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Kawasaki FX1000V - Service Manual

Manual is about: 4-Stroke Air-Cooled V-Twin Gasoline Engine

Summary of FX1000V -

  • Page 1

    Fx921v dfi fx1000v dfi 4-stroke air-cooled v-twin gasoline engine 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: Fx921V Dfi

    Fx921v dfi fx1000v dfi 4-stroke air-cooled v-twin gasoline engine 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 prio...

  • Page 6

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

  • Page 7

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

  • Page 8: Foreword

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

  • Page 9: General Information

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

  • Page 10

    1-2 general information before servicing before starting to service the engine, carefully read the applicable section to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been in- cluded wherever necessary. Nevertheless, even a detailed acco...

  • Page 11

    General information 1-3 before servicing (12)oil seal and grease seal replace any oil or grease seals that were removed with new ones, as removal generally dam- ages seals. When pressing in a seal which has manufacturer’s marks, press it in with the marks facing out. Seals should be pressed into pla...

  • Page 12

    1-4 general information before servicing “service limits” indicate the usable limits. If the measurement shows excessive wear or deteri- orated performance, replace the damaged parts..

  • Page 13

    General information 1-5 model identification fx921v dfi, fx1000v dfi cylinder number designation: no.1 cylinder is the left-hand cylinder viewed from the intake pipe. No.2 cylinder is the right-hand cylinder viewed from the intake pipe..

  • Page 14

    1-6 general information general specifications item fx921v dfi, fx1000v dfi type of engine forced air-cooled, vertical shaft, ohv 6 valves, 4-stroke gasoline engine. Cylinder layout 90° v-twin bore × stroke 89.15 mm × 80 mm (3.5 in. × 3.15 in.) piston displacement 999 cm³ (61 cu. In.) direction of r...

  • Page 15: Periodic Maintenance

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

  • Page 16

    2-2 periodic maintenance periodic maintenance chart to ensure satisfactory operation over an extended period of time, any engine requires normal main- tenance regular intervals. The periodic maintenance chart below shows periodic inspection and maintenance items and suitable intervals. The bullet ma...

  • Page 17

    Periodic maintenance 2-3 torque and locking agent the following tables list the tightening torque for the major fasteners and the parts requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “remarks” column mean: eo: apply oil to the threads. L: apply a non-permanent l...

  • Page 18

    2-4 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks crankcase cover bolts 46 4.7 34 s crankcase cover oil passage plugs 3.9 0.40 35 in·lb l crankcase oil passage plugs 3.9 0.40 35 in·lb l starter system starter motor mounting bolts 19.6 2.0 14 starter motor term...

  • Page 19

    Periodic maintenance 2-5 specifications item standard fuel system (dfi) idle speed: (1) low idle speed 1 550 r/min (rpm) (for reference) high idle speed 3 600 r/min (rpm) (for reference) air cleaner: type heavy duty type pre-cleaner primary element second-stage cleaner secondary element engine top e...

  • Page 20

    2-6 periodic maintenance special tools valve seat cutter, 45° - 27.5: 57001-1114 valve seat cutter, 45° - 32: 57001-1115 valve seat cutter, 32° - 28: 57001-1119 valve seat cutter holder, 7: 57001-1126 valve seat cutter holder bar: 57001-1128 valve seat cutter, 32° - 33: 57001-1199 oil filter wrench:...

  • Page 21

    Periodic maintenance 2-7 periodic maintenance procedures fuel system (dfi) element cleaning and inspection air cleaner elements are not recommended to be cleaned, and each air cleaner element should be replaced with new ones at the maintenance time as shown in the maintenance chart. Note ○ operating...

  • Page 22

    2-8 periodic maintenance periodic maintenance procedures valve clearance inspection note ○ valve clearance must be checked when the engine is cold (at room temperature). • remove the rocker covers (see cylinder head assembly removal in the engine top end chapter). • place the piston at the top dead ...

  • Page 23

    Periodic maintenance 2-9 periodic maintenance procedures • holding the adjusting screw with a suitable tool, tighten the adjusting locknut [a] to the specified torque. Torque - valve clearance adjusting locknuts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • do not overtighten the valve clearance adjusting locknu...

  • Page 24

    2-10 periodic maintenance periodic maintenance procedures seat cutter operating cares 1. This valve seat cutter is designed only for valve seat repair. Therefore the cutter must not be used for other purposes. 2. Do not drop or hit the valve seat cutter, or the diamond particles may fall off. 3. Do ...

  • Page 25

    Periodic maintenance 2-11 periodic maintenance procedures • coat the seat with machinist’s dye. • fit a 45° cutter [a] to the holder and slide it into the valve guide. ○ resurface the valve seat with a 45° cutter, removing only enough material to produce a smooth and concentric seat. Caution do not ...

