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Kawasaki Ninja 1000 Service Manual

Other manuals for Ninja 1000: Fitting Instructions, Owner's Manual

Summary of Ninja 1000

  • Page 1

    Z1000sx z1000sx abs ninja 1000 ninja 1000 abs motorcycle service manual.

  • Page 3: Quick Reference Guide

    This quick reference guide will assist you in locating a desired topic or pro- cedure. •bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. •refer to the sectional table of contents for the exact pages to locate th...

  • Page 5: Z1000Sx

    Z1000sx z1000sx abs ninja 1000 ninja 1000 abs motorcycle service manual all rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written...

  • Page 6

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

  • Page 7

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

  • Page 8

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

  • Page 9: Foreword

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

  • Page 11: General Information 1-1

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

  • Page 12: 1-2 General Information

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

  • Page 13: General Information 1-3

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

  • Page 14: 1-4 General Information

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

  • Page 15: General Information 1-5

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

  • Page 16: 1-6 General Information

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

  • Page 17: General Information 1-7

    General information 1-7 model identification zx1000gb (united states and canada) left side view zx1000gb (united states and canada) right side view frame number engine number.

  • Page 18: 1-8 General Information

    1-8 general information model identification zx1000gb (europe) left side view zx1000gb (europe) right side view.

  • Page 19: General Information 1-9

    General information 1-9 model identification zx1000hb left side view zx1000hb right side view.

  • Page 20: 1-10 General Information

    1-10 general information general specifications items zx1000gb ∼ gc/hb ∼ hc dimensions overall length 2 105 mm (82.87 in.) overall width 790 mm (31.1 in.) overall height/high position 1 170 mm (40.06 in.)/1 230 mm (48.43 in.) wheelbase 1 445 mm (56.89 in.) road clearance 135 mm (5.31 in.) seat heigh...

  • Page 21: General Information 1-11

    General information 1-11 general specifications items zx1000gb ∼ gc/hb ∼ hc duration 276° exhaust: open 58° bbdc close 18° atdc duration 256° lubrication system forced lubrication (wet sump) engine oil: type api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity sae 10w-40 capacity 4.0 l (4.2 u...

  • Page 22: 1-12 General Information

    1-12 general information general specifications items zx1000gb ∼ gc/hb ∼ hc rear suspension: type swingarm wheel travel 138 mm (5.43 in.) brake type: front dual discs rear single disc electrical equipment battery 12 v 8 ah headlight: type semi-sealed beam high beam 12 v 55 w low beam 12 v 55 w tail/...

  • Page 23: General Information 1-13

    General information 1-13 unit conversion table prefixes for units: prefix symbol power mega m × 1 000 000 kilo k × 1 000 centi c × 0.01 milli m × 0.001 micro µ × 0.000001 units of mass: kg × 2.205 = lb g × 0.03527 = oz units of volume: l × 0.2642 = gal (us) l × 0.2200 = gal (imp) l × 1.057 = qt (us)...

  • Page 25: Periodic Maintenance 2-1

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

  • Page 26: 2-2 Periodic Maintenance

    2-2 periodic maintenance steering stem bearing lubrication ................................................................................... 2-43 electrical system ................................................................................................................. 2-44 lights and swit...

  • Page 27: Periodic Maintenance 2-3

    Periodic maintenance 2-3 periodic maintenance chart the scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic inspection frequency whichever comes first * odom...

  • Page 28: 2-4 Periodic Maintenance

    2-4 periodic maintenance periodic maintenance chart frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) 1 6 12 18 24 30 36 item every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) see page final drive drive chain lubrication condition - inspect # every 600 km (400 mile) 2-3...

  • Page 29: Periodic Maintenance 2-5

    Periodic maintenance 2-5 periodic maintenance chart #: service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping. *: for higher odometer readings, repeat at the frequency interval established here..

  • Page 30: 2-6 Periodic Maintenance

    2-6 periodic maintenance periodic maintenance chart periodic replacement parts frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) 1 12 24 36 48 item every (0.6) (7.5) (15) (22.5) (30) see page air cleaner element # - replace every 18 000 km (11 250 mile) 2-52 fuel hose - re...

  • Page 31: Periodic Maintenance 2-7

    Periodic maintenance 2-7 torque and locking agent the following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “remarks” column mean: al: tighten the two clamp bolts alternately two times to ensure...

  • Page 32: 2-8 Periodic Maintenance

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks cylinder head bolts (m6) 12 1.2 106 in·lb s upper camshaft chain guide bolts 12 1.2 106 in·lb s plugs 19.6 2.0 14 l camshaft cap bolts 12 1.2 106 in·lb s cylinder head bolts (m10) (first) 20 2.0 15 s, mo cylind...

  • Page 33: Periodic Maintenance 2-9

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks crankshaft/transmission balancer shaft clamp bolt 9.8 1.0 87 in·lb balancer shaft lever bolt 25 2.5 18 l breather side plate bolt 5.9 0.60 52 in·lb l connecting rod big end nuts see the text ← ← mo breather pla...

  • Page 34: 2-10 Periodic Maintenance

    2-10 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks rear master cylinder mounting bolts 25 2.5 18 brake pedal bolt 8.8 0.90 78 in·lb l rear master cylinder push rod locknut 17 1.7 12 rear brake disc mounting bolts 27 2.8 20 l rear caliper mounting bolts 25 2.5 ...

  • Page 35: Periodic Maintenance 2-11

    Periodic maintenance 2-11 torque and locking agent torque fastener n·m kgf·m ft·lb remarks sidestand bolt 44 4.5 32 grab rail mounting bolts 25 2.5 18 ft·lb electrical system switch housing screws 3.5 0.36 31 in·lb oxygen sensor (equipped models) 44 4.5 32 front brake light switch screw 1.2 0.12 11 ...

  • Page 36: 2-12 Periodic Maintenance

    2-12 periodic maintenance torque and locking agent the table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cl...

  • Page 37: Periodic Maintenance 2-13

    Periodic maintenance 2-13 specifications item standard service limit fuel system (dfi) throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 1 100 ±50 r/min (rpm) – – – bypass screws (turn out) 2 1/2 (for reference) – – – throttle body vacuum 40.7 ±1.3 kpa (305 ±10 mmhg) at idle speed ...

  • Page 38: 2-14 Periodic Maintenance

    2-14 periodic maintenance specifications item standard service limit drive chain wear (20-link length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 319 mm (12.56 in.) standard chain: make enuma – – – type ek525zx – – – link 112 links – – – brakes brake fluid: grade dot4 – – – brake pad lining thickness: fro...

  • Page 39: Periodic Maintenance 2-15

    Periodic maintenance 2-15 special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 jack: 57001-1238 pilot screw adjuster, a: 57001-1239 oil filter wrench: 57001-1249 attachment jack: 57001-1252 spark plug wrench, hex 16: 57001-1262 vacuum gauge: 57001-1369 throttle sensor ...

  • Page 40: 2-16 Periodic Maintenance

    2-16 periodic maintenance special tools jack attachment: 57001-1608.

  • Page 41: Periodic Maintenance 2-17

    Periodic maintenance 2-17 periodic maintenance procedures fuel system (dfi) throttle control system inspection • check that the throttle grip [a] moves smoothly from full open to close, and the throttle closes quickly and com- pletely by the return spring in all steering positions. If the throttle g...

  • Page 42: 2-18 Periodic Maintenance

    2-18 periodic maintenance periodic maintenance procedures • plug the vacuum hose end [a]. • connect a vacuum gauge (special tool) and hoses [a] to the fittings on the throttle body. Special tool - vacuum gauge: 57001-1369 • connect a highly accurate tachometer [b] to one of the stick coil primary le...

  • Page 43: Periodic Maintenance 2-19

    Periodic maintenance 2-19 periodic maintenance procedures • start the engine and warm it up thoroughly. • check the idle speed, using a highly accurate tachometer [a]. Idle speed standard: 1 100 ±50 r/min (rpm) if the idle speed is out of the specified range, adjust it with the adjusting screw (see ...

  • Page 44: 2-20 Periodic Maintenance

    2-20 periodic maintenance periodic maintenance procedures if any one vacuum measurement is out of the specified range after left (#1, #2) and right (#2, #3) synchronization, adjust the bypass screws [a]. Special tool - pilot screw adjuster, a [b]: 57001-1239 • adjust the lower vacuum between #1 and ...

  • Page 45: Periodic Maintenance 2-21

    Periodic maintenance 2-21 periodic maintenance procedures • back out the same number of turns counted when first turned in. This is to set the screw to its original position. Note ○ a throttle body has different “turns out” of the bypass screw for each individual unit. On setting the bypass screw, u...

  • Page 46: 2-22 Periodic Maintenance

    2-22 periodic maintenance periodic maintenance procedures idle speed adjustment • start the engine and warm it up thoroughly. • turn the adjusting screw [a] until the idle speed is correct. ○ open and close the throttle a few times to make sure that the idle speed is within the specified range. Read...

  • Page 47: Periodic Maintenance 2-23

    Periodic maintenance 2-23 periodic maintenance procedures evaporative emission control system (cal and sea-b1 models) inspection • inspect the canister as follows. ○ remove the front seat (see front seat removal in the frame chapter). ○ remove the canister [a], and disconnect the hoses from the cani...

  • Page 48: 2-24 Periodic Maintenance

    2-24 periodic maintenance periodic maintenance procedures cooling system coolant level inspection note ○ check the level when the engine is cold (room or ambi- ent temperature). • check the coolant level in the reserve tank [a] with the motorcycle held perpendicular (do not use the side- stand.). If...

  • Page 49: Periodic Maintenance 2-25

    Periodic maintenance 2-25 periodic maintenance procedures • turn the crankshaft, align the #1, 4 mark on the timing rotor with the crankcase timing mark. Tdc mark [a] for #1, 4 pistons timing mark [b] (crankcase halves mating surface) • using the thickness gauge [a], measure the valve clear- ance be...

  • Page 50: 2-26 Periodic Maintenance

    2-26 periodic maintenance periodic maintenance procedures valve clearance adjustment • to change the valve clearance, remove the camshaft chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. Note ○ mark and record the locations of the valve lifters and sh...

  • Page 51: Periodic Maintenance 2-27

    Periodic maintenance 2-27 periodic maintenance procedures valve clearance adjustment chart intake valve 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where t...

  • Page 52: 2-28 Periodic Maintenance

    2-28 periodic maintenance periodic maintenance procedures valve clearance adjustment chart exhaust valve 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where ...

  • Page 53: Periodic Maintenance 2-29

    Periodic maintenance 2-29 periodic maintenance procedures notice be sure to remeasure the clearance after selecting a shim according to the table. If the clearance is out of the specified range, use the additional shim. ○ if there is no valve clearance, use a shim that is a few sizes smaller, and re...

  • Page 54: 2-30 Periodic Maintenance

    2-30 periodic maintenance periodic maintenance procedures clutch clutch operation inspection • pull the clutch lever just enough to take up the free play [a]. • measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow,...

