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Kawasaki KX450F - Service Manual

Manual is about: Motorcycle

Summary of KX450F -

  • Page 1

    Kx450f 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: Kx450F

    Kx450f 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 assurance divisi...

  • Page 6

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

  • Page 7: Foreword

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

  • Page 9: General Information

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

  • Page 10

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

  • Page 11

    General information 1-3 before servicing storage of removed parts after all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly. Inspectio...

  • Page 12

    1-4 general information before servicing tightening torque incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice-initial tightening and final tighten...

  • Page 13

    General information 1-5 before servicing ball bearing and needle bearing do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressu...

  • Page 14

    1-6 general information before servicing direction of engine rotation when rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro- tate the crankshaft to positive direction (clockwise viewed from output side). Electrical leads a two-color lead is i...

  • Page 15

    General information 1-7 model identification kx450e9f left side view kx450e9f right side view frame number engine number.

  • Page 16

    1-8 general information general specifications items kx450e9f dimensions overall length 2 185 mm (86.02 in.) overall width 820 mm (32.3 in.) overall height 1 280 mm (50.39 in.) wheelbase 1 480 mm (58.27 in.) road clearance 340 mm (13.4 in.) seat height 965 mm (38.0 in.) curb mass: 112.1 kg (247.1 lb...

  • Page 17

    General information 1-9 general specifications items kx450e9f transmission: type 5-speed, constant wesh, return shift gear ratios: 1st 1.750 (28/16) 2nd 1.412 (24/17) 3rd 1.188 (19/16) 4th 1.000 (19/19) 5th 0.875 (21/24) final drive system: type chain drive reduction ratio 3.846 (50/13) overall driv...

  • Page 18

    1-10 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 19: Periodic Maintenance

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

  • Page 20

    2-2 periodic maintenance rear sprocket warp (runout) inspection ......................................................................... 2-34 brakes.................................................................................................................................. 2-34 brake lever and...

  • Page 21

    Periodic maintenance 2-3 periodic maintenance chart the maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. Frequency operation each race or 2.5 hr every 3 races or 7.5 hr every 6 races or 15 hr every 12 races or 30 hr see page spark plug-clean, i...

  • Page 22

    2-4 periodic maintenance periodic maintenance chart frequency operation each race or 2.5 hr every 3 races or 7.5 hr every 6 races or 15 hr every 12 races or 30 hr see page wheels/tires-inspect • 2-29 rear sprocket-inspect † • 2-34 front fork-inspect and clean • 2-46 front fork oil-change • 2-46 rear...

  • Page 23

    Periodic maintenance 2-5 torque and locking agent tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening toque for t...

  • Page 24

    2-6 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks camshaft chain tensioner cap bolt 5.0 0.51 44 in·lb cylinder bolt 12 1.2 106 in·lb s exhaust pipe cover bolts 12 1.2 106 in·lb exhaust pipe holder nuts 20 2.0 15 s muffler mounting bolts 20 2.0 15 s muffler cla...

  • Page 25

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks gear positioning lever nut 8.8 0.90 78 in·lb shift drum cam bolt 24 2.4 18 l balancer weight mounting nut 52 5.3 38 primary gear nut 98 10 72 lh wheels/tires front axle 79 8.0 58 front axle clamp bolts 20 2.0 1...

  • Page 26

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks steering steering stem head nut 98 10 72 steering stem nut 4.9 0.50 43 in·lb handlebar clamp bolts 25 2.5 18 2t, al frame rear frame mounting bolts 34 3.5 25 upper footpeg bracket bolts 54 5.5 40 l radiator shr...

  • Page 27

    Periodic maintenance 2-9 specifications item standard service limit fuel system throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 2 000± 50 r/min (rpm) – – – air cleaner element oil high quality foam air filter oil – – – cooling system coolant: type (recommended) permanent type ant...

  • Page 28

    2-10 periodic maintenance specifications item standard service limit standard tire: front: size 90/100-21 57m – – – make dunlop type d742f, tube rear: size 120/80-19 63m – – – make dunlop type d756, tube final drive drive chain slack 52 ∼ 58 mm (2.0 ∼ 2.3 in.) – – – drive chain 20 link length 317.5 ...

  • Page 29

    Periodic maintenance 2-11 special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 jack: 57001-1238 spark plug wrench, hex 16: 57001-1262 filler cap driver: 57001-1454 top plug wrench, 49 mm: 57001-1653 top plug wrench, 36 mm: 57001-1705.

  • Page 30

    2-12 periodic maintenance periodic maintenance procedures fuel system fuel hose and connections inspection ○ if the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak [a] or the hose burst. Replace the fuel hose if any fraying, cracks [b] or bulges [c...

  • Page 31

    Periodic maintenance 2-13 periodic maintenance procedures throttle body cleaning • check the throttle bore for cleanliness as follows. ○ remove the throttle body assy (see throttle body assy removal in the fuel system (dfi) chapter). ○ check the throttle bore [a] at the throttle valve for carbon dep...

  • Page 32

    2-14 periodic maintenance periodic maintenance procedures idle speed inspection caution this motorcycle is designed for competition use only. Therefore, the radiator does not incorporate a coolant reserve tank or cooling fan. Prolonged idling of the engine with no airflow through the radiator can ca...

  • Page 33

    Periodic maintenance 2-15 periodic maintenance procedures air cleaner element cleaning and inspection note ○ in dusty areas, the element should be cleaned more frequently than recommended interval. ○ after riding through rain or on muddy roads, the element should be cleaned immediately. ○ since repe...

  • Page 34

    2-16 periodic maintenance periodic maintenance procedures • clean the element [a] in a bath of a high-flash point sol- vent using a soft bristle brush. • squeeze it dry in a clean towel [a]. Do not wring the ele- ment or blow it dry; the element can be damaged. • check all the parts of the element f...

  • Page 35

    Periodic maintenance 2-17 periodic maintenance procedures fuel tank cleaning warning clean the fuel tank in a well-ventilated area, and take care that there is no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low flash-point...

  • Page 36

    2-18 periodic maintenance periodic maintenance procedures • check the coolant level. The coolant level [a] should be at the bottom of the filler neck [b]. If the coolant level is low, add coolant through the filler opening to the bottom of the filler neck. Install the cap. Recommended coolant: perma...

  • Page 37

    Periodic maintenance 2-19 periodic maintenance procedures water hoses and connections inspection ○ the high pressure inside the water hoses [a] can cause coolant to leak [b] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze th...

  • Page 38

    2-20 periodic maintenance periodic maintenance procedures • using a thickness gauge [a], measure the clearance be- tween each cam lob and valve lifter for all four valves. ○ for the purpose of adjusting the valve clearances, record the measured values. Valve clearance: between cam and valve lifter s...

  • Page 39

    Periodic maintenance 2-21 periodic maintenance procedures adjustment shims thick- ness p/no. Mark thick- ness p/no. Mark 2.00 92025-1870 0 2.55 92025-1881 55 2.05 92025-1871 5 2.575 92025-1985 58 2.10 92025-1872 10 2.60 92025-1882 60 2.15 92025-1873 15 2.625 92180-1059 63 2.20 92025-1874 20 2.625 92...

  • Page 40

    2-22 periodic maintenance periodic maintenance procedures cylinder head warp inspection • remove the cylinder head (see cylinder head removal in the engine top end chapter). • lay a straightedge [a] across the lower surface of the head at several different points, and measure warp by inserting a thi...

  • Page 41

    Periodic maintenance 2-23 periodic maintenance procedures piston/cylinder clearance inspection the piston-to-cylinder clearance is measured whenever a piston or cylinder is replaced with a new one. The standard piston-to-cylinder clearance must be adhered to whenever the cylinder is replaced. If onl...

  • Page 42

    2-24 periodic maintenance periodic maintenance procedures • pull off the old muffler baffle assembly [a]. • clean the adhered silicone sealant. • install the new muffler baffle assembly [a] into the inner pipe [b]. • while suppressing the muffler baffle for shrink, install the muffler body [c]. Note...

  • Page 43

    Periodic maintenance 2-25 periodic maintenance procedures clutch clutch lever (clutch cable) free play inspection • slide the clutch lever dust cover [a] out of place. • check that the clutch cable upper end is fully seated in the adjusting bolt [b]. • check that the clutch lever [c] has 8 ∼ 13 mm (...

  • Page 44

    2-26 periodic maintenance periodic maintenance procedures clutch plates inspection • remove the clutch plates (see clutch removal in the clutch chapter). • visually inspect the friction and steel plates to see if they show any signs of seizure, or uneven wear. If any plates show signs of damage, rep...

  • Page 45

    Periodic maintenance 2-27 periodic maintenance procedures recommended engine type castrol “power1 r4 racing” 5w-40 or api sg api sh, sj or sl with jaso ma, ma1 or ma2 viscosity sae 10w-30, 10w-40, 10w-50 capacity 0.96 l (1.01 us qt.) (when filter is not removed) 0.98 l (1.03 us qt.) (when filter is ...

  • Page 46

    2-28 periodic maintenance periodic maintenance procedures • apply grease to the grommet [a]. • install the filter to the filter cover [b] so that the grommet faces outside. Caution inside out installation stop oil flow, causing engine seizure. • replace the oil filter cover o-rings [a] with new ones...

  • Page 47

    Periodic maintenance 2-29 periodic maintenance procedures wheel/tires air pressure inspection/adjustment • using tire air pressure gauge [a], measure the tire pres- sure when the tires are cold. Adjust the tire air pressure to suit track conditions and rider preference, but do not stray too far from...

  • Page 48

    2-30 periodic maintenance periodic maintenance procedures spoke tightness inspection • check that all the spokes are tightened evenly. If spoke tightness is uneven or loose, tighten the spoke nipples evenly. Torque - spoke nipples: 2.2 n·m (0.22 kgf·m, 19 in·lb) warning if any spoke breaks, it shoul...

  • Page 49

    Periodic maintenance 2-31 periodic maintenance procedures wheel bearing inspection • raise the front/rear wheel off the ground. Special tool - jack: 57001-1238 • spin the wheel lightly, and check for roughness, binding or noise. If roughness, binding, abnormal noise is found, replace the hub bearing...

  • Page 50

    2-32 periodic maintenance periodic maintenance procedures drive chain slack adjustment • loosen the left and right chain adjuster locknuts [a]. • remove the cotter pin [b] and loosen the axle nut [c]. If the chain is too tight, back out the left and right chain adjusting bolts [d] evenly, and push t...

  • Page 51

    Periodic maintenance 2-33 periodic maintenance procedures drive chain wear inspection • rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry. [a] bushing [b...

  • Page 52

    2-34 periodic maintenance periodic maintenance procedures • if a special lubricant is not available, a heavy oil such as sae90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. • apply oil to the sides of the rollers so that oil will penetrate int...

  • Page 53

    Periodic maintenance 2-35 periodic maintenance procedures note ○ usually it is not necessary to adjust the pedal position, but always adjust it when the master cylinder is disas- sembled or pedal position is incorrect. ○ usually it is not necessary to adjust the pedal position, but alway adjust it w...

  • Page 54

    2-36 periodic maintenance periodic maintenance procedures brake fluid level inspection • check the brake fluid level in the front or rear brake reser- voir [a] and the front or rear reservoir must be kept above the lower level line [b]. If the fluid level in front or rear reservoir is lower than the...

  • Page 55

    Periodic maintenance 2-37 periodic maintenance procedures brake fluid change 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...

  • Page 56

    2-38 periodic maintenance periodic maintenance procedures • remove the rubber cap [a] on the bleed valve [b]. • attach a clear plastic hose [a] to the bleed valve on the caliper, and run the other end of the hose into a container. • change the brake fluid as follows: ○ repeat this operation until fr...

  • Page 57

    Periodic maintenance 2-39 periodic maintenance procedures brake pad wear inspection • remove the front brake caliper (see caliper removal in the brakes chapter). • check the lining thickness and condition of the pads in each caliper. If either pad is damaged, replace both pads in the caliper as a se...

  • Page 58

    2-40 periodic maintenance periodic maintenance procedures • remove the reservoir cap and diaphragm, and pour the brake fluid into a container. • slide the dust cover [a] on the push rod [b] out of place, and remove the circlip [c]. Special tool - inside circlip pliers: 57001-143 • pull out the push ...

  • Page 59

    Periodic maintenance 2-41 periodic maintenance procedures • remove the caliper holder [a] from the caliper [b] and remove the anti-rattle spring [c]. • using compressed air, remove the pistons. One way to remove the pistons is as follows. ○ cover the caliper opening with a clean, heavy cloth [a]. ○ ...

  • Page 60

    2-42 periodic maintenance periodic maintenance procedures • using compressed air, remove the piston. ○ cover the caliper opening with a clean, heavy cloth [a]. ○ remove the piston by lightly applying compressed air [b] to where the brake line fits into the caliper. Warning to avoid serious injury, n...

  • Page 61

    Periodic maintenance 2-43 periodic maintenance procedures • install the anti-rattle springs [a] in the caliper as shown. • replace the shaft rubber boot [a] and dust boot [b] if they are damaged. • apply a thin coat of pbc (poly butyl cuprysil) grease to the caliper holder shafts [c] and holder hole...

  • Page 62

    2-44 periodic maintenance periodic maintenance procedures brake hoses and connections inspection • inspect the brake hose and fittings for deterioration, cracks and signs of leakage. ○ the high pressure inside the brake line can cause fluid to leak [a] or the hose to burst if the line is not properl...