  • Page 26

    2-12 periodic maintenance periodic maintenance procedures • when lapping is completed, wash all parts in solvent to remove lapping compound. Dry the parts thoroughly. • note the position of the lapping mark on the valve face. The lapping mark should appear on or near the center of the valve face. • ...

  • Page 27

    Periodic maintenance 2-13 periodic maintenance procedures • remove the oil filler cap and pour in the specified type and the amount of oil. Engine oil: grade: sf, sg, sh, sj or sl class viscosity: sae40, sae30, sae10w-30/sae10w-40, or sae5w-20 capacity: [when the oil filter is not removed] 1.7 l (1....

  • Page 28

    2-14 periodic maintenance periodic maintenance procedures oil cooler fin cleaning • clean dirt off the outside fins [a] with brush or with com- pressed air. Electrical system spark plug cleaning and inspection • remove the spark plug (see spark plug removal in the electrical system chapter). If the ...

  • Page 29: Fuel System (Dfi)

    Fuel system (dfi) 3-1 3 fuel system (dfi) table of contents exploded view................................... 3-2 specifications .................................... 3-4 throttle body assy ............................ 3-5 intake pipe removal.................... 3-5 intake pipe installation..............

  • Page 30

    3-2 fuel system (dfi) exploded view.

  • Page 31

    Fuel system (dfi) 3-3 exploded view torque no. Fastener n·m kg·m ft·lb remarks 1 air cleaner bracket mounting bolts 5.9 0.60 52 in·lb 2 air cleaner bracket mounting nut 19.6 2.0 14 3 air cleaner mounting bracket bolt 19.6 2.0 14 4 engine temperature sensor mounting bolt 5.9 0.60 52 in·lb 5 fuel pump...

  • Page 32

    3-4 fuel system (dfi) specifications item standard digital fuel injection system throttle body assy: type two barrel type bore 28 mm (1.1 in.) engine temperature sensor: resistance 10 k Ω at 25°c (77°f) fuel injectors: nozzle type fine atomizing type with 1 hole resistance 23.5 ±1 Ω at 25°c (77°f) f...

  • Page 33

    Fuel system (dfi) 3-5 throttle body assy intake pipe removal • remove: air cleaner (see air cleaner body and bracket removal) bolts [a] intake pipe outer cover [b] • remove: clamp [a] breather hose [b] nuts [c] bolts [d] intake pipe [e] and gasket intake pipe installation • replace the gasket [a] wi...

  • Page 34

    3-6 fuel system (dfi) throttle body assy throttle body assy removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch off. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes an...

  • Page 35

    Fuel system (dfi) 3-7 throttle body assy throttle body assy installation • clean the mating surface of the throttle body assy and intake manifold. • replace the gaskets [a] with new ones. • install the insulator [b], throttle body assy [c] and new gaskets sequence as shown in the figure. • install t...

  • Page 36

    3-8 fuel system (dfi) intake manifold intake manifold removal • remove: fan housing (see flywheel and stator coil removal in the electrical system chapter) throttle body assy (see throttle body assy removal) • cut off the bands [a] holding the wire lead and/or harness. • unscrew the intake manifold ...

  • Page 37

    Fuel system (dfi) 3-9 digital fuel injection (dfi) system dfi system 1. Fuel tank 2. Fuel filter 3. Fuel pump 4. Fuel regulator 5. Fuel injectors 6. Governor motor 7. Engine temperature sensor 8. Ignition coils 9. Crankshaft position sensor 10. Air flow 11. Fuel flow.

  • Page 38

    3-10 fuel system (dfi) digital fuel injection (dfi) system dfi system wiring diagram note ○ portion surrounded by shows khi procurement parts. 1. Ecu connector of throttle body assy 2. Fuel pump 3. Engine temperature sensor 4. Fuel injector #2 5. Governor motor 6. Fuel injector #1 7. Ignition coil #...

  • Page 39

    Fuel system (dfi) 3-11 digital fuel injection (dfi) system terminal numbers of ecu connectors (view from wire side) 1. Battery 12 v 2. Unused 3. Unused 4. Power supply to sensor 5. Ground for engine temperature sensor 6. Ground for crankshaft position sensor 7. Unused 8. Self-diagnosis light 9. Igni...

  • Page 40

    3-12 fuel system (dfi) digital fuel injection (dfi) system 2. Conversely, make sure that all electrical connections are firmly reconnected before staring the engine. 3. The fuel injection system is designed to be used with a 12 v battery as its power source. 4. Always disconnect the battery positive...

  • Page 41

    Fuel system (dfi) 3-13 digital fuel injection (dfi) system ecu connector inspection • visually inspect the connection of the ecu connector. If the connector is clogged with mud or dust, blow it off with compressed air. • disconnect the ecu connector and then visually inspect the connectors. Replace ...