  • Page 55: Periodic Maintenance 2-31

    Periodic maintenance 2-31 periodic maintenance procedures wheels/tires air pressure inspection • remove the air valve cap. • measure the tire air pressure with an air pressure gauge [a] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours...

  • Page 56: 2-32 Periodic Maintenance

    2-32 periodic maintenance periodic maintenance procedures tread depth standard: front 3.6 mm (0.14 in.) rear 5.3 mm (0.21 in.) service limit: front 1 mm (0.04 in.) (at, ch, de) 1.6 mm (0.06 in.) rear 2 mm (0.08 in.) up to 130 km/h (80 mph) 3 mm (0.12 in.) over 130 km/h (80 mph) warning some replacem...

  • Page 57: Periodic Maintenance 2-33

    Periodic maintenance 2-33 periodic maintenance procedures final drive drive chain lubrication condition inspection • if a special lubricant is not available, a heavy oil such as sae 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. • if the cha...

  • Page 58: 2-34 Periodic Maintenance

    2-34 periodic maintenance periodic maintenance procedures drive chain slack adjustment • loosen the left and right chain adjuster clamp bolts [a]. • using an allen wrench [b], turn the adjusters [c] forward or rearward until the drive chain has the correct amount of chain slack. • tighten: torque - ...

  • Page 59: Periodic Maintenance 2-35

    Periodic maintenance 2-35 periodic maintenance procedures drive chain wear inspection • remove the chain cover (see drive chain removal in the final drive chapter). • rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, repla...

  • Page 60: 2-36 Periodic Maintenance

    2-36 periodic maintenance periodic maintenance procedures brakes brake fluid leak (brake hose and pipe) inspection • for abs equipped models, remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • apply the brake lever or pedal and inspect the brake fluid leak from the brak...

  • Page 61: Periodic Maintenance 2-37

    Periodic maintenance 2-37 periodic maintenance procedures brake hose and pipe damage and installation condition inspection • for abs equipped models, remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • inspect the brake hoses and fittings for deterioration, cracks and si...

  • Page 62: 2-38 Periodic Maintenance

    2-38 periodic maintenance periodic maintenance procedures • check that the brake fluid level in the rear brake reservoir [a] is above the lower level line [b]. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [c]. ○ remove the stopper [d]. Warning mix...

  • Page 63: Periodic Maintenance 2-39

    Periodic maintenance 2-39 periodic maintenance procedures brake light switch operation inspection • turn on the ignition switch. • the brake light [a] should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm (0.39 in.). If it does not, adjust the brake light swi...

  • Page 64: 2-40 Periodic Maintenance

    2-40 periodic maintenance periodic maintenance procedures suspension front forks/rear shock absorber operation inspection • pump the forks down and up [a] 4 or 5 times, and inspect the smooth stroke. If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see front...

  • Page 65: Periodic Maintenance 2-41

    Periodic maintenance 2-41 periodic maintenance procedures tie-rod operation inspection • pump the seat down and up 4 or 5 times, and inspect the smooth stroke. If the tie-rod [a] does not smoothly stroke or noise is found, inspect the fasteners and tie-rod bearings (see rocker arm/tie-rod bearing, s...

  • Page 66: 2-42 Periodic Maintenance

    2-42 periodic maintenance periodic maintenance procedures • bend the claws [a] of the claw washer back. • remove the steering stem locknut [b] and claw washer [c]. • adjust the steering. Special tool - steering stem nut wrench [a]: 57001-1100 if the steering is too tight, loosen the stem nut a fract...

  • Page 67: Periodic Maintenance 2-43

    Periodic maintenance 2-43 periodic maintenance procedures steering stem bearing lubrication • remove the steering stem (see stem, stem bearing re- moval in the steering chapter). • using a high-flash point solvent, wash the upper and lower ball bearings in the cages, and wipe the upper and lower out...

  • Page 68: 2-44 Periodic Maintenance

    2-44 periodic maintenance periodic maintenance procedures electrical system lights and switches operation inspection first step • turn on the ignition switch. • the following lights should go on according to below table. City lights [a] goes on taillight [b] goes on license plate light [c] goes on m...

  • Page 69: Periodic Maintenance 2-45

    Periodic maintenance 2-45 periodic maintenance procedures third step • turn on the turn signal switch [a] (left or right position). • the left or right turn signal lights [b] (front and rear) ac- cording to the switch position should flash. • the turn signal indicator light (led) [c] in the meter un...

  • Page 70: 2-46 Periodic Maintenance

    2-46 periodic maintenance periodic maintenance procedures • set the dimmer switch to high beam position. • the low beam [a] and high beam [b] headlights should go on. • the high beam indicator light (led) [c] should go on. If the high beam headlight and/or high beam indicator light (led) does not go...

  • Page 71: Periodic Maintenance 2-47

    Periodic maintenance 2-47 periodic maintenance procedures note ○ for us model, the proper angle is 0.4 degrees below horizontal. This is 50 mm (2 in.) drop at 7.6 m (25 ft) measured from the center of the headlight with the motorcycle on its wheels and the rider seated. 50 mm (2 in.) [a] center of b...

  • Page 72: 2-48 Periodic Maintenance

    2-48 periodic maintenance periodic maintenance procedures if the sidestand switch operation does not work, inspect or replace the following item. Battery (see charging condition inspection in the elec- trical system chapter) main fuse 30 a (see fuse inspection in the electrical system chapter) ignit...

  • Page 73: Periodic Maintenance 2-49

    Periodic maintenance 2-49 periodic maintenance procedures others chassis parts lubrication • before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • lubricate the points listed below with indicated lubricant. Note ○ whenever the vehic...

  • Page 74: 2-50 Periodic Maintenance

    2-50 periodic maintenance periodic maintenance procedures • with the cable disconnected at 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], replace the cable..

  • Page 75: Periodic Maintenance 2-51

    Periodic maintenance 2-51 periodic maintenance procedures bolts, nuts and fasteners tightness inspection • check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. Note ○ for the engine fasteners, check the tightness of them wh...

  • Page 76: 2-52 Periodic Maintenance

    2-52 periodic maintenance periodic maintenance procedures replacement parts air cleaner element replacement note ○ in dusty areas, the element should be replaced more frequently than the recommended interval. Warning if dirt or dust is allowed to pass through into the throttle body assy, the throttl...

  • Page 77: Periodic Maintenance 2-53

    Periodic maintenance 2-53 periodic maintenance procedures • be sure to place a piece of cloth [a] around the fuel hose joint. • insert a thin blade screwdriver [b] into the slit [c] on the joint lock [d]. • turn the driver to disconnect the joint lock. • pull the fuel hose joint [a] out of the deliv...

  • Page 78: 2-54 Periodic Maintenance

    2-54 periodic maintenance periodic maintenance procedures coolant change warning coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it cool completely. Immediately wipe any spi...

  • Page 79: Periodic Maintenance 2-55

    Periodic maintenance 2-55 periodic maintenance procedures • when filling the coolant, choose a suitable mixture ratio by referring to the coolant manufacturer’s directions. Notice soft or distilled water must be used with the an- tifreeze in the cooling system. If hard water is used in the system, i...

  • Page 80: 2-56 Periodic Maintenance

    2-56 periodic maintenance periodic maintenance procedures radiator hose and o-ring replacement • drain the coolant (see coolant change). • remove: thermostat housing [a] (see thermostat removal in the cooling system chapter) water pump cover [b] (see water pump removal in the cooling system chapter)...

  • Page 81: Periodic Maintenance 2-57

    Periodic maintenance 2-57 periodic maintenance procedures engine oil change • situate the motorcycle so that it is vertical after warming up the engine. • remove the engine oil drain bolt [a] to drain the oil. ○ the oil in the oil filter can be drained by removing the filter (see oil filter replacem...

  • Page 82: 2-58 Periodic Maintenance

    2-58 periodic maintenance periodic maintenance procedures brake hose replacement • remove: upper fairing (see upper fairing removal in the frame chapter) brake hose fitting bolt [a] notice brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediat...

  • Page 83: Periodic Maintenance 2-59

    Periodic maintenance 2-59 periodic maintenance procedures • for abs equipped models; note the following. • remove: air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter) battery case (see battery case removal in the frame chapter) brake pipe joint nuts [a] bolts [b] c...

  • Page 84: 2-60 Periodic Maintenance

    2-60 periodic maintenance periodic maintenance procedures • level the brake fluid reservoir. • remove the reservoir cap. • remove the rubber cap from the bleed valve [a] on the caliper. • attach a clear plastic hose [b] to the bleed valve, and run the other end of the hose into a container. • fill t...

  • Page 85: Periodic Maintenance 2-61

    Periodic maintenance 2-61 periodic maintenance procedures master cylinder rubber parts replacement front master cylinder disassembly • remove the front master cylinder (see front master cylin- der removal in the brakes chapter). • remove the seal cover [a], circlip [b], connector [c] and o-ring [d]....

  • Page 86: 2-62 Periodic Maintenance

    2-62 periodic maintenance periodic maintenance procedures master cylinder assembly • before assembly, clean all parts including the master cylinder with brake fluid or alcohol. Notice except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake...

  • Page 87: Periodic Maintenance 2-63

    Periodic maintenance 2-63 periodic maintenance procedures • remove: pad spring o-ring [a] • using compressed air, remove the pistons. One way to remove the pistons is as follows. ○ install a rubber gasket [a] and a wooden board [b] more than 10 mm (0.4 in.) thick on the caliper half. ○ for inside ca...

  • Page 88: 2-64 Periodic Maintenance

    2-64 periodic maintenance periodic maintenance procedures front caliper assembly • clean the caliper parts except for the pads. Notice for cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • install the bleed valve and rubber cap. Torque - bleed valves: 7.8 n·m (0.8...

  • Page 89: Periodic Maintenance 2-65

    Periodic maintenance 2-65 periodic maintenance procedures • using a rear caliper mounting bolt [a], screw the thread hole for banjo bolt to remove the piston [b]. • remove the pad spring [c]. • remove: dust seal [a] and fluid seal [b] bleed valve [c] and rubber cap [d] dust boot [e] friction boot [f...

  • Page 90: 2-66 Periodic Maintenance

    2-66 periodic maintenance periodic maintenance procedures spark plug replacement • remove the stick coils (see stick coil removal in the electrical system chapter). • remove the spark plugs [a] using the plug wrench [b] vertically. Special tool - spark plug wrench, hex 16: 57001-1262 • replace the s...

  • Page 91: Fuel System (Dfi) 3-1

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

  • Page 92: 3-2 Fuel System (Dfi)

    3-2 fuel system (dfi) vehicle-down sensor removal ......................................................................................... 3-69 vehicle-down sensor installation ...................................................................................... 3-70 vehicle-down sensor input volt...

  • Page 93: Fuel System (Dfi) 3-3

    Fuel system (dfi) 3-3 ecu power supply inspection.......................................................................................... 3-107 dfi power source .................................................................................................................. 3-110 ecu fuse removal...

  • Page 94: 3-4 Fuel System (Dfi)

    3-4 fuel system (dfi) exploded view.

