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Kawasaki KX450F - Service Manual

Manual is about: Motorcycle

Summary of KX450F -

  • Page 1

    Kx450f.

  • 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) in. Inch(es) abdc after bottom dead center kds kawasaki diagnostic system ac alternating current km/h kilometers per hour ah ampere hour l liter(s) atdc after top dead center lb pound(s) bbdc before bottom dead center led light emitting diode bdc bottom dead center ...

  • 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. All of the tightening torque values are for use with dry, solvent - cleaned threads u...

  • 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 kx450hg left side view kx450hg right side view frame number engine number.

  • Page 16

    1-8 general information general specifications items kx450hg dimensions overall length 2 195 mm (86.42 in.) overall width 820 mm (32.3 in.) overall height 1 290 mm (50.79 in.) wheelbase 1 495 mm (58.86 in.) road clearance 345 mm (13.6 in.) seat height 960 mm (37.8 in.) curb mass: 108.7 kg (239.7 lb)...

  • Page 17

    General information 1-9 general specifications items kx450hg capacity 1.0 l (1.1 us qt) drive train primary reduction system: type gear reduction ratio 2.727 (60/22) clutch type wet multi disc, manual transmission: type 5-speed, constant mesh, return shift gear ratios: 1st 1.750 (28/16) 2nd 1.412 (2...

  • 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 ......................................................................... 2-37 brakes.................................................................................................................................. 2-37 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 ...

  • 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 drive chain - lubricate • 2-36 wheels/tires - inspect • 2-33 rear sprocket - inspect † • 2-37 front fork - clean and inspect • 2...

  • 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 torque for ...

  • Page 24

    2-6 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks radiator screen bolts 10 1.0 89 in·lb air bleeder screw 1.6 0.16 14 in·lb water hose fitting bolts 10 1.0 89 in·lb water pump cover bolt (l = 70 mm) 12 1.2 106 in·lb water pump cover bolts (l = 25 mm) 10 1.0 89...

  • Page 25

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks oil screen bolt 10 1.0 89 in·lb engine oil drain bolt 20 2.0 15 engine removal/installation middle engine bracket nuts 30 3.1 22 r, s middle engine mounting nut 50 5.1 37 r, s upper engine mounting bolts 50 5.1...

  • Page 26

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks rear sprocket nuts 35 3.6 26 r, s brakes brake lever pivot bolt 5.9 0.60 52 in·lb si brake lever pivot bolt locknut 5.9 0.60 52 in·lb front master cylinder clamp bolts 9.0 0.92 80 in·lb s front brake reservoir ...

  • Page 27

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks steering handlebar clamp bolts 25 2.5 18 al steering stem head nut 100 10.2 73.8 front fork clamp bolts (upper) 23 2.3 17 al steering stem nut 5.0 0.51 44 in·lb t handlebar holder nuts 35 3.6 26 r front brake h...

  • Page 28

    2-10 periodic maintenance torque and locking agent basic torque for general fasteners threads diameter torque (mm) n·m kgf·m ft·lb 5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb 6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb 8 14 ∼ 19 1.4 ∼ 1.9 10.0 ∼ 13.5 10 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 25 12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45 1...

  • Page 29

    Periodic maintenance 2-11 specifications item standard service limit fuel system throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 2 000 ±50 r/min (rpm) – – – air cleaner element oil high-quality foam air filter oil – – – cooling system coolant: type (recommended) permanent type an...

  • Page 30

    2-12 periodic maintenance specifications item standard service limit wheels/tires rim runout (with tire installed): axial tir 1.0 mm (0.04 in.) or less tir 2.0 mm (0.08 in.) radial tir 1.0 mm (0.04 in.) or less tir 2.0 mm (0.08 in.) tires air pressure (front/rear) 100 kpa (1.02 kgf/cm², 14.5 psi) – ...

  • Page 31

    Periodic maintenance 2-13 specifications item standard service limit suspension oil kawasaki ss-19 or equivalent – – – amount: left front fork: cylinder unit 310 ml (10.5 us oz.) – – – outer tube 345 ml (11.7 us oz.) (adjustable range) 300 ∼ 398 ml (10.1 ∼ 13.5us oz.) right front fork: cylinder unit...

  • Page 32

    2-14 periodic maintenance special tools and sealant inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 jack: 57001-1238 spark plug wrench, hex 16: 57001-1262 fork oil level gauge: 57001-1290 filler cap driver: 57001-1454 jack attachment: 57001-1608 top plug wrench, 50 mm: 57001-16...

  • Page 33

    Periodic maintenance 2-15 periodic maintenance procedures fuel system (dfi) 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. Remove the fuel tank (see fuel tank re- moval in the fu...

  • Page 34

    2-16 periodic maintenance 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 valve [a] and the throttle bore [b] for carbo...

  • Page 35

    Periodic maintenance 2-17 periodic maintenance procedures • remove the vinyl bag on the pipe. • check that there are no flaws, burrs, and adhesion of foreign materials on the delivery pipe [a]. • replace the fuel hose with a new one. • run the fuel hose correctly (see cable, wire, and hose routing s...

  • Page 36

    2-18 periodic maintenance periodic maintenance procedures • start the engine and warm it up thoroughly. • with the engine idling, turn the handlebar to both sides [a]. If handlebar movement changes the idle speed, the throt- tle cable may be improperly adjusted or incorrectly routed, or it may be da...

  • Page 37

    Periodic maintenance 2-19 periodic maintenance procedures • remove: seat (see seat removal in the frame chapter) wing bolt [a] air cleaner element [b] • stuff a clean, lint-free towel into the air cleaner duct so no dirt is allowed to enter the throttle body assy. • wipe out the inside of the air cl...

  • Page 38

    2-20 periodic maintenance periodic maintenance procedures • apply grease to all connections and screw holes in the air cleaner housing and intake tract. • install the element onto its frame, and coat the element lip and lip seat with a thick layer of grease [a] to assure a complete seal. • install t...

  • Page 39

    Periodic maintenance 2-21 periodic maintenance procedures coolant level inspection note ○ check the level when the engine is cold (room or ambi- ent temperature). • lean the motorcycle slightly until the radiator cap is level to the ground so that the radiator cap is located uppermost in order to ex...

  • Page 40

    2-22 periodic maintenance periodic maintenance procedures water hoses and connections inspection • remove the radiator shrouds (see radiator shroud re- moval in the frame chapter). ○ the high pressure inside the water hoses [a] can cause coolant to leak [b] or the hose to burst if the line is not pr...

  • Page 41

    Periodic maintenance 2-23 periodic maintenance procedures • using a thickness gauge [a], measure the clearance be- tween each cam lobe and valve lifter for all 4 valves. ○ for the purpose of adjusting the valve clearances, record the measured values. Valve clearance standard: exhaust 0.17 ∼ 0.22 mm ...

  • Page 42

    2-24 periodic maintenance 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 2.65 920...

  • Page 43

    Periodic maintenance 2-25 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 44

    2-26 periodic maintenance periodic maintenance procedures piston/cylinder clearance inspection the piston/cylinder clearance is measured whenever a piston or cylinder is replaced with a new one. The standard piston/cylinder clearance must be adhered to whenever the cylinder is replaced. If only a pi...

  • Page 45

    Periodic maintenance 2-27 periodic maintenance procedures • remove the silencer wool [a] and discard it. • using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. • apply liquid gasket to the mating surface [a]. Sealant ...

  • Page 46

    2-28 periodic maintenance periodic maintenance procedures • pull the clutch lever [a] lightly, and check the flee play [b]. Clutch lever free play standard: 8 ∼ 13 mm (0.31 ∼ 0.51 in.) if the play is too wide, the clutch may not release fully. If the play is too narrow, the clutch may not engage ful...

  • Page 47

    Periodic maintenance 2-29 periodic maintenance procedures • place each friction plate or steel plate on a surface plate [a]. • measure the gap between the surface plate and each fric- tion plate or steel plate [b] with a thickness gauge [c]. The gap is the amount of friction or steel plate warp. Fri...

  • Page 48

    2-30 periodic maintenance periodic maintenance procedures • pour in the specified type and amount of oil. Recommended engine oil type: castrol “power1 racing 4t” 5w-40 or api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity: sae 10w-30, 10w-40 or 10w-50 capacity: 0.8 l (0.8 us qt) (when filte...

  • Page 49

    Periodic maintenance 2-31 periodic maintenance procedures • replace the oil filter [a] with a new one. • apply grease to the grommet [b]. • install the oil filter so that grommet faces engine side. Notice inside out installation stop oil flow, causing engine seizure. • replace the oil filter cap o-r...

  • Page 50

    2-32 periodic maintenance periodic maintenance procedures connecting rod big end side clearance • measure the connecting rod big end side clearance at right side of big end using a thickness gauge [a]. Connecting rod big end side clearance standard: 0.25 ∼ 0.35 mm (0.0098 ∼ 0.0138 in.) service limit...

  • Page 51

    Periodic maintenance 2-33 periodic maintenance procedures tires inspection • remove any imbedded stones or other foreign particles from the tread. Repair or replace with a new one if necessary. • visually inspect the tire for cracks and cuts. Replace the tire, if any damage are noticed. ○ swelling o...

  • Page 52

    2-34 periodic maintenance periodic maintenance procedures • set a dial gauge against the side of the rim, and rotate the rim to measure the axial runout [a]. ○ the difference between the highest and lowest dial read- ings is the amount of runout. • set a dial gauge against the outer circumference of...

  • Page 53

    Periodic maintenance 2-35 periodic maintenance procedures • stretch the chain taut by hanging a 98 n (10 kg, 20 lb) weight [a] on the chain. • measure the length of 20 links [b] on the straight part [c] of the chain from the pin center of the 1st pin to the pin center of the 21st pin. Since the chai...

  • Page 54

    2-36 periodic maintenance periodic maintenance procedures rear axle nut inspection • visually inspect the rear axle nut for deformation or dam- age at the friction ring [a] and caulking [b]. If it is deformed or damaged, replace the axle nut with a new one. Drive chain slack adjustment • loosen the ...

  • Page 55

    Periodic maintenance 2-37 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 56

    2-38 periodic maintenance periodic maintenance procedures • measure the length [a] indicated in the figure. Rear master cylinder push rod length standard: 68.5 ±1 mm (2.70 ±0.04 in.) if it is not within the standard, adjust the push rod in the master cylinder as follows. Note ○ usually it is not nec...

  • Page 57

    Periodic maintenance 2-39 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]. Note ○ hold the reservoir horizontal when checking brake fluid ...

  • Page 58

    2-40 periodic maintenance periodic maintenance procedures brake fluid change warning when working with the disc brake, observe the pre- cautions listed below. • never reuse old brake fluid. • do not use fluid from a container that has been left unsealed or that has been open for a long time. • do no...

  • Page 59

    Periodic maintenance 2-41 periodic maintenance procedures note ○ the procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is the same as for the front brake. Notice brake fluid quickly damages painted plastic sur- faces; any spilled fluid should be completely wash...

  • Page 60

    2-42 periodic maintenance periodic maintenance procedures • change the brake fluid as follows: ○ repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. 1. Open the bleed valve [a]. 2. Apply the brake and hold it [b]. 3. Close the bleed valve ...

  • Page 61

    Periodic maintenance 2-43 periodic maintenance procedures brake pad wear inspection • remove: front brake caliper (see caliper removal in the brakes chapter) • check the lining thickness and condition of the brake pads in each caliper. Note ○ it is able to check with the pads installed. If either pa...

  • Page 62

    2-44 periodic maintenance periodic maintenance procedures • 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 rod. • remove the piston assy [d] (include primary and sec- ondary cups). Assembly • ...

  • Page 63

    Periodic maintenance 2-45 periodic maintenance procedures • separate the caliper holder [a] from the caliper [b]. • remove the anti-rattle springs [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 64

    2-46 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 the hose joint opening. Warning the piston in the brake caliper can crush hands...

  • Page 65

    Periodic maintenance 2-47 periodic maintenance procedures • install the anti-rattle springs [a] as shown. • replace the friction boot [a] and dust boot [b] if they are damaged. • apply a thin coat of silicone grease to the caliper holder shafts [c] and holder holes. • assemble the caliper and calipe...

  • Page 66

    2-48 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 67

    Periodic maintenance 2-49 periodic maintenance procedures • remove: rear master cylinder mounting bolts [a] • remove the front/rear brake hose banjo bolts [a] and washers [b]. • replace the washers with new ones. ○ when removing the brake hose, take care not to spill the brake fluid on the painted o...

  • Page 68

    2-50 periodic maintenance periodic maintenance procedures front fork oil change • remove: number plate (see number plate removal in the frame chapter) front wheel (see front wheel removal in the wheels/tires chapter) • loosen the front fork clamp bolts (upper) [a]. Note ○ set rebound and compression...

  • Page 69

    Periodic maintenance 2-51 periodic maintenance procedures • raise the outer tube and temporarily install the cylinder unit [a] to the outer tube [b] with the top plug wrench [c]. Special tool - top plug wrench, 50 mm: 57001-1645 • hold the axle holder [a] with a vise. ○ protect the axle holder with ...

  • Page 70

    2-52 periodic maintenance periodic maintenance procedures • remove the cylinder unit [a] with the top plug wrench [b]. Special tool - top plug wrench, 50 mm: 57001-1645 • remove the cylinder unit [a] from the outer tube [b]. Notice do not make the piston rod contact to the outer tube. The piston rod...

  • Page 71

    Periodic maintenance 2-53 periodic maintenance procedures • drain the fork oil [a] from the cylinder unit [b] by pumping the piston rod several times. • clean the threads [a] of cylinder unit and base valve as- sembly. • with the piston rod in fully stretched, pour 310 ml (10.5 us oz.) of fork oil [...