  • Page 63

    Periodic maintenance 2-45 periodic maintenance procedures rear brake • remove: brake hose clamps [a] • remove: rear master cylinder mounting bolts [a] • slide the rear master cylinder [a] backward. • remove: banjo bolt [b] washers [c] • remove: bolts [a] rear caliper guard [b].

  • Page 64

    2-46 periodic maintenance periodic maintenance procedures • remove: banjo bolt [a] washers [b] brake hose [c] • there are washers on each side of the brake hose fitting. Replace them with new ones when installing. • when installing the hoses, avoid sharp bending, kink- ing, flatting or twisting, and...

  • Page 65

    Periodic maintenance 2-47 periodic maintenance procedures • turn the handlebar to one side, and loosen the fork top plug [a]. Special tool - top plug wrench, 49 mm: 57001-1653 [b] • remove: front fork (see front fork removal in the suspension chapter) note ○ set rebound and compression damping setti...

  • Page 66

    2-48 periodic maintenance periodic maintenance procedures • raise the outer tube and temporarily install the fork top plug [a] (subtank) to the outer tube [b] with the top plug wrench [c]. Special tool - top plug wrench, 49 mm: 57001-1653 • hold the axle holder [a] with a vise. ○ protect the axle ho...

  • Page 67

    Periodic maintenance 2-49 periodic maintenance procedures • with the outer tube compressed by hands, remove the top plug wrench [a]. Caution removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal. Do not remove the locknut from the piston rod. • remove...

  • Page 68

    2-50 periodic maintenance periodic maintenance procedures • drain the fork oil [a] from the cylinder unit [b] by pumping the piston rod several times. ○ plug the two oil holes on the subtank [c] with fingers. • hold the front fork inverted position for more than 20 min- utes to allow the fork oil to...

  • Page 69

    Periodic maintenance 2-51 periodic maintenance procedures • pump [a] the piston rod [b] slowly several times to expel air. • with the piston rod held immovable in fully compressed position [a], gently install the base valve assembly [b] to the subtank. • screw in the base valve assembly in the subta...

  • Page 70

    2-52 periodic maintenance periodic maintenance procedures • drain the extra oil from the subtank oil hole [a]. • with the cylinder unit in horizontal position, move [a] the piston rod [b] by hand to inspect it if operating smoothly. ○ if the piston rod is not extend, remove the base valve assembly a...

  • Page 71

    Periodic maintenance 2-53 periodic maintenance procedures • compress the outer tube by hands and install the top plug wrench [a] between the axle holder bottom and locknut. Special tool - top plug wrench, 49 mm: 57001-1653 warning be careful of reaction force in spring and fix surely so that special...

  • Page 72

    2-54 periodic maintenance periodic maintenance procedures • apply a non-permanent locking agent to the threads of a adjuster assembly. • torque the adjuster assembly [a]. Torque - adjuster assembly: 55 n·m (5.6 kgf·m, 40 ft·lb) • loosen and remove the fork top plug (subtank) from the outer tube and ...

  • Page 73

    Periodic maintenance 2-55 periodic maintenance procedures the torque of fork top plug is specified to 30 n·m (3.0 kgf·m, 22 ft·lb) however, when you use the top plug wrench (special tool) [a], reduce the torque to 90% of the spec- ified value [27 n·m (2.8 kgf·m, 20 ft·lb)] due to the dis- tance [b] ...

  • Page 74

    2-56 periodic maintenance periodic maintenance procedures • adjust the gas reservoir damping adjusters [a] to the soft- est position. • pry or tap [a] at the gaps [b] in the stop [c] with suitable tools to free the stop from the rear shock body [d]. • slide the stop up the top of the piston rod then...

  • Page 75

    Periodic maintenance 2-57 periodic maintenance procedures • pour kyb k2-c oil into the gas reservoir to 30 mm (1.2 in.) [a] from the rear shock body upper end [b]. Push the piston rod assembly and seal downward again into the place where circlip is installed, and then fit the circlip [c] into the re...

  • Page 76

    2-58 periodic maintenance periodic maintenance procedures • press the reservoir cap [a] assembly downward slowly into the gas reservoir to 10 mm (0.4 in.) [b] from the gas reservoir upper end. Caution ensure that no air remains in the system. • replace the circlip with a new one. Warning if weakened...

  • Page 77

    Periodic maintenance 2-59 periodic maintenance procedures • pour kyb k2-c oil into the rear shock body to 50 mm (2.0 in.) [a] from the lower end of the rear shock body [b]. Recommended oil: k2-c (kayaba) or equivalent • insert the piston end [a] of the piston rod assembly into the rear shock body [c...

  • Page 78

    2-60 periodic maintenance periodic maintenance procedures • insert a suitable jig to center of the reservoir cap, and operate the piston rod assembly after poor 98kpa (1.0 kgf/cm², 14 psi) nitrogen gas, and then push out to the place where the reservoir cap hits the circlip. Now, check that the edge...

  • Page 79

    Periodic maintenance 2-61 periodic maintenance procedures steering steering inspection • using the jack, raise the front wheel off the ground. Special tool - jack: 57001-1238 • with the front wheel pointing straight ahead, alternately nudge each end of the handlebar. The front wheel should swing ful...

  • Page 80

    2-62 periodic maintenance periodic maintenance procedures steering adjustment • using the jack, raise the front wheel off the ground. Special tool - jack: 57001-1238 • remove number plate (see number plate removal in the frame chapter). • remove the handlebar pad [a]. • remove: handlebar clamp bolts...

  • Page 81

    Periodic maintenance 2-63 periodic maintenance procedures • install the steering stem head to the front fork. • tighten the steering stem head nut. Torque - steering stem head nut: 98 n·m (10 kgf·m, 72 ft·lb) • tighten the loosened front fork clamp bolts. Torque - upper front fork clamp bolts: 20 n·...

  • Page 82

    2-64 periodic maintenance periodic maintenance procedures frame frame inspection • clean the frame with steam cleaner. • visually inspect the frame and rear 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 ...

  • Page 83

    Periodic maintenance 2-65 periodic maintenance procedures • fit the spark plug cap [a] so that align it to the rised line [b] on the head cover. ○ pull the plug cap to make sure the installation of the spark plug cap. Spark plug replacement • refer to the spark plug cleaning and inspection. General ...

  • Page 84

    2-66 periodic maintenance periodic maintenance procedures cable inspection • with the cable disconnected at the both ends, the cable should move freely [a] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [b], or if the cable housing is kinked [c], re...

  • Page 85

    Periodic maintenance 2-67 periodic maintenance procedures brakes: front master cylinder clamp bolts front caliper mounting bolts brake lever pivot nut brake pedal mounting bolt rear master cylinder push rod cotter pin rear caliper holder shaft rear master cylinder mounting bolts suspension: front fo...

  • Page 87: Fuel System (Dfi)

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

  • Page 88

    3-2 fuel system (dfi) fuel injector removal ....................................................................................................... 3-60 fuel injector installation .................................................................................................... 3-61 fuel injector ...

  • Page 89

    Fuel system (dfi) 3-3 dummy page.

  • Page 90

    3-4 fuel system (dfi) exploded view.

  • Page 91

    Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 throttle pulley cover bolts 7.0 0.71 62 in·lb 2 throttle cable mounting bolts 7.0 0.71 62 in·lb 3 air cleaner duct mounting bolt 2.0 0.20 18 in·lb 4 air cleaner duct mounting nuts 3.0 0.30 26 in·lb 5 air cleaner housin...

  • Page 92

    3-6 fuel system (dfi) exploded view.

  • Page 93

    Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 fuel pump bolts 9.8 1.0 87 in·lb l, s 2 water temperature sensor 12 1.2 106 in·lb 3 gear position switch screws 2.9 0.30 26 in·lb l 4. Fuel pump 5. Vehicle-down sensor 6. Capacitor 7. Ignition coil 8. Ecu ad: apply adh...

  • Page 94

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

  • Page 95

    Fuel system (dfi) 3-9 dfi system 1. Capacitor 2. Ecu 3. Gear position switch 4. Water temperature sensor 5. Crankshaft sensor 6. Vehicle-down sensor 7. Ignition coil 8. Fuel tank 9. Fuel pump 10. Pressure regulator 11. Inlet air pressure sensor 12. Fuel injector 13. Throttle sensor 14. Inlet air tem...

  • Page 96

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

  • Page 97

    Fuel system (dfi) 3-11 dfi system part names 1. Ecu 2. Fi indicator light harness connector 3. Fuel injector 4. Inlet air pressure sensor 5. Inlet air temperature sensor 6. Throttle sensor 7. Water temperature sensor 8. Spark plug 9. Ignition coil 10. Frame ground 11. Fuel pump 12. Vehicle-down sens...

  • Page 98

    3-12 fuel system (dfi) dfi system terminal numbers of ecu connectors terminal names 1. Power supply to ecu 2. Vehicle-down sensor 3. Crankshaft sensor (+) 4. Gear position switch 5. Main throttle sensor 6. Inlet air pressure sensor 7. Unused 8. Ground for control system 9. Crankshaft sensor 10. Exte...

  • Page 99

    Fuel system (dfi) 3-13 dfi system 35. Ground for ecu 36. Ground for ecu *: kds (kawasaki diagnostic system).

  • Page 100

    3-14 fuel system (dfi) dfi parts location ecu [a] kawasaki diagnostic system connector [b] fuel pump [a] throttle body assy [b] inlet air temperature sensor [a] throttle sensor [a] water temperature sensor [b] crankshaft sensor [c] vehicle-down sensor [a] ignition coil [b] capacitor [c].

  • Page 101

    Fuel system (dfi) 3-15 dfi parts location fuel injector [a] inlet air pressure sensor [b] fi indicator light harness connector [a].

  • Page 102

    3-16 fuel system (dfi) specifications item standard digital fuel injection system idle speed 2 000 ±50 r/min (rpm) throttle body assy: type single barrel bore 43 (1.69 in.) ecu: make keihin type digital memory type, with built in ic igniter, sealed with resin fuel pressure (high pressure line) 294 k...

  • Page 103

    Fuel system (dfi) 3-17 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 needle adapter set: 57001-1457 sensor harness adapter: 57001-1561 fuel pressure gauge adapter: 57001-1593 fuel hose: 57001-1607 ...

  • Page 104

    3-18 fuel system (dfi) dfi servicing precautions dfi servicing precautions there are a number of important precautions that should be followed servicing the dfi system. ○ connect these connectors until they click [a]. ○ never any of the dfi electrical connectors are discon- nected. The ecu memorizes...

  • Page 105

    Fuel system (dfi) 3-19 troubleshooting the dfi system outline when an abnormality in the system occurs, the condition of the problem is stored in the memory of the ecu (elec- tronic control unit). With the engine stopped and conduct a self-diagnosis inspection, the service code [a] is indicated by t...

  • Page 106

    3-20 fuel system (dfi) 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 - kawasaki bond (silicone sealant): 56019-120 • always check the connected battery condition before re- ...

  • Page 107

    Fuel system (dfi) 3-21 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 108

    3-22 fuel system (dfi) troubleshooting the dfi system dfi diagnosis flow chart inquiries to rider ○ each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ try to find out exactly what problem occurred under exactly what condi...

  • Page 109

    Fuel system (dfi) 3-23 troubleshooting the dfi system sample diagnosis sheet rider name model engine no. Frame no. Date problem occurred environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ always, □ other: temperature □ hot, □ warm, □ cold, □ very cold, □ always problem fr...

  • Page 110

    3-24 fuel system (dfi) troubleshooting the dfi system □ spark plug loose (tighten it). □ spark plug dirty, broken, or gap maladjusted (remedy it). □ spark plug incorrect (replace it). □ knocking (fuel poor quality or incorrect). □ brake dragging. □ clutch slipping. □ engine overheating. □ engine oil...

  • Page 111

    Fuel system (dfi) 3-25 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

    3-26 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) water temperature sensor trouble inspect (see chapter 3). Inlet air temperature sensor trouble inspect (see chapter 3). Throttle sensor trouble inspect (see chapter 3). Unstable (rough) idling: fuel...

  • Page 113

    Fuel system (dfi) 3-27 dfi system troubleshooting guide symptoms or possible causes actions (chapter) surge: unstable fuel pressure fuel pressure regulator trouble (inspect and replace fuel pump) or kinked fuel line (inspect and replace fuel pump) (see chapter 3). Fuel injector trouble inspect (see ...

  • Page 114

    3-28 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) water temperature sensor trouble inspect (see chapter 3). Inlet air temperature sensor trouble inspect (see chapter 3). Throttle sensor trouble inspect (see chapter 3). Knocking: fuel poor quality o...

  • Page 115

    Fuel system (dfi) 3-29 self-diagnosis self-diagnosis outline the self-diagnosis system has two modes and can be switched to another mode by grounding the self-diagnosis terminal. User mode the ecu connected fi indicator light goes on when dfi system and ignition system parts are faulty. In case of s...

  • Page 116

    3-30 fuel system (dfi) self-diagnosis • keep the fi indicator light assy (option p/no. 23016 -0034) gy/r lead [a] ground. ○ count the blinks of the light to read the service code. Keep the lead ground until you finish reading the service code. • to enter the self-diagnosis dealer mode, ground the se...

  • Page 117

    Fuel system (dfi) 3-31 self-diagnosis self-diagnosis flow chart.