  • Page 95: Fuel System (Dfi) 3-5

    Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper air cleaner housing screws 1.1 0.11 9.7 in·lb 2 throttle body assy holder clamp bolts 2.9 0.30 26 in·lb 3 air cleaner duct clamp bolts 2.0 0.20 18 in·lb 4 delivery pipe assy mounting screws 3.4 0.35 30 in·lb 5. T...

  • Page 96: 3-6 Fuel System (Dfi)

    3-6 fuel system (dfi) exploded view.

  • Page 97: Fuel System (Dfi) 3-7

    Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oxygen sensor (equipped models) 44 4.5 32 2 intake air temperature sensor mounting screw 1.2 0.12 11 in·lb 3 water temperature sensor 30 3.0 22 4 exhaust butterfly valve actuator pulley bolt 5.0 0.51 44 in·lb 5 exhaust...

  • Page 98: 3-8 Fuel System (Dfi)

    3-8 fuel system (dfi) exploded view.

  • Page 99: Fuel System (Dfi) 3-9

    Fuel system (dfi) 3-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 fuel pump bolts 9.8 1.0 87 in·lb l 2. Other than cal and sea-b1 models 3. Cal and sea-b1 models 4. Separator 5. Canister 6. Blue hose (breather) 7. Green hose (purge) 8. Red hose (return) 9. White hose (vacuum) l: appl...

  • Page 100: 3-10 Fuel System (Dfi)

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

  • Page 101: Fuel System (Dfi) 3-11

    Fuel system (dfi) 3-11 dfi system 1. Ecu 2. Battery 12 v 8 ah 3. Air switching valve 4. Intake air pressure sensor #1 5. Intake air pressure sensor #2 6. Crankshaft sensor 7. Subthrottle valve actuator 8. Subthrottle sensor 9. Intake air temperature sensor 10. Main throttle sensor 11. Water temperat...

  • Page 102: 3-12 Fuel System (Dfi)

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

  • Page 103: Fuel System (Dfi) 3-13

    Fuel system (dfi) 3-13 dfi system part names 1. Ecu 2. Exhaust butterfly valve actuator 3. Water temperature sensor 4. Crankshaft sensor 5. Intake air pressure sensor #1 6. Frame ground 7. Meter ground 8. Intake air pressure sensor #2 9. Intake air temperature sensor 10. Speed sensor 11. Oxygen sens...

  • Page 104: 3-14 Fuel System (Dfi)

    3-14 fuel system (dfi) dfi system terminal numbers of ecu connectors terminal names 1. Subthrottle valve actuator: lg/r 2. Exhaust butterfly valve actuator (–): gy 3. Exhaust butterfly valve actuator (+): g/r 4. Fuel pump relay: br/y 5. Power supply to sensors: bl 6. Power supply to ecu (from ecu ma...

  • Page 105: Fuel System (Dfi) 3-15

    Fuel system (dfi) 3-15 dfi system 35. Starter button: bk/r 36. Fuel injector #1: bl/r 37. Engine stop switch: r 38. Stick coil #4: bk/o 39. Stick coil #3: bk/w 40. Stick coil #1: bk 41. External communication line (immobilizer system, equipped models/*kds): lg/bk 42. Unused 43. Neutral switch: lg 44...

  • Page 106: 3-16 Fuel System (Dfi)

    3-16 fuel system (dfi) dfi parts location main throttle sensor [a] subthrottle sensor [b] crankshaft sensor [a] oxygen sensor [b] (equipped models) ignition key (transponder, equipped models) [a] ignition switch [b] immobilizer antenna [c] (equipped models) warning indicator light (led) [d] stick co...

  • Page 107: Fuel System (Dfi) 3-17

    Fuel system (dfi) 3-17 dfi parts location immobilizer amplifier [a] (equipped models) intake air temperature sensor [a] frame ground [b] exhaust butterfly valve actuator [a] battery 12 v 8 ah [b] vehicle-down sensor [c] fi fuse 15 a [d] relay box (ecu main relay, radiator fan relay, fuel pump relay)...

  • Page 108: 3-18 Fuel System (Dfi)

    3-18 fuel system (dfi) specifications item standard digital fuel injection system idle speed 1 100 ±50 r/min (rpm) throttle body assy: throttle valve dual throttle bore 38 mm (1.42 in.) throttle body vacuum 40.7 ±1.3 kpa (305 ±10 mmhg) bypass screws (turn out) 2 1/2 (for reference) ecu: make denso t...

  • Page 109: Fuel System (Dfi) 3-19

    Fuel system (dfi) 3-19 specifications item standard subthrottle sensor: input voltage dc 4.75 ∼ 5.25 v output voltage dc 1.08 ∼ 1.12 v at subthrottle valve full close position dc 4.2 ∼ 4.4 v at subthrottle valve full open position (for reference) resistance 4 ∼ 6 k Ω exhaust butterfly valve actuator...

  • Page 110: 3-20 Fuel System (Dfi)

    3-20 fuel system (dfi) special tools and sealant oil pressure gauge, 5 kgf/cm²: 57001-125 carburetor drain plug wrench, hex 3: 57001-1269 fork oil level gauge: 57001-1290 vacuum gauge: 57001-1369 hand tester: 57001-1394 throttle sensor setting adapter #1: 57001-1400 peak voltage adapter: 57001-1415 ...

  • Page 111: Fuel System (Dfi) 3-21

    Fuel system (dfi) 3-21 special tools and sealant fuel hose: 57001-1607 measuring adapter: 57001-1700 liquid gasket, tb1211: 56019-120

  • Page 112: 3-22 Fuel System (Dfi)

    3-22 fuel system (dfi) dfi servicing precautions dfi servicing precautions there are a number of important precautions that should be followed servicing the dfi system. ○ this dfi system is designed to be used with a 12 v sealed battery as its power source. Do not use any other battery except for a ...

  • Page 113: Fuel System (Dfi) 3-23

    Fuel system (dfi) 3-23 dfi servicing precautions ○ if the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see fuel tank removal) and check the fuel hose [a]. Replace the fuel hose if any fraying, cracks o...

  • Page 114: 3-24 Fuel System (Dfi)

    3-24 fuel system (dfi) troubleshooting the dfi system the warning indicator light (led) [a] is used for the fi indicator, immobilizer indicator (equipped models) and oil pressure warning indicator. Outline when a problem occurs with dfi system, the warning in- dicator light (led) [a] and fi warning ...

  • Page 115: Fuel System (Dfi) 3-25

    Fuel system (dfi) 3-25 troubleshooting the dfi system when the service code [a] is displayed, for first ask the rider about the conditions [b] of trouble, and then start to determine the cause [c] of problem. As a pre-diagnosis inspection, check the ecu for ground and power supply, the fuel line for...

  • Page 116: 3-26 Fuel System (Dfi)

    3-26 fuel system (dfi) 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 117: Fuel System (Dfi) 3-27

    Fuel system (dfi) 3-27 troubleshooting the dfi system • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. • check the wiring for continuity. ○ use the...

  • Page 118: 3-28 Fuel System (Dfi)

    3-28 fuel system (dfi) troubleshooting the dfi system dfi diagnosis flow chart inquiries to rider ○ each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ try to find out exactly what problem occurred under exactly what condi...

  • Page 119: Fuel System (Dfi) 3-29

    Fuel system (dfi) 3-29 troubleshooting the dfi system sample diagnosis sheet rider name: registration no. (license plate no.): year of initial registration: model: engine no.: frame no.: date problem occurred: mileage: environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ al...

  • Page 120: 3-30 Fuel System (Dfi)

    3-30 fuel system (dfi) troubleshooting the dfi system □ very low idle speed, □ very high idle speed, □ rough idle speed. □ battery voltage is low (charge the battery). □ spark plug loose (tighten it). □ spark plug dirty, broken, or gap maladjusted (remedy it). □ backfiring. □ afterfiring. □ hesitati...

  • Page 121: Fuel System (Dfi) 3-31

    Fuel system (dfi) 3-31 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 122: 3-32 Fuel System (Dfi)

    3-32 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) fuel pressure regulator trouble inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged inspect and repair (see chapter 3). Intake air pressure sensor #1 trouble inspect (see ...

  • Page 123: Fuel System (Dfi) 3-33

    Fuel system (dfi) 3-33 dfi system troubleshooting guide symptoms or possible causes actions (chapter) subthrottle sensor trouble inspect (see chapter 3). Subthrottle valve actuator trouble inspect (see chapter 3). Intake air pressure sensor #1 trouble inspect (see chapter 3). Intake air pressure sen...

  • Page 124: 3-34 Fuel System (Dfi)

    3-34 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) other: intermittent any dfi fault and its recovery check that dfi connectors are clean and tight, and examine leads for signs of burning or fraying (see chapter 3). Poor running or no power at high ...

  • Page 125: Fuel System (Dfi) 3-35

    Fuel system (dfi) 3-35 dfi system troubleshooting guide symptoms or possible causes actions (chapter) intake air temperature sensor trouble inspect (see chapter 3). Miscellaneous: subthrottle sensor trouble inspect (see chapter 3). Subthrottle valve actuator trouble inspect (see chapter 3). Speed se...

  • Page 126: 3-36 Fuel System (Dfi)

    3-36 fuel system (dfi) self-diagnosis the warning indicator light (led) [a] is used for the fi indicator, immobilizer indicator (equipped models) and oil pressure warning indicator. Self-diagnosis outline the self-diagnosis system has two modes and can be switched to another mode by operating the me...

  • Page 127: Fuel System (Dfi) 3-37

    Fuel system (dfi) 3-37 self-diagnosis dealer mode the lcd (liquid crystal display) display the service code(s) [a] to show the problem(s) which the dfi system, ignition system and immobilizer system has at the moment of diagnosis. Self-diagnosis procedures ○ when a problem occurs with the dfi system...

  • Page 128: 3-38 Fuel System (Dfi)

    3-38 fuel system (dfi) self-diagnosis • turn the ignition switch on. • push the mode button [a] to display the odometer. • push the mode button [a] for more than two seconds. • the service code [b] is displayed on the lcd by the num- ber of two digits. • any of the following procedures ends self-dia...

  • Page 129: Fuel System (Dfi) 3-39

    Fuel system (dfi) 3-39 self-diagnosis self-diagnosis flow chart.

  • Page 130: 3-40 Fuel System (Dfi)

    3-40 fuel system (dfi) self-diagnosis service code reading ○ the service code(s) is displayed on the lcd by the number of two digits. ○ when there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical or...

  • Page 131: Fuel System (Dfi) 3-41

    Fuel system (dfi) 3-41 self-diagnosis service code erasing ○ when repair has been done, fi and/or immobilizer warning symbols go off and service code is not displayed. But the service codes stored in memory of the ecu are not erased to preserve the problem history. In this model, the problem history...

  • Page 132: 3-42 Fuel System (Dfi)

    3-42 fuel system (dfi) self-diagnosis backups ○ the ecu takes the following measures to prevent engine damage when the dfi, ignition or immo- bilizer system parts have troubles. Service codes parts output signal usable range or criteria backups by ecu 11 main throttle sensor output voltage 0.2 ∼ 4.8...