  • Page 72

    2-54 periodic maintenance periodic maintenance procedures • replace the o-rings [a] on the base valve assembly with new ones. • apply specified fork oil to the o-rings and bushings [b]. Notice do not damage the bushings when assembling the base valve. • with the piston rod [a] appear about 20 mm (0....

  • Page 73

    Periodic maintenance 2-55 periodic maintenance procedures • drain the extra oil from the cylinder unit oil hole [a]. • blow out the extra oil from the oil hole of the cylinder unit with the compressed air [b] blow to the oil hole. • wipe the oil off completely from the cylinder unit. Note ○ if you c...

  • Page 74

    2-56 periodic maintenance periodic maintenance procedures • completely wipe off the fork oil from the cylinder unit [a]. • insert the cylinder unit to the outer tube [b]. Notice do not make the piston rod contact to the outer tube. The piston rod could be damage. • temporarily tighten the cylinder u...

  • Page 75

    Periodic maintenance 2-57 periodic maintenance procedures • turn the locknut [a] counterclockwise until it contacts with the adjuster assembly [b]. • with the locknut held immovable using a wrench [c], tighten the adjuster assembly to the specified torque. Torque - adjuster assembly (to piston rod):...

  • Page 76

    2-58 periodic maintenance periodic maintenance procedures right front fork • remove the air valve caps [a]. • set the front fork upright state. • bleed air by pushing down the air valves in the order of balance chamber air valve [a], outer chamber air valve [b] and inner chamber air valve [c]. Note ...

  • Page 77

    Periodic maintenance 2-59 periodic maintenance procedures • place the a drain pan under the front fork and drain fork oil [a] so that the oil hole [b] positions upward for the oil spout from the oil hole. Note ○ pump the outer tube several times to drain the fork oil. • using the top plug wrench [a]...

  • Page 78

    2-60 periodic maintenance periodic maintenance procedures • place the drain pan under the front fork and drain fork oil [a]. • hold the axle holder with a vise. ○ protect the axle holder with a soft jaw or heavy cloth when using a vise. Warning clamping the axle holder part too tight can damage it w...

  • Page 79

    Periodic maintenance 2-61 periodic maintenance procedures • remove the cylinder unit [a] from the outer tube [b]. Notice do not make the piston rod contact to the outer tube. The piston rod could be damage. Disassem- bling the cylinder unit can cause internal damage. Do not disassemble the cylinder ...

  • Page 80

    2-62 periodic maintenance periodic maintenance procedures • replace the circlip [a] with a new one and install the circlip in the groove in the cylinder unit [b]. Warning if the circlip is damaged or not correctly installed in the groove in the cylinder unit, the chamber cap may come out of the fron...

  • Page 81

    Periodic maintenance 2-63 periodic maintenance procedures • insert the cylinder unit [a] to the outer tube [b]. Notice do not make the piston rod contact to the outer tube. The piston rod could be damage. • temporarily install the cylinder unit [a] to the outer tube [b] using the top plug wrench [c]...

  • Page 82

    2-64 periodic maintenance periodic maintenance procedures • turn the locknut [a] counterclockwise until it contacts with the sealing bolt [b]. • with the locknut held immovable using a wrench [c], tighten the sealing bolt to the specified torque. Torque - sealing bolt (to piston rod): 28 n·m (2.9 kg...

  • Page 83

    Periodic maintenance 2-65 periodic maintenance procedures • temporarily install the cylinder unit [a] to the outer tube [b] using the top plug wrench [c]. Special tool - top plug wrench, 50 mm: 57001-1645 • inject the air of specified pressure to the outer chamber by using a suitable air pump [a]. O...

  • Page 84

    2-66 periodic maintenance periodic maintenance procedures • replace the o-ring [a] on the plug bolt with a new one. • apply teflon grease to the o-ring on the plug cap. • tighten the plug bolt [a] to the specified torque. Torque - plug bolt: 45 n·m (4.6 kgf·m, 33 ft·lb) • inject the air of specified...

  • Page 85

    Periodic maintenance 2-67 periodic maintenance procedures note ○ the cylinder unit torque is specified to 76 n·m (7.7 kgf·m, 56 ft·lb) however, when you use the top plug wrench, 50 mm (special tool: 57001-1645) [a], reduce the torque to 90% of the specified value [67 n·m (6.8 kgf·m, 49 ft·lb)] due t...

  • Page 86

    2-68 periodic maintenance periodic maintenance procedures rear shock absorber inspection • bounce [a] the rear of the motorcycle up and down and check for smooth suspension stroke. • remove the rear frame (see rear frame removal in the frame chapter). • check for a broken or collapsed spring. • chec...

  • Page 87

    Periodic maintenance 2-69 periodic maintenance procedures • using the hand press, push the reservoir cap [a]. • remove: circlip [b] • using the flat tip screwdrivers [a], remove the reservoir cap [b] with the bladder. • hold the lower portion of the rear shock absorber in a vise with soft jaws or he...

  • Page 88

    2-70 periodic maintenance periodic maintenance procedures • replace the o-ring [a] with a new one. • visually inspect the piston [b] and oil seal assembly [c]. If the piston and oil seal assembly are badly scored, rusty or damaged, replace them. • check the bladder [a] for sign of damage or crack. I...

  • Page 89

    Periodic maintenance 2-71 periodic maintenance procedures • apply shock absorber oil to the bushing and o-ring of the piston rod assembly. • insert the piston end [a] of the piston rod assembly into the rear shock body [b] slowly. Do not insert the seal assembly [c] yet. • purge the air from rear sh...

  • Page 90

    2-72 periodic maintenance periodic maintenance procedures • purge the air from between the gas reservoir [a] and rear shock body [b] by slowly pumping the piston rod [c] in and out. • add the specified oil up to the damping adjuster assembly hole neck [a]. Note ○ hold the adjuster assembly hole faci...

  • Page 91

    Periodic maintenance 2-73 periodic maintenance procedures swingarm and uni-trak linkage inspection • check the uni-trak component parts for wear periodically, or whenever excessive play is suspected. • using the jack under the frame, raise the rear wheel off the ground. Special tools - jack: 57001-1...

  • Page 92

    2-74 periodic maintenance periodic maintenance procedures • feel for steering looseness by pushing and pulling [a] the forks. If you feel looseness, adjust the steering. Steering adjustment • using the jack, raise the front wheel off the ground. Special tools - jack: 57001-1238 jack attachment: 5700...

  • Page 93

    Periodic maintenance 2-75 periodic maintenance procedures • turn the steering stem nut [a] with the steering stem nut wrench [b] to obtain the proper adjustment. If the steering is too tight, loosen the stem nut a fraction of a turn; if the steering is too loose, tighten the nut a fraction of a turn...

  • Page 94

    2-76 periodic maintenance periodic maintenance procedures electrical system spark plug cleaning and inspection • remove: seat (see seat removal in the frame chapter) fuel tank (see fuel tank removal in the fuel system (dfi) chapter) spark plug cap notice when removing the spark plug cap, do not pull...

  • Page 95

    Periodic maintenance 2-77 periodic maintenance procedures • fit the spark plug cap [a] so that it is aligned with the line [b] on the cylinder head cover. • pull up the plug cap to make sure the installation of the spark plug cap. • install the removed parts (see appropriate chapters). Spark plug re...

  • Page 96

    2-78 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 97

    Periodic maintenance 2-79 periodic maintenance procedures if there are loose fasteners, retighten them to the spec- ified torque following the specified tightening sequence. Refer to the torque and locking agent section in this chapter for torque specifications. For each fastener, first loosen it by...

  • Page 99: Fuel System (Dfi)

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

  • Page 100

    3-2 fuel system (dfi) fuel injector removal ....................................................................................................... 3-56 fuel injector installation .................................................................................................... 3-56 fuel injector ...

  • Page 101

    Fuel system (dfi) 3-3 this page intentionally left blank..

  • Page 102

    3-4 fuel system (dfi) exploded view.

  • Page 103

    Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 intake air pressure sensor bracket screw 3.4 0.35 30 in·lb 2 delivery pipe joint screw 3.4 0.35 30 in·lb 3 delivery pipe screws 3.4 0.35 30 in·lb 4 accelerator cable bolt 3.0 0.31 27 in·lb 5 decelerator cable bolt lock...

  • Page 104

    3-6 fuel system (dfi) exploded view.

  • Page 105

    Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 fuel tank bolt 8.0 0.82 71 in·lb 2 diagnostic connector bracket bolt 5.0 0.51 44 in·lb 3 ecu bracket bolts 8.0 0.82 71 in·lb 4 vehicle-down sensor bracket bolt 7.0 0.71 62 in·lb 5 ignition coil bolts 8.0 0.82 71 in·lb ...

  • Page 106

    3-8 fuel system (dfi) specifications item standard digital fuel injection system idle speed 2 000 ±50 r/min (rpm) throttle body assy: throttle valve single throttle valve bore 43 mm (1.7 in.) ecu: make keihin type digital memory type, with built in ic igniter, sealed with resin fuel pressure 294 kpa...

  • Page 107

    Fuel system (dfi) 3-9 special tools and sealant oil pressure gauge, 5 kgf/cm²: 57001-125 fork oil level gauge: 57001-1290 vacuum gauge: 57001-1369 filler cap driver: 57001-1454 needle adapter set: 57001-1457 fuel pressure gauge adapter: 57001-1593 fuel hose: 57001-1607 measuring adapter: 57001-1700 ...

  • Page 108

    3-10 fuel system (dfi) dfi system dfi system 1. Fuel tank 2. Pressure regulator 3. Fuel pump 4. Intake air pressure sensor 5. Fuel injector 6. Intake air temperature sensor 7. Air cleaner housing 8. Ignition coil 9. Vehicle-down sensor 10. Crankshaft sensor 11. Water temperature sensor 12. Throttle ...

  • Page 109

    Fuel system (dfi) 3-11 dfi system dfi system wiring diagram part names 1. Vehicle-down sensor 2. Water temperature sensor 3. Intake air temperature sensor 4. Throttle sensor 5. Intake air pressure sensor 6. Fuel injector 7. Ecu 8. Fuel pump 9. Crankshaft sensor 10. Water-proof joint 1 11. Capacitor ...

  • Page 110

    3-12 fuel system (dfi) dfi system terminal numbers of ecu connectors terminal names 1. Power supply to ecu 2. Unused 3. Dfi setting data selection 1 4. Fuel injector 5. Unused 6. Ground for ecu 7. Orange launch control mode/fi warning indicator light (led) 8. Unused 9. Unused 10. Fuel pump 11. Ignit...

  • Page 111

    Fuel system (dfi) 3-13 dfi parts location kawasaki diagnostic system connector [a] ecu [b] self-diagnosis terminal [c] orange launch control mode/fi warning indicator light (led) [a] water temperature sensor [a] crankshaft sensor [a] vehicle-down sensor [a] capacitor [b] ignition coil [c].

  • Page 112

    3-14 fuel system (dfi) dfi parts location intake air pressure sensor [a] fuel pump [b] fuel injector [a] throttle sensor [b] throttle body assy [c] intake air temperature sensor [a].

  • Page 113

    Fuel system (dfi) 3-15 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 114

    3-16 fuel system (dfi) troubleshooting the dfi system outline when an abnormality in the system occurs, the orange fi warning indicator light (led) goes on to alert the rider. In addition, the condition of the problem is stored in the mem- ory of the ecu (electronic control unit). With the engine st...

  • Page 115

    Fuel system (dfi) 3-17 troubleshooting the dfi system • when checking the dfi parts, use a digital meter which can be read two decimal place voltage or resistance. ○ the dfi part connectors [a] have seals [b], including the ecu. When measuring the input or output voltage with the connector joined, u...

  • Page 116

    3-18 fuel system (dfi) troubleshooting the dfi system • pull each connectors [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect them securely. • check the wiring for continuity. ○ use the wiring d...

  • Page 117

    Fuel system (dfi) 3-19 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 118

    3-20 fuel system (dfi) 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 119

    Fuel system (dfi) 3-21 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 120

    3-22 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) water temperature sensor trouble inspect (see chapter 3). Intake air temperature sensor trouble inspect (see chapter 3). Throttle sensor trouble inspect (see chapter 3). Unstable (rough) idling: fue...

  • Page 121

    Fuel system (dfi) 3-23 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 122

    3-24 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) water temperature sensor trouble inspect (see chapter 3). Intake air temperature sensor trouble inspect (see chapter 3). Throttle sensor trouble inspect (see chapter 3). Knocking: fuel poor quality ...

  • Page 123

    Fuel system (dfi) 3-25 self-diagnosis self-diagnosis outline the self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User mode the ecu connected orange fi warning indicator light (led) goes on when dfi system and ignition system parts a...

  • Page 124

    3-26 fuel system (dfi) self-diagnosis • disconnect the self-diagnosis terminal [a] from the cover [b]. • connect an auxiliary lead [c] for grounding to the self -diagnosis terminal. Note ○ keep the self-diagnosis terminal grounded during self -diagnosis. • to enter the self-diagnosis dealer mode 1, ...

  • Page 125

    Fuel system (dfi) 3-27 self-diagnosis self-diagnosis flow chart.

  • Page 126

    3-28 fuel system (dfi) self-diagnosis how to read service codes ○ service codes are shown by a series of long and short blinks of the orange fi warning indicator light (led) as shown below. ○ read 10th digit and unit digit as the orange fi warning indicator light (led) blinks. ○ when there are a num...

  • Page 127

    Fuel system (dfi) 3-29 self-diagnosis service code table service codes orange fi warning indicator light (led) problems 11 throttle sensor malfunction, wiring open or short 12 intake air pressure sensor malfunction, wiring open or short 13 intake air temperature sensor malfunction, wiring open or sh...