  • Page 118

    3-32 fuel system (dfi) self-diagnosis how to read service codes ○ service codes are shown by a series of long and short blinks of the fi indicator light as shown below. ○ read 10th digit and unit digit as the fi indicator light blinks. ○ when there are a number of problems, all the service codes can...

  • Page 119

    Fuel system (dfi) 3-33 self-diagnosis service code table service code fi indicator light problems 11 throttle sensor malfunction, wiring open or short 12 inlet air pressure sensor malfunction, wiring open or short 13 inlet air temperature sensor malfunction, wiring open or short 14 water temperature...

  • Page 120

    3-34 fuel system (dfi) 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 throttle sensor throttle sensor output voltage 0.391 ∼ 4...

  • Page 121

    Fuel system (dfi) 3-35 throttle sensor (service code 11) the throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ecu senses this voltage change and determines fuel injection quantity, and ignition timing according to engine rpm, and throttl...

  • Page 122

    3-36 fuel system (dfi) throttle sensor (service code 11) • remove: left radiator shroud (see radiator shroud removal in the frame chapter) capacitor lead connector [a] • connect the power supply harness (option p/no. 26011 -0246) [a] to the capacitor lead connector [b] of the main harness. • connect...

  • Page 123

    Fuel system (dfi) 3-37 throttle sensor (service code 11) throttle sensor output voltage inspection • measure the output voltage at the throttle sensor in the same way as input voltage inspection, note the following. ○ disconnect the throttle sensor connector and connect the measuring adapter [a] bet...

  • Page 124

    3-38 fuel system (dfi) throttle sensor (service code 11) if the reading is within the standard, remove the ecu and check the wiring for continuity between main harness and sub harness connectors. ○ disconnect the ecu and sensor connectors. Wiring inspection ecu connector [a] ←→ throttle sensor conne...

  • Page 125

    Fuel system (dfi) 3-39 throttle sensor (service code 11) throttle sensor circuit 1. Ecu 2. Throttle sensor.

  • Page 126

    3-40 fuel system (dfi) inlet air pressure sensor (service code 12) inlet air pressure sensor removal caution never drop the inlet air pressure sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove: fuel tank (see fuel tank removal) inlet air pressure sensor connect...

  • Page 127

    Fuel system (dfi) 3-41 inlet air pressure sensor (service code 12) • tighten the screws [a] securely. • connect the inlet air pressure sensor connector [b]. Inlet air pressure sensor input voltage inspection note ○ be sure the battery is fully charged. • disconnect the inlet air pressure sensor conn...

  • Page 128

    3-42 fuel system (dfi) inlet 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 and sub harness connectors. ○ disconnect the ecu and sensor connectors. Wiring inspection ecu connector [a] ←→ inlet air p...

  • Page 129

    Fuel system (dfi) 3-43 inlet air pressure sensor (service code 12) if the wiring is good, check the sensor for various vacuum. • remove the inlet air pressure sensor [a] and disconnect the vacuum hose from the sensor. • connect an auxiliary hose [b] to the inlet air pressure sen- sor. • temporarily ...

  • Page 130

    3-44 fuel system (dfi) inlet air pressure sensor (service code 12) 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: inlet air pressure sen...

  • Page 131

    Fuel system (dfi) 3-45 inlet air pressure sensor (service code 12) inlet air pressure sensor circuit 1. Ecu 2. Inlet air pressure sensor.

  • Page 132

    3-46 fuel system (dfi) inlet air temperature sensor (service code 13) inlet air temperature sensor removal/installation caution never drop the inlet air temperature sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove the seat (see seat removal in the frame chap...

  • Page 133

    Fuel system (dfi) 3-47 inlet air temperature sensor (service code 13) • remove: left radiator shroud (see radiator shroud removal in the frame chapter) capacitor lead connector [a] • connect the power supply harness (option p/no. 26011 -0246) [a] to the capacitor lead connector [b] of the main harne...

  • Page 134

    3-48 fuel system (dfi) inlet air temperature sensor (service code 13) inlet air temperature sensor resistance inspection • remove the inlet air temperature sensor (see inlet air temperature sensor removal/installation). • suspend the sensor [a] in a container of machine oil so that the heat-sensitiv...

  • Page 135

    Fuel system (dfi) 3-49 water temperature sensor (service code 14) water temperature sensor removal/installation caution never drop the water temperature sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • drain the coolant (see coolant draining in the cooling system c...

  • Page 136

    3-50 fuel system (dfi) water temperature sensor (service code 14) • connect the power supply harness (option p/no. 26011 -0246) [a] to the capacitor lead connector [b] of the main harness. • connect the power supply harness (option p/no. 26011 -0246) to the 12 v battery [c] as shown. • measure the o...

  • Page 137

    Fuel system (dfi) 3-51 water temperature sensor (service code 14) water temperature sensor inspection • remove the water temperature sensor (see water tem- perature sensor removal/installation). • suspend the sensor [a] in a container of machine oil so that the heat-sensitive portion and threaded po...

  • Page 138

    3-52 fuel system (dfi) 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 starter coil removal/installation in the elec- trical system chapter. C...

  • Page 139

    Fuel system (dfi) 3-53 gear position switch (service code 25) gear position switch removal • remove: shift pedal (external shift mechanism removal in the crankshaft/transmission chapter) • remove the gear position switch connector [a]. • open the clamps [a]. • remove: screws [a] gear position switch...

  • Page 140

    3-54 fuel system (dfi) gear position switch (service code 25) gear position switch inspection note ○ be sure the transmission mechanism is good condition. • remove the left radiator shroud (see radiator shroud re- moval in the frame chapter). • disconnect the gear position switch lead connector [a]....

  • Page 141

    Fuel system (dfi) 3-55 gear position switch (service code 25) gear position switch circuit 1. Ecu 2. Frame ground 3. Gear position switch.

  • Page 142

    3-56 fuel system (dfi) vehicle-down sensor (service code 31) when motorcycle is down, if opening of the throttle valve is 3/8 or more, stop the engine after 3 seconds. If throt- tle valve opening is 3/8 or less, hold the engine speed at 3000rpm for 3 seconds after the motorcycle fell over the 3 seco...

  • Page 143

    Fuel system (dfi) 3-57 vehicle-down sensor (service code 31) • remove: capacitor lead connector [a] • connect the power supply harness (option p/no. 26011 -0246) [a] to the capacitor lead connector [b] of the main harness. • connect the power supply harness (option p/no. 26011 -0246) to the 12 v bat...

  • Page 144

    3-58 fuel system (dfi) vehicle-down sensor (service code 31) vehicle-down sensor output voltage inspection • remove the vehicle-down sensor. ○ remove the vehicle-down sensor, and connect the mea- suring adapter [a]. Special tool - measuring adapter: 57001-1700 main harness [b] vehicle-down sensor [c...

  • Page 145

    Fuel system (dfi) 3-59 vehicle-down sensor (service code 31) vehicle-down sensor circuit 1. Ecu 2. Vehicle-down sensor.

  • Page 146

    3-60 fuel system (dfi) fuel injector (service code 41) caution never drop the fuel injector, especially on a hard surface. Such a shock to the injector can damage it. Fuel injector removal • remove: rear frame (see rear frame removal in the frame chapter) fuel tank (see fuel tank removal) • be sure ...

  • Page 147

    Fuel system (dfi) 3-61 fuel injector (service code 41) fuel injector installation • replace the o-ring [a] and dust seal [b] with a new one. • assemble the delivery pipe [a] and the fuel injector [b]. • fit the projections [a] on the delivery pipe to the hollows [b] of the throttle body assy. • tigh...

  • Page 148

    3-62 fuel system (dfi) fuel injector (service code 41) fuel injector audible inspection note ○ be sure the battery is fully charged. • remove: fuel tank (see fuel tank removal) fuel hose (see fuel injector removal) • connect the following parts. Fuel pump lead connector fuel hose [a] special tool - ...

  • Page 149

    Fuel system (dfi) 3-63 fuel injector (service code 41) fuel injector power supply voltage inspection note ○ be sure the battery is fully charged. • disconnect the injector connector and connect the mea- suring adapter [a] between these connector. Main harness [b] fuel injector [c] special tool - mea...

  • Page 150

    3-64 fuel system (dfi) fuel injector (service code 41) fuel injector output voltage inspection note ○ be sure the battery is fully charged. • remove the ecu (see ecu removal). ○ do not disconnect the ecu connector. • connect the power supply harness (option p/no. 26011 -0246) and 12 v battery to the...

  • Page 151

    Fuel system (dfi) 3-65 fuel injector (service code 41) injector fuel line inspection • remove: fuel tank (see fuel tank removal) fuel hose (see fuel injector removal) ○ be sure to place a piece of cloth around the fuel outlet pipe of fuel pump and delivery pipe of throttle body assy. • check the inj...

  • Page 152

    3-66 fuel system (dfi) fuel injector (service code 41) fuel injector circuit 1. Ecu 2. Fuel injector 3. Frame ground 4. Capacitor 5. Engine stop switch.

  • Page 153

    Fuel system (dfi) 3-67 fuel pump (service code 46) fuel pump removal warning gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smok...

  • Page 154

    3-68 fuel system (dfi) fuel pump (service code 46) fuel pump installation • remove the dirt or dust from the fuel pump [a] by lightly applying compressed air. • replace the fuel pump gasket with a new one. • apply a non-permanent locking agent to the threads of the fuel pump bolts. • install the fue...

  • Page 155

    Fuel system (dfi) 3-69 fuel pump (service code 46) fuel pump operation inspection note ○ be sure the battery is fully charged. • remove: left radiator shroud (see radiator shroud removal in the frame chapter) capacitor lead connector [a] • connect the power supply harness (option p/no. 26011 -0246) ...

  • Page 156

    3-70 fuel system (dfi) fuel pump (service code 46) fuel pump operating voltage inspection note ○ be sure the battery is fully charged. • remove the left radiator shroud (see radiator shroud re- moval in the frame chapter). • disconnect the fuel pump lead connector and connect the harness adapter [a]...

  • Page 157

    Fuel system (dfi) 3-71 fuel pump (service code 46) pressure regulator removal ○ the pressure regulator [a] is built into the fuel pump and can not be removed. Fuel filter cleaning ○ the fuel filter [a] is built into the pump and can not be cleaned or checked. If the fuel filter is suspected of clogg...

  • Page 158

    3-72 fuel system (dfi) ignition coil (service code 51) ignition coil removal/installation • refer to the ignition coil removal/installation in the elec- trical system chapter. Ignition coil input voltage inspection • refer to the ignition coil peak voltage inspection in the electrical system chapter...

  • Page 159

    Fuel system (dfi) 3-73 ecu caution never drop the ecu, especially on a hard surface. Such a shock to the ecu can damage it. Ecu removal • remove: number plate (see number plate removal in the frame chapter) bolt [a] connector bracket [b] ecu connector [c] • pull the ecu [a] together with rubber prot...

  • Page 160

    3-74 fuel system (dfi) ecu ecu power supply inspection • remove the number plate (see number plate removal in the frame chapter). • visually inspect the ecu connectors. If the connector is clogged with mud or dust, blow it off with compressed air. • remove the ecu (see ecu removal). • visually inspe...

  • Page 161

    Fuel system (dfi) 3-75 ecu • connect the power supply harness (option p/no. 26011 -0246) [a] to the capacitor lead connector [b] of the main harness. • connect the power supply harness (option p/no. 26011 -0246) to the 12 v battery [c] as shown. • connect a digital meter [a] to the connector [b] wit...

  • Page 162

    3-76 fuel system (dfi) fuel line fuel pressure inspection note ○ be sure the battery is fully charged. • remove: left radiator shroud (see radiator shroud removal in the frame chapter) fuel tank (see fuel tank removal) fuel hose (see fuel injector removal) ○ be sure to place a piece of cloth around ...

  • Page 163

    Fuel system (dfi) 3-77 fuel line • connect the power supply harness (option p/no. 26011 -0246) [a] to the capacitor lead connector [b] of the main harness. • connect the power supply harness (option p/no. 26011 -0246) to the 12 v battery [c] as shown. Note ○ inspect the fuel leakage from the connect...

  • Page 164

    3-78 fuel system (dfi) fuel line fuel flow rate inspection warning gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn th...

  • Page 165

    Fuel system (dfi) 3-79 fuel line • disconnect: capacitor lead connector [a] • connect the power supply harness (option p/no. 26011 -0246) [a] to the capacitor lead connector [b] of the main harness. • connect the power supply harness (option p/no. 26011 -0246) to the 12 v battery [c] as shown then, ...

  • Page 166

    3-80 fuel system (dfi) throttle grip and cable if the throttle grip has excessive free play due to cable stretch or misadjustment, there will be a delay in throttle re- sponse. Also, the throttle valve may not open fully at full throttle. On the other hand, if the throttle grip has no play, the thro...

  • Page 167

    Fuel system (dfi) 3-81 throttle grip and cable • loosen the mounting bolts [a]. • remove the cables [b] from the throttle body assy. • free the tips [c] from the pulley. • pull out the cables from the frame. • lubricate the cable. • apply grease to the tips of the cables. • install the throttle cabl...

  • Page 168

    3-82 fuel system (dfi) throttle body assy idle speed inspection • refer to the idle speed inspection in the periodic main- tenance chapter. Throttle bore cleaning • refer to the throttle body cleaning in the periodic main- tenance chapter. Throttle body assy removal warning gasoline is extremely fla...