  • Page 133: Fuel System (Dfi) 3-43

    Fuel system (dfi) 3-43 self-diagnosis service codes parts output signal usable range or criteria backups by ecu 34 exhaust butterfly valve actuator sensor output voltage 0.1 ∼ 4.8 v if the exhaust butterfly valve sensor system fails (the output voltage is out of the usable range, wiring short or ope...

  • Page 134: 3-44 Fuel System (Dfi)

    3-44 fuel system (dfi) self-diagnosis service codes parts output signal usable range or criteria backups by ecu 67 oxygen sensor heater (equipped models) the oxygen sensor heater raise temperature of the sensor for its earlier activation. If the oxygen sensor heater fails (wiring short or open), the...

  • Page 135: Fuel System (Dfi) 3-45

    Fuel system (dfi) 3-45 main throttle sensor (service code 11) the main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ecu senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm,...

  • Page 136: 3-46 Fuel System (Dfi)

    3-46 fuel system (dfi) main throttle sensor (service code 11) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main harness connectors. ○ disconnect the ecu and sensor connectors. Wiring inspection ecu connector [a] ←→ main throttle sensor connector [...

  • Page 137: Fuel System (Dfi) 3-47

    Fuel system (dfi) 3-47 main throttle sensor (service code 11) • turn the ignition switch off. • measure the output voltage with the engine stopped and with the connector joined. • turn the ignition switch on. Output voltage standard: dc 1.02 ∼ 1.06 v at idle throttle opening dc 4.22 ∼ 4.42 v at full...

  • Page 138: 3-48 Fuel System (Dfi)

    3-48 fuel system (dfi) main throttle sensor (service code 11) main throttle sensor resistance inspection • turn the ignition switch off. • disconnect the main throttle sensor connector. ○ disconnect the main throttle sensor connector and con- nect the harness adapter [a] to the sensor connector only...

  • Page 139: Fuel System (Dfi) 3-49

    Fuel system (dfi) 3-49 intake air pressure sensor #1 (service code 12) intake air pressure sensor #1 removal notice never drop the intake air pressure sensor #1 espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove: air cleaner housing (see air cleaner housing removal) i...

  • Page 140: 3-50 Fuel System (Dfi)

    3-50 fuel system (dfi) intake air pressure sensor #1 (service code 12) intake air pressure sensor #1 input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the air cleaner housing (see air cleaner housing removal). • disconnect the intake air p...

  • Page 141: Fuel System (Dfi) 3-51

    Fuel system (dfi) 3-51 intake air pressure sensor #1 (service code 12) intake air pressure sensor #1 output voltage inspection • measure the output voltage at the intake air pressure sen- sor #1 in the same way as input voltage inspection, note the following. ○ disconnect the intake air pressure sen...

  • Page 142: 3-52 Fuel System (Dfi)

    3-52 fuel system (dfi) intake air pressure sensor #1 (service code 12) if the wiring is good, check the sensor for various vacuum. • remove the intake air pressure sensor #1 [a] and discon- nect the vacuum hose from the sensor. • connect an auxiliary hose [b] to the intake air pressure sensor #1. • ...

  • Page 143: Fuel System (Dfi) 3-53

    Fuel system (dfi) 3-53 intake air pressure sensor #1 (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 pressur...

  • Page 144: 3-54 Fuel System (Dfi)

    3-54 fuel system (dfi) intake air pressure sensor #1 (service code 12) intake air pressure sensor #1 circuit 1. Ecu 2. Intake air pressure sensor #1.

  • Page 145: Fuel System (Dfi) 3-55

    Fuel system (dfi) 3-55 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 fuel tank (see fuel tank removal). • ...

  • Page 146: 3-56 Fuel System (Dfi)

    3-56 fuel system (dfi) intake air temperature sensor (service code 13) • turn the ignition switch off. If the reading is within the standard, check the ecu for its ground, and power supply (see ecu power supply inspection). If the ground and power supply are good, replace the ecu (see ecu removal/in...

  • Page 147: Fuel System (Dfi) 3-57

    Fuel system (dfi) 3-57 intake air temperature sensor (service code 13) intake air temperature sensor circuit 1. Ecu 2. Intake air temperature sensor.

  • Page 148: 3-58 Fuel System (Dfi)

    3-58 fuel system (dfi) water temperature sensor (service code 14) water temperature sensor removal/installation notice never drop the water temperature sensor especially on a hard surface. Such a shock to the sensor can damage it. • drain the coolant (see coolant change in the periodic maintenance c...

  • Page 149: Fuel System (Dfi) 3-59

    Fuel system (dfi) 3-59 water temperature sensor (service code 14) water temperature sensor output voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the left lower fairing (see lower fairing removal in the frame chapter) • disconnect the water te...

  • Page 150: 3-60 Fuel System (Dfi)

    3-60 fuel system (dfi) water temperature sensor (service code 14) sub harness connector [a] ←→ sub harness connector [b] w/r lead [c] w/bl lead [d] if the wiring is good, check the water temperature sensor resistance (see water temperature sensor resistance inspection). Water temperature sensor resi...

  • Page 151: Fuel System (Dfi) 3-61

    Fuel system (dfi) 3-61 intake air pressure sensor #2 (service code 16) intake air pressure sensor #2 removal notice never drop the intake air pressure sensor #2 espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove the air cleaner housing (see air cleaner housing removal...

  • Page 152: 3-62 Fuel System (Dfi)

    3-62 fuel system (dfi) intake air pressure sensor #2 (service code 16) intake air pressure sensor #2 input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the air cleaner housing (see air cleaner housing removal). • disconnect the intake air p...

  • Page 153: Fuel System (Dfi) 3-63

    Fuel system (dfi) 3-63 intake air pressure sensor #2 (service code 16) intake air pressure sensor #2 output voltage inspection • measure the output voltage at the intake air pressure sen- sor #2 in the same way as input voltage inspection, note the following. ○ disconnect the intake air pressure sen...

  • Page 154: 3-64 Fuel System (Dfi)

    3-64 fuel system (dfi) intake air pressure sensor #2 (service code 16) intake air pressure sensor #2 circuit 1. Ecu 2. Intake air pressure sensor #2.

  • Page 155: Fuel System (Dfi) 3-65

    Fuel system (dfi) 3-65 crankshaft sensor (service code 21) the crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no sig- nals. Crankshaft sensor removal/installation • refer to the crankshaft sensor removal/installation in the electrical system chapter...

  • Page 156: 3-66 Fuel System (Dfi)

    3-66 fuel system (dfi) speed sensor (service code 24, 25) speed sensor removal/installation • refer to the speed sensor removal/installation in the electrical system chapter. Speed sensor inspection • refer to the speed sensor inspection in the electrical system chapter. Speed sensor input voltage i...

  • Page 157: Fuel System (Dfi) 3-67

    Fuel system (dfi) 3-67 speed sensor (service code 24, 25) speed sensor output voltage inspection • using the stand, raise the rear wheel off the ground. • measure the output voltage at the speed sensor in the same way as input voltage inspection, note the following. ○ disconnect the speed sensor con...

  • Page 158: 3-68 Fuel System (Dfi)

    3-68 fuel system (dfi) speed sensor (service code 24, 25) speed sensor circuit 1. Ecu 2. Speed sensor 3. Meter unit 4. Meter ground.

  • Page 159: Fuel System (Dfi) 3-69

    Fuel system (dfi) 3-69 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 160: 3-70 Fuel System (Dfi)

    3-70 fuel system (dfi) vehicle-down sensor (service code 31) vehicle-down sensor installation • be sure to install the rubber dampers [a] and collars [b] on the battery case. • the up mark [a] of the sensor should face upward. Warning incorrect installation of the vehicle-down sensor could cause sud...

  • Page 161: Fuel System (Dfi) 3-71

    Fuel system (dfi) 3-71 vehicle-down sensor (service code 31) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main harness connectors. ○ disconnect the ecu and sensor connections. Wiring inspection ecu connector [a] ←→ vehicle-down sensor connector [b...

  • Page 162: 3-72 Fuel System (Dfi)

    3-72 fuel system (dfi) vehicle-down sensor (service code 31) • hold the sensor vertically. • measure the output voltage with the engine stopped and with the connector joined. • turn the ignition switch on. • tilt the sensor 60 ∼ 70° or more [a] right or left, then hold the sensor almost vertical wit...

  • Page 163: Fuel System (Dfi) 3-73

    Fuel system (dfi) 3-73 vehicle-down sensor (service code 31) vehicle-down sensor circuit 1. Ecu 2. Vehicle-down sensor.

  • Page 164: 3-74 Fuel System (Dfi)

    3-74 fuel system (dfi) subthrottle sensor (service code 32) the subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ecu senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and...

  • Page 165: Fuel System (Dfi) 3-75

    Fuel system (dfi) 3-75 subthrottle sensor (service code 32) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main harness connectors. ○ disconnect the ecu and sensor connectors. Wiring inspection ecu connector [a] ←→ subthrottle sensor connector [b] b...

  • Page 166: 3-76 Fuel System (Dfi)

    3-76 fuel system (dfi) subthrottle sensor (service code 32) • measure the output voltage with the engine stopped with the connector joined. • remove the left lower side fairing (see left lower side fairing removal in the frame chapter). • turn the ignition switch on. • measure the output voltage whe...

  • Page 167: Fuel System (Dfi) 3-77

    Fuel system (dfi) 3-77 subthrottle sensor (service code 32) subthrottle sensor resistance inspection • turn the ignition switch off. • disconnect the subthrottle sensor connector. ○ disconnect the subthrottle sensor connector and connect the harness adapter [a] to the sensor connector only. Special ...

  • Page 168: 3-78 Fuel System (Dfi)

    3-78 fuel system (dfi) oxygen sensor - not activated (service code 33, equipped models) oxygen sensor removal/installation • refer to the oxygen sensor removal/installation in the electrical system chapter. Oxygen sensor inspection • warm up the engine thoroughly until the radiator fan starts. • tur...

  • Page 169: Fuel System (Dfi) 3-79

    Fuel system (dfi) 3-79 oxygen sensor - not activated (service code 33, equipped models) • install the suitable plugs [a] on the fitting of the air suction valve covers, and shut off the secondary air. • connect the stick coil connectors. • install the air cleaner housing temporarily (see air cleaner...

  • Page 170: 3-80 Fuel System (Dfi)

    3-80 fuel system (dfi) oxygen sensor - not activated (service code 33, equipped models) oxygen sensor circuit 1. Ecu 2. Meter ground 3. Frame ground 4. Oxygen sensor 5. Ignition switch 6. Relay box 7. Ecu main relay 8. Starter relay 9. Fi fuse 15 a 10. Main fuse 30 a 11. Battery 12 v 8 ah 12. Water-...

  • Page 171: Fuel System (Dfi) 3-81

    Fuel system (dfi) 3-81 exhaust butterfly valve actuator sensor (service code 34) exhaust butterfly valve actuator sensor removal/installation the exhaust butterfly valve actuator sensor is built in the exhaust butterfly valve actuator. So, the sensor itself can not be removed. Remove the exhaust but...