  • Page 128

    3-30 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 129

    Fuel system (dfi) 3-31 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 130

    3-32 fuel system (dfi) throttle sensor (service code 11) • replace: throttle sensor mounting screw [a] throttle sensor [b] o-ring [c] • apply engine oil to the new o-ring, and install it to the new throttle sensor. • engage the inner rotor groove [a] with the throttle shaft [b]. • insert the throttl...

  • Page 131

    Fuel system (dfi) 3-33 throttle sensor (service code 11) • adjust the sensor position so that the output voltage is within the specified voltage range. Throttle sensor output voltage standard: dc 0.57 ∼ 0.63 v if the input voltage reading shows other than 5 v, calculate a valid output voltage range ...

  • Page 132

    3-34 fuel system (dfi) throttle sensor (service code 11) • measure the input voltage with the engine stopped and with the connector joined. Input voltage standard: dc 4.75 ∼ 5.25 v • disconnect the power supply harness. If the reading is within the standard, check the output volt- age (see throttle ...

  • Page 133

    Fuel system (dfi) 3-35 throttle sensor (service code 11) • measure the output voltage with the engine stopped, and with the connector joined. • refer to the self-diagnosis procedures, connect the 12 v battery to the main harness. Output voltage standard: dc 0.57 ∼ 0.63 v at idle throttle opening dc ...

  • Page 134

    3-36 fuel system (dfi) throttle sensor (service code 11) throttle sensor circuit 1. Throttle sensor 2. Ecu.

  • Page 135

    Fuel system (dfi) 3-37 intake air pressure sensor (service code 12) intake air pressure sensor removal notice never drop the intake air pressure sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove: fuel tank (see fuel tank removal) fuel hose (see fuel hose repl...

  • Page 136

    3-38 fuel system (dfi) intake air pressure sensor (service code 12) intake air pressure sensor input voltage inspection note ○ be sure the battery is fully charged. • disconnect the intake air pressure sensor connector and connect the measuring adapter [a] between these con- nectors. Main harness [b...

  • Page 137

    Fuel system (dfi) 3-39 intake air pressure sensor (service code 12) intake air pressure sensor output voltage inspection • measure the intake air pressure sensor output voltage in the same way as input voltage inspection. Note the fol- lowing. ○ disconnect the intake air pressure sensor connector an...

  • Page 138

    3-40 fuel system (dfi) intake air pressure sensor (service code 12) if the wiring is good, check the sensor for various vacuum. • remove the intake air pressure sensor [a] and disconnect the vacuum hose from the sensor. • connect an auxiliary hose [b] to the intake air pressure sensor. • temporarily...

  • Page 139

    Fuel system (dfi) 3-41 intake 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: intake air pressure s...

  • Page 140

    3-42 fuel system (dfi) intake air pressure sensor (service code 12) intake air pressure sensor circuit 1. Intake air pressure sensor 2. Ecu.

  • Page 141

    Fuel system (dfi) 3-43 intake air temperature sensor (service code 13) intake air temperature sensor removal/instal- lation notice never drop the intake 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 ...

  • Page 142

    3-44 fuel system (dfi) intake air temperature sensor (service code 13) • measure the output voltage with the engine stopped and the connector joined. Output voltage standard: about dc 2.28 ∼ 3.43 v @20°c (68°f) note ○ the output voltage changes according to the intake air temperature. • disconnect t...

  • Page 143

    Fuel system (dfi) 3-45 intake air temperature sensor (service code 13) intake air temperature sensor circuit 1. Intake air temperature sensor 2. Ecu.

  • Page 144

    3-46 fuel system (dfi) water temperature sensor (service code 14) water temperature sensor removal/installation notice 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 ch...

  • Page 145

    Fuel system (dfi) 3-47 water temperature sensor (service code 14) • refer to the self-diagnosis procedures, connect the 12 v battery to the main harness. • measure the output voltage with the engine stopped and the connector joined. Output voltage standard: about dc 2.80 ∼ 2.97 v @20°c (68°f) note ○...

  • Page 146

    3-48 fuel system (dfi) water temperature sensor (service code 14) water temperature sensor resistance 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 ...

  • Page 147

    Fuel system (dfi) 3-49 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 stator coil removal/installation in the elec- trical system chapter. Cr...

  • Page 148

    3-50 fuel system (dfi) gear position switch (service code 25) gear position switch removal • remove: shift pedal (external shift mechanism removal in the crankshaft/transmission chapter) gear position switch connector [a] (gray, 2-pin) • open the clamp [b]. • open the clamps [a]. • remove: screws [a...

  • Page 149

    Fuel system (dfi) 3-51 gear position switch (service code 25) gear position switch inspection note ○ be sure the transmission mechanism is good condition. • disconnect the gear position switch lead connector [a] (gray, 2-pin). • set a digital meter [a] and connect it to the terminals in the gear pos...

  • Page 150

    3-52 fuel system (dfi) vehicle-down sensor (service code 31) this sensor has a weight [a] with two magnets inside, and sends a signal to the ecu. But when the motorcycle banks 60 ∼ 70° or more to either side (in fact falls down), the weight turns and the signal changes. The ecu senses this change, a...

  • Page 151

    Fuel system (dfi) 3-53 vehicle-down sensor (service code 31) vehicle-down sensor input voltage inspection note ○ be sure the battery is fully charged. • disconnect the vehicle-down sensor connector and con- nect the measuring adapter [a] between these connec- tors. Main harness [b] vehicle-down sens...

  • Page 152

    3-54 fuel system (dfi) vehicle-down sensor (service code 31) vehicle-down sensor output voltage inspection • 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] • connect a digital meter [d] to...

  • Page 153

    Fuel system (dfi) 3-55 vehicle-down sensor (service code 31) if the reading is within the standard, remove the ecu and check the wiring for continuity between the main harness connectors. ○ disconnect the ecu and sensor connectors. Wiring continuity inspection ecu connector [a] ←→ vehicle-down senso...

  • Page 154

    3-56 fuel system (dfi) fuel injector (service code 41) notice never drop the fuel injector, especially on a hard surface. Such a shock to the injector can damage it. Fuel injector removal • remove: air cleaner housing (see air cleaner housing removal) fuel tank (see fuel tank removal) fuel hose (see...

  • Page 155

    Fuel system (dfi) 3-57 fuel injector (service code 41) • install the delivery pipe assy [a]. • tighten the delivery pipe screws [b]. Torque - delivery pipe screws: 3.4 n·m (0.35 kgf·m, 30 in·lb) • install the removed parts (see appropriate chapters). Fuel injector audible inspection • start the engi...

  • Page 156

    3-58 fuel system (dfi) 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 connectors. Main harness [b] fuel injector [c] special tool - me...

  • Page 157

    Fuel system (dfi) 3-59 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. • refer to the self-diagnosis procedures, connect the 12 v battery to the main harnes...

  • Page 158

    3-60 fuel system (dfi) fuel injector (service code 41) • check the injector fuel line for leakage as follows: ○ connect a commercially available vacuum/pressure pump [a] to the delivery pipe [b] with the fuel hose [c]. ○ hold both ends with the clamps [d]. • apply a soap and water solution to the ar...

  • Page 159

    Fuel system (dfi) 3-61 fuel pump (service code 46) fuel pump removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any ...

  • Page 160

    3-62 fuel system (dfi) fuel pump (service code 46) • install the fuel pump [a] to the fuel tank. • apply a non-permanent locking agent to the threads of the fuel pump bolts. • gradually tighten the fuel pump bolts evenly following the specified tightening sequence [1 ∼ 6]. Torque - fuel pump bolts: ...

  • Page 161

    Fuel system (dfi) 3-63 fuel pump (service code 46) • measure the operating voltage with engine stopped and with the connector joined. Operating voltage standard: battery voltage if the reading is not battery voltage, check the wiring for continuity (see fuel pump circuit). If the wiring is good, che...

  • Page 162

    3-64 fuel system (dfi) fuel pump (service code 46) fuel pump circuit 1. Ecu 2. Fuel pump 3. Capacitor 4. Frame ground 1.

  • Page 163

    Fuel system (dfi) 3-65 ignition coil (service code 51) ignition coil removal/installation • refer to the ignition coil removal/installation in the elec- trical system chapter. Ignition coil primary peak voltage inspection • refer to the ignition coil primary peak voltage check in the electrical syst...

  • Page 164

    3-66 fuel system (dfi) orange fi warning indicator light (led) orange fi warning indicator light (led) inspection note ○ be sure the battery is fully charged. • refer to the self-diagnosis procedures, connect the 12 v battery to the main harness. • confirm that the orange fi warning indicator light ...

  • Page 165

    Fuel system (dfi) 3-67 orange fi warning indicator light (led) orange fi warning indicator light (led) circuit 1. Ecu 2. Capacitor 3. Frame ground 1 4. Orange fi warning indicator light (led).

  • Page 166

    3-68 fuel system (dfi) ecu ecu identification ○ most countries have their own regulations, so each ecu has different characteristic. So, do not confuse ecu with each other and use only the ecu for your model. Other- wise, the motorcycle cannot clear the regulation. Ecu identification part number [a]...

  • Page 167

    Fuel system (dfi) 3-69 ecu ecu power supply inspection • remove the number plate (see number plate removal in the frame chapter). • visually inspect the ecu connector. If the connector is clogged with mud or dust, blow it off with compressed air. • remove the ecu (see ecu removal). • visually inspec...

  • Page 168

    3-70 fuel system (dfi) ecu • connect a digital meter [a] to the ecu connector [b] with the needle adapter set. Special tool - needle adapter set: 57001-1457 ecu power supply inspection connections: digital meter (+) → r/w lead (ecu terminal 1) digital meter (–) → battery (–) terminal standard: when ...

  • Page 169

    Fuel system (dfi) 3-71 fuel line fuel pressure inspection note ○ be sure the battery is fully charged. • remove: fuel tank (see fuel tank removal) fuel hose (see fuel hose replacement in the periodic maintenance chapter) ○ be sure to place a piece of cloth around the fuel outlet pipe of the fuel pum...

  • Page 170

    3-72 fuel system (dfi) fuel line • start the engine, and let it idle. • measure the fuel pressure with the engine idling. Fuel pressure standard: 294 kpa (3.0 kgf/cm², 43 psi) with engine idling note ○ the gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indic...

  • Page 171

    Fuel system (dfi) 3-73 fuel line • open the fuel tank cap [a] to lower the pressure in the tank. • disconnect the fuel hose from the fuel pump (see fuel tank removal). ○ be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump. Warning fuel is flammable and explosive under cert...

  • Page 172

    3-74 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 173

    Fuel system (dfi) 3-75 throttle grip and cable • loosen: decelerator cable bolt locknut [a] accelerator cable bolt [b] • take the cables [c] off the throttle body assy. • free the throttle cable tips [d] from the pulley. • remove the throttle cables. • lubricate the throttle cables (see lubrication ...

  • Page 174

    3-76 fuel system (dfi) throttle grip and cable throttle cable inspection • refer to the cable inspection in the periodic maintenance chapter..

  • Page 175

    Fuel system (dfi) 3-77 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 176

    3-78 fuel system (dfi) throttle body assy • take the throttle body assy [a] off the engine as shown. • remove the throttle cable lower ends (see throttle cable replacement). Throttle body assy installation • install the throttle body assy. • tighten: torque - throttle body assy clamp bolt: 2.0 n·m (...

  • Page 177

    Fuel system (dfi) 3-79 throttle body assy • separate the injector [a] and the delivery pipe [b]. Note ○ do not damage the insertion portion of the fuel injector when it is pulled out from the delivery pipe. Notice never drop the fuel injector, especially on a hard surface. Such a shock to the inject...

  • Page 178

    3-80 fuel system (dfi) throttle body assy • replace the fuel injector o-ring [a] and the dust seal [b] with new ones. • apply engine oil to the o-ring and dust seal. • install the fuel injector [a] to the delivery pipe [b]. • install the delivery pipe assy [a]. • tighten the delivery pipe screws [b]...

  • Page 179

    Fuel system (dfi) 3-81 air cleaner air cleaner housing removal • remove: rear frame (rear frame removal in the frame chap- ter) rear flap (rear flap removal in the frame chapter) • loosen the air cleaner duct clamp bolt [a]. • remove the air cleaner housing [b]. Air cleaner housing installation • po...

  • Page 180

    3-82 fuel system (dfi) fuel tank fuel tank removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a p...

  • Page 181

    Fuel system (dfi) 3-83 fuel tank when removing with flat tip screwdriver: • insert the flat tip screwdriver [a] into the slit [b] on the joint lock. • turn the driver to disconnect the joint lock. When removing with fingers: • open and push up [c] the joint lock with your fingers. Notice prying or e...

  • Page 182

    3-84 fuel system (dfi) fuel tank fuel tank installation • note the above warning (see fuel tank removal). • run the hoses correctly (see cable, wire, and hose rout- ing section in the appendix chapter). • check that the dampers [a] are in place on the frame. If the dampers are damaged or deteriorate...

  • Page 183: Cooling System

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

  • Page 184

    4-2 cooling system exploded view.

  • Page 185

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 radiator mounting bolts 10 1.0 89 in·lb 2 radiator screen bolts 10 1.0 89 in·lb 3 air bleeder screw 1.6 0.16 14 in·lb 4 water hose fitting bolts 10 1.0 89 in·lb 5 water pump cover bolt (l = 70 mm) 12 1.2 106 in·lb 6 water...

  • Page 186

    4-4 cooling system specifications item standard recommended coolant type permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) color green mixed ratio soft water 50%, coolant 50% freezing point –35°c (–31°f) total am...