  • Page 169

    Fuel system (dfi) 3-83 throttle body assy throttle body assy installation • install the throttle body assy so that fit the projection [b] on throttle body assy and groove [a] of the throttle body holder. • install the removed parts (see appropriate chapters). • remove: left radiator shroud (see radi...

  • Page 170

    3-84 fuel system (dfi) throttle body assy • remove the screw [a] to pull out the injector from the throttle body assy together with the delivery pipe assy [b]. Note ○ do not damage the insertion portions of the injector when they are pulled out from the throttle body. • pull out the injector [a] fro...

  • Page 171

    Fuel system (dfi) 3-85 throttle body assy • tighten the delivery pipe mounting screw [a] securely. • install the inlet air pressure sensor [a] to the vacuum hose. • install the plate so that fit the hollow [a] on the plate and projection [b] on the throttle body assy. • tighten the plate mounting sc...

  • Page 172

    3-86 fuel system (dfi) air cleaner air cleaner housing removal • remove the rear frame (see rear frame removal in the frame chapter). • unscrew the bolts [a]. • remove the air cleaner housing [b] from the rear frame. Air cleaner housing installation • install the air cleaner housing to the rear fram...

  • Page 173

    Fuel system (dfi) 3-87 fuel tank fuel tank removal warning gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. To avoid fire, ...

  • Page 174

    3-88 fuel system (dfi) fuel tank • be sure to place a piece of cloth around the fuel hose joint [a]. • insert a minus screw driver [b] into the slit on the joint lock [c]. • turn the driver to disconnect the joint look. • pull [b] the fuel hose joint [a] out of the fuel outlet pipe. Warning be prepa...

  • Page 175

    Fuel system (dfi) 3-89 fuel tank • insert the fuel hose joint [a] straight onto the fuel outlet pipe until the hose joint clicks. • push the joint lock [b] until the hose joint clicks. • push and pull [b] the hose joint [a] back and forth more than two times, and make sure it is locked and does not ...

  • Page 177: Cooling System

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

  • Page 178

    4-2 cooling system exploded view.

  • Page 179

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 water pump cover bolts 9.8 1.0 87 in·lb 2 coolant drain bolt 6.9 0.70 61 in·lb 3 water pump impeller bolt 9.8 1.0 87 in·lb 4 water hose clamp screws 1.5 0.15 13 in·lb 5 radiator mounting bolts 9.8 1.0 87 in·lb 6 radiator ...

  • Page 180

    4-4 cooling system specifications item service limit coolant type permanent type antifreeze for aluminum engines and radiators color green mixed ratio soft water 50%, antifreeze 50% freezing point -35°c (-31°f) total amount 1.1 l (1.2 us qt.) radiator cap relief pressure 112 ∼ 142 kpa (1.14 ∼ 1.45 k...

  • Page 181

    Cooling system 4-5 special tool bearing driver set: 57001-1129.

  • Page 182

    4-6 cooling system coolant coolant level inspection • refer to the coolant level inspection in the periodic main- tenance chapter. Coolant deterioration inspection • refer to the coolant deterioration inspection in the peri- odic maintenance chapter. Coolant draining warning to avoid burns, do not r...

  • Page 183

    Cooling system 4-7 coolant coolant filling caution use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufac- ture’s. Soft or distilled water must be used with the antifreeze (see below for antifreeze) in the co...

  • Page 184

    4-8 cooling system coolant cooling system pressure testing caution during pressure testing, do not exceed the pres- sure for which the system is designed to work. The maximum pressure is 123 kpa (1.25 kgf/cm², 18 psi). • remove the radiator cap, and install a cooling system pressure tester [a] and a...

  • Page 185

    Cooling system 4-9 water pump water pump cover removal • drain the coolant (see coolant draining). • loosen the clamp screw [a], and remove the water hose [b] from the water pump cover. • unscrew the cover bolts [c]. • using the pry points [a], remove the pump cover [b]. Water pump cover installatio...

  • Page 186

    4-10 cooling system water pump impeller removal • drain: coolant (see coolant draining) • remove: water pump cover (see water pump cover removal) impeller bolt [a] impeller [b] impeller installation • install: impeller [a] • tighten: torque - water pump impeller bolt [b]: 9.8 n·m (1.0 kgf·m, 87 in·l...

  • Page 187

    Cooling system 4-11 water pump • insert a bar [a] into the water pump shaft hole from the outside of the right engine cover, and remove the ball bearing [b] by tapping [c] evenly around the bearing in- ner race. • remove the spacer [d]. • remove the ball bearing [e] and oil seal [f] from the right e...

  • Page 188

    4-12 cooling system radiator radiator removal • drain the coolant (see coolant draining). • remove: radiator shrouds (see radiator shroud removal in the frame chapter) regulator/rectifier (see regulator/rectifier removal in the electrical system chapter) • loosen: clamp screws [a] • remove: clamp [b...

  • Page 189

    Cooling system 4-13 radiator radiator installation • fit the projections [a] of the screen in the holes [b] of the radiator. Torque - water hose clamp screws: 1.5 n·m (0.15 kgf·m, 13 in·lb) radiator mounting bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) radiator screen bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • ...

  • Page 190

    4-14 cooling system radiator • wet the top and bottom valve seals with water or coolant to prevent pressure leaks. • install the cap [a] on a cooling system pressure tester [b]. • watching the pressure gauge, slowly pump the pressure tester to build up the pressure. The gauge hand must remain within...

  • Page 191: Engine Top End

    Engine top end 5-1 5 engine top end table of contents exploded view................................... 5-2 specifications .................................... 5-6 special tools and sealant ................. 5-8 cylinder head cover ......................... 5-11 cylinder head cover removal .... 5-11 ...

  • Page 192

    5-2 engine top end exploded view.

  • Page 193

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 cylinder head cover bolts 9.8 1.0 87 in·lb 2 cylinder head bolts (m10) 59 6.0 44 s, mo 3 cylinder head bolts (m6) 12 1.2 106 in·lb s 4 camshaft cap bolts 9.8 1.0 87 in·lb s, mo 5 camshaft sprocket bolts 12 1.2 106 in·lb l...

  • Page 194

    5-4 engine top end exploded view.

  • Page 195

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 exhaust pipe cover bolts 12 1.2 106 in·lb 2 exhaust pipe holder nuts 20 2.0 15 s 3 muffler mounting bolts 20 2.0 15 s 4 cylinder bolt 12 1.2 106 in·lb s 5 muffler clamp bolt 16 1.6 12 6 camshaft chain tensioner mounting b...

  • Page 196

    5-6 engine top end specifications item standard service limit camshafts cam height: exhaust 36.943 ∼ 37.057 mm (1.4544 ∼ 1.4589 in.) 36.84 mm (1.450 in.) inlet 37.743 ∼ 37.857 mm (1.4859 ∼ 1.4904 in.) 37.64 mm (1.482 in.) camshaft journal/camshaft cap clearance 0.020 ∼ 0.062 mm (0.00079 ∼ 0.0024 in....

  • Page 197

    Engine top end 5-7 specifications item standard service limit inlet outer 39.28 mm (1.546 in.) 37.8 mm (1.49 in.) inner 36.05 mm (1.419 in.) 34.5 mm (1.36 in.) cylinder and pistons cylinder inside diameter 96.000 ∼ 96.012 mm (3.7795 ∼ 3.7800 in.) 96.10 mm (3.783 in.) piston diameter 95.970 ∼ 95.980 ...

  • Page 198

    5-8 engine top end special tools and sealant compression gauge, 20 kgf/cm²: 57001-221 valve spring compressor assembly: 57001-241 valve guide arbor, 5.5: 57001-1021 valve guide reamer, 5.5: 57001-1079 piston ring compressor grip: 57001-1095 valve seat cutter, 45° - 35: 57001-1116 valve seat cutter, ...

  • Page 199

    Engine top end 5-9 special tools and sealant valve seat cutter, 55° - 35: 57001-1247 spark plug wrench, hex 16: 57001-1262 compression gauge adapter, m10 × 1.0: 57001-1317 piston ring compressor belt, 95 ∼ 108: 57001-1358 filler cap driver: 57001-1454 valve seat cutter, 45° - 40: 57001-1496 valve se...

  • Page 200

    5-10 engine top end special tools and sealant valve guide driver attachment d: 57001-1659 valve guide driver attachment g: 57001-1728 kawasaki bond (silicone sealant): 92104-0004.

  • Page 201

    Engine top end 5-11 cylinder head cover cylinder head cover removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) fuel hose spark plug cap [a] cylinder head cover bolts [b] cylinder head cover [c] cylinder head cover installation • apply silicon sealant [a] to the cyli...

  • Page 202

    5-12 engine top end cylinder head cover • install the spark plug cap [a] so that align it to the rised line [b] on the head cover. ○ pull up the spark plug cap lightly to make sure of the in- stallation of the spark plug cap..

  • Page 203

    Engine top end 5-13 camshaft chain tensioner camshaft chain tensioner removal caution this is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: when removing the ten...

  • Page 204

    5-14 engine top end camshaft chain tensioner • replace the chain tensioner gasket with a new one. • tighten: torque - camshaft chain tensioner mounting bolts [a]: 9.8 n·m (1.0 kgf·m, 87 in·lb) • take out the holder plate [b]. • install the o-ring and tighten the cap bolt. Torque - camshaft chain ten...

  • Page 205

    Engine top end 5-15 camshaft camshaft removal • remove: cylinder head cover (see cylinder head cover re- moval) timing inspection cap [a] flywheel nut cap[b] special tool - filler cap driver: 57001-1454 • first, bring the piston to the tdc (of either the compres- sion or exhaust stroke). ○ place a w...

  • Page 206

    5-16 engine top end camshaft • remove: bolts [a] auto-decompressor [b] (with the sprocket) • remove: circlips [a] camshaft installation • assemble the auto-decompressor weights [a] and spring [b] to install it to the sprocket [c]. • replace the circlips [d] with new ones, and install them. • fit the...

  • Page 207

    Engine top end 5-17 camshaft 1st pin [a] 2nd pin [b] 29th pin [c] mark (exhaust) [d] punch mark (inlet) [e] cylinder head upper surface [f] • plug the oil passage and camshaft chain tunnel with a clean cloth for prevent the any parts from dropping in the crankcase. • be sure to install the positioni...

  • Page 208

    5-18 engine top end camshaft • uniformly tighten all bolts and after the camshaft has set- tled, uniformly tighten all the bolts. ○ following the sequence numbers on the camshaft caps. Tighten the cap bolts [1 ∼ 8] after applying molybdenum disulfide oil to the thread of them. Torque - camshaft cap ...

  • Page 209

    Engine top end 5-19 camshaft camshaft and camshaft cap wear inspection • measure each clearance between the camshaft journal and camshaft cap using plastigauge (press gauge) [a]. • install the camshaft caps (see camshaft installation) note ○ do not turn the camshaft when the plastigauge is be- tween...

  • Page 210

    5-20 engine top end cylinder head cylinder compression measurement • start the engine. • thoroughly warm up the engine so that the engine oil be- tween the piston and cylinder wall will help seal compres- sion as it does during normal running. • stop the engine. • remove: fuel tank (see fuel tank re...

  • Page 211

    Engine top end 5-21 cylinder head problem diagnosis remedy (action) carbon accumulation on piston and in cylinder head (combustion chamber) is suspected due to damaged valve stem or piston oil rings. Remove the carbon deposits and replace damaged parts if necessary. The cylinder compression is highe...

  • Page 212

    5-22 engine top end cylinder head • remove the cylinder head bolts (m6) [a] and loosen the cylinder bolt [b] for prevent damage. • remove the cylinder head bolts (m10) following the loos- ening sequence as shown. • remove the cylinder head [a]. Note ○ when do not remove the cylinder head easily, tap...

  • Page 213

    Engine top end 5-23 cylinder head • install: dowel pins [a] new cylinder head gasket [b] • install the cylinder head. ○ the camshaft caps are machined with the cylinder head; therefore, if a new cylinder head is installed, use the caps that are supplied with the new head. • replace all the cylinder ...

  • Page 214

    5-24 engine top end valves valve clearance inspection • refer to the valve clearance inspection in the periodic maintenance chapter. Valve removal • remove the cylinder head (see cylinder head removal). • remove the valve lifter and the shim from the valve. Note ○ use the valve spring compressor ass...

  • Page 215

    Engine top end 5-25 valves • hammer lightly on the valve guide arbor [a] to remove the guide. Special tool - valve guide arbor, 5.5: 57001-1021 valve guide installation • apply a thin coat of oil to the outer surface of the valve guide. • heat the area around the valve guide up to 120 ∼ 150°c (248 ∼...

  • Page 216

    5-26 engine top end valves valve/valve guide clearance measurement (wobble method) ○ if a small bore gauge is not available, inspect the valve guide wear by measuring the valve/valve guide clearance with the wobble method as indicated below. • insert a new valve [a] into the guide [b] and set a dial...

  • Page 217

    Engine top end 5-27 valves valve seat repair • for the instructions on how to use the valve seat cutter [a], follow the operation manual provided by the manu- facturer. Special tools - valve seat cutter holder, 5.5: 57001-1125 [b] valve seat cutter holder bar: 57001-1128 exhaust: valve seat cutter, ...

  • Page 218

    5-28 engine top end valves marks stamped on the cutter the marks stamped on the back of the cutter [a] represent the following. 60° ........................... Cutter angle [b] 37.5 ....................... Cutter outer diameter [c] repair operating procedures • clean the seat area carefully. • coat ...