  • Page 42

    3-14 fuel system (dfi) digital fuel injection (dfi) system how to read fault codes ○ fault codes are shown by a series of long and short blinks of the self-diagnosis light as shown below. ○ read 10th digit and unit digit as the self-diagnosis light blinks. ○ when there are a number of problems, all ...

  • Page 43

    Fuel system (dfi) 3-15 digital fuel injection (dfi) system fxt00v-as01 fault code self-diagnoss light problems (1) 11 governor motor malfunction, wiring open or short 12 map sensor malfunction, wiring open or short 17 engine temperature sensor malfunction, wiring open or short 18 throttle (accelerat...

  • Page 44

    3-16 fuel system (dfi) digital fuel injection (dfi) system engine temperature sensor installation • install the engine temperature sensor [a] as shown in the figure, and tighten the bolt [b]. 10° [c] torque - engine temperature sensor mounting bolt: 5.9 n·m (0.60 kgf·m, 52 in·lb) • connect the engin...

  • Page 45

    Fuel system (dfi) 3-17 digital fuel injection (dfi) system crankshaft position sensor inspection • remove the crankshaft position sensor (see crankshaft position sensor removal). • connect the crankshaft position sensor connector [a] with the battery [b], 10 k Ω resistor [c] and hand tester [d] as s...

  • Page 46

    3-18 fuel system (dfi) digital fuel injection (dfi) system • install the fuel injectors [a] with the holders to the throttle body assy [b]. • tighten the screws [c]. Audible inspection note ○ be sure the battery is fully charged. • start the engine and let it idle. • apply the tip of a screwdriver [...

  • Page 47

    Fuel system (dfi) 3-19 digital fuel injection (dfi) system fuel pump (fault code 45) fuel pump removal • disconnect the fuel pump connector [a]. • remove: bolt [b] clamps [c] fuel hoses [d] (from the fuel pump [e]) fuel pump installation • connect the fuel hoses [a] fully and install the clamps [b]....

  • Page 48

    3-20 fuel system (dfi) digital fuel injection (dfi) system ignition coil (fault code 51, 52) (models except for fxt00v-as01) ignition coil #1: (fault code 51) ignition coil #2: (fault code 52) ignition coil removal/installation • refer to the ignition coil removal and installation in the electrical ...

  • Page 49

    Fuel system (dfi) 3-21 digital fuel injection (dfi) system wiring continuity inspection engine main harness connector [a] ←→ ignition coil #2 connector [b] r lead [c] if the wiring is good, replace the throttle body assy (see throttle body assy removal). Throttle motor (fault code 58) (models except...

  • Page 50

    3-22 fuel system (dfi) digital fuel injection (dfi) system governor motor (fault code 11) (fxt00v-as01) governor motor removal/adjustment caution do not remove or adjust the governor motor [a] since they have been adjusted and set with preci- sion at the factory. Never drop the throttle body assy, e...

  • Page 51

    Fuel system (dfi) 3-23 fuel filter fuel filter removal/installation • remove: clamp [a] fuel filter [b] • when install the fuel filter, arrow mark [c] faces fuel pump side. Fuel filter inspection • visually inspect the fuel filter [a]. If the filter is clear with no signs of dirt or other contami- n...

  • Page 52

    3-24 fuel system (dfi) air cleaner element removal • while pulling up the knob [a], turn the cap [b] to counter- clockwise. • align the arrow mark [a] and unlock mark [b] to remove the cap. • remove the primary element [a]. • remove the secondary element [a]. Element installation • slide the seconda...

  • Page 53

    Fuel system (dfi) 3-25 air cleaner • turn the cap to the clockwise until the lock mark [a]. Element cleaning and inspection air cleaner elements are not recommended to be cleaned, and each air cleaner element should be replaced with new ones. • refer to the element cleaning and inspection in the pe-...

  • Page 54

    3-26 fuel system (dfi) air cleaner • set the air cleaner body [a] onto the lower bracket so that the air intake duct [b] is facing upward. • install the intake hose [c], and tighten the clamp [d]. • install the upper bracket [e]. • tighten: torque - air cleaner mounting bracket bolt [f]: 19.6 n·m (2...

  • Page 55: Cooling System

    Cooling system 4-1 4 cooling system table of contents exploded view........................................................................................................................ 4-2 cooling fan ...................................................................................................

  • Page 56

    4-2 cooling system exploded view.

  • Page 57

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 cooling fan plate mounting stud bolts 5.9 0.60 52 in·lb 2 cooling fan screen bolts 5.9 0.60 52 in·lb 3 engine shroud bolts 5.9 0.60 52 in·lb 4 fan housing bolts 5.9 0.60 52 in·lb 5 guard mounting bolts 5.9 0.60 52 in·lb.