  • Page 187

    Cooling system 4-5 special tools outside circlip pliers: 57001-144 bearing driver set: 57001-1129.

  • Page 188

    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 coolant can be extremely...

  • Page 189

    Cooling system 4-7 coolant coolant filling notice 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 coo...

  • Page 190

    4-8 cooling system coolant air bleeding • start the engine, warm up the engine thoroughly, and then stop the engine. • wait until the engine cools down. • remove the radiator cap. • check the coolant level (see coolant level inspection in the periodic maintenance chapter). If the coolant level is lo...

  • Page 191

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

  • Page 192

    4-10 cooling system water pump water pump cover removal • drain the coolant (see coolant draining). • remove the right engine guard (see engine guard re- moval in the frame chapter). • remove the water pump cover bolts [a]. • remove the water pump cover [a]. • slide the clamp and disconnect the wate...

  • Page 193

    Cooling system 4-11 water pump impeller installation • install: impeller [a] • tighten: torque - water pump impeller bolt [b]: 10 n·m (1.0 kgf·m, 89 in·lb) • install: water pump cover (see water pump cover installation) water pump inspection • visually check the impeller [a]. If the surface is corro...

  • Page 194

    4-12 cooling system water pump • insert a bar [a] into the water pump shaft hole from the inside of the right engine cover, and remove the oil seal [b] by tapping [c] evenly around the seal lips. Oil seal and bearing installation notice if the oil seal or ball bearing is removed, replace all of them...

  • Page 195

    Cooling system 4-13 radiator radiator removal • drain the coolant (see coolant draining). • remove: radiator shrouds (see radiator shroud removal in the frame chapter) • slide the clamps and disconnect the water hoses [a]. • remove: bolt [b] left radiator screen [c] • remove: radiator mounting bolts...

  • Page 196

    4-14 cooling system radiator radiator installation • run the clutch cable correctly (see cable, wire, and hose routing section in the appendix chapter). • install: radiators washers clutch cable clamps [a] (left side) • tighten: torque - radiator mounting bolts: 10 n·m (1.0 kgf·m, 89 in·lb) • run th...

  • Page 197

    Cooling system 4-15 radiator radiator cap inspection • check the condition of the valve spring [a], and the top and bottom valve seals [b] of the radiator cap. If any one of them shows visible damage, replace the cap. • wet the top and bottom valve seals with water or coolant to prevent pressure lea...

  • Page 199: 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 ................. 5-9 cylinder head cover ......................... 5-12 cylinder head cover removal .... 5-12 ...

  • Page 200

    5-2 engine top end exploded view.

  • Page 201

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 cylinder head cover bolts 10 1.0 89 in·lb 2 cylinder head bolts (m10) 59 6.0 44 mo, s 3 camshaft cap bolts 10 1.0 89 in·lb mo, s 4 camshaft sprocket bolts 12 1.2 106 in·lb l 5 plug 20 2.0 15 l 6 oil line plug 3.0 0.31 27 ...

  • Page 202

    5-4 engine top end exploded view.

  • Page 203

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 exhaust pipe holder nuts 15 1.5 11 s 2 exhaust pipe cover bolts 12 1.2 106 in·lb s 3 muffler clamp bolt 11 1.1 97 in·lb s 4 muffler mounting bolts 21 2.1 15 s 15 muffler cover bolts 10 1.0 89 in·lb l 6. Other than us and ...

  • Page 204

    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.) intake 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 (0.0008 ∼ 0.0024 in....

  • Page 205

    Engine top end 5-7 specifications item standard service limit valve seating surface: outside diameter: exhaust 30.4 ∼ 30.6 mm (1.197 ∼ 1.205 in.) – – – intake 35.4 ∼ 35.6 mm (1.394 ∼ 1.402 in.) – – – width: exhaust 0.8 ∼ 1.2 mm (0.03 ∼ 0.05 in.) – – – intake 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) – – – valv...

  • Page 206

    5-8 engine top end specifications valve stem diameter valve stem diameter [a] 45° [b] valve stem bend dial gauge [a].

  • Page 207

    Engine top end 5-9 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 208

    5-10 engine top end special tools and sealant valve seat cutter, 55° - 35: 57001-1247 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 seat cutter, 55° - 38.5: 57001-1497 val...

  • Page 209

    Engine top end 5-11 special tools and sealant valve guide driver attachment, g: 57001-1728 liquid gasket, tb1216b: 92104-1064.

  • Page 210

    5-12 engine top end cylinder head cover cylinder head cover removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) fuel hose (see fuel hose replacement in the periodic maintenance chapter) spark plug cap [a] cylinder head cover bolts [b] and washers cylinder head cover ...

  • Page 211

    Engine top end 5-13 cylinder head cover • install the cylinder head cover bolt washers with the metal side [a] upwards. • tighten: torque - cylinder head cover bolts [b]: 10 n·m (1.0 kgf·m, 89 in·lb) • install the spark plug cap [a] so that it is aligned with the line [b] on the cylinder head cover....

  • Page 212

    5-14 engine top end camshaft chain tensioner camshaft chain tensioner removal notice this is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: when removing the tens...

  • Page 213

    Engine top end 5-15 camshaft chain tensioner • replace the chain tensioner gasket with a new one. • install the chain tensioner body. • tighten: torque - camshaft chain tensioner mounting bolts [a]: 10 n·m (1.0 kgf·m, 89 in·lb) • take out the holder plate [b]. • replace the o-ring with a new one. • ...

  • Page 214

    5-16 engine top end camshafts 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 • bring the piston to the tdc of the compression stroke. ○ place a wrench over the flywheel nut...

  • Page 215

    Engine top end 5-17 camshafts • while holding the exhaust camshaft with a vise, remove the camshaft sprocket bolts [a]. • remove: auto-decompressor [b] (with sprocket) • remove: circlips [a] camshaft installation • assemble the auto-decompressor weights [a] and spring [b] to install it to the sprock...

  • Page 216

    5-18 engine top end camshafts • engage the camshaft chain with the camshaft sprockets. ○ align the timing mark on the sprocket with the cylinder head upper surface as shown. ○ starting with the timing mark on the front of the exhaust sprocket, count to the 1st pin. Feed the exhaust camshaft thought ...

  • Page 217

    Engine top end 5-19 camshafts • install the camshaft cap [a]. • apply molybdenum disulfide oil to the threads of the camshaft cap bolts. • tighten all camshaft cap bolts evenly and lightly, and then tighten them with specified torque. ○ follow the numbers [1 ∼ 8] of tightening sequence on the camsha...

  • Page 218

    5-20 engine top end camshafts camshaft chain installation • engage the camshaft chain to the crankshaft. • install the lower camshaft chain guide. • tighten: torque - lower camshaft chain guide bolt: 7.0 n·m (0.71 kgf·m, 62 in·lb) • install: flywheel (see flywheel installation in the electrical sys-...

  • Page 219

    Engine top end 5-21 camshafts cam wear inspection • remove the camshafts (see camshaft removal). • measure the height [a] of each cam with a micrometer. If the cams are worn down past the service limit, replace the camshaft. Cam height standard: exhaust 36.943 ∼ 37.057 mm (1.4544 ∼ 1.4589 in.) intak...

  • Page 220

    5-22 engine top end cylinder head cylinder compression measurement • warm up the engine thoroughly. • stop the engine. • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) spark plug (see spark plug cleaning and inspection in the periodic maintenance chapter) • attach the com...

  • Page 221

    Engine top end 5-23 cylinder head • clear the breather hose [a]. • remove (both sides): upper engine bracket [a] (see engine removal in the engine removal/installation chapter) • remove: cylinder head bolts (m6) [b] clamp [c] • loosen: cylinder bolt [d] throttle body assy clamp bolt [e] • slide the ...

  • Page 222

    5-24 engine top end cylinder head ○ take care not to damage the chain guides [a]. Notice do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling effi- ciency. • remove the cylinder head gasket [b]. Cylinder head installation • fit the projections [a] of the ...

  • Page 223

    Engine top end 5-25 cylinder head • install the clamp [a]. • tighten: torque - cylinder bolt [b]: 12 n·m (1.2 kgf·m, 106 in·lb) cylinder head bolts (m6) [c]: 12 n·m (1.2 kgf·m, 106 in·lb) throttle body assy clamp bolt [d]: 2.0 n·m (0.20 kgf·m, 18 in·lb) note ○ after tightening the cylinder head bolt...

  • Page 224

    5-26 engine top end valves valve clearance inspection • refer to the valve clearance inspection in the periodic maintenance chapter. Valve clearance adjustment • refer to the valve clearance adjustment in the periodic maintenance chapter. Valve removal • remove the cylinder head (see cylinder head r...

  • Page 225

    Engine top end 5-27 valves valve installation notice do not lap the valve to the valve seat, using the grinding compound. It will come off oxide film treated surface of the valve. • visually inspect the valve surface. If the surface is damaged, replace the valve. • replace the oil seal [a] with a ne...

  • Page 226

    5-28 engine top end 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 engine oil to the outer surface of the valve guide. • heat the area around the valve guide up to 120 ∼ 150°c...

  • Page 227

    Engine top end 5-29 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 g...

  • Page 228

    5-30 engine top end valves valve seat repair • for the instructions on how to use the valve seat cutter [a], follow the operation manual provided by the tool man- ufacturer. Special tools - valve seat cutter holder, 5.5 [b]: 57001 -1125 valve seat cutter holder bar: 57001-1128 exhaust: valve seat cu...

  • Page 229

    Engine top end 5-31 valves repair operating procedures • clean the seat area carefully. • coat the seat with machinist’s dye. • fit a 45° cutter into the holder and slide it into the valve guide. • press down lightly on the handle and turn it right or left. Grind the seating surface only until it is...

  • Page 230

    5-32 engine top end valves notice the 32° cutter removes material very quickly. Check the seat outside diameter frequently to pre- vent overgrinding. ○ after making the 32° grind, return to the seat outside di- ameter measurement step above. • to measure the seat width, use a vernier caliper to mea-...

  • Page 231

    Engine top end 5-33 valves valve seat repair.

  • Page 232

    5-34 engine top end 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] (disconnect) • tap lightly up with a plastic mallet to separate the cylinder from the crankcase. • remo...

  • Page 233

    Engine top end 5-35 cylinder and piston note ○ the oil ring rails have no “top” or “bottom”. • install the oil ring expander [a] in the bottom piston ring groove so the ends [b] butt together. • install the oil ring steel rails, one above the expander and one below it. ○ spread the rail with your th...

  • Page 234

    5-36 engine top end cylinder and piston • the piston ring openings must be positioned as shown in the figure. The openings of the oil ring steel rails must be about 20° [a] of angle from the opening of the oil ring expander. Circle mark [b] top ring [c] upper oil ring steel rail [d] oil ring expande...

  • Page 235

    Engine top end 5-37 cylinder and piston piston ring/ring groove clearance inspection • check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. • with the piston rings in their groo...

  • Page 236

    5-38 engine top end cylinder and piston piston ring end gap measurement • place the piston ring [a] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. • measure the gap [b] between the ends of the ring...

  • Page 237

    Engine top end 5-39 throttle body holder throttle body assy holder removal • remove: throttle body assy (see throttle body assy removal in the fuel system (dfi) chapter) throttle body assy clamp [a] throttle body assy holder screws [b] clamp [c] throttle body assy holder [d] throttle body assy holde...

  • Page 238

    5-40 engine top end muffler warning the muffler can become extremely hot during nor- mal operation and cause severe burns. Do not re- move the muffler while it is hot. Muffler body removal • remove the right side cover (see side cover removal in the frame chapter). • loosen the muffler clamp bolt [a...

  • Page 239

    Engine top end 5-41 muffler • install the exhaust pipe and muffler body temporary. • align the slit [a] of the muffler clamp with the projection of the muffler body. Viewed from behind [b] ○ face the muffler clamp bolt [c] upward. • first, temporarily tighten the exhaust pipe holder nuts [d], and th...

  • Page 241: Clutch

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

  • Page 242

    6-2 clutch exploded view.

  • Page 243

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 clutch lever clamp bolts 4.0 0.41 35 in·lb al 2 clutch hub nut 100 10.2 73.8 r 3 clutch spring bolts 9.0 0.92 80 in·lb 4 oil filter cap bolts 12 1.2 106 in·lb 5 clutch cover bolts 12 1.2 106 in·lb 6 oil filler plug 3.5 0.36 31 in...

  • Page 244

    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.) 2.7 mm (0.11 in.) friction plate warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.012 in.) steel plate warp 0.20 mm ...

  • Page 245

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

  • Page 246

    6-6 clutch clutch lever and 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 the engine and exhaust system get extremely hot during normal operation and can cause serious burn...

  • Page 247

    Clutch 6-7 clutch lever and cable • loosen the adjusting nut fully and align the slit [a] of the adjusting nut to the slit [b] of the clutch lever. • free the clutch cable upper end from the clutch lever. • free the clutch cable lower end [a] from the clutch release lever [b]. Notice do not remove t...

  • Page 248

    6-8 clutch clutch lever and cable clutch cable inspection and lubrication • during a periodic inspection or when the cable has been removed, inspect and lubricate the cable (see general lubrication and cable inspection section in the periodic maintenance chapter)..

  • Page 249

    Clutch 6-9 clutch cover and right engine cover clutch cover removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: brake pedal bolt [a] and washer brake pedal return spring [b] brake pedal [c] • remove: clutch cover bolts [a] clutch cover [b] clutch c...

  • Page 250

    6-10 clutch clutch cover and right engine cover • remove: right engine guard (see engine guard removal in the frame chapter) kick pedal (see kick pedal removal in the crank- shaft/transmission chapter) brake pedal bolt [a] and washer brake pedal return spring [b] brake pedal [c] • remove: water pump...