  • Page 219

    Engine top end 5-29 valves if the outside diameter [a] of the seating surface is too large, make the 32° grind described below. If the outside diameter of the seating surface is within the specified range, measure the seat width as described be- low. • grind the seat at a 32° angle [b] until the sea...

  • Page 220

    5-30 engine top end valves valve seat repair.

  • Page 221

    Engine top end 5-31 cylinder and piston cylinder removal • remove: cylinder head (see cylinder head removal) front camshaft chain guide [a] cylinder bolt [b] water temperature sensor connector [c] • tap lightly up with a plastic mallet to separate the cylinder from the crankcase. • remove the cylind...

  • Page 222

    5-32 engine top end cylinder and piston • install the top ring [a] so that the "r" mark [b] faces up. Note ○ if a new piston or cylinder is used, check piston to cylin- der clearance (see piston/cylinder clearance), and use new piston rings. • apply engine oil to the inside wall of the small end of ...

  • Page 223

    Engine top end 5-33 cylinder and piston • apply engine oil to the cylinder bore. • determine the position of the piston ring ends. • install the cylinder while compressing the piston rings with your fingers or the special tool [a]. Special tools - piston ring compressor grip: 57001-1095 piston ring ...

  • Page 224

    5-34 engine top end cylinder and piston piston ring groove width inspection • measure the groove width at several points around the piston with a vernier caliper. Piston ring groove width standard: top 1.03 ∼ 1.05 mm (0.0406 ∼ 0.0413 in.) service limit: top 1.13 mm (0.0445 in.) if any of the groove ...

  • Page 225

    Engine top end 5-35 cylinder and piston piston, piston pin, connecting rod wear inspection • visually inspect the snap rings [a] still fitted in place. If the ring shows weakness or deformation, replace the ring. Also if the pin hole groove shows excessive wear, replace the piston. • measure the dia...

  • Page 226

    5-36 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) throttle body assy holder bolts [a] throttle body assy holder [b] throttle body assy holder installation • replace the o-ring...

  • Page 227

    Engine top end 5-37 muffler warning to avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cools down. Muffler removal • loosen the muffler clamp bolt [a]. • remove the exhaust pipe holder nuts [b]. • remove the exhaust pipe [c]. • remove seat (see se...

  • Page 228

    5-38 engine top end muffler muffler baffle replacement • refer to the muffler baffle change in the periodic main- tenance chapter..

  • Page 229: Clutch

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

  • Page 230

    6-2 clutch exploded view.

  • Page 231

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 clutch cover bolts 9.8 1.0 87 in·lb 2 right engine cover bolts 9.8 1.0 87 in·lb 3 clutch spring bolts 8.8 0.90 78 in·lb 4 clutch hub nut 98 10 72 5. Friction plates (the lining blocks are many.) 6. Friction plates (the lining blo...

  • Page 232

    6-4 clutch specifications item standard service limit clutch lever clutch lever free play 8 ∼ 13 mm (0.3 ∼ 0.5 in.) – – – clutch friction plate thickness 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) 2.6 mm (0.10 in.) friction plate warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.01 in.) steel plate warp 0.2 mm (0...

  • Page 233

    Clutch 6-5 special tools inside circlip pliers: 57001-143 bearing driver set: 57001-1129 clutch holder: 57001-1243.

  • Page 234

    6-6 clutch clutch lever and clutch cable due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the periodic maintenance chart. Warning to avoid a serious burn, never touch the hot engine or exhaust chamber during clutch adjust...

  • Page 235

    Clutch 6-7 clutch lever and clutch cable • loosen the adjusting nuts [a] fully. • free the clutch inner cable tip [b] from the clutch release lever [c]. Caution do not remove the clutch release shaft unless it is absolutely necessary. If removed, release shaft oil seal must be replaced with a new on...

  • Page 236

    6-8 clutch clutch cover and right engine cover clutch cover removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove the brake pedal (see brake pedal removal in the brakes chapter). • remove: clutch cover bolts [a] clutch cover [b] clutch cover installat...

  • Page 237

    Clutch 6-9 clutch cover and right engine cover right engine cover installation • three dowel pins [a] are installed at the mating surface between the crankcase and the right engine cover. • apply grease to the o-rings [b], and install them to the crankcase. ○ install the lower o-ring so that the tap...

  • Page 238

    6-10 clutch clutch cover and right engine cover • press the kick shaft oil seal [b] so that the bearing surface flush with the right engine cover surface [a]. Special tool - bearing driver set: 57001-1129 • apply grease to the oil seal lip..

  • Page 239

    Clutch 6-11 clutch clutch removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove the clutch cover (see clutch cover removal). • remove: clutch spring bolts [a] clutch spring clutch spring plate [b] • remove: washer [a] needle bearing [b] push rod holde...

  • Page 240

    6-12 clutch clutch clutch installation • check the clutch plate assembly free play (see clutch plate assembly free play inspection/adjustment). • apply molybdenum disulfide oil to the inside of the clutch housing. • install: clutch housing [a] toothed washer [b] • install the clutch hub [a]. • insta...

  • Page 241

    Clutch 6-13 clutch • install the clutch spring plate [a]. • tighten: torque - clutch spring bolts [b]: 8.8 n·m (0.90 kgf·m, 78 in·lb) • install the clutch cover (see clutch cover installation). • check the release shaft lever positions. ○ pushing [b] the release shaft lever [c] lightly forward, meas...

  • Page 242

    6-14 clutch clutch clutch plate assembly free play inspection/ad- justment • assemble the following parts. Clutch hub [a] friction plates [b] steel plates [c] friction plates [d] spring plates [e] spring [f] bolts [g] ○ the friction plates [b] have many lining blocks than other plates [d]. These pla...

  • Page 243

    Clutch 6-15 clutch clutch housing finger damage inspection • visually inspect the clutch housing fingers [a] that come in contact with the friction plate tangs. If they are damaged or if there are groove cuts in the areas that come in contact with the tangs, replace the housing. Replace the friction...

  • Page 244

    6-16 clutch clutch release shaft installation • replace the oil seal with a new one. • apply grease to the oil seal lip. • apply engine oil to the bearing in the hole of the crankcase. • apply grease to the part where the push rod comes in contact. • insert the release shaft straight into the hole o...

  • Page 245: Engine Lubrication System

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

  • Page 246

    7-2 engine lubrication system exploded view.

  • Page 247

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine oil drain bolt (m10) 20 2.0 15 2 engine oil drain bolt (m6) 7.0 0.71 62 in·lb 3 oil pump (scavenge) cover bolts 9.8 1.0 87 in·lb 4 oil pump (feed) cover bolts 9.8 1.0 87 in·lb 5 oil filter cover (right e...

  • Page 248

    7-4 engine lubrication system lubrication system chart.

  • Page 249

    Engine lubrication system 7-5 lubrication system chart 1. Oil screen (feed) 2. Oil pump (feed) 3. Oil pressure relief valve 4. Right engine cover oil passage (from feed oil pump to oil filter) 5. Oil filter 6. Right engine cover oil passage (from oil filter to crankshaft) 7. Crankshaft 8. Piston oil...

  • Page 250

    7-6 engine lubrication system specifications item standard engine oil grade castrol “power1 r4 racing” 5w-40 or api sg api sh, sj or sl with jaso ma, ma1 or ma2 viscosity sae 10w-30, 10w-40, or 10w-50 capacity oil change - when filter is not removed 0.96 l (1.01 us qt) oil change - when filter is re...

  • Page 251

    Engine lubrication system 7-7 special tools oil pressure gauge, 5 kgf/cm²: 57001-125 outside circlip pliers: 57001-144 oil pressure gauge adapter, m10 × 1.25: 57001-1182 oil pressure cap: 57001-1656.

  • Page 252

    7-8 engine lubrication system engine oil and oil filter warning motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. The engine oil level indicated in the right engine ...

  • Page 253

    Engine lubrication system 7-9 engine oil and oil filter oil filter change • refer to the oil filter change in the periodic maintenance chapter. Oil screen (scavenge) removal • remove the oil pump (scavenge) cover (see oil pump (scavenge) cover removal). • pull out the oil screen [a] from the crankca...

  • Page 254

    7-10 engine lubrication system engine oil and oil filter • install the oil screen [a], and tighten the bolts [b]. Torque - oil screen (feed) mounting bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) oil screen (scavenge) cleaning • remove the oil screen (see oil screen (scavenge) re- moval). • clean the oil scr...

  • Page 255

    Engine lubrication system 7-11 engine oil and oil filter oil screen (feed) cleaning • remove the oil screen (see oil screen (feed) removal) • clean the oil screen with a high-flash point solvent and remove the particles stuck. • blow away the particles by applying compressed air [a] from the inside ...

  • Page 256

    7-12 engine lubrication system oil pressure relief valve oil pressure relief valve removal • remove: right engine cover (see right engine cover removal in the clutch chapter) • remove the oil pressure relief valve [a]. Oil pressure relief valve installation • apply a non-permanent locking agent to t...

  • Page 257

    Engine lubrication system 7-13 oil pump oil pump (scavenge) removal • drain: engine oil (see engine oil change in the periodic main- tenance chapter) • remove: flywheel (see flywheel removal in the electrical sys- tem chapter) • remove: oil pump cover bolts [a] lower camshaft chain guide [b] oil pum...

  • Page 258

    7-14 engine lubrication system oil pump • install: oil pump cover [a] lower camshaft chain guide [b] • while pushing the oil pump cover, tighten the oil pump cover bolts [c]. Torque - oil pump (scavenge) cover bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) oil pump (feed) removal • remove: clutch (clutch remo...

  • Page 259

    Engine lubrication system 7-15 oil pump • while pushing the oil pump cover [a], tighten the oil pump cover bolts. [b] l = 20mm [c] l = 16mm torque - oil pump (feed) cover bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install the oil pump idle gear [a] facing the stepped side [b] to the outside. • replace t...

  • Page 260

    7-16 engine lubrication system oil pressure oil pressure measurement • remove: oil filter cover bolts [a] oil filter cover [b] • install the o-rings to the oil pressure cap. Special tool - oil pressure cap: 57001–1656 • install the oil pressure cap. • attach the oil pressure gauge adapter [a] and oi...

  • Page 261: Engine Removal/installation

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

  • Page 262

    8-2 engine removal/installation exploded view.

  • Page 263

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 middle engine mounting nut 49 5.0 36 s 2 middle engine bracket nuts 29 3.0 21 s 3 upper engine mounting bolts 49 5.0 36 s 4 upper engine bracket bolts 29 3.0 21 s 5 lower engine mounting nut 49 5.0 36 s 6 swi...

  • Page 264

    8-4 engine removal/installation special tool jack: 57001-1238.

  • Page 265

    Engine removal/installation 8-5 engine removal/installation engine removal • raise the rear wheel off the ground with the jack [a]. Special tool - jack: 57001-1238 warning for engine removal, the swingarm pivot shaft must be pulled out, causing the swingarm and rear wheel assembly to become detached...

  • Page 266

    8-6 engine removal/installation engine removal/installation • remove: water hoses [a] right engine guard [b] • remove the bolts [c], and remove the brake pedal [d] and rear master cylinder [e] as a set. • remove: upper engine bracket bolts (left and right) [a] upper engine mounting bolts and nuts (l...

  • Page 267

    Engine removal/installation 8-7 engine removal/installation engine installation • install the engine. ○ first, insert the front portion of the engine, and then install the rear portion. • install the swingarm pivot shaft, all engine bracket and mounting bolts temporarily. ○ insert the swingarm pivot...

  • Page 269: Crankshaft/transmission

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

  • Page 270

    9-2 crankshaft/transmission exploded view.

  • Page 271

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 crankcase bolts (m6) 12 1.2 106 in·lb s 2 crankcase bolts (m7) 15 1.5 11 s 3 engine oil drain bolt (m10) 20 2.0 15 4 engine oil drain bolt (m6) 7.0 0.71 62 in·lb 5 piston oil nozzle 3.0 0.30 26 in·lb 6 piston oil...

  • Page 272

    9-4 crankshaft/transmission exploded view.

  • Page 273

    Crankshaft/transmission 9-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 ratchet guide bolt 8.8 0.90 78 in·lb 2 kick pedal bolt 25 2.5 18 l 3 shift pedal bolt 9.8 1.0 87 in·lb 4 upper ratchet plate mounting bolt 9.8 1.0 87 in·lb s 5 lower ratchet plate mounting bolt 15 1.5 11 l, s 6 g...

  • Page 274

    9-6 crankshaft/transmission specifications item standard service limit crankshaft connecting rod big end radial clearance 0.002 ∼ 0.014 mm (0.00008 ∼ 0.00055 in.) 0.06 mm (0.002 in.) connecting rod big end side clearance 0.25 ∼ 0.35 mm (0.0098 ∼ 0.014 in.) 0.6 mm (0.02 in.) crankshaft runout tir 0.0...

  • Page 275

    Crankshaft/transmission 9-7 special tools and sealant inside circlip pliers: 57001-143 outside circlip pliers: 57001-144 bearing driver set: 57001-1129 crankshaft jig: 57001-1174 crankcase splitting tool assembly: 57001-1362 gear holder, m2.0: 57001-1557 grip: 57001-1591 rotor holder: 57001-1730 kaw...