  • Page 58

    4-4 cooling system cooling fan cooling fan removal • refer to the flywheel and stator coil removal in the elec- trical system chapter. Cooling fan installation • refer to the flywheel and stator coil installation in the electrical system chapter. Cooling fan inspection • remove the fan housing (see ...

  • Page 59

    Cooling system 4-5 engine shroud engine shroud removal • remove: fan housing (see flywheel and stator coil removal in the electrical system chapter) spark plug caps (see ignition coil removal in the elec- trical system chapter) rocker covers (see cylinder head assembly removal in the engine top end ...

  • Page 60

    4-6 cooling system engine shroud engine shroud installation • install the engine shrouds [a]. • tighten: torque - engine shroud bolts [b]: 5.9 n·m (0.60 kgf·m, 52 in·lb) • install the engine ground leads and tighten the bolt [a]. Torque - engine ground terminal bolt: 5.9 n·m (0.60 kgf·m, 52 in·lb) •...

  • Page 61: Engine Top End

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

  • Page 62

    5-2 engine top end exploded view.

  • Page 63

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 connecting rod big end cap bolts 20.6 2.10 15.2 eo 2 cylinder head bolts 46 4.7 34 s 3 engine temperature sensor lead clamp bolt 19.6 2.0 14 4 exhaust pipe nuts 22 2.2 16 5 rocker cover bolts 5.9 0.60 52 in·lb 6 spark plu...

  • Page 64

    5-4 engine top end specifications item service limit cylinder head cylinder compression (min) 555 kpa (80 psi) @ engine oil temperature 50 ∼ 60°c (122 ∼ 144°f), cranking speed 500 rpm/5 seconds cylinder head warp 0.05 mm (0.002 in.) valves valve head thickness intake, exhaust 0.4 mm (0.016 in.) valv...

  • Page 65

    Engine top end 5-5 specifications item standard valve clearance: intake, exhaust 0.10 ∼ 0.15 mm (0.004 ∼ 0.006 in.) valve seating surface angle: intake, exhaust 45° valve seating surface width: intake 0.7 ∼ 1.1 mm (0.028 ∼ 0.043 in.) exhaust 1.0 ∼ 1.5 mm (0.039 ∼ 0.059 in.) valves guide inside diame...

  • Page 66

    5-6 engine top end special tools piston ring pliers: 57001-115 compression gauge, 20 kgf/cm²: 57001-221 piston ring compressor grip: 57001-1095 compression gauge adapter, m14 × 1.25: 57001-1159 piston ring compressor belt, 80 ∼ 91: 57001-1320

  • Page 67

    Engine top end 5-7 cylinder head compression measurement • before measuring compression, do the following. ○ be sure the battery is fully charged. ○ thoroughly warm up the engine so that engine oil be- tween the piston and cylinder wall will help sealing the compression as it does during normal runn...

  • Page 68

    5-8 engine top end cylinder head cylinder head assembly removal • remove: intake manifold (see intake manifold removal in the fuel system chapter) spark plugs (see spark plug removal in the electrical system chapter) • unscrew the rocker cover bolts [a], and remove the cover [b] and the gasket. • wh...

  • Page 69

    Engine top end 5-9 cylinder head • tighten the cylinder head bolts following the tightening sequence as shown in the figure. Torque - cylinder head bolts: 46 n·m (4.7 kgf·m, 34 ft·lb) #1 cylinder [a] #2 cylinder [b] caution a torque wrench must be used to assure proper torque. Improper tightening of...

  • Page 70

    5-10 engine top end cylinder head push rod installation • set each piston at the t.D.C of the compression stroke. • apply engine oil to the both ends and shaft of the push rod. • install the push rods in their original positions of the tappet hollow [a]. • check that both intake and exhaust push rod...

  • Page 71

    Engine top end 5-11 cylinder head • remove the stem seals [a]. Note ○ it is not necessary to remove the stem seal unless it is being replaced. ○ valve guide [b] is not replaceable, do not remove it. • apply engine oil to the valve stem to avoid damaging the stem seal. • check to see that the valve m...

  • Page 72

    5-12 engine top end cylinder head rocker arm inspection • measure the diameter [a] of the rocker shafts with a mi- crometer at several points of bearing the rocker arm. If the outside diameter is less than the service limit, re- place the rocker shaft. Rocker shafts outside diameter service limit: i...

  • Page 73

    Engine top end 5-13 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 seat inspection • refer to the valve seat inspection in...

  • Page 74

    5-14 engine top end valves valve guide inside diameter • use a small bore gauge or a micrometer to measure the inside diameter [a] of the valve guide [b] at three positions down the guide length. If the measurement is more than the service limit, replace the cylinder head with a new one. Valve guide...

  • Page 75

    Engine top end 5-15 cylinder, piston piston removal • remove: cylinder head assembly (see cylinder head assembly removal) crankcase cover (see crankcase cover removal in the camshaft/crankshaft chapter) camshaft (see camshaft, tappet removal in the camshaft/crankshaft chapter) • turn the crankshaft ...