  • Page 251

    Clutch 6-11 clutch cover and right engine cover • pour: engine oil (see engine oil change in the periodic main- tenance chapter) coolant (see coolant filling in the cooling system chap- ter) • check the rear brake effectiveness (see brakes section in the periodic maintenance chapter). Right engine c...

  • Page 252

    6-12 clutch clutch clutch removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: clutch cover (see clutch cover removal) clutch spring bolts [a] clutch springs clutch spring plate [b] • remove: washer [a] needle bearing [b] push rod holder [c] push ro...

  • Page 253

    Clutch 6-13 clutch • remove: toothed washer [a] clutch housing [b] clutch installation • check the clutch plate assembly free play (see clutch plate assembly free play inspection/adjustment). • apply molybdenum disulfide oil to the sliding area [a] of the shaft. • install: clutch housing [a] toothed...

  • Page 254

    6-14 clutch clutch • install the friction plates and steel plates, starting with a friction plate and alternating them. Finishing with a friction plate [a]. Note ○ there are 2 different friction plates installed in the clutch plate assembly. ○ when servicing the clutch, use a permanent marker to ide...

  • Page 255

    Clutch 6-15 clutch • install the clutch spring plate [a] and clutch springs. • tighten: torque - clutch spring bolts [b]: 9.0 n·m (0.92 kgf·m, 80 in·lb) • install the clutch cover (see clutch cover installation). • check the release shaft lever position. • pushing [a] the release shaft lever [b] lig...

  • Page 256

    6-16 clutch clutch clutch plate assembly free play inspection/ad- justment • assemble the following parts. Clutch hub [a] friction plates [b, c] steel plates [d] spring plate [e] spring [f] bolts [g] note ○ there are 2 different friction plates installed in the clutch plate assembly. ○ when servicin...

  • Page 257

    Clutch 6-17 clutch release shaft installation • apply engine oil to the needle bearings in the hole of the crankcase. • apply grease to the release shaft lower end [a] and oil seal lips. • insert the release shaft straight into the hole of the crankcase. Notice when inserting the release shaft, be c...

  • Page 258

    6-18 clutch clutch clutch hub spline damage inspection • visually inspect the areas of the clutch hub splines that come in contact with the teeth of the steel plates. If there are notches worn into the clutch hub splines [a], replace the clutch hub. Replace the steel plates if their teeth are damage...

  • Page 259: Engine Lubrication System

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

  • Page 260

    7-2 engine lubrication system exploded view.

  • Page 261

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oil filter cap bolts 12 1.2 106 in·lb 2 oil filler plug 3.5 0.36 31 in·lb 3 oil pump idle gear shaft retainer screw 6.0 0.61 53 in·lb l 4 oil pump bolts 10 1.0 89 in·lb 5 piston oil nozzle bolt 7.0 0.71 62 in·l...

  • Page 262

    7-4 engine lubrication system lubrication system chart.

  • Page 263

    Engine lubrication system 7-5 lubrication system chart 1. Camshaft cap 2. Breather hose 3. Cylinder oil passage (from crankcase oil passage to cylinder head oil passage) 4. Oil nozzle 5. Left crankcase oil passage (from oil filter to transmission oil passage) 6. Camshafts 7. Piston oil nozzle 8. Oil...

  • Page 264

    7-6 engine lubrication system specifications item standard engine oil type castrol “power1 racing 4t” 5w-40 or api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity sae 10w-30, 10w-40, or 10w-50 capacity 0.8 l (0.8 us qt) (when filter is not removed) 0.9 l (1.0 us qt) (when filter is removed) ...

  • Page 265

    Engine lubrication system 7-7 special tools oil pressure gauge, 5 kgf/cm²: 57001-125 outside circlip pliers: 57001-144 oil pressure gauge adapter, m6 × 1.0: 57001-1088 oil pressure cap: 57001-1848.

  • Page 266

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

  • Page 267

    Engine lubrication system 7-9 engine oil and oil filter oil filter replacement • refer to the oil filter replacement in the periodic main- tenance chapter. Oil screen (scavenge) removal • remove: oil screen bolt [a] oil screen [b] oil screen (scavenge) installation • replace the o-rings [a] with new...

  • Page 268

    7-10 engine lubrication system engine oil and oil filter oil screen cleaning • remove the oil screens (see oil screen (scavenge/feed) removal). • clean the oil screen with a high flash-point solvent and remove any particles stuck to them. Warning gasoline and low flash-point solvents can be flammabl...

  • Page 269

    Engine lubrication system 7-11 oil pump oil pump removal • remove: clutch (see clutch removal in the clutch chapter) circlip [a] oil pump idle gear [b] special tool - outside circlip pliers: 57001-144 • remove the oil pump bolts [a]. • remove the oil pump assembly [a]. • remove the outer rotor (scav...

  • Page 270

    7-12 engine lubrication system oil pump • remove: pin [a] oil pump shaft [b] oil pump installation • apply molybdenum disulfide grease [a] to the oil pump shaft [b] as shown. • install the oil pump shaft to the oil pump housing [c]. • install the pin [d] to the oil pump shaft. • apply engine oil to ...

  • Page 271

    Engine lubrication system 7-13 oil pump • apply engine oil to the each oil pump rotor. • install the inner rotor (scavenge) [a] so that the grooves [b] fit the pin. • install outer rotor (scavenge) [c] so that the hole mark [d] faces to the pump housing side. • install the dowel pins [e] to the cran...

  • Page 272

    7-14 engine lubrication system oil pressure oil pressure measurement • remove: oil filter cap bolts [a] oil filter cap [b] • install the new o-ring to the oil pressure cap [a]. Special tool - oil pressure cap: 57001-1848 • install the oil pressure cap, and tighten the oil filter cap bolts. Torque - ...

  • Page 273: Engine Removal/installation

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

  • Page 274

    8-2 engine removal/installation exploded view.

  • Page 275

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 middle engine bracket nuts 30 3.1 22 r, s 2 middle engine mounting nut 50 5.1 37 r, s 3 upper engine mounting bolts 50 5.1 37 s 4 upper engine bracket bolts 30 3.1 22 s 5 lower engine mounting nut 50 5.1 37 r...

  • Page 276

    8-4 engine removal/installation special tools jack: 57001-1238 jack attachment: 57001-1608.

  • Page 277

    Engine removal/installation 8-5 engine removal/installation engine removal • place the jack under the frame to support the motorcycle. Special tools - jack: 57001-1238 jack attachment: 57001-1608 warning when the swingarm pivot shaft is removed the swingarm and rear wheel assembly will become detach...

  • Page 278

    8-6 engine removal/installation engine removal/installation • disconnect: water temperature sensor connector (see water tem- perature sensor removal/installation in the fuel system (dfi) chapter) gear position switch lead connector [a] magneto lead connector [b] • remove: water hoses [a] • remove (b...

  • Page 279

    Engine removal/installation 8-7 engine removal/installation engine installation • replace the following parts with new ones. Upper engine mounting nuts middle engine mounting nut middle engine bracket nuts lower engine mounting nut swingarm pivot shaft nut • install the engine. ○ first, insert the f...

  • Page 280

    8-8 engine removal/installation engine removal/installation • install the removed parts (see appropriate chapters). • run the cables, hoses, and leads according to the cable, wire and hose routing section in the appendix chapter. • pour: engine oil (see engine oil change in the periodic main- tenanc...

  • Page 281: Crankshaft/transmission

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

  • Page 282

    9-2 crankshaft/transmission exploded view.

  • Page 283

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 primary gear nut 100 10.2 73.8 lh, r 2 crankcase bearing retainer screws (m6) 15 1.5 11 l 3 breather plate bolts 7 0.71 62 in·lb 4 piston oil nozzle bolt 7 0.71 62 in·lb l 5 crankcase bearing retainer screws (m8)...

  • Page 284

    9-4 crankshaft/transmission exploded view.

  • Page 285

    Crankshaft/transmission 9-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 kick pedal bolt 35 3.6 26 l 2 ratchet guide bolt 9.0 0.92 80 in·lb 3 ratchet plate bolt 10 1.0 89 in·lb s 4 ratchet plate screw 15 1.5 11 l, s 5 gear positioning lever nut 9.0 0.92 80 in·lb 6 shift drum cam bolt ...

  • Page 286

    9-6 crankshaft/transmission specifications item standard service limit crankshaft, connection rod connecting rod big end: radial clearance 0.002 ∼ 0.014 mm (0.00008 ∼ 0.00055 in.) 0.06 mm (0.0024 in.) side clearance 0.25 ∼ 0.35 mm (0.0098 ∼ 0.0138 in.) 0.6 mm (0.02 in.) crankshaft runout tir 0.03 mm...

  • Page 287

    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 grip: 57001-1591 rotor holder: 57001-1730 liquid gasket, tb1216: 92104-1063.

  • Page 288

    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 289

    Crankshaft/transmission 9-9 crankcase • remove the o-ring [a]. • remove the circlip [a]. Special tool - outside circlip pliers: 57001-144 • remove: circlip [a] balancer drive gear [b] special tool - outside circlip pliers: 57001-144 • remove: crankcase bolts [a] washers [b] clamp [c] • position the ...

  • Page 290

    9-10 crankshaft/transmission crankcase • remove: shift rods [a] (see transmission shaft removal) shift forks [b] (see transmission shaft removal) shift drum [c] (see transmission shaft removal) transmission shafts [d] (see transmission shaft re- moval) crankshaft [e] (see crankshaft removal) transmi...

  • Page 291

    Crankshaft/transmission 9-11 crankcase • support the crankcase bearing boss with a suitable re- tainer [a]. • install a new bearing [b] using a press and the bearing driver set [c]. ○ install the bearings except for the needle bearings until they bottom out. Special tool - bearing driver set: 57001-...

  • Page 292

    9-12 crankshaft/transmission crankcase • press the new shift drum needle bearing [a] and shift shaft needle bearing [b] in the left crankcase half so that bear- ing surface flush with the crankcase surface [c]. Special tool - bearing driver set: 57001-1129 • press the new shift drum bearing [a] in t...

  • Page 293

    Crankshaft/transmission 9-13 crankcase • install the crankcase bearing retainers so that the cham- fered side faces inside of the engine. • apply a non-permanent locking agent to the threads of the crankcase bearing retainer screws (m8) [a] and crankcase bearing retainer screws (m6) [b]. • tighten: ...

  • Page 294

    9-14 crankshaft/transmission crankcase • install the nozzle [a] and tighten it. Torque - nozzle: 3.0 n·m (0.31 kgf·m, 27 in·lb) • replace the o-ring [a] with a new one. • apply grease to the o-ring and install it to the piston oil nozzle [b]. • apply a non-parmanent locking agent to the threads of t...

  • Page 295

    Crankshaft/transmission 9-15 crankcase • install the oil screen (feed) [a] to the guide [b] on the right crankcase so that the non-mesh area [c] faces to the right crankcase side. • replace the o-ring [a] with a new one, and apply grease. • install: dowel pins [b] o-ring.

  • Page 296

    9-16 crankshaft/transmission crankcase • using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. • apply liquid gasket to the mating surface [a] of the left crankcase half. ○ be careful not apply liquid gasket to the ins...

  • Page 297

    Crankshaft/transmission 9-17 crankcase • replace the washers [a] with new ones. • tighten the crankcase bolts using the following steps. • install the clamp [b]. • tighten the crankcase bolts in the numbered sequence [1 ∼ 13]. Torque - crankcase bolts (m7) [c]: 15 n·m (1.5 kgf·m, 11 ft·lb) crankcase...

  • Page 298

    9-18 crankshaft/transmission crankcase • press the new oil seal [a] so that the flat side faces to the engine outside. ○ press the oil seal from the outside (clutch cover side) so that the oil seal end is flush with the crankcase surface. Special tool - bearing driver set: 57001-1129 • apply grease ...

  • Page 299

    Crankshaft/transmission 9-19 crankshaft crankshaft removal • split the crankcase (see crankcase disassembly). • remove the crankshaft [a] from the right crankcase half [b]. Crankshaft installation • install the crankshaft to the right crankcase half. • apply engine oil to the connecting rod big end ...

  • Page 300

    9-20 crankshaft/transmission crankshaft crankshaft inspection connecting rod big end radial clearance inspection • set the crankshaft on v blocks, and place a dial gauge [a] against the connecting rod big end. • push [b] the connecting rod first towards the gauge and then in the opposite direction. ...

  • Page 301

    Crankshaft/transmission 9-21 crankshaft • next, correct the vertical misalignment by either driving a wedge [a] in between the crank halves or by squeezing them in a vise, depending on the nature of the misalign- ment. Notice do not hammer the crank half at the point [b]. If flywheel misalignment ca...

  • Page 302

    9-22 crankshaft/transmission 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 (3.94 in.) length of the arbor...

  • Page 303

    Crankshaft/transmission 9-23 transmission transmission shaft removal • split the crankcase (see crankcase disassembly). • pull out the shift rods [a] allowing the shift fork guide pins to free from the shift drum [b]. • remove: shift drum shift forks [c] • pull out the drive shaft [d] and output sha...

  • Page 304

    9-24 crankshaft/transmission transmission transmission shaft assembly • apply engine oil liberally to the transmission shaft, gears and bearings. • replace any circlips that were removed with new ones. ○ always install the circlips [a] so that the opening [b] is aligned with a spline groove [c], and...

  • Page 305

    Crankshaft/transmission 9-25 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 306

    9-26 crankshaft/transmission transmission shift fork bending inspection • visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [a] shift fork/gear groove wear inspectio...