  • Page 172: 3-82 Fuel System (Dfi)

    3-82 fuel system (dfi) exhaust butterfly valve actuator sensor (service code 34) exhaust butterfly valve actuator sensor output voltage inspection note ○ before this inspection, confirm the pulley [a] is original position (see exhaust butterfly valve actuator installa- tion). • disconnect: 2 pins co...

  • Page 173: Fuel System (Dfi) 3-83

    Fuel system (dfi) 3-83 exhaust butterfly valve actuator sensor (service code 34) exhaust butterfly valve actuator sensor resistance inspection • turn the ignition switch off. • disconnect the exhaust butterfly valve actuator sensor connector (3 pins connector) [a]. • connect a digital meter [b] to t...

  • Page 174: 3-84 Fuel System (Dfi)

    3-84 fuel system (dfi) immobilizer amplifier (service code 35, equipped models) antenna resistance inspection • turn the ignition switch off. • remove the left lower fairing (see lower fairing removal in the frame chapter). • remove the band [a]. • disconnect the antenna lead connector [a]. • measur...

  • Page 175: Fuel System (Dfi) 3-85

    Fuel system (dfi) 3-85 immobilizer amplifier (service code 35, equipped models) amplifier input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the left lower fairing (see lower fairing removal in the frame chapter). ○ do not disconnect the co...

  • Page 176: 3-86 Fuel System (Dfi)

    3-86 fuel system (dfi) blank key detection (service code 36, equipped models) • this code appears in the following conditions. ○ the transponder [a] in the ignition key is malfunction. ○ when the spare ignition key of unregistration is used. ○ when the ignition key is registered in the registered ec...

  • Page 177: Fuel System (Dfi) 3-87

    Fuel system (dfi) 3-87 ecu communication error (service code 39) ecu communication line inspection ○ when the data is not sent from the ecu to the meter unit for more than about 10 seconds, the service code 39 is displayed. ○ the service code 39 is detected with meter unit. • remove the ecu and mete...

  • Page 178: 3-88 Fuel System (Dfi)

    3-88 fuel system (dfi) stick coils #1, #2, #3, #4 (service code 51, 52, 53, 54) stick coil #1: service code 51 stick coil #2: service code 52 stick coil #3: service code 53 stick coil #4: service code 54 stick coil removal/installation • refer to the stick coil removal/installation in the electri- c...

  • Page 179: Fuel System (Dfi) 3-89

    Fuel system (dfi) 3-89 stick coils #1, #2, #3, #4 (service code 51, 52, 53, 54) • turn the ignition switch off. If the input voltage is out of the standard, check the wiring for continuity (see wiring diagram in this section). If the wiring is good, check the ecu for its ground and power supply (see...

  • Page 180: 3-90 Fuel System (Dfi)

    3-90 fuel system (dfi) radiator fan relay (service code 56) radiator fan relay removal/installation ○ the radiator fan relay is built in the relay box [a]. • refer to the relay box removal in the electrical system chapter. Radiator fan relay inspection • refer to the relay circuit inspection in the ...

  • Page 181: Fuel System (Dfi) 3-91

    Fuel system (dfi) 3-91 subthrottle valve actuator (service code 62) subthrottle valve actuator removal notice do not remove the subthrottle valve actuator [a] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy especially on a hard surface. Such a shoc...

  • Page 182: 3-92 Fuel System (Dfi)

    3-92 fuel system (dfi) subthrottle valve actuator (service code 62) subthrottle valve actuator input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • disconnect the subthrottle valve actuator connector and connect the harness adapter [a] between these...

  • Page 183: Fuel System (Dfi) 3-93

    Fuel system (dfi) 3-93 subthrottle valve actuator (service code 62) subthrottle valve actuator circuit 1. Ecu 2. Subthrottle valve actuator.

  • Page 184: 3-94 Fuel System (Dfi)

    3-94 fuel system (dfi) exhaust butterfly valve actuator (service code 63) exhaust butterfly valve actuator removal notice never drop the exhaust butterfly valve actuator es- pecially on a hard surface. Such a shock to the ac- tuator can damage it. • remove: front seat (see front seat removal in the ...

  • Page 185: Fuel System (Dfi) 3-95

    Fuel system (dfi) 3-95 exhaust butterfly valve actuator (service code 63) • after tightening the pulley bolt, confirm whether pulley [a] is an angle shown in the figure. 41.7° ±7° [b] ○ this position is original position of the pulley. Note ○ correct the position electrically after confirming the us...

  • Page 186: 3-96 Fuel System (Dfi)

    3-96 fuel system (dfi) exhaust butterfly valve actuator (service code 63) • be sure to install the washers [a] on the exhaust butterfly valve actuator [b]. • tighten: torque - exhaust butterfly valve actuator mounting screws [c]: 1.2 n ·m (0.12 kgf ·m, 11 in·lb) • install the close cable first and t...

  • Page 187: Fuel System (Dfi) 3-97

    Fuel system (dfi) 3-97 exhaust butterfly valve actuator (service code 63) if the reading is in specification, remove the ecu and check the wiring for continuity between main harness con- nectors. ○ disconnect the ecu and actuator connectors. Wiring inspection ecu connector [a] ←→ exhaust butterfly v...

  • Page 188: 3-98 Fuel System (Dfi)

    3-98 fuel system (dfi) air switching valve (service code 64) air switching valve removal/installation • refer to the air switching valve removal/installation in the engine top end chapter. Air switching valve inspection • refer to the air switching valve unit test in the electrical system chapter. I...

  • Page 189: Fuel System (Dfi) 3-99

    Fuel system (dfi) 3-99 oxygen sensor heater (service code 67, equipped models) oxygen sensor heater removal/installation the oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see oxygen sensor removal (equipped mod- els) in the ...

  • Page 190: 3-100 Fuel System (Dfi)

    3-100 fuel system (dfi) oxygen sensor heater (service code 67, equipped models) oxygen sensor heater power source voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • disconnect the oxygen sensor lead connector and con- nect the harness adapter [a] betwee...

  • Page 191: Fuel System (Dfi) 3-101

    Fuel system (dfi) 3-101 oxygen sensor heater (service code 67, equipped models) oxygen sensor circuit 1. Ecu 2. Meter ground 3. Frame ground 4. Oxygen sensor 5. Ignition switch 6. Relay box 7. Ecu main relay 8. Starter relay 9. Fi fuse 15 a 10. Main fuse 30 a 11. Battery 12 v 8 ah 12. Water-proof jo...

  • Page 192: 3-102 Fuel System (Dfi)

    3-102 fuel system (dfi) oxygen sensor - incorrect output voltage (service code 94, equipped models) oxygen sensor removal/installation • refer to the oxygen sensor removal/installation in the electrical system chapter. Oxygen sensor inspection • warm up the engine thoroughly until the radiator fan s...

  • Page 193: Fuel System (Dfi) 3-103

    Fuel system (dfi) 3-103 oxygen sensor - incorrect output voltage (service code 94, equipped models) • install the suitable plugs [a] on the fitting of the air suction valve covers, and shut off the secondary air. • connect the stick coil connectors. • install the air cleaner housing temporarily (see...

  • Page 194: 3-104 Fuel System (Dfi)

    3-104 fuel system (dfi) oxygen sensor - incorrect output voltage (service code 94, equipped models) oxygen sensor circuit 1. Ecu 2. Meter ground 3. Frame ground 4. Oxygen sensor 5. Ignition switch 6. Relay box 7. Ecu main relay 8. Starter relay 9. Fi fuse 15 a 10. Main fuse 30 a 11. Battery 12 v 8 a...

  • Page 195: Fuel System (Dfi) 3-105

    Fuel system (dfi) 3-105 warning indicator light (led) light (led) inspection ○ the warning indicator light (led) [a] is used for the fi indicator, immobilizer indicator (immobilizer models) and oil pressure warning indicator. ○ in this model, the warning indicator light (led) (fi/immo- bilizer) blin...

  • Page 196: 3-106 Fuel System (Dfi)

    3-106 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 197: Fuel System (Dfi) 3-107

    Fuel system (dfi) 3-107 ecu ecu power supply inspection • visually inspect the ecu connectors. If the connector is clogged with mud or dust, blow it off with compressed air. • remove the ecu (see ecu removal). • visually inspect the terminals [a] of the ecu connectors. If the terminals of the main h...

  • Page 198: 3-108 Fuel System (Dfi)

    3-108 fuel system (dfi) ecu if the wiring is good, check the power source voltage of the ecu. Note ○ be sure the battery is fully charged. • connect the ecu and relay box connectors. • connect a digital meter [a] to the connectors [b] with the needle adapter set. Special tool - needle adapter set: 5...

  • Page 199: Fuel System (Dfi) 3-109

    Fuel system (dfi) 3-109 ecu ecu power source circuit 1. Ecu 2. Meter ground 3. Frame ground 4. Ignition switch 5. Relay box 6. Ecu main relay 7. Starter relay 8. Fi fuse 15 a 9. Main fuse 30 a 10. Battery 12 v 8 ah 11. Water-proof joint c.

  • Page 200: 3-110 Fuel System (Dfi)

    3-110 fuel system (dfi) dfi power source ecu fuse removal • refer to the 15 a fi fuse removal in the electrical sys- tem chapter. Ecu fuse installation if a fuse fails during operation, inspect the dfi system to determine the cause, and then replace it with a new fuse of proper amperage. • refer to ...

  • Page 201: Fuel System (Dfi) 3-111

    Fuel system (dfi) 3-111 fuel line fuel pressure inspection note ○ be sure the battery is fully charged. • remove: fuel hose (see fuel hose replacement in the periodic maintenance chapter) • support the fuel tank with a suitable bar (see fuel tank removal in the fuel system (dfi) chapter). ○ be sure ...

  • Page 202: 3-112 Fuel System (Dfi)

    3-112 fuel system (dfi) fuel line • start the engine, and let it idle. • measure the fuel pressure with the engine idling. Fuel pressure (with engine idling) standard: 294 kpa (3.0 kgf/cm², 43 psi) note ○ the gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum in...

  • Page 203: Fuel System (Dfi) 3-113

    Fuel system (dfi) 3-113 fuel line • open the fuel tank cap [a] to lower the pressure in the tank. • remove the fuel hose from the fuel pump (see fuel tank removal). ○ be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump. Warning fuel is flammable and explosive under certain...

  • Page 204: 3-114 Fuel System (Dfi)

    3-114 fuel system (dfi) fuel pump fuel pump removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a...

  • Page 205: Fuel System (Dfi) 3-115

    Fuel system (dfi) 3-115 fuel pump fuel pump installation • remove dirt or dust from the fuel pump [a] by lightly ap- plying compressed air. • replace the fuel pump gasket with a new one. • check that the fuel pump terminal [a] and band [b] are in place. • apply a non-permanent locking agent to the t...

  • Page 206: 3-116 Fuel System (Dfi)

    3-116 fuel system (dfi) fuel pump fuel pump operating voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the front seat (see front seat removal in the frame chapter). • disconnect the fuel pump lead connector and connect the harness adapter [a] b...