  • Page 76

    5-16 engine top end cylinder, piston • remove the top and second rings with piston ring pliers. Special tool - piston ring pliers: 57001-115 • if the special tool is not available, carefully spread the ring opening with your thumbs, then push up to the opposite side of the ring [a] to remove it. • r...

  • Page 77

    Engine top end 5-17 cylinder, piston • fit a new piston pin snap ring into the side of the piston so that the ring opening [a] does not coincide with the notch [b] in the edge of the piston pin hole. ○ when installing a piston pin snap ring, compress it only enough to install it and no more. Caution...

  • Page 78

    5-18 engine top end cylinder, piston piston/cylinder seizure • in case of seizure, remove the pistons (see piston re- moval). • visually inspect the cylinder and pistons for damage. If there is only light damage, repair the damaged piston surface with #400 emery cloth. Remove the small alu- minum de...

  • Page 79

    Engine top end 5-19 cylinder, piston • measure the piston ring thickness [a]. ○ use a micrometer to measure at several points around the rings. If any of the measurement are less than the service limit, replace the entire set of rings with new ones. Piston ring thickness service limit top 1.9 mm (0....

  • Page 80

    5-20 engine top end cylinder, piston • measure the inside diameter [a] of the connecting rod small end at several points. Use a dial bore gauge. If the inside diameter is more than the service limit, re- place the connecting rod with a new one. Connecting rod small end inside diameter service limit:...

  • Page 81

    Engine top end 5-21 cylinder, piston cylinder boring and honing always resize to exactly 0.5 mm (0.02 in.) over the stan- dard bore size. If this is done accurately, the stock oversize rings and piston will fit perfectly and proper clearance will be maintained. Resizing the cylinder bore can be done...

  • Page 83: Lubrication System

    Lubrication system 6-1 6 lubrication system table of contents exploded view........................................................................................................................ 6-2 engine oil flow chart..................................................................................

  • Page 84

    6-2 lubrication system exploded view.

  • Page 85

    Lubrication system 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine oil drain plugs 6.9 0.70 61 in·lb 2 oil cooler bolts 5.9 0.60 52 in·lb 3 oil filler mounting bolt 5.9 0.60 52 in·lb 4 oil filter 11.8 1.2 104 in·lb r 5 oil filter joint pipe 6.9 0.70 61 in·lb 6 oil pump cover p...

  • Page 86

    6-4 lubrication system engine oil flow chart.

  • Page 87

    Lubrication system 6-5 specifications item standard engine oil grade sf, sg, sh, sj or sl class viscosity sae40, sae30, sae10w-30/sae10w-40, or sae5w-20 capacity 1.7 l (1.8 us qt) (when filter is not removed) 1.9 l (2.0 us qt) (when filter is removed) level operating range (grid area (add and full))...

  • Page 88

    6-6 lubrication system special tools oil pressure gauge, 10 kgf/cm²: 57001-164 oil pressure gauge adapter, pt 1/8: 57001-1033.

  • Page 89

    Lubrication system 6-7 engine oil, oil filter and oil cooler caution engine operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure and accident. Engine oil level inspection • refer to the engine oil level inspection in the p...

  • Page 90

    6-8 lubrication system pressurized lubrication system the engine lubrication circuit is a pressurized system consisting of a positive displacement pump which picks up oil through a filter screen from the crankcase. The oil is pumped to a replaceable oil filter cartridge, through the engine’s oil pas...

  • Page 91

    Lubrication system 6-9 oil pump, relief valve oil pump, relief valve removal • remove: crankshaft (see crankshaft removal in the camshaft/crankshaft chapter) bolts [a] • take out the pump cover plate [b] , pump gear [c] and pump shaft [d] as a set. • remove the pins [a], oil pump cover plate [b] and...

  • Page 92

    6-10 lubrication system oil pump, relief valve oil pump, relief valve inspection • remove the oil pump parts assembly (see oil pump, re- lief valve removal). • visually inspect the pump gear, outer and inner rotor, and cover plate. If there is any damage or uneven wear, replace them with new ones. ○...

  • Page 93

    Lubrication system 6-11 oil pump, relief valve • measure the outside diameter [a] of the pump shaft with a micrometer at several points. If the diameter is less than the service limit, replace the pump shaft with a new one. Pump shaft outside diameter service limit: 10.923 mm (0.43004 in.) • measure...

  • Page 94

    6-12 lubrication system oil screen oil screen removal • remove the oil pump parts assembly (see oil pump, re- lief valve removal). • remove the oil screen [a]. Oil screen installation • clean the oil screen thoroughly whenever it is removed for any reason (see cleaning and inspection). • insert the ...