  • Page 307

    Crankshaft/transmission 9-27 balancer balancer removal • remove: magneto cover (see magneto cover removal in the electrical system chapter) • hold the flywheel [a] steady with the rotor holder [b], and loosen the balancer weight mounting nut [c]. Special tools - grip [d]: 57001-1591 rotor holder: 57...

  • Page 308

    9-28 crankshaft/transmission balancer • align the punch mark [a] on the balancer drive gear and punch mark [b] on the balancer gear. • install the balancer weight. ○ align the punch mark [a] on the balancer weight and punch mark [b] on the balancer gear. • install the flywheel [a] (see flywheel inst...

  • Page 309

    Crankshaft/transmission 9-29 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) magneto cover (see magneto cover removal in the electrical system chapter) • hold the flywheel [a] stea...

  • Page 310

    9-30 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 slit [a] on the pedal aligns with the line mark [b] on the shift shaft. • tighten: torque - shift pedal bolt: 10 n·m...

  • Page 311

    Crankshaft/transmission 9-31 external shift mechanism • remove: gear position lever nut [a] and washer [b] gear position lever [c] collar spring external shift mechanism installation • install the spring [a], collar [b] and gear positioning lever [c]. ○ fit each end of the spring to the original pos...

  • Page 312

    9-32 crankshaft/transmission external shift mechanism • install the shift ratchet assembly [a] to the ratchet plate [b] as shown. ○ while compressing the pawls, install the shift ratchet as- sembly to the ratchet plate. • apply a non-permanent locking agent to the threads of the ratchet plate screw ...

  • Page 313

    Crankshaft/transmission 9-33 external shift mechanism • visually inspect the shift drum cam [a]. If it is badly worn or if it shows any damage, replace it. • check the gear positioning lever [a] and its spring [b] for breaks or distortion. If the lever or spring is damaged in any way, replace them..

  • Page 314

    9-34 crankshaft/transmission kickstarter kick pedal assy removal • remove: kick pedal bolt [a] and washer kick pedal assy [b] kick pedal assy installation • install the kick pedal assy. ○ fit the flat portion [a] of the pedal to the line mark [b] on the clutch cover as shown. • apply a non-permanent...

  • Page 315

    Crankshaft/transmission 9-35 kickstarter idle gear removal • remove: right engine cover (see right engine cover removal in the clutch chapter) clutch (see clutch removal in the clutch chapter) circlip [a] idle gear [b] special tool - outside circlip pliers: 57001-144 idle gear installation • make su...

  • Page 316

    9-36 crankshaft/transmission kickstarter kickshaft installation • install the ratchet guide [a] and the tighten the ratchet guide bolt [b]. Torque - ratchet guide bolt: 9.0 n·m (0.92 kgf·m, 80 in·lb) • apply molybdenum disulfide grease to the end [c] of the kick shaft. • insert the kick shaft assemb...

  • Page 317

    Crankshaft/transmission 9-37 kickstarter • apply grease to the inside of the spring guide [a]. • fit the spring end [b] and hollow [c] on the spring guide..

  • Page 318

    9-38 crankshaft/transmission bearings/oil seals bearing replacement notice do not remove the ball or needle bearings unless it is necessary. Removal may damage them. • using a press or puller, remove the ball bearing and/or needle bearings. Note ○ in the absence of the above mentioned tools, satisfa...

  • Page 319

    Crankshaft/transmission 9-39 bearings/oil seals • inspect the needle bearings. ○ 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 conditi...

  • Page 321: Wheels/tires

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

  • Page 322

    10-2 wheels/tires exploded view.

  • Page 323

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 spoke nipples 3.9 0.40 35 in·lb 2 front axle clamp bolts 23 2.3 17 al, s 3 front axle nut 80 8.2 59 s 4 rear axle nut 110 11.2 81.1 5 bead protector nut 6.0 0.61 53 in·lb al: tighten the two clamp bolts alternately two tim...

  • Page 324

    10-4 wheels/tires specifications item standard service limit wheels (rims) rim size: front 21 × 1.60 – – – rear 19 × 2.15 – – – rim runout: axial tir 1.0 mm (0.04 in.) or less tir 2.0 mm (0.08 in.) radial tir 1.0 mm (0.04 in.) or less tir 2.0 mm (0.08 in.) axle runout/100 mm (3.94 in.) tir 0.03 mm (...

  • Page 325

    Wheels/tires 10-5 special tools inside circlip pliers: 57001-143 rim protector: 57001-1063 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 jack attachment: 57001-1608.

  • Page 326

    10-6 wheels/tires wheels (rims) front wheel removal • remove the axle nut [a]. • loosen the axle clamp bolts [b] on both sides. • raise the front wheel off the ground with jack. Special tools - jack: 57001-1238 jack attachment: 57001-1608 • pull out the axle and remove the wheel. • remove the collar...

  • Page 327

    Wheels/tires 10-7 wheels (rims) • insert the axle [a] from right side. • screw the front axle clamp bolts (right) [b] temporarily. • install the front axle nut [c] with the flange side facing inward. • tighten: torque - front axle nut: 80 n·m (8.2 kgf·m, 59 ft·lb) front axle clamp bolts (left) [d]: ...

  • Page 328

    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 motorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to hold the front brake when removing the rear wheel. Notice be sure ...

  • Page 329

    Wheels/tires 10-9 wheels (rims) • apply high-temperature grease to the oil seal lips. • install the caps and collars to the hub on both sides. ○ fit the projection [a] and groove [b]. • install the rear wheel. • install the chain adjusters on the swingarm as shown in the figure. Adjuster [a] (left s...

  • Page 330

    10-10 wheels/tires wheels (rims) spoke tightness inspection • refer to the spoke tightness inspection in the periodic maintenance chapter. Rim runout inspection • refer to the rim runout inspection in the periodic main- tenance chapter. Rim installation position • when installing the rim, set the ri...

  • Page 331

    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 (see front/rear wheel removal). Notice do not lay the front wheel on the ground with the disc facing down. This can dam...

  • Page 332

    10-12 wheels/tires tires • break the beads away from both sides of the rim with a suitable bead breaker. • lubricate the suitable tire irons [a] and rim protectors [b] with soap and water solution or rubber lubricant. Special tool - rim protector: 57001-1063 • step on the side of the tire opposite a...

  • Page 333

    Wheels/tires 10-13 tires • install the bead protector nut [a] with the flatted side fac- ing inward. • tighten the bead protector nut, air valve nut [b] and air valve cap [c]. Torque - bead protector nut: 6.0 n·m (0.61 kgf·m, 53 in·lb) • adjust the tire air pressure to the specified pressure (see ai...

  • Page 334

    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]. Notice do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place wooden bloc...

  • Page 335

    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 336

    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 337: Final Drive

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

  • Page 338

    11-2 final drive exploded view.

  • Page 339

    Final drive 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper chain guide roller bolt 20 2.0 15 2 lower chain guide roller nut 8.0 0.82 71 in·lb r 3 chain slipper screws 2.5 0.25 22 in·lb l, s 4 engine sprocket cover bolts 5.0 0.51 44 in·lb 5 engine sprocket nut 70 7.1 52 6 chai...

  • Page 340

    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 520dma4 – – – link 114 links – – – sprocket rear sprocket warp ti...

  • Page 341

    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 notch [...

  • Page 342

    11-6 final drive drive chain • install the link plate [a] so that the mark faces out. • install the clip [b] so that the closed end [c] of the “u” pointed in the direction of chain rotation [d]. • adjust the drive chain slack (see drive chain slack ad- justment in the periodic maintenance chapter)..

  • Page 343

    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 engine sprocket [c] from the drive chain [d]. Engine sprocket i...

  • Page 344

    11-8 final drive sprockets rear sprocket installation • replace the rear sprocket nuts with new ones. • install the rear sprocket [a] so that the marked side [b] faces out. • install the rear sprocket bolts [a] and washers [b]. • install the rear sprocket nuts [c] with the flange side facing inward,...

  • Page 345: Brakes

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

  • Page 346

    12-2 brakes exploded view.

  • Page 347

    Brakes 12-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake lever pivot bolt 5.9 0.60 52 in·lb si 2 brake lever pivot bolt locknut 5.9 0.60 52 in·lb 3 front master cylinder clamp bolts 9.0 0.92 80 in·lb s 4 front brake reservoir cap screws 1.5 0.15 13 in·lb 5 brake hose banjo bolts...

  • Page 348

    12-4 brakes exploded view.

  • Page 349

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear master cylinder mounting bolts 10 1.0 89 in·lb 2 rear brake reservoir cap bolts 1.5 0.15 13 in·lb 3 brake hose banjo bolts 25 2.5 18 4 rear master cylinder push rod locknut 17 1.7 13 5 rear brake hose clamp screws 2.5 0.25 ...

  • Page 350

    12-6 brakes specifications item standard service limit brake fluid grade: front dot3 or dot4 – – – rear dot3 or 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 (0.04 in.) brake discs thickness: front 2.9 ∼ 3.2 mm (0.11 ∼ 0.13 in.) 2.5 mm (0...

  • Page 351

    Brakes 12-7 special tools jack: 57001-1238 jack attachment: 57001-1608.

  • Page 352

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

  • Page 353

    Brakes 12-9 brake lever, brake pedal • replace the cotter pin with a new one. • install the joint pin, washer and new cotter pin. ○ bend the ends [a] of the cotter pin as shown. • check the brake pedal position (see brake lever and pedal adjustment in the periodic maintenance chapter)..

  • Page 354

    12-10 brakes brake fluid warning when working with the disc brake, observe the pre- cautions listed below. • never reuse old brake fluid. • do not use fluid from a container that has been left unsealed or that has been open for a long time. • do not mix two types and brands of fluid for use in the b...

  • Page 355

    Brakes 12-11 brake fluid brake line bleeding 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 lever ...

  • Page 356

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

  • Page 357

    Brakes 12-13 caliper caliper removal front brake • loosen the brake pad pin [a] before the caliper [b] re- moval if the caliper is to be disassembled. • loosen the banjo bolt [c] so as not to spill brake fluid. • remove: caliper mounting bolts [d] banjo bolt caliper notice brake fluid quickly damage...

  • Page 358

    12-14 brakes caliper • install the brake hose lower end. ○ replace the washers [a] on each side of hose fitting [b] with new ones. ○ touch the brake hose to the stopper of the caliper. • tighten: torque - brake hose banjo bolt: 25 n·m (2.5 kgf·m, 18 ft·lb) • install the caliper guard and tighten the...

  • Page 359

    Brakes 12-15 caliper fluid seal damage inspection the fluid seal(s) [a] around the piston maintains the proper pad/disc clearance. If this seal is not in good condi- tion, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid temperature. • replace the fluid seal...

  • Page 360

    12-16 brakes caliper caliper piston and cylinder damage inspection • visually inspect the piston(s) [a] and cylinder surfaces. Replace the caliper if the cylinder and piston are badly scores or rusty. Front caliper [b] rear caliper [c] caliper holder shaft wear inspection the caliper body must slide...

  • Page 361

    Brakes 12-17 brake pad brake pad removal front brake • loosen the pad pin [a]. • remove the bolts [b]. • remove the caliper with the hose installed. • remove: pad pin [a] brake pads [b] rear brake • remove: pad pin plug [a] • remove the pad pin [a]. • remove the piston side pad [b]. • push the calip...

  • Page 362

    12-18 brakes brake pad brake pad installation • check that the anti-rattle springs [a] are in place on the caliper. Front brake [b] rear brake [c] • push the caliper piston(s) in by hand as far as they will go. • install the piston side pad first, and then another pad. ○ fit the pad end into the gro...

  • Page 363

    Brakes 12-19 brake pad • install the front caliper and tighten the bolts. Torque - front caliper mounting bolts: 25 n·m (2.5 kgf·m, 18 ft·lb) • tighten the brake pad pin. Torque - brake pad pin: 17 n·m (1.7 kgf·m, 13 ft·lb) brake pad pin plug: 2.5 n·m (0.25 kgf·m, 22 in·lb) • check the brake for goo...

  • Page 364

    12-20 brakes master cylinder front master cylinder removal • remove the banjo bolt [a] to disconnect the brake hose upper end [b] from the master cylinder [c]. ○ when removing the brake hose, temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum. • remove th...

  • Page 365

    Brakes 12-21 master cylinder • install the brake hose. ○ replace the washers [a] on each side of hose fitting [b] with new ones. ○ touch the brake hose to the stopper of the front master cylinder. • tighten: torque - brake hose banjo bolt: 25 n·m (2.5 kgf·m, 18 ft·lb) • bleed the brake line (see bra...

  • Page 366

    12-22 brakes master cylinder • replace the cotter pin with a new one. • install the joint pin, washer and new cotter pin. • bend the ends [a] of the cotter pin as shown. • check the brake pedal position (see brake lever and pedal adjustment in the periodic maintenance chapter). • bleed the brake lin...

  • Page 367

    Brakes 12-23 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 368

    12-24 brakes brake disk brake disc removal • remove the wheels (see front/rear wheel removal in the wheels/tires chapter). • remove the mounting bolts, and take off the disc. Brake disc installation • install the brake disc on the wheel so that the marked side [a] faces out. Front brake disk [b] rea...

  • Page 369

    Brakes 12-25 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 371: Suspension

    Suspension 13-1 13 suspension table of contents exploded view................................... 13-2 specifications .................................... 13-6 special tools ..................................... 13-8 front fork .......................................... 13-9 air pressure adjustment (...

  • Page 372

    13-2 suspension exploded view.

  • Page 373

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fork clamp bolts (upper) 23 2.3 17 al 2 front brake hose clamp bolt (stem base) 3.0 0.31 27 in·lb 3 air pressure relief screw 1.3 0.13 12 in·lb 4 base valve assembly 30 3.1 22 5 cylinder units 76 7.7 56 6 front fork cl...