  • Page 207: Fuel System (Dfi) 3-117

    Fuel system (dfi) 3-117 fuel pump pump screen, fuel filter cleaning ○ the pump screen [a] and fuel filter [b] are built into the pump and can not be cleaned or checked. If the pump screen or fuel filter is suspected of clogging or being damaged, replace it with the fuel pump as a set. Fuel pump rela...

  • Page 208: 3-118 Fuel System (Dfi)

    3-118 fuel system (dfi) fuel pump fuel pump circuit 1. Ecu 2. Meter ground 3. Frame ground 4. Engine stop switch 5. Fuel pump/fuel level sensor 6. Fuse box 2 7. Ignition fuse 15 a 8. Ignition switch 9. Meter unit 10. Relay box 11. Ecu main relay 12. Fuel pump relay 13. Starter relay 14. Fi fuse 15 a...

  • Page 209: Fuel System (Dfi) 3-119

    Fuel system (dfi) 3-119 fuel injectors fuel injector removal/installation • refer to the throttle body assy disassembly/assembly. Fuel injector audible inspection note ○ be sure the battery is fully charged. • remove the lower side fairing (see lower side fairing removal in the frame chapter). • sta...

  • Page 210: 3-120 Fuel System (Dfi)

    3-120 fuel system (dfi) fuel injectors fuel injector power source voltage inspection note ○ be sure the battery is fully charged. • remove the air cleaner housing (see air cleaner housing removal). • turn the ignition switch off. • disconnect the injector connector and connect the har- ness adapter ...

  • Page 211: Fuel System (Dfi) 3-121

    Fuel system (dfi) 3-121 fuel injectors fuel injector output voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the ecu (see ecu removal). ○ do not disconnect the ecu connector. ○ connect the relay box connectors. • connect a digital meter [a] to ...

  • Page 212: 3-122 Fuel System (Dfi)

    3-122 fuel system (dfi) fuel injectors fuel injector fuel line inspection • remove: fuel tank (see fuel tank removal) fuel hose (see fuel hose replacement in the periodic maintenance chapter) ○ be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of th...

  • Page 213: Fuel System (Dfi) 3-123

    Fuel system (dfi) 3-123 fuel injectors fuel injector circuit 1. Ecu 2. Meter ground 3. Frame ground 4. Fuel injectors 5. Engine stop switch 6. Fuse box 2 7. Ignition fuse 15 a 8. Ignition switch 9. Relay box 10. Ecu main relay 11. Fuel pump relay 12. Starter relay 13. Fi fuse 15 a 14. Main fuse 30 a...

  • Page 214: 3-124 Fuel System (Dfi)

    3-124 fuel system (dfi) throttle grip and cables free play inspection • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Free play adjustment • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Cable installation • install th...

  • Page 215: Fuel System (Dfi) 3-125

    Fuel system (dfi) 3-125 throttle body assy idle speed inspection/adjustment • refer to the idle speed inspection/adjustment in the pe- riodic maintenance chapter. Synchronization inspection/adjustment • refer to the engine vacuum synchronization inspection in the periodic maintenance chapter. Thrott...

  • Page 216: 3-126 Fuel System (Dfi)

    3-126 fuel system (dfi) throttle body assy • loosen the locknuts [a]. • turn the adjusters [b] to give the more free play. • remove: lower side fairing (see lower side fairing removal in the frame chapter) throttle cable holder clamp [a] throttle cable lower ends [b] • loosen the throttle body assy ...

  • Page 217: Fuel System (Dfi) 3-127

    Fuel system (dfi) 3-127 throttle body assy • remove the throttle body assy [a] from the throttle body assy holders. • disconnect the injector connectors [b]. • remove the clamps [c]. • after removing the throttle body assy, stuff pieces of lint -free, clean cloth into the throttle body assy holders....

  • Page 218: 3-128 Fuel System (Dfi)

    3-128 fuel system (dfi) throttle body assy throttle body assy disassembly 1. Subthrottle valve actuator 2. Subthrottle sensor 3. Main throttle sensor 4. Throttle body assy 5. Fuel injectors 6. Delivery pipe assy notice do not remove, disassemble or adjust the main throttle sensor, subthrottle sensor...

  • Page 219: Fuel System (Dfi) 3-129

    Fuel system (dfi) 3-129 throttle body assy • pull out the fuel injectors [a] from the delivery pipe assy [b]. Note ○ do not damage the insertion portions of the injectors when they are pulled out from the delivery pipe assy. Notice never drop the primary fuel injector, especially on a hard surface. ...

  • Page 220: 3-130 Fuel System (Dfi)

    3-130 fuel system (dfi) air cleaner air cleaner element removal/installation • refer to the air cleaner element replacement in the pe- riodic maintenance chapter. Air cleaner element inspection • remove the air cleaner element (see air cleaner element replacement in the periodic maintenance chapter)...

  • Page 221: Fuel System (Dfi) 3-131

    Fuel system (dfi) 3-131 air cleaner • loosen the both air cleaner duct clamp bolts [a]. • lift up the air cleaner housing, and remove the air switch- ing valve hose [a]. • after removing the air cleaner housing, cover the clean cloth on the throttle body assy. Warning if dirt or dust is allowed to p...

  • Page 222: 3-132 Fuel System (Dfi)

    3-132 fuel system (dfi) fuel tank fuel tank removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a...

  • Page 223: Fuel System (Dfi) 3-133

    Fuel system (dfi) 3-133 fuel tank • draw the fuel out from the fuel tank with a commercially available pump [a]. ○ use a soft plastic hose [b] as a pump inlet hose in order to insert the hose smoothly. ○ put the hose through the fill opening [c] into the tank and draw the fuel out. Warning spilled f...

  • Page 224: 3-134 Fuel System (Dfi)

    3-134 fuel system (dfi) fuel tank • pull [a] the fuel hose joint [b] out of the outlet pipe. Warning fuel is flammable and explosive under certain con- ditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is d...

  • Page 225: Fuel System (Dfi) 3-135

    Fuel system (dfi) 3-135 fuel tank • for the california and southeast asia models, note the following. Notice for the california and southeast asia models, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capac- ity is greatly reduced. If the caniste...

  • Page 226: 3-136 Fuel System (Dfi)

    3-136 fuel system (dfi) fuel tank • for the california and southeast asia models, note the following. ○ to prevent the gasoline from flowing into or out of the canister, hold the separator perpendicular to the ground. ○ connect the hoses according to the diagram of the evap- orative emission control...

  • Page 227: Fuel System (Dfi) 3-137

    Fuel system (dfi) 3-137 fuel tank fuel tank and cap inspection • open the tank cap. • visually inspect the gasket [a] on the tank cap for any damage. Replace the tank cap if gasket is damaged. • check to see if the water drain pipe [b] and fuel breather pipe [c] in the tank are not clogged. Check th...

  • Page 228: 3-138 Fuel System (Dfi)

    3-138 fuel system (dfi) evaporative emission control system (cal and sea-b1 models) the evaporative emission control system routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thoro...

  • Page 229: Fuel System (Dfi) 3-139

    Fuel system (dfi) 3-139 evaporative emission control system (cal and sea-b1 models) separator operation test warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch off. Do not smoke. Make sure the area is well-ventilated and free from any so...

  • Page 230: 3-140 Fuel System (Dfi)

    3-140 fuel system (dfi) evaporative emission control system (cal and sea-b1 models) 1. Fuel tank 2. Green hose (purge) 3. Clamps 4. White hose (vacuum) 5. Blue hose (breather) 6. Canister 7. Blue hose (breather) 8. Separator 9. Damper (for separator) 10. Bracket (for separator) 11. Red hose (return).

  • Page 231: Cooling System 4-1

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

  • Page 232: 4-2 Cooling System

    4-2 cooling system exploded view.

  • Page 233: Cooling System 4-3

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 hot windshield mounting bolts 9.8 1.0 87 in·lb 2 coolant by-pass fitting bolt 8.8 0.90 78 in·lb l 3 thermostat housing bolts 5.9 0.60 52 in·lb l 4 radiator (water) hose clamp screws 2.9 0.30 26 in·lb 5 water pipe bolts 12...

  • Page 234: 4-4 Cooling System

    4-4 cooling system coolant flow chart 1. Radiator cap 2. Radiator fan 3. Radiator 4. Oil cooler 5. Cylinder head jacket 6. Cylinder jacket 7. Inlet pipe 8. Water pump 9. Outlet pipe 10. Water temperature sensor 11. Thermostat housing 12. Reserve tank overflow hose 13. Reserve tank 14. Hot coolant 15...

  • Page 235: Cooling System 4-5

    Cooling system 4-5 coolant flow chart permanent type antifreeze is used as a coolant to protect the cooling system from rust and corro- sion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature ch...

  • Page 236: 4-6 Cooling System

    4-6 cooling system specifications item standard coolant provided when shipping type (recommended) permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) color green mixed ratio soft water 50%, coolant 50% freezing ...

  • Page 237: Cooling System 4-7

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

  • Page 238: 4-8 Cooling System

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

  • Page 239: Cooling System 4-9

    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 240: 4-10 Cooling System

    4-10 cooling system water pump water pump removal • drain: coolant (see coolant change in the periodic mainte- nance chapter) engine oil (see engine oil change in the periodic main- tenance chapter) • remove: left lower fairing (see lower fairing removal in the frame chapter) engine sprocket cover (...

  • Page 241: Cooling System 4-11

    Cooling system 4-11 water pump • be sure to install the dowel pins [a]. • install: water pump housing [a] water pump impeller [b] • tighten: torque - water pump impeller bolt [c]: 9.8 n·m (1.0 kgf·m, 87 in·lb) • be sure to install the dowel pins [d]. • replace the o-ring [a] with a new one, and inst...

  • Page 242: 4-12 Cooling System

    4-12 cooling system water pump water pump inspection • remove the left lower fairing (see lower fairing removal in the frame chapter). • check the drainage outlet passage [a] at the bottom of the water pump body for coolant leaks. If the mechanical seal is damaged, the coolant leaks through the seal...

  • Page 243: Cooling System 4-13

    Cooling system 4-13 water pump • take the oil seal [a] out of the housing [b] with a hook [c]. Water pump housing assembly notice do not reuse the mechanical seal and oil seal. • apply high-temperature grease to the oil seal lips [a]. • press the new oil seal into the housing with a bearing driver [...

  • Page 244: 4-14 Cooling System

    4-14 cooling system radiator radiator and radiator fan removal • remove: lower fairing (see lower fairing removal in the frame chapter) coolant (drain, see coolant change in the periodic maintenance chapter) • remove: radiator hose clamp [a] radiator cap mounting bolt [b] radiator hose [c] • remove:...

  • Page 245: Cooling System 4-15

    Cooling system 4-15 radiator • slide the connector cover [a] to disconnect the radiator fan motor lead connector [b]. • remove: radiator hose clamp screw [a] (loosen) radiator hose [b] radiator lower bolt [c] notice do not touch the radiator core. This could damage the radiator fins, resulting in lo...

  • Page 246: 4-16 Cooling System

    4-16 cooling system radiator radiator and radiator fan installation • installation is the reverse of removal. • install the rubber dampers [a] and radiator bracket collars [b] as shown in the figure. [c] larger [d] smaller • fit the slits [a] of the heat insulation rubber plate to the up- per mounti...