  • Page 95: Camshaft/crankshaft

    Camshaft/crankshaft 7-1 7 camshaft/crankshaft table of contents exploded view........................................................................................................................ 7-2 specifications ......................................................................................

  • Page 96

    7-2 camshaft/crankshaft exploded view.

  • Page 97

    Camshaft/crankshaft 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 breather chamber cover bolts 5.9 0.60 52 in·lb 2 breather pipe cover bolts 5.9 0.60 52 in·lb 3 breather valve mounting screws 2.0 0.20 18 in·lb 4 connecting rod big end cap bolts 20.6 2.10 15.2 eo 5 crankcase cover b...

  • Page 98

    7-4 camshaft/crankshaft specifications item service limit camshaft, tappet cam lobe height: intake 35.72 mm (1.406 in.) exhaust 36.84 mm (1.450 in.) camshaft journal diameter pto side 19.99 mm (0.787 in.) flywheel side 14.95 mm (0.589 in.) camshaft bearing inside diameter crankcase 20.14 mm (0.7929 ...

  • Page 99

    Camshaft/crankshaft 7-5 special tools and sealant oil seal & bearing remover: 57001-1058 bearing driver set: 57001-1129 liquid gasket, tb1217h: 92104-7001.

  • Page 100

    7-6 camshaft/crankshaft crankcase crankcase cover removal • set the engine on a clean surface while parts are being removed. • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: throttle body assy (see throttle body assy removal in the fuel system (dfi) cha...

  • Page 101

    Camshaft/crankshaft 7-7 crankcase • be sure to replace the ball bearing with a new one if re- moved. • apply engine oil to the ball bearing [a]. • press the ball bearing until bottom surface [b] of the crankcase cover. Special tool - bearing driver set: 57001-1129 • be sure to replace any oil seal w...

  • Page 102

    7-8 camshaft/crankshaft crankcase • install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence as shown in the figure. Torque - crankcase cover bolts: 46 n·m (4.7 kgf·m, 34 ft·lb) ○ do not turn one screw down completely before the others, as it may cause the ...

  • Page 103

    Camshaft/crankshaft 7-9 crankcase crankcase inspection • measure the inside diameter [a] of the crankshaft in- sert on the crankcase at several points. Replace the crankcase if the inside diameter is more than the service limit. Pto shaft bearing inside diameter service limit: 42.15 mm (1.659 in.) c...

  • Page 104

    7-10 camshaft/crankshaft breather the function of the breather is to create a negative pressure in the crankcase which prevents oil from being forced out of the engine through the piston rings, oil seals or gaskets. A sealed-type crankcase emission control system is used to prevent blow-by gases fro...

  • Page 105

    Camshaft/crankshaft 7-11 breather breather valve removal • remove: intake manifold (see intake manifold removal in the fuel system (dfi) chapter) bolts [a] breather chamber cover [b] and gasket • remove: screws [a] breather valve [b] breather valve installation • install the breather valve. • tighte...

  • Page 106

    7-12 camshaft/crankshaft breather breather pipe removal • remove: camshaft (see camshaft, tappet removal) bolts [a] breather pipe cover [b] • remove the upper breather pipe [a]. • remove the lower breather pipe [a]. Breather pipe installation • install the lower and upper breather pipes. • install t...

  • Page 107

    Camshaft/crankshaft 7-13 camshaft, tappet camshaft, tappet removal • set the engine on a clean surface while parts are re- moved. • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: crankcase cover (see crankcase cover removal) rocker covers (see cylinder ...

  • Page 108

    7-14 camshaft/crankshaft camshaft, tappet camshaft inspection • check the camshaft gear [a] for pitting, fatigue cracks, burrs or any evidence of improper tooth contact. Replace the camshaft with a new one if necessary. • check the top of the cam lobes [b] for wear, burrs or un- even contact. Replac...

  • Page 109

    Camshaft/crankshaft 7-15 crankshaft, connecting rod connecting rod removal • remove the piston (see piston removal in the engine top end chapter). Connecting rod installation • install the piston (see piston installation in the engine top end chapter). Crankshaft removal • drain the engine oil (see ...

  • Page 110

    7-16 camshaft/crankshaft crankshaft, connecting rod connecting rod bend/twist • measure the connecting rod bend. ○ select an arbor [a] of the same diameter as the connect- ing rod big end, and insert the arbor through the connect- ing rod big end. ○ select an arbor of the same diameter as the piston...

  • Page 111

    Camshaft/crankshaft 7-17 crankshaft, connecting rod • measure the crankpin width [a] with a dial caliper. If the crankpin width is more than the service limit, replace the crankshaft with a new one. Crankpin width service limit: 49.0 mm (1.93 in.) connecting rod big end bearing/crankpin wear • apply...