  • Page 374

    13-4 suspension exploded view.

  • Page 375

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear shock absorber nut (upper) 40 4.1 30 r 2 rear shock absorber nut (lower) 35 3.6 26 r 3 tie-rod mounting nuts 60 6.1 44 r 4 rocker arm pivot nut 60 6.1 44 r 5 swingarm pivot shaft nut 100 10.2 73.8 r 6 gas reservoir damp...

  • Page 376

    13-6 suspension specifications item standard service limit front fork left front fork: rebound damping adjustment (from the seated position adjuster turned fully clockwise) (us, ca, au) 13 clicks counterclockwise (eur, br) 14 clicks counterclockwise (adjustable range) 20 clicks compression damping a...

  • Page 377

    Suspension 13-7 specifications item standard service limit gas reservoir high speed compression damping adjustment (from the seated position adjuster turned fully clockwise) (us, ca, au) 1 3/4 turns out (eur, br) 2 turns out (adjustable range) 4 turns out low speed compression damping adjustment (fr...

  • Page 378

    13-8 suspension special tools oil seal & bearing remover: 57001-1058 hook wrench r37.5, r42: 57001-1101 bearing driver set: 57001-1129 jack: 57001-1238 hook wrench t=3.2 r37: 57001-1539 fork oil seal driver, 49: 57001-1589 jack attachment: 57001-1608 fork oil seal driver weight, 48 ∼ 54: 57001-1796 ...

  • Page 379

    Suspension 13-9 front fork air pressure adjustment (right front fork) before riding, adjust the air pressure to the specific value. • place the jack under the frame so that the front wheel off the ground. Special tools - jack: 57001-1238 jack attachment: 57001-1608 note ○ do not use the sidestand wh...

  • Page 380

    13-10 suspension front fork recommended hard setting inner chamber: (us, ca, au) 1 300 kpa (13.26 kgf/cm², 189 psi) (eur, br) 1 200 kpa (12.24 kgf/cm², 174 psi) outer chamber: 100 kpa (1.02 kgf/cm², 14.5 psi) balance chamber: (us, ca, au) 1 500 kpa (15.30 kgf/cm², 218 psi) (eur, br) 1 300 kpa (13.26...

  • Page 381

    Suspension 13-11 front fork rebound damping adjustment (left front fork) • place the jack under the frame so that the front wheel off the ground. Special tools - jack: 57001-1238 jack attachment: 57001-1608 • to adjust rebound damping, turn the adjuster [a] on the left front fork cylinder valve with...

  • Page 382

    13-12 suspension front fork • loosen: front fork clamp bolts (upper) [a] front fork clamp bolts (lower) [b] • 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 [a] between the top end of the outer ...

  • Page 383

    Suspension 13-13 front fork front fork disassembly • drain the folk oil (see front fork oil change in the peri- odic maintenance chapter). • remove the dust seal [a] and the retaining ring [b]. ○ be careful not to scratch the inner tube. • grasp the outer tube and stroke [a] the inner tube several t...

  • Page 384

    13-14 suspension front fork • replace the following parts with new ones. Dust seal [a] retaining ring [b] oil seal [c] guide bushes [d] • place an oil coated plastic bag [e] over the end of the inner tube to protect the oil seal. ○ the inner tube guide bush groove has a sharp edge [f] that cut out t...

  • Page 385

    Suspension 13-15 front fork cylinder unit inspection • inspect the piston rod [a] of cylinder unit [b] for scratches or bending. If it has scratches or is bent, replace cylinder unit with a new one. Inner tube inspection • visually inspect the inner tube [a]. If there is any damage, replace the inne...

  • Page 386

    13-16 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 387

    Suspension 13-17 rear shock absorber seated position [a]: adjuster turned fully clockwise. Notice do not force the compression damping force ad- juster beyond the fully seated position, or the ad- justing mechanism may be damaged. High speed compression damping adjuster setting standard: (us, ca, au...

  • Page 388

    13-18 suspension rear shock absorber • using the hook wrenches [a] (r42, 57001-1103 and 57001-1539), loosen the locknut [b]. ○ the hook wrench (r42, 57001-1103) is in the hook wrench r37.5, r42: 57001-1101. Special tools - hook wrench r37.5, r42: 57001-1101 hook wrench t=3.2 r37: 57001-1539 • using ...

  • Page 389

    Suspension 13-19 rear shock absorber notice when pulling out the mounting bolts, lift the rear wheel slightly. Forcing or tapping on a bolt could damage the bolt, sleeve, and bearing • remove the rear tie-rod mounting bolt and nut [a] and turn the tie-rod [b] downward. • remove the rear shock absorb...

  • Page 390

    13-20 suspension rear shock absorber • put the rear shock absorber upside down, and hold the upper end of the rear shock absorber in a vise with soft jaws or a heavy cloth. • slide the spring seat [a]. • remove the circlip [b] from the shock absorber and lift off the spring seat and spring [c]. • re...

  • Page 391

    Suspension 13-21 rear shock absorber • inspect the slide bushing [a]. If the bushing is damaged, replace it. ○ cut the slide bushing. • replace the o-rings [b] with new ones. • install the o-rings and a new bushing on the piston. • wrap the threads [a] of the piston rod with tape. • remove the oil s...

  • Page 392

    13-22 suspension rear shock absorber • remove: oil seal [a] notice to avoid damage to the surfaces of the oil seal as- sembly body [b], cover the screwdriver [c] with the cloth [d]. • remove: stopper [a] damper [b] damper holder [c] • inspect the piston rod sliding surface [a]. If the sliding surfac...

  • Page 393

    Suspension 13-23 rear shock absorber • replace the following parts with new ones. Oil seals rebound rubber (if damaged) o-ring • assemble the oil seal assembly as shown. Oil seal [a] oil seal [b] spring holder [c] collar [d] rebound rubber [e] spring [f] o-ring [g] • wrap the threads of the piston r...

  • Page 394

    13-24 suspension rear shock absorber rear shock absorber inspection • remove the rear shock absorber (see rear shock ab- sorber removal). • visually inspect the following items. Oil leakage crack or dent if there is any damage to the rear shock absorber, replace it. • visually inspect the oil seal [...

  • Page 395

    Suspension 13-25 swingarm swingarm removal • remove: rear wheel (see rear wheel removal in the wheels/tires chapter) rear flap (see rear flap removal in the frame chap- ter) rear brake hose clamp screws [a] rear brake hose clamps [b] ○ put the caliper on suitable stand so that it does not dangle. • ...

  • Page 396

    13-26 suspension swingarm • remove the chain slipper screws [a] and collars. • remove the chain slipper [b] from the swingarm. Swingarm installation • install the chain slipper [a] and collars. • apply a non-permanent locking agent to the chain slipper screws. • tighten the chain slipper screws foll...

  • Page 397

    Suspension 13-27 swingarm swingarm bearing installation • replace the needle bearings and grease seals with new ones. • install the needle bearing [a] and grease seal [b] as shown. Flush surface [c] 1.5 mm (0.059 in.) [d] note ○ install the needle bearings so that the manufacture’s marks face out. ○...

  • Page 398

    13-28 suspension swingarm swingarm bearing, sleeve inspection notice do not remove the bearings for inspection. Re- moval may damage them. • inspect the needle bearing [a] installed in the swingarm. ○ the rollers in a bearing normally wear very little, and wear is difficult to measure. Instead of me...

  • Page 399

    Suspension 13-29 tie-rod, rocker arm tie-rod removal • using the jack under the frame, raise the rear wheel off the ground. Special tools - jack: 57001-1238 jack attachment: 57001-1608 • remove: lower chain guide roller nut [a] lower chain guide roller [b] and collar • remove: rear tie-rod mounting ...

  • Page 400

    13-30 suspension tie-rod, rocker arm • remove: rear tie-rod mounting bolt and nut [a] rear shock absorber mounting bolt and nut (lower) [b] rocker arm pivot bolt and nut [c] rocker arm [d] notice when pulling out the mounting bolts, lift the rear wheel slightly. Forcing or tapping on bolt could dama...

  • Page 401

    Suspension 13-31 tie-rod, rocker arm tie-rod and rocker arm bearing installation • replace the needle bearings and grease seals with new ones. • install the needle bearings [a] as shown. Flush surface [b] 4 ±0.4 mm (0.16 ±0.016 in.) [c] note ○ install the bearings so that the marked side faces out. ...

  • Page 402

    13-32 suspension tie-rod, rocker arm needle bearing inspection notice do not remove the bearings for inspection. Re- moval may damage them. • inspect the needle bearings installed in the tie-rod and rocker arm. ○ the needle bearing normally wear very little, and wear is difficult to measure. Instead...

  • Page 403

    Suspension 13-33 uni-trak maintenance uni-trak linkage inspection • refer to the swingarm and 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. • measure the outside diameter of the...

  • Page 405: Steering

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

  • Page 406

    14-2 steering exploded view.

  • Page 407

    Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 handlebar clamp bolts 25 2.5 18 al 2 steering stem head nut 100 10.2 73.8 3 front fork clamp bolts (upper) 23 2.3 17 al 4 steering stem nut 5.0 0.51 44 in·lb t 5 handlebar holder nuts 35 3.6 26 r 6 front brake hose clamp bolt ...

  • Page 408

    14-4 steering special tools bearing puller: 57001-135 steering stem bearing driver: 57001-137 bearing puller adapter: 57001-317 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 drive...

  • Page 409

    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. Steering stem, stem bearing removal • remove: number plate (see number plate removal in t...

  • Page 410

    14-6 steering steering • hold the stem base [a] by hand, and remove the steering stem nut [b] with the steering stem nut wrench [c]. Special tool - steering stem nut wrench: 57001-1100 • remove the steering stem [d] and stem base from the head pipe. • remove the upper stem bearing inner race (tapere...

  • Page 411

    Steering 14-7 steering steering stem, stem bearing installation • replace the bearing outer race with new ones. • apply grease to the outer races. • drive the outer races into the head pipe at the same time with the special tools. Special tools - head pipe outer race press shaft [a]: 57001-1075 head...

  • Page 412

    14-8 steering steering • install the stem head. • install the washer, and tighten the stem head nut tem- porarily. • install the front forks (see front fork installation in the suspension chapter). Note ○ tighten the fork clamp bolts (upper) first, next the stem head nut, last the fork clamp bolt (l...

  • Page 413

    Steering 14-9 steering stem warp inspection • whenever the steering stem is removed, or if the steering cannot be adjusted for smooth action, check the steering stem shaft [a] for straightness. If the steering stem shaft is bent, replace the steering stem..

  • Page 414

    14-10 steering handlebar handlebar removal • remove: number plate (see number plate removal in the frame chapter) handlebar pad [a] • remove: clutch lever holder assembly [a] engine stop switch [b] launch control mode button [c] band [d] left handlebar grip [e] • remove: throttle grip assy [a] (see ...

  • Page 415

    Steering 14-11 handlebar handlebar installation • apply adhesive cement to the innermost area of the left handlebar grip and all-around inner surface of the left han- dlebar grip hole entrance and also apply it to the roulette area on the handlebars. • install the left handlebar grip [a] as shown. P...

  • Page 416

    14-12 steering handlebar • apply grease to the throttle cable upper end and clutch cable upper end. • apply 2-stroke oil to the edge (slash area) of the handle- bar. 120 mm (4.72 in.) [a] • install the throttle grip assembly so that the grip [a] is in as far as it will go. ○ position the throttle gr...

  • Page 417

    Steering 14-13 handlebar handlebar position adjustment the handlebar position can be adjusted in four positions back and forth. Front holes [a] rear holes [b] handlebar holders [c] to suit various riding positions, the handlebar holder po- sition can be changed and the handlebar can be adjusted by t...

  • Page 418

    14-14 steering handlebar • put the handlebar [a] on the handlebar holders [b]. • temporarily install the handlebar clamps [c] and tighten the handlebar clamp bolts [d]. • replace the handlebar holder nuts [e] with new ones. • install the round washers [f], flat washers [g], and han- dlebar holder nu...

  • Page 419: Frame

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

  • Page 420

    15-2 frame exploded view.

  • Page 421

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 number plate bolt 8.0 0.82 71 in·lb 2 radiator shroud bolts 7.0 0.71 62 in·lb 3 right engine guard bolt 8.0 0.82 71 in·lb 4 seat bolts 25 2.5 18 5 side cover bolts 7.0 0.71 62 in·lb 6 footpeg bracket bolts (upper) 35 3.6 26 l 7 f...

  • Page 422

    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) side covers (see side cover removal) radiator shroud (see radiator shroud removal) muffler body (see muffler body removal in the engine top en...

  • Page 423

    Frame 15-5 frame engine guards removal • remove the engine guards as shown. Right engine guard [a] lower engine guard [b] right engine guard bolt [c] lower engine guard bolts[d] engine guards installation • installation is the reverse of removal. • fit the projection [a] of the right engine guard to...

  • Page 424

    15-6 frame seat seat removal • remove the seat bolt [a] on both sides. • open the both side covers [a] slightly outward and slide the seat [b] rearward. Seat installation • install the seat. ○ insert the hooks [a] of the seat under the flange collar [b] and frame [c]. ○ take care not to damage the s...

  • Page 425

    Frame 15-7 side covers side cover removal • remove: side cover bolt [a] radiator shroud bolt [b] seat bolt [c] • pull the side cover [a] upward to clear the hooks [b] and remove the side cover. Side cover installation • stick the pad [a] on the inside of the right side cover. • install the damper [b...

  • Page 426

    15-8 frame radiator shroud radiator shroud removal • remove: side cover (see side cover removal) bolts [a] radiator shroud [b] radiator shroud installation • check the collars [a] are in place on the radiator shroud [b]. • install the radiator shroud [a]. • tighten the radiator shroud bolts. L = 9 m...