  • Page 247: Cooling System 4-17

    Cooling system 4-17 radiator radiator inspection • check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [a] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irrepa...

  • Page 248: 4-18 Cooling System

    4-18 cooling system radiator radiator filler neck inspection • remove: right lower fairing (see lower fairing removal in the frame chapter) radiator cap • check the radiator filler neck for signs of damage. • check the condition of the top and bottom sealing seats [a] in the filler neck. They must b...

  • Page 249: Cooling System 4-19

    Cooling system 4-19 thermostat thermostat removal • remove: coolant (drain, see coolant change in the periodic maintenance chapter) engine sprocket cover (see engine sprocket removal in the final drive chapter) harness holder clamp [a] water hose clamp [b] water hose [c] water pipe bolts [d] water p...

  • Page 250: 4-20 Cooling System

    4-20 cooling system thermostat • replace the o-ring [a] with a new one. • apply grease to the o-ring, and install it. • install the thermostat housing cover. Note ○ note that the thermostat does not move at the place when installing the thermostat housing cover. • tighten: torque - thermostat housin...

  • Page 251: Cooling System 4-21

    Cooling system 4-21 hose and pipes hose installation • install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • run the hoses (see cable, wire, and hose routing sec- tion in the appendix chapter). • install the clamp [a] as nea...

  • Page 252: 4-22 Cooling System

    4-22 cooling system water temperature sensor notice the water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it. Water temperature sensor removal/installation • refer to the water temperature sensor removal/instal- lati...

  • Page 253: Engine Top End 5-1

    Engine top end 5-1 5 engine top end table of contents exploded view................................... 5-2 exhaust system identification ........... 5-6 specifications .................................... 5-8 special tools and sealant ................. 5-10 clean air system.............................

  • Page 254: 5-2 Engine Top End

    5-2 engine top end exploded view.

  • Page 255: Engine Top End 5-3

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air suction valve cover bolts 9.8 1.0 87 in·lb l 2 spark plugs 13 1.3 115 in·lb 3 cylinder head cover bolts 9.8 1.0 87 in·lb s 4 hot windshield mounting bolts 9.8 1.0 87 in·lb 5 camshaft sprocket bolts 15 1.5 11 l 6 front...

  • Page 256: 5-4 Engine Top End

    5-4 engine top end exploded view.

  • Page 257: Engine Top End 5-5

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 exhaust butterfly valve actuator pulley bolt 5.0 0.51 44 in·lb 2 exhaust butterfly valve actuator bolts 1.2 0.12 11 in·lb 3 muffler body mounting bolts 34 3.5 25 4 premuffler chamber mounting bolt 34 3.5 25 5 muffler body...

  • Page 258: 5-6 Engine Top End

    5-6 engine top end exhaust system identification exhaust pipe mark position [a] left muffler body mark position [a].

  • Page 259: Engine Top End 5-7

    Engine top end 5-7 exhaust system identification right muffler body mark position [a] exhaust pipe [a] with hole [b] for oxygen sensor [c] (equipped models) honeycomb type catalyst positions [a].

  • Page 260: 5-8 Engine Top End

    5-8 engine top end specifications item standard service limit camshafts cam height: exhaust 33.743 ∼ 33.857 mm (1.3285 ∼ 1.3330 in.) 33.64 mm (1.324 in.) intake 34.743 ∼ 34.857 mm (1.3678 ∼ 1.3723 in.) 34.64 mm (1.364 in.) camshaft journal, camshaft cap clearance 0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in...

  • Page 261: Engine Top End 5-9

    Engine top end 5-9 specifications item standard service limit cylinder, pistons cylinder inside diameter 76.990 ∼ 77.006 mm (3.0311 ∼ 3.0317 in.) 77.09 mm (3.035 in.) piston diameter 76.974 ∼ 76.984 mm (3.0305 ∼ 3.0309 in.) 76.82 mm (3.024 in.) piston/cylinder clearance 0.010 ∼ 0.032 mm (0.0004 ∼ 0....

  • Page 262: 5-10 Engine Top End

    5-10 engine top end special tools and sealant compression gauge, 20 kgf/cm²: 57001-221 valve spring compressor assembly: 57001-241 piston pin puller assembly: 57001-910 valve seat cutter, 45° - 27.5: 57001-1114 valve seat cutter, 45° - 32: 57001-1115 valve seat cutter, 32° - 28: 57001-1119 valve sea...

  • Page 263: Engine Top End 5-11

    Engine top end 5-11 special tools and sealant valve guide reamer, 4.5: 57001-1333 valve seat cutter, 60° - 33: 57001-1334 valve seat cutter, 60° - 27: 57001-1409 engine mount nut wrench: 57001-1450 valve guide driver: 57001-1564 valve spring compressor adapter, 24: 57001-1586 compression gauge adapt...

  • Page 264: 5-12 Engine Top End

    5-12 engine top end clean air system air suction valve removal • remove: lower fairing (see lower fairing removal in the frame chapter) air switching valve (see air switching valve removal) stick coil connector (see stick coil removal in the elec- trical system chapter) connector [a] (from bracket [...

  • Page 265: Engine Top End 5-13

    Engine top end 5-13 clean air system air suction valve inspection • remove the air suction valve (see air suction valve re- moval). • visually inspect the reeds [a] for cracks, folds, warps, heat damage or other damage. If there is any doubt as to the condition of the reeds, re- place the air suctio...

  • Page 266: 5-14 Engine Top End

    5-14 engine top end clean air system clean air system hose inspection • be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the air cleaner housing, air switching valve and air suction valve covers. If they are not, correct them. Replace them ...

  • Page 267: Engine Top End 5-15

    Engine top end 5-15 cylinder head cover cylinder head cover removal • remove: lower fairing (see lower fairing removal in the frame chapter) air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter) • drain the coolant (see coolant change in the periodic maintenance chap...

  • Page 268: 5-16 Engine Top End

    5-16 engine top end cylinder head cover • remove: air suction valves [a] (see air suction valve removal) hot windshield [b] and air suction valve cover bracket [c] • remove: cylinder head cover bolts [a] cylinder head cover cylinder head cover installation • install: dowel pins [a] plug hole gaskets...

  • Page 269: Engine Top End 5-17

    Engine top end 5-17 cylinder head cover • replace the head cover gasket [a] with a new one. • install the gasket to the cylinder head cover [b]. • while pulling up the water hose on radiator cap, install the cylinder head cover from the right side. • apply sorp and water solution or rubber lubricant...

  • Page 270: 5-18 Engine Top End

    5-18 engine top end cylinder head cover • install the quick rivets [a]. • position the rubber cover [b] on the cylinder head cover as shown. • install the removed parts (see appropriate chapters)..

  • Page 271: Engine Top End 5-19

    Engine top end 5-19 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 272: 5-20 Engine Top End

    5-20 engine top end camshaft, camshaft chain camshaft removal • remove: cylinder head cover (see cylinder head cover re- moval) crankshaft sensor cover (see crankshaft sensor re- moval in the electrical system chapter) • turn the crankshaft clockwise, align the #1, 4 mark on the timing rotor with th...

  • Page 273: Engine Top End 5-21

    Engine top end 5-21 camshaft, camshaft chain camshaft installation • be sure to install the following parts. Plug hole gaskets [a] dowel pins [b] note ○ the exhaust camshaft has a 8943 ex mark [a] and the intake camshaft has a 8943 in mark [b]. Be careful not to mix up these shafts. • install the ca...

  • Page 274: 5-22 Engine Top End

    5-22 engine top end camshaft, camshaft chain • pull the tension side (exhaust side) [a] of the chain taut to install the chain. • engage the camshaft chain with the sprockets so that tim- ing marks on the sprockets are positioned as shown in the figure. ○ the timing marks must be aligned with the cy...

  • Page 275: Engine Top End 5-23

    Engine top end 5-23 camshaft, camshaft chain • before installing the camshaft caps and upper chain guide, install the camshaft chain tensioner body tem- porarily (see camshaft chain tensioner installation). • install the camshaft caps and upper camshaft chain guide [a] as shown in the figure. Identi...

  • Page 276: 5-24 Engine Top End

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

  • Page 277: Engine Top End 5-25

    Engine top end 5-25 camshaft, camshaft chain 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 33.743 ∼ 33.857 mm (1.3285 ∼ 1....

  • Page 278: 5-26 Engine Top End

    5-26 engine top end cylinder head cylinder compression measurement note ○ use the battery which is fully charged. • warm up the engine thoroughly. • stop the engine. • remove: stick coils (see stick coil removal in the electrical sys- tem chapter) spark plugs (see spark plug replacement in the peri-...

  • Page 279: Engine Top End 5-27

    Engine top end 5-27 cylinder head cylinder head removal • remove: coolant (drain, see coolant change in the periodic maintenance chapter) camshafts (see camshaft removal) throttle body assy (see throttle body assy removal in the fuel system (dfi) chapter) exhaust pipe (see exhaust pipe removal) • di...

  • Page 280: 5-28 Engine Top End

    5-28 engine top end cylinder head • replace the cylinder head gasket [a] with a new one. • install the dowel pins [b] and cylinder head gasket. • replace the cylinder head bolt washers [a] with new ones. • apply molybdenum disulfide oil solution to both sides [b] of the cylinder head bolt washers an...

  • Page 281: Engine Top End 5-29

    Engine top end 5-29 cylinder head • install: front camshaft chain guide [a] rear camshaft chain guide [b] new o-rings [c] collar [d] ○ apply grease to the new o-ring. • tighten: torque - front camshaft chain guide bolt (upper) [e]: 25 n·m (2.5 kgf·m, 18 ft·lb) front camshaft chain guide bolt (lower)...

  • Page 282: 5-30 Engine Top End

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

  • Page 283: Engine Top End 5-31

    Engine top end 5-31 valves valve guide installation • apply oil to the valve guide outer surface before installa- tion. • heat the area around the valve guide hole to about 120 ∼ 150°c (248 ∼ 302°f). Notice do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylind...

  • Page 284: 5-32 Engine Top End

    5-32 engine top end valves valve-to-guide clearance measurement (wobble method) if a small bore gauge is not available, inspect the valve guide wear by measuring the valve to 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 285: Engine Top End 5-33

    Engine top end 5-33 valves valve seat repair • repair the valve seat with the valve seat cutters [a]. Special tools - valve seat cutter holder bar [b]: 57001 -1128 valve seat cutter holder, 4.5 [c]: 57001 -1330 [for exhaust valve seat] valve seat cutter, 45° - 27.5: 57001-1114 valve seat cutter, 32°...

  • Page 286: 5-34 Engine Top End

    5-34 engine top end valves 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 smooth...

  • Page 287: Engine Top End 5-35

    Engine top end 5-35 valves if the outside diameter [a] of the seating surface is too large, make the 32° grind described below. If the outside diameter of the seating surface is within the specified range, measure the seat width as described be- low. • grind the seat at a 32° angle [b] until the sea...