  • Page 112

    7-18 camshaft/crankshaft crankshaft, connecting rod crankshaft main journal/wear • measure both main journals at several points around the journal circumference. If the journal diameter is less than the service limit, re- place the crankshaft with a new one. Crankshaft journal diameter service limit...

  • Page 113: Starter System

    Starter system 8-1 8 starter system table of contents exploded view........................................................................................................................ 8-2 specifications ................................................................................................

  • Page 114

    8-2 starter system exploded view.

  • Page 115

    Starter system 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 starter motor mounting bolts 19.6 2.0 14 2 starter motor terminal nut 8.8 0.90 78 in·lb g: apply grease. R: replacement parts.

  • Page 116

    8-4 starter system specifications item standard service limit electric starter system starter motor: carbon brush length 10.0 mm (0.39 in.) 6.0 mm (0.24 in.) commutator groove depth 0.6 mm (0.02 in.) 0.2 mm (0.008 in.) commutator diameter 28.0 mm (1.10 in.) 27.0 mm (1.06 in.) commutator runout – – –...

  • Page 117

    Starter system 8-5 electric starter system starter motor removal • disconnect the wire. • remove the mounting bolts [a] and pull the starter motor [b] from the engine with the switch lead attached. Starter motor installation • clean the starter motor and engine mounting flanges to ensure good electr...

  • Page 118

    8-6 starter system electric starter system • disconnect the switch lead [a]. • set the hand tester to the r × 1 Ω position and connect the leads as shown in the figure. Switch terminal [a] to ground [b] if the tester does not read close to 0 Ω , the solenoid is faulty. Replace it. If the tester read...

  • Page 119

    Starter system 8-7 electric starter system starter motor disassembly • loosen the terminal nut [a]. • remove the lead [b] from the starter motor to the sole- noid. • unscrew the mounting nuts [a] and remove the solenoid assembly [b]. • remove the through bolts [a] and end cover [b]. ○ slide the (–) ...

  • Page 120

    8-8 starter system electric starter system • remove: brush holder [a] yoke [b] • remove the armature assembly [a] with the pinion gear fork [b]. • remove the front stopper [a]. • push the rear stopper [b] downward and remove the snap ring [c]. • pull the rear stopper and pinion clutch [d] from the a...

  • Page 121

    Starter system 8-9 electric starter system • install the pinion clutch [a]. • install the rear stopper [b] so that the hollow side face the outside. • install the snap ring [c] to the groove of the shaft. • slide the rear stopper until the stopping with the snap ring. • install the front stopper [d]...

  • Page 122

    8-10 starter system electric starter system • install the insulator [a]. • install the end cover so that the slit [a] fit the groove [b] of the grommet. • tighten the through bolts. • engage the hook on the starter solenoid with the hook [a] on the pinion gear fork [b]. • tighten the solenoid mounti...

  • Page 123

    Starter system 8-11 electric starter system armature inspection • inspect the surface of the commutator [a]. If it is scratched or dirty, polish it with a piece of very fine emery cloth [b], and clean out the grooves. • measure the depth of the grooves between the commu- tator segments. If the groov...

  • Page 124

    8-12 starter system electric starter system • measure the armature winding resistance. ○ set the multimeter selector switch to the r × 1 Ω position and check the resistance between each segment and all the others. If the resistance it too high or even infinite, the armature winding has an open circu...

  • Page 125

    Starter system 8-13 electric starter system pinion clutch inspection • remove the pinion clutch. • turn the pinion gear [a] by hand. The pinion gear should turn counterclockwise freely, but should not turn clock- wise. If the pinion clutch dose not operate as it should, or if it makes noise, replace...

  • Page 127: Electrical System

    Electrical system 9-1 9 electrical system table of contents exploded view........................................................................................................................ 9-2 specifications ..........................................................................................

  • Page 128

    9-2 electrical system exploded view.

  • Page 129

    Electrical system 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 crankshaft position sensor mounting bolt 5.9 0.60 52 in·lb 2 engine ground terminal bolt 5.9 0.60 52 in·lb 3 flywheel bolt 56 5.7 41 4 ignition coil bolts 7.0 0.71 62 in·lb 5 ignition coil bracket bolts 5.9 0.60 52 in·...

  • Page 130

    9-4 electrical system specifications item standard service limit charging system regulated output voltage 14.1 v dc 15 v dc stator coil resistance 0.1 ∼ 0.14 Ω – – – unregulated stator output 26 ∼ 34 v ac/3 000 rpm 26 v ac/3 000 rpm regulator resistance in the text – – – ignition system crankshaft p...

  • Page 131

    Electrical system 9-5 special tool hand tester: 57001-1394.

  • Page 132

    9-6 electrical system wiring diagram.

  • Page 133

    Electrical system 9-7 wiring diagram 1. R 2. R 3. R 4. Bk 5. Br 6. O 7. Lg 8. R 9. Bk 10. R 11. V 12. Engine main harness connector.