  • Page 276

    9-8 crankshaft/transmission crankcase crankcase disassembly • remove the engine from the frame (see engine removal in the engine removal/installation chapter). • set the engine on clean surface while parts are being re- moved. • remove: piston (see piston removal in the engine top end chap- ter) rig...

  • Page 277

    Crankshaft/transmission 9-9 crankcase • remove: circlip [a] balancer drive gear [b] • remove the crankcase bolts [a]. • pry a pry point [a] at the crankcase mating surface, and split the crankcase. If crankcase splitting can not easily, split the crankcase according to the following procedures. ○ in...

  • Page 278

    9-10 crankshaft/transmission crankcase caution do not remove the bearings and the oil seals unless it is necessary. Removal may damage them. Crankcase assembly caution right and left crankcase halves are machined at the factory in the assembled state, so if replaced, they must be replaced as a set. ...

  • Page 279

    Crankshaft/transmission 9-11 crankcase • press the new drive shaft bearing [a] in the right crankcase [b] half so that the stepped side [c] faces inside of the engine. Special tool - bearing driver set: 57001-1129 • press the new crankshaft bearings [a] in the left and right crankcase halves [b] so ...

  • Page 280

    9-12 crankshaft/transmission crankcase • replace the oil seals, if removed. • press the output shaft, shift shaft and release shaft oil seals [c] so that oil seal lip [a] face to the engine outside and oil seal surface flush with the left crankcase surface [b]. Special tool - bearing driver set: 570...

  • Page 281

    Crankshaft/transmission 9-13 crankcase • apply a non-parmanent locking agent to the piston oil noz- zle bolt [a]. • tighten: torque - piston oil nozzle bolt: 7.0 n·m (0.71 kgf·m, 62 in·lb) • install: crankshaft (see crankshaft installation) oil screen (feed) (see oil screen (feed) installation in th...

  • Page 282

    9-14 crankshaft/transmission crankcase • using a plastic hammer, press the rear portion of the crankcase, and tap the area around the crankshaft of the left crankcase half. While maintaining the mating sur- faces of the right and left crankcase halves constantly par- allel, mate the crankcase halves...

  • Page 283

    Crankshaft/transmission 9-15 crankcase • replace the o-ring [a] on the output shaft with new ones. • install o-ring on the grinding faces of the output shaft while expanding the o-ring by the hand. • apply grease to the inside of the output shaft collar [b]. • insert the collar with the groove [c] f...

  • Page 284

    9-16 crankshaft/transmission crankshaft crankshaft removal • disassemble the crankcase (see crankcase disassem- bly). • using the hand pull out the crankshaft [a] from the right crankcase half [b]. Crankshaft installation • apply grease to the outer side of the crankshaft bearings and use the bearin...

  • Page 285

    Crankshaft/transmission 9-17 crankshaft • carefully align the oil passage hole in the right flywheel [a] with the one in the crankpin [b] at rebuilding of the crankshaft as shown. Crankshaft inspection connecting rod big end radial clearance inspection • set the crankshaft on v blocks, and place a d...

  • Page 286

    9-18 crankshaft/transmission crankshaft • next, correct the vertical misalignment by either driving a wedge [a] in between the crank halves or by squeezing them in a vice, depending on the nature of the misalign- ment. Caution do not hammer the crank half at the point [b]. If flywheel misalignment c...

  • Page 287

    Crankshaft/transmission 9-19 crankshaft connecting rod twist inspection • with the big-end arbor [a] still on the v block [c], hold the connecting rod horizontally and measure the amount that the arbor [b] varies from being parallel with the surface plate over a 100 mm length of the arbor to determi...

  • Page 288

    9-20 crankshaft/transmission transmission transmission shaft removal • disassemble the crankcase (see crankcase disassem- bly). • pull out the shift rods [a] allowing the shift fork guide pins to free from the shift drum [b]. • remove the shift forks [c]. • remove the shift drum. • pull out the driv...

  • Page 289

    Crankshaft/transmission 9-21 transmission transmission shaft disassembly • remove the transmission shafts. • remove the circlips, washers, then gears. Special tool - outside circlip pliers: 57001-144 • do not reuse the removed circlips. Transmission shaft assembly • apply engine oil liberally to the...

  • Page 290

    9-22 crankshaft/transmission transmission 1. 2nd gear (17t) 2. Circlip 3. Toothed washer 4. Bushing 5. 4th gear (19t) 6. 3rd gear (16t) 7. 5th gear (24t) 8. 1st gear (16t) 9. Drive shaft 10. Output shaft 11. 1st gear (28t) 12. 5th gear (21t) 13. 3rd gear (19t) 14. 4th gear (19t) 15. 2nd gear (24t) 1...

  • Page 291

    Crankshaft/transmission 9-23 transmission shift fork bending inspection • visually inspect the shift forks, and replace any fork that is bent. A bent fork may cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [a] shift fork/gear groove wear inspection ...

  • Page 292

    9-24 crankshaft/transmission balancer balancer removal • hold the flywheel [a] with the rotor holder [b] to loosen the balancer weight mounting nut [c] special tools - grip [d]: 57001-1591 rotor holder: 57001-1730 • remove: right engine cover (see right engine cover removal in the clutch chapter) ma...

  • Page 293

    Crankshaft/transmission 9-25 primary gear primary gear removal • remove: right engine cover (see right engine cover removal in the clutch chapter) clutch (see clutch removal in the clutch chapter) • temporarily install the clutch housing [a]. • remove: oil pump drive shaft [b] oil pump gear [c] • us...

  • Page 294

    9-26 crankshaft/transmission external shift mechanism shift pedal removal • remove: shift pedal bolt [a] shift pedal [b] shift pedal installation • install the shift pedal so that the split portion [a] on the pedal align with the punch mark [b] on the shift shaft. • tighten: torque - shift pedal bol...

  • Page 295

    Crankshaft/transmission 9-27 external shift mechanism external shift mechanism installation • install the gear positioning lever [a]. ○ fit each end of the spring [b] or original positions. ○ install the color and washer [c]. • tighten: torque - gear positioning lever nut [d]: 8.8 n·m (0.90 kgf·m, 7...

  • Page 296

    9-28 crankshaft/transmission external shift mechanism • before installing the shift shaft, apply grease to the oil seal lips and shift shaft splines. • insert the shift shaft [a]. • replace the circlip [b] with a new one. • install the oil pump driver gear [c]. • install the removed parts (see appro...

  • Page 297

    Crankshaft/transmission 9-29 kickstarter kick pedal assy removal • remove: mounting bolt [a] kick pedal assy [b] kick pedal assy installation • install the kick pedal assy [a] as shown. 15.6 ∼ 25.6mm (0.614 ∼ 1.00 in.) [b] • apply a non-permanent locking agent to the kick pedal bolt. • tighten: torq...

  • Page 298

    9-30 crankshaft/transmission kickstarter idle gear installation • make sure to position the circlip [a] in original position. Replace it, if removed. • apply molybdenum disulfide oil to the inside [b] of the idle gear. • replace the circlip [a] with a new one. • install the idle gear [c] facing embo...

  • Page 299

    Crankshaft/transmission 9-31 kickstarter • install the ratchet guide [a]. • tighten: torque - ratchet guide bolt: 8.8 n·m (0.90 kgf·m, 78 in·lb) • insert the kick shaft assembly [b] into the crankcase. ○ securely engage the stopper portion [c] of the ratchet gear with the guide. • insert the spring ...

  • Page 300

    9-32 crankshaft/transmission kickstarter • fit the spring end [a] and hollow [b] on the spring guide..

  • Page 301

    Crankshaft/transmission 9-33 bearings/oil seals bearing replacement caution do not remove the ball bearings unless it is neces- sary. Removal may damaged them. • remove the ball bearing and/or needle bearing outer race using a press or puller. Note ○ in the absence of the above mentioned tools, sati...

  • Page 302

    9-34 crankshaft/transmission bearings/oil seals • check the needle bearing. ○ the rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage. If there is any doubt as to the condition ...

  • Page 303: Wheels/tires

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

  • Page 304

    10-2 wheels/tires exploded view.

  • Page 305

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 spoke nipples not less than 2.2 not less than 0.22 not less than 19 in·lb 2 front axle nut 79 8.0 58 3 front axle clamp bolts 20 2.0 15 al, s 4 rear axle nut 110 11.2 81.1 al: tighten the two clamp bolts alternately two ti...

  • Page 306

    10-4 wheels/tires specifications item standard service limit wheels (rims) rim runout (with tire installted): axial tir 1.0 mm (0.039 in.) or less tir 2 mm (0.08 in.) radial tir 1.0 mm (0.039 in.) or less tir 2 mm (0.08 in.) axle runout/100 mm (3.94 in.) tir 0.1 mm (0.004 in.) or less tir 0.2 mm (0....

  • Page 307

    Wheels/tires 10-5 special tools inside circlip pliers: 57001-143 rim protector: 57001-1063 bead breaker assembly: 57001-1072 bearing driver set: 57001-1129 jack: 57001-1238 bearing remover head, 20 × 22: 57001-1293 bearing remover head, 25 × 28: 57001-1346 bearing remover shaft, 13: 57001-1377.

  • Page 308

    10-6 wheels/tires wheels (rims) front wheel removal • unscrew the axle nut [a]. • loosen the left and right axle clamp bolts [b]. • using the jack under the frame, and raise the front wheel off the ground. • special tool - jack: 57001-1238 • apply the rear brake to rear wheel so that it does not tur...

  • Page 309

    Wheels/tires 10-7 wheels (rims) • tighten the axle nut [a]. • tighten the left axle clamp bolts [b]. Torque - front axle nut: 79 n·m (8.0 kgf·m, 58 ft·lb) left front axle clamp bolts: 20 n·m (2.0 kgf·m, 15 ft·lb) note ○ tighten the two clamp bolts alternately two times to en- sure even tightening to...

  • Page 310

    10-8 wheels/tires wheels (rims) • squeeze the front brake lever, and hold it with a band [a] to prevent the motorcycle from running forward. Warning be sure to hold the front brake when removing the rear wheel, or the motorcycle may fall over. It could cause an accident and injury. • remove: rear ax...

  • Page 311

    Wheels/tires 10-9 wheels (rims) • fit the projection [a] on the cap to the groove [b] on the collar. ○ the collars are identical. • apply grease to the grease seal lips of the rear hub. • fit the collars [a] and caps [b] on the both sides of the rear hub. • engage the joint of the drive chain, and i...

  • Page 312

    10-10 wheels/tires wheels (rims) note ○ when inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle shaft, tighten the nut clockwise [a] up to next alignment. ○ it should be within 30 degree. ○ loosen one and tighten again when the slot goes past the near...

  • Page 313

    Wheels/tires 10-11 tires air pressure inspection/adjustment • refer to the air pressure inspection/adjustment in the pe- riodic maintenance chapter. Tire removal • remove the wheel from the motorcycle. Caution do not lay the wheel on the ground with the disc facing down. This can damage or warp the ...

  • Page 314

    10-12 wheels/tires tires • step on the side of the tire opposite valve stem, pry the tire off the rim with the tire irons [a] of the bead breaker protecting the rim with rim protectors [b]. • begin to remove the tire beads from the rim, and com- pletely remove the tire beads that are valve stem of t...

  • Page 315

    Wheels/tires 10-13 tires • tighten the bead protector nut [a] and valve stem nut [b], and put on the valve cap [c]. ○ check and adjust the air pressure after installing..

  • Page 316

    10-14 wheels/tires hub bearing front hub bearing removal • remove front wheel (see front wheel removal) grease seals [a] • use the bearing remover to remove the hub bearings [a]. Caution do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place wooden bloc...

  • Page 317

    Wheels/tires 10-15 hub bearing • using a suitable bar [a], tap the around of the bearing inner race evenly to remove the bearings [b]. Hub bearing installation • before installing the hub bearings, blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the ...

  • Page 318

    10-16 wheels/tires hub bearing hub bearing inspection since the hub bearings are made to extremely close tol- erances, the clearance can not normally be measured. Note ○ do not remove any bearings for inspection. If any bear- ings are removed, they will need to be replaced with new ones. • turn each...

  • Page 319: Final Drive

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

  • Page 320

    11-2 final drive exploded view.

  • Page 321

    Final drive 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear sprocket nuts 34 3.5 25 2 engine sprocket nut 70 7.1 52 3 engine sprocket cover bolts 9.8 1.0 87 in·lb g: apply grease. Ho: apply heavy oil. L: apply a non-permanent locking agent. R: replacement parts.

  • Page 322

    11-4 final drive specifications item standard service limit drive chain chain slack 52 ∼ 58 mm (2.0 ∼ 2.3 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 520dma2 – – – length 114 links – – – sprocket rear sprocket warp ...

  • Page 323

    Final drive 11-5 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 • check that the rear en...

  • Page 324

    11-6 final drive drive chain • install the clip [a] so that the closed end [b] of the "u" pointed in the direction of chain rotation [c]. • adjust the drive chain slack (see drive chain slack ad- justment). • check the rear brake effectiveness..

  • Page 325

    Final drive 11-7 sprockets engine sprocket removal • remove: engine sprocket cover bolts [a] engine sprocket cover [b] drive chain guide [c] • flatten the bended sprocket washer [a]. • remove: engine sprocket nut [b] washer • remove the drive chain [d] from the engine sprocket [c]. Engine sprocket i...

  • Page 326

    11-8 final drive sprockets rear sprocket installation • install the rear sprocket [a] so that the marked side [b] faces out. • tighten: torque - rear sprocket nuts: 34 n·m (3.5 kgf·m, 25 ft·lb) sprocket wear inspection • refer to the sprocket wear inspection in the periodic maintenance chapter. Rear...

