold the intake air pressure sensor lead.) 2. Vehicle-down sensor lead 3. Fix the ignition switch lead connector (upper) and the left switch housing lead connector (lower) to the bracket. 4. Bracket 5. Stick coil lead 6. Clamps 7. Run the main ha...

  • Page 584

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

  • Page 585

    Appendix 17-7 cable, wire, and hose routing 1. Fix the clamp to the frame gusset. 2. Run the frame ground lead on the left side of the air cleaner housing. 3. Run the frame ground lead terminal to the outside from between the frame gussets, and fix the lead terminal on the gusset. 4. Frame ground le...

  • Page 586

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

  • Page 587

    Appendix 17-9 cable, wire, and hose routing 1. Run the rear brake light switch lead through the hole on frame. 2. Hook (hold the main harness.) 3. Fix the starter relay to the ribs on the battery case. 4. Run the tail/brake light lead into the groove on the battery case. 5. Hook (hold the battery ne...

  • Page 588

    17-10 appendix cable, wire, and hose routing abs equipped models.

  • Page 589

    Appendix 17-11 cable, wire, and hose routing 1. Run the abs hydraulic unit lead through the hole on the frame. 2. From rear to front, run the following under the hook on the battery case; starter relay lead, battery positive (+) cable connector lead, battery negative (–) cable. 3. Locate the abs kaw...

  • Page 590

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

  • Page 591

    Appendix 17-13 cable, wire, and hose routing 1. Do not loosen the leads in this area. 2. Run the leads above the hook on the reinforce. 3. Fix the clamp to the reinforce. 4. Run the leads under the hook on the reinforce. 5. Run the rear right turn signal light lead behind the hook on the reinforce. ...

  • Page 592

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

  • Page 593

    Appendix 17-15 cable, wire, and hose routing 1. From upper to lower, run the following on the left side of the head pipe; clutch cable, left switch housing lead, main harness. 2. Guide 3. Run the main harness as follows; through the guide, on the left side of the head pipe, inside the clamp on the b...

  • Page 594

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

  • Page 595

    Appendix 17-17 cable, wire, and hose routing 1. Meter unit lead 2. Fix the clamp to the bracket. 3. Bracket 4. Run the left city light lead through the clamp and locate its connector in front of the main harness. 5. Headlight lead connector (low beam) 6. Fix the clamp to the bracket. 7. Headlight le...

  • Page 596

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

  • Page 597

    Appendix 17-19 cable, wire, and hose routing 1. Turn signal relay 2. Run the horn lead inside the water hose. 3. Run the radiator fan lead inside the frame. 4. Fix the clamps to the frame bracket. 5. Fix the clamp to the engine mounting bracket. 6. Connect the horn lead terminals as shown. 7. Fix th...

  • Page 598

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

  • Page 599

    Appendix 17-21 cable, wire, and hose routing 1. Fix the fuel pump lead connector (upper) and the alternator lead connector (lower) to the bracket. 2. Canister* 3. Purge valve* 4. Run the harness in front of the tube (purge valve ~ canister)* 5. Clamp (hold the following; alternator lead, speed senso...

  • Page 600

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

  • Page 601

    Appendix 17-23 cable, wire, and hose routing 1. Guide 2. Run the brake hose (front master cylinder ~ front right caliper) through the guide. 3. Fix the clamp to the bracket. 4. Bracket 5. Run the brake hose inside the front fork. 6. Brake hose (front master cylinder ~ front right caliper) 7. Brake h...

  • Page 602

    17-24 appendix cable, wire, and hose routing abs equipped models.

  • Page 603

    Appendix 17-25 cable, wire, and hose routing 1. Guide 2. Fix the front wheel rotation sensor lead connector to the bracket. 3. Bracket 4. Fix the clamp to the bracket. 5. Brake hose (abs hydraulic unit ~ front caliper) 6. Run the brake hose (front master cylinder ~ abs hydraulic unit) through the gu...

  • Page 604

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

  • Page 605

    Appendix 17-27 cable, wire, and hose routing 1. Fix the rear brake reservoir tank to the battery case. 2. Clamps 3. Run the brake hose (rear master cylinder ~ rear caliper) through the swingarm. 4. Fix the brake hose (rear brake reservoir tank ~ rear master cylinder) to the frame with the clamps. 5....