  • Page 134

    9-8 electrical system precautions there are a number of important precautions that you must follow when servicing electrical systems. Learn and observe all the rules below. ○ do not reverse the battery cable connections. This will burn out the diodes in the electrical parts. ○ always check the batte...

  • Page 135

    Electrical system 9-9 charging system flywheel and stator coil removal • remove: air cleaner (see air cleaner body and bracket removal in the fuel system chapter) oil cooler (see oil cooler removal in the lubrication system chapter) regulator (see regulator removal) fuel pump (see fuel pump removal ...

  • Page 136

    9-10 electrical system charging system • using a suitable flywheel puller [a], remove the flywheel [b]. Caution always use flywheel puller. • remove the bolt [a]. • lift up the engine shroud [a] lightly and free the stator coil lead [b]. • remove: woodruff key [a] stator coil screws [b] stator coil ...

  • Page 137

    Electrical system 9-11 charging system • lift up the engine shroud [a] lightly and install the stator coil lead [b] in the original position. • tighten the engine shroud bolt [a]. Torque - engine shroud bolt: 5.9 n·m (0.60 kgf·m, 52 in·lb) • using a cleaning fluid, clean off any oil or dirt on the f...

  • Page 138

    9-12 electrical system charging system • install the cooling fan [a]. • install the plate [b] so that the slit [c] fit to the bosses [d] on the cooling fan. • tighten: torque - cooling fan plate mounting stud bolts: 5.9 n·m (0.60 kgf·m, 52 in·lb) • install the fan housing. • tighten: torque - fan ho...

  • Page 139

    Electrical system 9-13 charging system stator coil resistance • disconnect the stator coil lead connector [a]. • measure the stator coil resistance. ○ connect an hand tester between stator pins [b]. Special tool - hand tester: 57001-1394 stator coil resistance 0.1 ∼ 0.14 Ω if the measured value is n...

  • Page 140

    9-14 electrical system charging system regulator resistance • remove the regulator (see regulator removal). • set the kawasaki hand tester selector switch to the r × 100 Ω position. • connect the test leads to the points shown on the chart and read the resistance. (without charging monitor type …3 b...

  • Page 141

    Electrical system 9-15 ignition system ignition coil removal • remove: fan housing (see flywheel and stator coil removal) spark plug caps [a] ignition coil connector [b] crankshaft position sensor connector [c] #1 ignition coil [d] #2 ignition coil [e] • remove: bolts [a] ignition coil assembly [b] ...

  • Page 142

    9-16 electrical system ignition system no.2 ignition coil • remove the bolts [a] and ignition coil [b] from the bracket [c]. Ignition coil installation no.1 ignition coil • install the ignition coil [a] and crankshaft position sensor [b] into the bracket [c]. • tighten: torque - ignition coil bolts ...

  • Page 143

    Electrical system 9-17 ignition system • install the ignition coil assembly [a] on the crankcase, and tighten the bolts [b]. Torque - ignition coil bracket bolts: 5.9 n·m (0.60 kgf·m, 52 in·lb) • connect the ignition coil connector [c]. • fit the ignition coil leads [a] to the each engine shroud gro...

  • Page 144

    9-18 electrical system ignition system spark plug removal • carefully pull the plug caps from the spark plugs. • remove the spark plugs using a suitable plug wrench. Spark plug installation • insert the spark plug vertically into the plug hole with the plug installed in the plug wrench. • tighten th...

  • Page 145: Troubleshooting

    Troubleshooting 10-1 10 troubleshooting table of contents engine troubleshooting guide ............................................................................................... 10-2 dfi system troubleshooting ........................................................................................

  • Page 146

    10-2 troubleshooting engine troubleshooting guide if the engine malfunctions, check if the way the engine is used is correct. If the engine malfunc- tions even if the engine is used correctly, systematically carry out troubleshooting starting with simple points. This chart describes typical troubles...

  • Page 147

    Troubleshooting 10-3 engine troubleshooting guide.

  • Page 148

    10-4 troubleshooting engine troubleshooting guide.

  • Page 149

    Troubleshooting 10-5 engine troubleshooting guide.

  • Page 150

    10-6 troubleshooting engine troubleshooting guide dfi system troubleshooting troubleshooting guide shows the relationship between systems and inspection items which could be causing the trouble. Symptoms → engine will not start engine starts but falls to keep running engine runs but misses engine wi...

  • Page 151

    Troubleshooting 10-7 starter motor troubleshooting guide 1. Disconnect spark plug caps from the spark plugs. 2. Turn engine switch to “start” position and check condition. Warning engine may be cranked in this test. Do not touch any rotating parts of engine and equip- ment during test. Caution if st...

  • Page 152

    Part no.99924-2095-01 printed in japan.