  • Page 327: Brakes

    Brakes 12-1 12 brakes table of contents exploded view........................................................................................................................ 12-2 specifications .............................................................................................................

  • Page 328

    12-2 brakes exploded view.

  • Page 329

    Brakes 12-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front master cylinder clamp bolts 8.8 0.90 78 in·lb s 2 brake hose banjo bolts 25 2.5 18 3 brake pad pin 17 1.7 12 4 caliper bleed valve 7.8 0.80 69 in·lb 5 front caliper mounting bolts 25 2.5 18 6 front brake disc mounting bolt...

  • Page 330

    12-4 brakes exploded view.

  • Page 331

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb re- marks 1 brake hose banjo bolts 25 2.5 18 2 rear master cylinder mounting bolts 10 1.0 88 in·lb 3 rear master cylinder push rod locknut 17 1.7 12 4 caliper bleed valve 7.8 0.80 69 in·lb 5 brake pad pin 17 1.7 12 6 rear brake pad pin pl...

  • Page 332

    12-6 brakes specifications item standard service limit brake adjustment lever play adjustable (to suit rider) – – – brake fluid recommended disc brake fluid: – – – type front dot3 or dot4 – – – rear dot4 brake pads lining thickness: front 4.0 mm (0.16 in.) 1 mm (0.04 in.) rear 6.4 mm (0.25 in.) 1 mm...

  • Page 333

    Brakes 12-7 special tool jack: 57001-1238.

  • Page 334

    12-8 brakes brake lever, brake pedal brake lever adjustment • refer to the brake lever and pedal position adjustment in the periodic maintenance chapter. Brake pedal position adjustment • refer to the brake lever and pedal position adjustment in the periodic maintenance chapter. Brake pedal removal ...

  • Page 335

    Brakes 12-9 brake lever, brake pedal • install the joint pin [a], washer [b] and a new cotter pin [c]. ○ bend the ends [d] of the cotter pin. • adjust the brake pedal position (see brake lever and pedal position adjustment in the periodic maintenance chapter)..

  • Page 336

    12-10 brakes 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 337

    Brakes 12-11 brake fluid bleeding the brake line the brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air enters the brake lines, brake le...

  • Page 338

    12-12 brakes brake fluid • 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 the bleed valve while holding the brake applied [b]. 3. Release the brake [...

  • Page 339

    Brakes 12-13 calipers caliper removal front brake • loosen the banjo bolt [a] on the caliper side once, and tighten again lightly. • loosen the brake pad pin [b] before the caliper removal if the caliper is to be disassembled. • remove the caliper mounting bolts [c] and remove the caliper [d] from t...

  • Page 340

    12-14 brakes calipers • bleed the brake line (see bleeding the brake line). • check the brake for good braking power, no brake drag, and no fluid leakage. Warning do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads a...

  • Page 341

    Brakes 12-15 calipers caliper dust boot and friction boot damage • check that the dust boot [a] and friction boot [b] are not cracked, worn, swollen, or other wise damaged. If they show any damage, replace it. [c] front caliper [d] rear caliper caliper piston and cylinder damage • visually inspect t...

  • Page 342

    12-16 brakes calipers caliper holder shaft wear the caliper body must slide smoothly on the caliper holder shafts [a]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and con- stant drag on the disc will raise brake and brake fluid tem- perature. •...

  • Page 343

    Brakes 12-17 brake pad brake pad removal front brake • unscrew the pad pin [a]. • take the piston side pad [b]. • remove another pad [c] from the caliper holder. Rear brake • remove: pad pin plug [a] • unscrew the pad pin[a]. • take the piston side pad [b]. • remove another pad [c] from the caliper ...

  • Page 344

    12-18 brakes master cylinder caution brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wiped up immediately. Front master cylinder removal • remove the banjo bolt [a] to disconnect the upper brake hose [b] from the master cylinder [c]. • when removing th...

  • Page 345

    Brakes 12-19 master cylinder rear master cylinder removal • remove the brake pedal joint pin (see brake pedal re- moval). • unscrew the master cylinder mounting bolts [a], and re- move the master cylinder [b] backward. • unscrew the brake hose banjo bolt [c]. • when removing the brake hose, temporar...

  • Page 346

    12-20 brakes master cylinder master cylinder inspection (visual inspection) • disassemble the front and rear master cylinders. • check that there are no scratches, rust or pitting on the inner wall of each master cylinder [a] and on the outside of each piston [b]. If a master cylinder or piston show...

  • Page 347

    Brakes 12-21 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]. Brake disc installation • install the brake disc on the wheel so that the marked side [a] faces out. • apply a non-pe...

  • Page 348

    12-22 brakes brake hose brake hose removal/installation • refer to the brake hose replacement in the periodic maintenance chapter. Brake hose inspection • refer to the brake hoses and connections inspection in the periodic maintenance chapter..

  • Page 349: Suspension

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

  • Page 350

    13-2 suspension exploded view.

  • Page 351

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 base valve assembly 28 2.9 21 2 front fork top plugs 30 3.1 22 3 upper front fork clamp bolts 20 2.0 15 al 4 lower front fork clamp bolts 20 2.0 15 al 5 adjuster assembly locknut 28 2.9 22 6 adjuster assembly 55 5.6 40 l al:...

  • Page 352

    13-4 suspension exploded view.

  • Page 353

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 swingarm pivot shaft nut 98 10 72 2 rocker arm pivot nut 59 6.0 44 3 tie-rod mounting nuts 59 6.0 44 4 upper rear shock absorber mounting nut 39 4.0 29 5 lower rear shock absorber mounting nut 34 3.5 25 2t: apply 2-stroke oi...

  • Page 354

    13-6 suspension specifications item standard service limit front fork air pressure atmospheric pressure – – – (adjustable range) rebound damping adjustment (from the seated position adjuster turned fully clockwise) 13 clicks counterclockwise 20 clicks (adjustable range) compression damping adjustmen...

  • Page 355

    Suspension 13-7 special tools oil seal & bearing remover: 57001-1058 steering stem nut wrench: 57001-1100 hook wrench r37.5, r42: 57001-1101 bearing driver set: 57001-1129 jack: 57001-1238 bearing remover head, 20 × 22: 57001-1293 bearing remover shaft, 13: 57001-1377 fork oil seal driver, 48: 57001...

  • Page 356

    13-8 suspension front fork air pressure if you felt that a front fork is strong during a driving, place the jack under the frame so that the front wheel off the ground, and remove the screw [a] at the top of the front fork top plugs to let the air pressure equalize. Special tool - jack: 57001-1238 n...

  • Page 357

    Suspension 13-9 front fork seated positions adjuster turned fully clockwise [a]. Rebound damping adjuster setting standard: 13 clicks [b] softer (counterclockwise) [c] harder (clockwise) [d] *: although you can turn the adjuster beyond the ad- justable range, effecting no changes to damping force, u...

  • Page 358

    13-10 suspension front fork • remove the front fork. ○ with a twisting motion [a], work the fork leg [b] down and out. Front fork installation • install the fork so that the distance between the top end of the outer tube and the upper surface of the steering stem head is specified dimension. [a] 10 ...

  • Page 359

    Suspension 13-11 front fork • grasp the outer tube and stroke [a] the inner tube several times. The shock to fork seal separates the inner tube from the outer tube. • remove the following parts from the inner tube. [a] guide bushes [b] washer [c] oil seal [d] retaining ring [e] dust seal front fork ...

  • Page 360

    13-12 suspension front fork • install the oil seal by using the fork oil seal driver [a]. Special tool - fork oil seal driver, 48: 57001-1509 • install the retaining ring to the outer tube. • push the dust seal into the outer tube, and put the spring band on the dust seal. • pour the fork oil (see f...

  • Page 361

    Suspension 13-13 front fork • temporarily assemble the inner [a] and outer tubes [b], and pump them back and forth manually to check for smooth operation. Caution if the inner tube is badly bent or creased, replace it. Excessive bending, followed by subsequent straightening, can weaken the inner tub...

  • Page 362

    13-14 suspension rear shock absorber to suit to various riding conditions, the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional one. Also the damping force can be adjusted easily so changing oil viscosity unnecessary. Rebound damping adjustment • tu...

  • Page 363

    Suspension 13-15 rear shock absorber seated position: adjuster turned fully clockwise [a]. Low speed compression damping standard: 12 clicks [b] (eur) 11 clicks [c] softer (counterclockwise) [d] harder (clockwise) [e] * : although you can turn the adjuster beyond the ad- justable range, effecting no...

  • Page 364

    13-16 suspension rear shock absorber • using the stem nut wrench [a], turn the adjusting nut [b] as required. Turning the adjusting nut downward marks the spring action harder and upward softer. Special tool - steering stem nut wrench: 57001-1100 spring preload adjustment (adjusting nut position at ...

  • Page 365

    Suspension 13-17 rear shock absorber remove the rear shock absorber upper mounting bolt [a], nut, and pull out the rear shock absorber [b] down and out. Rear shock absorber installation • pack the rocker arm needle bearings with grease. • apply the tie-rod mounting bolts (rear) to the 2-stroke oil. ...

  • Page 366

    13-18 suspension rear shock absorber • remove the rear shock absorber from the vise. • slide up the rubber bumper [a]. • remove the spring guides [b] from the shock absorber and lift off the spring [c]. • exchange the spring for an optional part. ○ install the spring so that closed coil large diamet...

  • Page 367

    Suspension 13-19 swingarm swingarm removal • remove: rear wheel (see rear wheel removal in the wheels/tires chapter) rear flap (see rear fender flap removal in the frame chapter) brake hose clamps [a] • remove: bolts [a] and nuts [b] chain guide plate [c] chain guide [d] • unscrew the rocker arm piv...

  • Page 368

    13-20 suspension swingarm • remove the screws [a] • remove the chain slipper [b] from the swingarm. Swingarm installation • apply plenty of grease to the inside of the needle bear- ings, sleeves, and grease seals. • install the collars to the both sides of the swingarm. • tighten: torque - swingarm ...

  • Page 369

    Suspension 13-21 swingarm swingarm bearing, sleeve inspection caution do not remove the bearings for inspection. Re- moval may damage them. • inspect the needle bearings installed in the swingarm. ○ the rollers in a bearing normally wear very little, and wear is difficult to measure. Instead of meas...

  • Page 370

    13-22 suspension tie-rod, rocker arm tie-rod removal • using the jack under the frame, raise the rear wheel off the ground. Special tool - jack: 57001-1238 • unscrew the nut [a] and remove the chain guide roller [b]. Caution when pulling out the mounting bolts, lift the rear wheel slightly. Forcing ...

  • Page 371

    Suspension 13-23 tie-rod, rocker arm rocker arm installation • apply plenty of grease to the inside of the rocker arm, needle bearings, grease seals and outside of the sleeve. • tighten: torque - rocker arm pivot nut: 59 n·m (6.0 kgf·m, 44 ft·lb) lower rear shock absorber mounting nut: 34 n·m (3.5 k...

  • Page 372

    13-24 suspension tie-rod, rocker arm tie-rod and rocker arm bearing installation • replace the needle bearing and grease seals with new ones. • apply plenty of grease to the grease seal and needle bearings [a]. Note ○ install the grease seals so that the deep groove side of the rip out-ward. • insta...

  • Page 373

    Suspension 13-25 uni-trak maintenance uni-trak linkage inspection • refer to the uni-trak linkage inspection in the periodic maintenance chapter. Tie-rod and rocker arm sleeve wear inspection • pull out the sleeves [a] of the tie-rod and rocker arm and measure the outside diameter of the sleeve. If ...

  • Page 375: Steering

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

  • Page 376

    14-2 steering exploded view.

  • Page 377

    Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 handlebar clamp bolts 25 2.5 18 2t, al 2 steering stem head nut 98 10 72 3 steering stem nut 4.9 0.50 43 in·lb t 4 upper front fork clamp bolts 20 2.0 15 al 5 lower front fork clamp bolts 20 2.0 15 al ad: apply adhesive cement...

  • Page 378

    14-4 steering special tools bearing puller: 57001-135 steering stem bearing driver: 57001-137 steering stem bearing driver adapter, 34.5: 57001-1074 head pipe outer race press shaft: 57001-1075 head pipe outer race driver, 51.5: 57001-1076 head pipe outer race driver, 54.5: 57001-1077 steering stem ...

  • Page 379

    Steering 14-5 steering steering inspection • refer to the steering inspection in the periodic mainte- nance chapter. Steering adjustment • refer to the steering adjustment in the periodic mainte- nance chapter..

  • Page 380

    14-6 steering steering stem steering stem, stem bearing removal • remove: front wheel (see front wheel removal in the wheels/tires chapter) front fender (see front fender removal in the frame chapter) number plate (see number plate removal in the frame chapter) handlebar pad [a] breather hose [b] (p...

  • Page 381

    Steering 14-7 steering stem • take off the upper stem bearing inner race (tapered roller bearing) [a]. • drive out the bearing outer races from the head pipe. ○ remove the outer races pressed into the head pipe, using the head pipe outer race remover [a], and hammer the head pipe outer race remover ...

  • Page 382

    14-8 steering steering stem • replace the lower inner races with new ones. ○ apply grease to the lower tapered roller bearing [a], and drive it onto the stem using the steering stem bearing driver [b] and adapter [c]. Special tools - steering stem bearing driver: 57001-137 steering stem bearing driv...