  • Page 606

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

  • Page 607

    Appendix 17-29 cable, wire, and hose routing 1. Fix the rear brake reservoir tank to the battery case. 2. Clamps 3. Run the brake hose (abs hydraulic unit ~ rear caliper) through the swingarm. 4. Fix the brake hose (rear brake reservoir tank ~ rear master cylinder) to the frame with the clamps. 5. F...

  • Page 608

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

  • Page 609

    Appendix 17-31 cable, wire, and hose routing abs equipped models 1. Collar and damper (hold the brake pipes.) 2. Run the brake pipe (front master cylinder ~ abs hydraulic unit) inside the brake pipe (abs hydraulic unit ~ front caliper). 3. Run the brake pipe (abs hydraulic unit ~ front caliper) betw...

  • Page 610

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

  • Page 611

    Appendix 17-33 cable, wire, and hose routing 1. Guide (run the front brake hose through the guide.) 2. Clamps (hold the front brake hose.) 3. Clamps (hold the rear brake hose.) 4. Clamp with damper (hold the rear brake hose.).

  • Page 612

    17-34 appendix cable, wire, and hose routing abs equipped models.

  • Page 613

    Appendix 17-35 cable, wire, and hose routing abs equipped models 1. Guide (run the front brake hose through the guide.) 2. Clamps (hold the front brake hose.) 3. Clamp (hold the front wheel rotation sensor lead.) 4. Clamps (hold the brake pipe.) 5. Abs hydraulic unit 6. Front wheel rotation sensor 7...

  • Page 614

    17-36 appendix cable, wire, and hose routing abs equipped models.

  • Page 615

    Appendix 17-37 cable, wire, and hose routing 1. Front 2. Brake hose (to front master cylinder) 3. About 50° 4. Brake hose (to front caliper) 5. About 65° 6. Abs hydraulic unit 7. Brake pipe (to rear caliper) 8. About 29.9° 9. Brake pipe (to rear master cylinder) 10. About 28.3°.

  • Page 616

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

  • Page 617

    Appendix 17-39 cable, wire, and hose routing 1. Reserve tank overflow hose 2. Reserve tank hose 3. Fit the reserve tank hose into the groove on the reserve tank. 4. Brake pipe (er650f model) 5. White paint mark 6. Throttle cables 7. Run the reserve tank overflow hose under the brake pipe and the thr...

  • Page 618

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

  • Page 619

    Appendix 17-41 cable, wire, and hose routing 1. Reserve tank overflow hose 2. Run the reserve tank overflow hose between the air suction valve cover and the stick coil. 3. Run the reserve tank overflow hose under the stick coil lead. 4. Run the reserve tank overflow hose above the hose on the thrott...

  • Page 620

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

  • Page 621

    Appendix 17-43 cable, wire, and hose routing 1. Air cleaner housing 2. Air switching valve 3. Air switching valve hoses 4. Ecu 5. Breather hose 6. Clamp 7. Drain hose 8. Throttle body assy 9. Vacuum hose 10. To the intake air pressure sensor 11. View from a 12. Clamp 13. View from b 14. White paint ...

  • Page 622

    17-44 appendix cable, wire, and hose routing sea-b1 and th models.

  • Page 623

    Appendix 17-45 cable, wire, and hose routing 1. Blue label 2. Tube (fuel tank ~ canister) 3. Purge valve 4. Canister 5. Green paint marks 6. Tube (canister ~ purge valve) 7. Tube (purge valve ~ throttle body assy).

  • Page 624

    17-46 appendix troubleshooting guide note ○ refer to the fuel system (dfi) 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 com...

  • Page 625

    Appendix 17-47 troubleshooting guide compression low: spark plug loose cylinder head not sufficiently tightened down no valve clearance cylinder, piston worn piston ring bad (worn, weak, broken, or sticking) piston ring/groove clearance excessive cylinder head warped cylinder head gasket damaged val...

  • Page 626

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

  • Page 627

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

  • Page 628

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

  • Page 629

    Model application year model beginning frame no. 2012 er650ec jkaeree1 □ cda00001 jkaer650eeda00001 2012 er650fc jkaeref1 □ cda00001 jkaer650efda00001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1453-01 printed in japan.