  • Page 427

    Frame 15-9 number plate number plate removal • unlock the band [a] of the number plate [b]. • remove the bolt [c]. • clear the projections [d] and remove the number plate. Number plate installation • fit the holes [a] of the number plate and projections [b] of the steering stem base. ○ run the brake...

  • Page 428

    15-10 frame fender front fender removal • remove the bolts [a] and take off the front fender. Front fender installation • tighten: torque - front fender bolts: 8.0 n·m (0.82 kgf·m, 71 in·lb) rear fender removal • remove the side covers (see side cover removal). • remove the rear fender bolts (front)...

  • Page 429

    Frame 15-11 footpegs footpeg removal • for the right footpeg removal, remove the brake pedal assy (see right engine cover removal in the clutch chapter). • remove: cotter pin [a] washer [b] pivot pin [c] spring [d] footpeg [e] footpeg bracket bolt [f] footpeg bracket [g] footpeg installation note ○ ...

  • Page 430

    15-12 frame footpegs footpeg height adjustment ○ the footpeg can be adjusted in two positions. Footpeg bracket [a] bolts [b] bolt holes [c] upper position [d] lower position [e] • remove: footpegs (see footpeg removal) • adjust the footpeg height. Note ○ install the footpegs with same height on both...

  • Page 431: Electrical System

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

  • Page 432

    16-2 electrical system exploded view.

  • Page 433

    Electrical system 16-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 diagnostic connector bracket bolt 5.0 0.51 44 in·lb 2 ecu bracket bolts 8.0 0.82 71 in·lb 3 engine stop switch clamp screw 1.2 0.12 11 in·lb 4 launch control mode button clamp screw 1.2 0.12 11 in·lb 5 regulator/recti...

  • Page 434

    16-4 electrical system specifications item standard flywheel magneto magneto output voltage 37 v or more @4 000 r/min (rpm) stator coil resistance 0.4 ∼ 1.1 Ω @23°c (73°f) charging system charging voltage (regulator/rectifier output voltage) 14.0 ∼ 14.5 v capacitor internal resistance see text ignit...

  • Page 435

    Electrical system 16-5 special tools and sealant rotor puller, m16/m18/m20/m22 × 1.5: 57001-1216 timing light: 57001-1241 peak voltage adapter: 57001-1415 filler cap driver: 57001-1454 needle adapter set: 57001-1457 flywheel puller, m28 × 1.0: 57001-1471 grip: 57001-1591 measuring adapter: 57001-170...

  • Page 436

    16-6 electrical system wiring diagram.

  • Page 437

    Electrical system 16-7 wiring diagram.

  • Page 438

    16-8 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 439

    Electrical system 16-9 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, clean...

  • Page 440

    16-10 electrical system flywheel magneto magneto cover removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: shift pedal (see shift pedal removal in the crank- shaft/transmission chapter) • disconnect the magneto lead connector [a] from the main harn...

  • Page 441

    Electrical system 16-11 flywheel magneto • hold the flywheel steady with the rotor holder [a], and remove the flywheel nut [b]. Special tools - grip [c]: 57001-1591 rotor holder: 57001-1730 • remove the rotor holder. • install the flywheel puller [a] to the flywheel. • install the rotor puller [b] t...

  • Page 442

    16-12 electrical system flywheel magneto • hold the flywheel steady with the rotor holder, and tighten the flywheel nut. Special tools - grip: 57001-1591 rotor holder: 57001-1730 torque - flywheel nut: 80 n·m (8.2 kgf·m, 59 ft·lb) • install the magneto cover (see magneto cover installa- tion). Stato...

  • Page 443

    Electrical system 16-13 flywheel magneto flywheel magneto inspection there are three types of magneto problems: short, open (lead burned out), or loss in flywheel magnetism. A short or open in one of the coil leads will result in either a low output, or no output at all. A loss in flywheel magnetism...

  • Page 444

    16-14 electrical system flywheel magneto if there is more resistance than shown in the table, or no tester reading (infinity), the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced. • using the highest resistance range of t...

  • Page 445

    Electrical system 16-15 charging system regulator/rectifier removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) • open the clamps [a], and free the leads. • slide the dust cover [b]. • disconnect the regulator/rectifier lead connector [c]. • remove: regulator/rectifi...

  • Page 446

    16-16 electrical system charging system • connect the 12 v battery to the main harness (see self -diagnosis procedures in the fuel system (dfi) chapter). • connect a tester [a] to the battery terminals [b]. • start the engine, and note the voltage readings at various engine speeds. But they must be ...

  • Page 447

    Electrical system 16-17 charging system charging system troubleshooting if the charging system is correct, check the ignition sys- tem (see ignition system section). If the ignition system is correct, replace the capacitor (see capacitor removal/in- stallation)..

  • Page 448

    16-18 electrical system charging system capacitor removal • remove the left radiator with the water hose installed (see radiator removal in the cooling system). • disconnect the capacitor lead connector [a]. • remove: capacitor bracket bolt [a] capacitor [b] bracket [c] capacitor installation • inst...

  • Page 449

    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 • star...

  • Page 450

    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 ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. Ignition coil removal • remove: f...

  • Page 451

    Electrical system 16-21 ignition system • install: vehicle-down sensor bracket [a] frame ground lead [b] • tighten: torque - vehicle-down sensor bracket bolt [c]: 7.0 n·m (0.71 kgf·m, 62 in·lb) • install the spark plug cap [a] so that it is aligned with the line [b] on the cylinder head cover. • pul...

  • Page 452

    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 a digital meter. However, the digital meter cannot detect layer shorts and shorts resulting from insulation breakdown under high...

  • Page 453

    Electrical system 16-23 ignition system ignition coil primary peak voltage check • remove the spark plug cap from the spark plug, but do not remove the spark plug. Notice when removing the spark plug cap, do not pull the lead. The lead could be broken off or damaged the wires inside. • install the g...

  • Page 454

    16-24 electrical system ignition system if the ignition system is correct, check the charging sys- tem (see charging system section). If the charging sys- tem is correct, replace the capacitor (see capacitor re- moval/installation)..

  • Page 455

    Electrical system 16-25 ignition system crankshaft sensor peak voltage check • disconnect the magneto lead connector (see magneto cover removal). Note ○ measure the voltage with each lead connected cor- rectly. The correct value may not be obtained if disconnected. ○ maintain the correct value of co...

  • Page 456

    16-26 electrical system ignition system engine stop switch system check • start the engine. • push the engine stop switch [a], stop the engine. If the engine does not stop, check the engine stop switch for continuity (see engine stop switch inspection). If the engine stop switch is good, check the w...

  • Page 457

    Electrical system 16-27 ignition system • check the wiring for continuity between the terminals of each connector referring the connector circuit. White connector [a] green connector [b] black connector [c] if a digital meter [d] does not read 0 Ω , the connector is defective. Replace the connector ...

  • Page 458

    16-28 electrical system switches engine stop switch inspection • using a digital meter, check to see that the connections shown in the table have continuity (about zero ohms). If the switch has an open or short, replace it with a new one. Engine stop switch connection launch control mode button insp...

  • Page 459: Appendix

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

  • Page 460

    17-2 appendix cable, wire, and hose routing 1. Throttle cable (decelerator) 2. Throttle cable (accelerator) 3. Run the clutch cable to the inside of the number plate. 4. Clutch cable 5. Run the throttle cables to the inside of the number plate. 6. Run the front brake hose to the outside of the numbe...

  • Page 461

    Appendix 17-3 cable, wire, and hose routing 1. Throttle cable (decelerator) 2. Throttle cable (accelerator) 3. Clutch cable 4. Front brake hose 5. Run the throttle cables into the guide. 6. Run the engine stop switch lead, launch control mode button lead and clutch cable into the guide. Run the clut...

  • Page 462

    17-4 appendix cable, wire, and hose routing 1. Main harness 2. Clamp (hold the main harness.) 3. Install the clamp so that its opening faces downward. 4. Water hose 5. Run the leads to the inside of the water hose. 6. Clamp (hold the kx fi calibration kit lead, capacitor lead, magneto lead and gear ...

  • Page 463

    Appendix 17-5 cable, wire, and hose routing 1. Magneto lead 2. Clamp (hold the magneto lead and gear position switch lead.) 3. Gear position switch lead 4. Clamps (hold the gear position switch lead.) 5. Run the magneto lead and gear position switch lead to the rear side of the water hose. 6. Clutch...

  • Page 464

    17-6 appendix cable, wire, and hose routing 1. Clamp (hold the clutch cable at the white mark portion. Wind the clamp around the clutch cable upward.) 2. The white mark portion is located within the washer diameter 20 mm (0.79 in.). 3. White mark 4. Washer 5. Clutch cable 6. Clamp (hold the clutch c...

  • Page 465

    Appendix 17-7 cable, wire, and hose routing 1. Front 2. Clamp (hold the main harness at the white tape portion of the main harness.) 3. Main harness 4. Clamp (hold the lead just before a branched point.) 5. Regulator/rectifier lead 6. Ignition coil lead 7. Hold the main harness with the clamp at the...

  • Page 466

    17-8 appendix cable, wire, and hose routing 1. Vehicle-down sensor lead 2. Main harness 3. Run the vehicle-down sensor lead and main harness above the frame. 4. Ignition coil 5. Run the throttle cables between the frames. 6. Throttle cables 7. Capacitor 8. Frame ground lead 9. Install the frame grou...

  • Page 467

    Appendix 17-9 cable, wire, and hose routing 1. Radiator overflow hose 2. Run the throttle cables above the radiator overflow hose. 3. Throttle cables 4. Run the fuel pump lead above the fuel hose. 5. Fuel pump lead 6. Fuel hose 7. Run the intake air pressure sensor lead and throttle sensor lead unde...

  • Page 468

    17-10 appendix cable, wire, and hose routing 1. Intake air pressure sensor lead 2. Run the throttle sensor lead under the in- take air pressure sensor lead. Run the main harness under the intake air pres- sure sensor lead. 3. Throttle sensor lead 4. Run the main harness under the intake air pressure...

  • Page 469

    Appendix 17-11 cable, wire, and hose routing 1. Intake air temperature sensor 2. Clamp (hold the breather hose.) 3. Breather hose 4. Water temperature sensor 5. Viewed from back.

  • Page 470

    17-12 appendix cable, wire, and hose routing 1. Radiator overflow hose 2. Frame downtube 3. Run the radiator overflow hose to the left side of the frame downtube. Run the radiator overflow hose to the front side of the water hose. 4. Water hoses 5. Capacitor lead 6. Run the radiator overflow house t...

  • Page 471

    Appendix 17-13 cable, wire, and hose routing 1. Left radiator 2. Right radiator 3. Projection 4. White paint mark (align the white paint mark to the projection of the water hose fitting.) 5. White paint mark (align the white paint mark to the stopper rib of the water hose fitting.) 6. Viewed from ou...

  • Page 472

    17-14 appendix cable, wire, and hose routing 1. Stopper rib 2. White paint mark (align the white paint mark to the stopper rib of the water hose fitting.) 3. All clamp position: 1 ∼ 3 mm (0.04 ∼ 0.12 in.). 4. Projection 5. White paint mark (align the white paint mark to the projection of the water h...

  • Page 473

    Appendix 17-15 cable, wire, and hose routing 1. Stopper rib (center) 2. White paint mark (align the white paint mark to the stopper rib (side) of the water hose fitting.) 3. Stopper rib (side) 4. White paint mark (align the white paint mark to the stopper rib (center) of the water hose fitting.) 5. ...

  • Page 474

    17-16 appendix cable, wire, and hose routing 1. Fuel hose 2. Fuel tank 3. White paint mark (install the white paint mark side of the fuel hose to the throttle body assy.) 4. Throttle body assy.

  • Page 475

    Appendix 17-17 cable, wire, and hose routing 1. Breather hose 2. Clamp (hold the breather hose so that clamp faces outward.) 3. Clamps position: 1 mm (0.04 in.) or less. 4. Clamp (hold the breather hose.).

  • Page 476

    17-18 appendix cable, wire, and hose routing 1. Touch the front brake hose fitting to the stopper. 2. Front brake hose 3. Clamp (run the front brake hose into the clamp.) 4. Viewed from a 5. Clamps (hold the front brake hose.).

  • Page 477

    Appendix 17-19 cable, wire, and hose routing 1. Rear brake hose 2. Clamps (hold the rear brake hose.) 3. Cotter pin 4. Touch the rear brake hose fitting to the stopper. 5. Viewed from a.

  • Page 478

    17-20 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 479

    Appendix 17-21 troubleshooting guide spark plug cap or spark plug lead trouble spark plug cap shorted or not in good con- tact spark plug incorrect heat value ecu trouble crankshaft sensor trouble flywheel damage ignition coil trouble wiring connector not in good contact fuel/air mixture incorrect: ...

  • Page 480

    17-22 appendix troubleshooting guide gear seized gear positioning lever operation trouble shift drum broken jumps out of gear: shift fork ear worn, bent gear groove worn gear dogs and/or dog holes worn shift drum groove worn gear positioning lever spring weak or bro- ken shift fork guide pin worn dr...

  • Page 481

    Appendix 17-23 troubleshooting guide steering stem bent tire air pressure too low handlebar shakes or excessively vibrates: tire worn swingarm pivot bearings worn rim warped, or not balanced spokes loose wheel bearing worn handlebar clamp bolt loose steering stem head nut loose front, rear axle runo...

  • Page 482

    Part no.99924-1502-01 model application year model beginning frame no. 2016 kx450hg jkakxghc □ ga000001 jkakx450hha000001 □ :this digit in the frame number changes from one machine to another..