  • Page 383

    Steering 14-9 steering stem • install the parts removed (see the appropriate chapter). Warning do not impede the handlebar turning by routing the cables, wires, and hoses improperly (see cable, wire, and hose routing in the appendix chapter). • check and adjust: steering front brake clutch cable thr...

  • Page 384

    14-10 steering handlebar handlebar removal • remove: number plate (see number plate removal in the frame chapter) clutch holder [a] engine stop switch [b] clamps [c] left handlebar grip [d] • remove: throttle grip assy [a] (see throttle cable replacement in the fuel system (dfi) chapter) master cyli...

  • Page 385

    Steering 14-11 handlebar • apply grease to the throttle cable upper end and clutch cable upper end. • apply a 2-stroke oil to the edge (slash area) of the han- dlebar. [a] 120mm (4.72in.) • install the throttle grip assy so that the grip [a] is in as far as it will go. • position the throttle grip a...

  • Page 387: Frame

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

  • Page 388

    15-2 frame exploded view.

  • Page 389

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear frame mounting bolts 34 3.5 25 2 upper footpeg bracket bolts 54 5.5 40 l 3 radiator shroud bolts 9.8 1.0 87 in·lb g: apply grease. L: apply a non-permanent locking agent. R: replacement parts.

  • Page 390

    15-4 frame frame frame inspection • refer to the frame inspection in the periodic mainte- nance chapter. Rear frame removal • remove: seat (see seat removal) right and left side cover (see side cover removal) muffler (see muffler removal in the engine top end chapter) rear fender (see rear fender re...

  • Page 391

    Frame 15-5 frame engine guard installation • install the engine guard as shown. Right engine guard [a] collar [b] bolt [c] engine guard [d] bolts [e].

  • Page 392

    15-6 frame seat seat removal • remove the bolts [a]. • pull the seat [b] out from the back. Seat installation • insert the hooks [a] of the seat under the flange collar [b] and brackets [c]. • tighten the seat mounting bolts..

  • Page 393

    Frame 15-7 side cover side cover removal • remove: bolts [a] side cover [b] • remove the other side according to similar procedure. Side cover installation • stick the pad [a] on the inside of the right side cover [b]. • install the damper [c]. • insert the tabs [a] of the side cover into slits [b] ...

  • Page 394

    15-8 frame radiator shroud radiator shroud removal • remove: bolts [a] radiator shroud [b] radiator shroud installation • install: radiator shroud [a] bolts (l = 12) [b] bolt (l = 16) [c].

  • Page 395

    Frame 15-9 number plate number plate removal • remove the bolt [a]. • remove the band [b] from the handlebar. • remove the number plate [c] upward. Number plate installation • insert the projections [a] of the number plate into the holes [b] of the steering stem. ○ run the cluth cable through front ...

  • Page 396

    15-10 frame fender front fender removal • unscrew the bolts [a] and remove the front fender [b]. Rear fender removal • remove: seat (see seat removal) sidecover (see side cover removal) • unscrew the bolts [a] and remove the rear fender [b]. Rear flap removal • unscrew the screws [a] and remove the ...

  • Page 397: Electrical System

    Electrical system 16-1 16 electrical system table of contents exploded view........................................................................................................................ 16-2 specifications .......................................................................................

  • Page 398

    16-2 electrical system exploded view.

  • Page 399

    Electrical system 16-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 gear position switch screws 2.9 0.30 26 in·lb l 2 flywheel nut 78 8.0 58 3 stator coil bolts 9.8 1.0 87 in·lb l 4 spark plug 13 1.3 115 in·lb 5 magneto cover bolts 9.8 1.0 87 in·lb 6 crankshaft sensor bolts 7.0 0.71 6...

  • Page 400

    16-4 electrical system specifications item standard magneto magneto output voltage 37 v or more at 4 000 r/min (rpm) stator coil resistance 0.4 ∼ 1.1 Ω (at 20°c (68°f)) ignition system ignition timing 10° btdc @2 000 r/min (rpm) ignition coil: 3 needle arcing distance 7 mm (0.26 in.) or more primary...

  • Page 401

    Electrical system 16-5 special tools and sealant bearing driver set: 57001-1129 rotor puller, m16/m18/m20/m22 × 1.5: 57001-1216 timing light: 57001-1241 hand tester: 57001-1394 peak voltage adapter: 57001-1415 filler cap driver: 57001-1454 needle adapter set: 57001-1457 flywheel puller, m28 × 1.0: 5...

  • Page 402

    16-6 electrical system special tools and sealant kawasaki bond (silicone sealant): 92104-0004.

  • Page 403

    Electrical system 16-7 special tools and sealant dummy page.

  • Page 404

    16-8 electrical system wiring diagram.

  • Page 405

    Electrical system 16-9 wiring diagram.

  • Page 406

    16-10 electrical system precautions there are numbers of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ the electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the...

  • Page 407

    Electrical system 16-11 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 408

    16-12 electrical system flywheel magneto magneto cover removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove the left radiator shroud (see radiator shroud re- moval in the frame chapter). • disconnect the magneto lead connector [a] from the main harne...

  • Page 409

    Electrical system 16-13 flywheel magneto magneto cover assembly • if removed, the oil seal replacement may be required. • press the balancer shaft oil seal [b] so that the magneto cover end [a] is flushed as shown. Special tool - bearing driver set: 57001-1129 • apply grease to the oil seal lips. • ...

  • Page 410

    16-14 electrical system flywheel magneto flywheel installation • using a high-flash point solvent, clean off any oil or dirt that may be on the crankshaft taper [a] or in the hole [b] of the flywheel. Dry them with a clean cloth. • fit the woodruff key [c] securely in the slot of the crank- shaft. •...

  • Page 411

    Electrical system 16-15 flywheel magneto stator coil installation • route the leads according to the cable, wire, and hose routing section in the appendix chapter. • apply a non-permanent locking agent to the stator coil bolts. • install the stator and tighten the stator coil bolts. Torque - stator ...

  • Page 412

    16-16 electrical system flywheel magneto table 2 stator coil resistance connections tester range tester (+) to tester (–) to reading × 1 Ω one yellow lead another yellow lead 0.4 ∼ 1.1 Ω if there is more resistance than shown in the table, or no hand tester reading (infinity), the stator has an open...

  • Page 413

    Electrical system 16-17 charging system regulator/rectifier removal • remove: right radiator shroud (see radiator shroud removal in the frame chapter) nuts [a] bolts [b] bracket [c] • remove the regulator/rectifier connector [d]. Regulator/rectifier installation • install the regulator/rectifier con...

  • Page 414

    16-18 electrical system charging system capacitor removal • remove: left radiator shroud (see radiator shroud removal in the frame chapter) • remove the connector [a], and pull the capacitor [b] up- ward. Capacitor installation • face the lead of the capacitor upward, and insert to the bracket. • co...

  • Page 415

    Electrical system 16-19 ignition timing ignition timing inspection • remove the timing inspection cap[a]. Special tool - filler cap driver: 57001-1454 • attach the timing light [a] to the ignition coil lead in the manner prescribed by the manufacturer. Special tool - timing light: 57001-1241 • start...

  • Page 416

    16-20 electrical system ignition system safety instructions warning the ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil, or high tension lead while the engine is running, or you could receive a severe electrical shock. Ignition coil removal • remove: fue...

  • Page 417

    Electrical system 16-21 ignition system • install the spark plug cap [a] aligned with the line [b] of the cylinder head cover. Ignition coil inspection measuring arcing distance the most accurate test for determining the condition of the ignition coil is made by measuring arcing distance using the c...

  • Page 418

    16-22 electrical system ignition system measuring coil resistance if the arcing tester is not available, the coil can be checked for a broken or badly shorted winding with an ohmmeter. However, an ohmmeter cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage. ...

  • Page 419

    Electrical system 16-23 ignition system ignition coil primary peak voltage check • disconnect the spark plug cap from the spark plug, but do not remove the spark plug. • connect the good spark plug [a] to the spark plug cap, then touch the engine with it. Note ○ measure the voltage with each lead co...

  • Page 420

    16-24 electrical system ignition system.

  • Page 421

    Electrical system 16-25 ignition system crankshaft sensor peak voltage check • to check the peak voltage, do the following procedures. ○ disconnect the connector of the magneto lead connector from the main harness. Note ○ measure the voltage with each lead connected cor- rectly. The correct value ma...

  • Page 422

    16-26 electrical system ignition system crankshaft sensor inspection • remove: magneto lead connector (see magneto cover re- moval). • set the hand tester [a] to the × 100 Ω range and connect it to the green/white [b] and white/yellow [c] leads in the connector. Special tool - hand tester: 57001-139...

  • Page 423

    Electrical system 16-27 switches engine stop switch inspection • using the hand tester, check to see that only the con- nections shown in the table have continuity (about zero ohms). Special tool - hand tester: 57001-1394 if the switch has an open or short, repair it or replace it with a new one. En...

  • Page 425: Appendix

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

  • Page 426

    17-2 appendix cable, wire, and hose routing 1. Throttle cables 2. Marked (aaa) cable is accelerator side. 3. Bands (hold the engine stop switch lead.) 4. Engine stop switch lead 5. Clutch cable 6. Clamp (clamp the clutch cable and en- gine stop switch lead.) 7. Clamp (clamp the throttle cables.) 8. ...

  • Page 427

    Appendix 17-3 cable, wire, and hose routing 1. Clutch cable 2. Kawasaki diagnostic system connector 3. Ecu 4. Main harness 5. Clamp the clutch cable. 6. Gear position switch lead 7. Magneto lead 8. Water temperature sensor connector 9. Clamp the main harness and engine stop switch lead. 10. Engine s...

  • Page 428

    17-4 appendix cable, wire, and hose routing 1. Sub-harness connector (black) 2. Sub-harness connector (gray) 3. Bracket 4. Insert the sub-harness connectors into the bracket. 5. Regulator/rectifier connector 6. Sub-harness 7. Water temperature sensor connector.

  • Page 429

    Appendix 17-5 cable, wire, and hose routing 1. Engine stop switch lead 2. Radiator hose 3. Capacitor 4. Engine stop switch lead connector 5. Clamp the engine stop switch lead and regulator/rectifier lead with the frame pipe at the blue tape portion. 6. Ignition coil connector 7. Ignition coil 8. Sub...

  • Page 430

    17-6 appendix cable, wire, and hose routing 1. Spark plug cap 2. 45° 3. Gear position switch lead 4. Clamp the gear position switch lead. 5. Radiator overflow hose 6. Clamp (clamp the breather hose and ra- diator overflow hose.) 7. Breather hose 8. Install the clamp as shown. 9. Align the white mark...

  • Page 431

    Appendix 17-7 cable, wire, and hose routing 1. Left radiator 2. Right radiator 3. Radiator hose (to cylinder head) 4. Radiator hose (to water pump) 5. Radiator overflow hose 6. Joint pipe 7. Clamp (position the clamp claw left side.) 8. Clamp (position the clamp claw down- ward.) 9. Run the radiator...

  • Page 432

    17-8 appendix cable, wire, and hose routing 1. To main harness 2. Clamp the sub-harness at the blue tape portion. 3. To intake air temperature sensor 4. Clamp the water temperature sensor lead and throttle sensor lead at the blue tape portion. 5. To water temperature sensor 6. Throttle sensor connec...

  • Page 433

    Appendix 17-9 cable, wire, and hose routing 1. Intake air temperature sensor lead 2. Run the intake air temperature sensor lead through the hole of the guide as shown. 3. Do not touch the intake air temperature sensor lead and rear shock absorber. 4. Do not show up the intake air temperature sensor ...

  • Page 434

    17-10 appendix cable, wire, and hose routing 1. To spark plug cap 2. To main harness (black) 3. Vehicle-down sensor 4. Ignition coil 5. Capacitor 6. Do not touch the high tension lead and engine ground lead. 7. To main harness (green) 8. To main harness.

  • Page 435

    Appendix 17-11 cable, wire, and hose routing 1. Brake lever 2. Front brake master cylinder 3. Front brake hose 4. Clamp 5. Viewed 6. Clamps 7. Front brake caliper 8. Front brake disc 9. Brake pedal 10. Rear brake master cylinder 11. Rear brake hose 12. Clamps 13. Rear brake caliper 14. Rear brake ca...

  • Page 436

    17-12 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 437

    Appendix 17-13 troubleshooting guide poor running or no power at high speed: firing incorrect: spark plug dirty, broken, or gap malad- justed spark plug cap or high tension wiring trou- ble spark plug cap shorted or not in good con- tact spark plug incorrect heat value ecu trouble crankshaft sensor ...

  • Page 438

    17-14 appendix troubleshooting guide shift return spring weak or broken shift shaft lever broken pawl guide plate broken shift pawl broken shift pawl spring tension lose gear seized gear positioning lever operation trouble shift drum broken jumps out of gear: shift fork ear worn, bent gear groove wo...

  • Page 439

    Appendix 17-15 troubleshooting guide handling and/or stability unsatisfactory: handlebar hard to turn: cable, hose, wire routing incorrect steering stem nut too tight steering stem bearing damaged steering stem bearing lubrication inade- quate steering stem bent tire air pressure too low handlebar s...

  • Page 440

    Model application year model beginning frame no. 2009 kx450e9f jkakxgec □ 9a000001 or jkakx450eea000001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1410-01 printed in japan.