  • Page 288: 5-36 Engine Top End

    5-36 engine top end valves • lap the valve to the seat, once the seat width and outside diameter are within the ranges specified above. ○ put a little coarse grinding compound on the face of the valve in a number of places around the valve head. ○ spin the valve against the seat until the grinding c...

  • Page 289: Engine Top End 5-37

    Engine top end 5-37 valves.

  • Page 290: 5-38 Engine Top End

    5-38 engine top end cylinder, pistons cylinder removal • remove: lower radiator bolt [a] radiator bracket bolt [b] radiator bracket [c] cylinder head (see cylinder head removal) engine bracket (see engine removal in the engine re- moval/installation chapter) • remove: water hose clamp screw (loosen)...

  • Page 291: Engine Top End 5-39

    Engine top end 5-39 cylinder, pistons • the piston ring openings must be positioned as shown in the figure. The openings of the oil ring steel rails must be about 30 ∼ 40° of angle from the opening of the top ring. Top ring [a] second ring [b] upper oil ring steel rail [c] oil ring expander [d] lowe...

  • Page 292: 5-40 Engine Top End

    5-40 engine top end cylinder, pistons piston installation • apply molybdenum disulfide oil solution to the oil ring ex- pander, and install the oil ring expander [a] in the bottom piston ring groove so the ends [b] not butt together. • apply molybdenum disulfide oil solution to the oil ring steel ra...

  • Page 293: Engine Top End 5-41

    Engine top end 5-41 cylinder, pistons piston wear inspection • measure the outside diameter [a] of each piston 11 mm (0.43 in.) [b] up from the bottom of the piston at a right angle to the direction of the piston pin. If the measurement is under service limit, replace the pis- ton. Piston diameter s...

  • Page 294: 5-42 Engine Top End

    5-42 engine top end cylinder, pistons piston ring thickness inspection • measure the piston ring thickness. ○ use the micrometer to measure at several points around the ring. Piston ring thickness standard: top [a] 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) second [b] 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) ...

  • Page 295: Engine Top End 5-43

    Engine top end 5-43 throttle body assy holder throttle body assy holder removal • remove: throttle body assy (see throttle body assy removal in the fuel system (dfi) chapter) clamps [a] bolts [b] throttle body assy holders [c] throttle body assy holder installation • replace the o-rings [a] with new...

  • Page 296: 5-44 Engine Top End

    5-44 engine top end muffler warning the exhaust pipe or muffler body can become ex- tremely hot during normal operation and cause se- vere burns. Do not remove the exhaust pipe or muf- fler body while it is hot. Muffler body removal left muffler body • loosen the muffler body clamp bolt [a]. • remov...

  • Page 297: Engine Top End 5-45

    Engine top end 5-45 muffler • remove: muffler body clamp bolt [a] (loosen) right muffler body mounting bolt [b] and nut right muffler body [c] (with the cable installed) • remove: bolts [a] exhaust butterfly valve pulley cover [b] • loosen the locknuts [a]. • remove the cable lower ends [b]. Muffler...

  • Page 298: 5-46 Engine Top End

    5-46 engine top end muffler • thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts and nuts. • install the removed parts (see appropriate chapters). ○ when installing, run the cables correctly (see cable, wire, and hose routing section in the appendix chapter)..

  • Page 299: Engine Top End 5-47

    Engine top end 5-47 muffler exhaust pipe removal • remove: muffler bodies (see muffler body removal) oxygen sensor (see oxygen sensor removal (equipped models) in the electrical system chap- ter) • support the premuffler chamber with the suitable stand [a]. • loosen the premuffler chamber mounting b...

  • Page 300: 5-48 Engine Top End

    5-48 engine top end muffler exhaust butterfly valve cable installation • confirm whether pulley [a] is an angle as shown in the figure. 41.7° ±0.7° [b] ○ this position is original position of the pulley. Note ○ correct the position electrically after confirming use is discontinued and there is no da...

  • Page 301: Engine Top End 5-49

    Engine top end 5-49 muffler • install the upper ends of the exhaust butterfly valve ca- bles to the pulley of the exhaust butterfly valve actuator, following the specified installing sequence. ○ first, install the close cable (black) [a]. ○ second, install the open cable (white) [b]. ○ third, stretc...

  • Page 303: Clutch 6-1

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

  • Page 304: 6-2 Clutch

    6-2 clutch exploded view.

  • Page 305: Clutch 6-3

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 clutch lever assembly clamp bolts 7.8 0.80 69 in·lb s 2 clutch cover bolts 9.8 1.0 87 in·lb 3 oil filler plug 2.0 0.20 18 in·lb 4 clutch spring bolts 9.0 0.90 80 in·lb 5 clutch hub nut 135 13.8 99.6 r cl: apply cable lubricant. E...

  • Page 306: 6-4 Clutch

    6-4 clutch specifications item standard service limit clutch lever free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – clutch clutch plate assembly length 51.1 ∼ 51.7 mm (2.01 ∼ 2.04 in.) – – – friction plate thickness 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) 2.4 mm (0.094 in.) friction and steel plate warp 0.15 m...

  • Page 307: Clutch 6-5

    Clutch 6-5 special tool and sealant clutch holder: 57001-1243 liquid gasket, tb1211f: 92104-0004.

  • Page 308: 6-6 Clutch

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

  • Page 309: Clutch 6-7

    Clutch 6-7 clutch cover clutch cover removal • remove: rear lower fairing (see rear lower fairing removal in the frame chapter) engine oil (drain, see engine oil change in the periodic maintenance chapter) clutch cable lower end clutch cover mounting bolts [a] • turn the release lever [a] toward the...

  • Page 310: 6-8 Clutch

    6-8 clutch clutch cover release shaft installation • apply grease to the oil seal lips on the upper ridge of the clutch cover. • apply engine oil to the needle bearings in the hole of the clutch cover. • apply molybdenum disulfide grease to the pusher-holding portion [a] on the release shaft. • inst...

  • Page 311: Clutch 6-9

    Clutch 6-9 clutch cover clutch cover assembly • replace the needle bearings and oil seal with new ones. Note ○ install the needle bearings so that the manufacture’s mark face out. • install the needle bearings [a] and oil seal [b] position as shown in the figure. Press the needle bearing until the b...

  • Page 312: 6-10 Clutch

    6-10 clutch clutch clutch removal • remove: clutch cover (see clutch cover removal) clutch spring bolts [a] clutch springs clutch spring plate [b] (with washer, needle bearing and pusher [c]) • remove: friction plates and steel plates spring and spring seat note ○ the two plates at both ends are dif...

  • Page 313: Clutch 6-11

    Clutch 6-11 clutch • install the clutch housing [a] to the drive shaft. • while holding the clutch housing, install the needle bear- ing [b] and sleeve [c]. ○ the holes [d] of the sleeve face outward. • install the following parts to the drive shaft. Spacer ( 47 × 25.5) [a] clutch hub • install the ...

  • Page 314: 6-12 Clutch

    6-12 clutch clutch • install the friction plates and steel plates, starting with a friction plate and alternating them. Note ○ install the both ends marked two friction plates at dis- assembled to the their original position. ○ when replace the friction plates with new ones, mark the both ends two f...

  • Page 315: Clutch 6-13

    Clutch 6-13 clutch clutch plate assembly inspection • inspect the friction plate thickness (see clutch plate, wear, damage inspection). • measure the length [a] of the clutch plate assembly as shown in the figure. ○ assemble: clutch hub [b] spring seat [c] spring [d] friction plates [e] steel plates...

  • Page 316: 6-14 Clutch

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

  • Page 317: Engine Lubrication System

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

  • Page 318

    7-2 engine lubrication system exploded view.

  • Page 319

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oil filler plug 2.0 0.20 18 in·lb 2 oil cooler bolts 12 1.2 106 in·lb 3 oil passage plug 20 2.0 15 l 4 radiator (water) hose clamp screws 3.0 0.31 27 in·lb 5 oil pressure switch 15 1.5 11 ss 6 oil pressure reli...

  • Page 320

    7-4 engine lubrication system engine oil flow chart 1. Oil screen 2. Oil pump 3. Output shaft oil passage 4. Drive shaft oil passage 5. Crankshaft oil passage 6. Oil pipe 7. Camshaft oil passage 8. Balancer oil passage 9. Oil pressure switch 10. Main oil passage 11. Oil cooler 12. Oil filter 13. Oil...

  • Page 321

    Engine lubrication system 7-5 specifications item standard engine oil type api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity sae 10w-40 capacity: 3.2 l (3.4 us gt) (when filter is not removed) 3.8 l (4.0 us gt) (when filter is removed) 4.0 l (4.2 us gt) (when engine is completely dry) leve...

  • Page 322

    7-6 engine lubrication system special tools and sealants liquid gasket, tb1211: 56019-120 outside circlip pliers: 57001-144 oil pressure gauge, 10 kgf/cm²: 57001-164 oil pressure gauge adapter, pt3/8: 57001-1233 liquid gasket, tb1207b: 92104-2068.

  • Page 323

    Engine lubrication system 7-7 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 324

    7-8 engine lubrication system oil pan oil pan removal • remove: exhaust pipe (see exhaust pipe removal in the engine top end chapter) oil filter (see oil filter replacement in the periodic maintenance chapter) oil pan bolts [a] oil pan [b] • remove the following parts if necessary. Oil screen (see o...

  • Page 325

    Engine lubrication system 7-9 oil pan note ○ make the application finish within 7 minutes when the liquid gasket to the mating surface of the oil pan is ap- plied. ○ moreover fit the oil pan and tighten the bolts just after application of the liquid gasket. • tighten the oil pan bolts following sequ...

  • Page 326

    7-10 engine lubrication system oil screen oil screen removal • remove: oil pan (see oil pan removal) oil screen [a] oil screen installation • clean the oil screen (see oil screen cleaning). • replace the o-ring [a] with a new one, and install it. • apply grease to the o-ring. • install the rubber da...

  • Page 327

    Engine lubrication system 7-11 oil pressure relief valve oil pressure relief valve removal • remove: oil screen (see oil screen removal) oil pressure relief valve [a] oil pressure relief valve installation • apply a non-parmanent locking agent to the threads of the oil pressure relief valve, and tig...

  • Page 328

    7-12 engine lubrication system oil pump oil pump removal • remove: water pump (see water pump removal in the cooling system chapter) oil pump cover [a] • remove: oil (water) pump shaft [a] with inner rotor [b] outer rotor [c] oil pump installation • install the outer rotor [a] into the crankcase. • ...

  • Page 329

    Engine lubrication system 7-13 oil pump • install the dowel pin [a]. • install the oil pump cover [b] so that the dowel pin fits into the hole [c] of the oil pump cover. • install the water pump (see water pump installation in the cooling system chapter). Oil pump drive gear removal • remove: clutch...

  • Page 330

    7-14 engine lubrication system oil cooler oil cooler removal • remove: left lower fairing assembly (see lower fairing assem- bly removal in the frame chapter) coolant (drain, see coolant change in the periodic maintenance chapter) engine oil (drain, see engine oil change in the periodic maintenance ...

  • Page 331

    Engine lubrication system 7-15 oil pressure measurement oil pressure measurement • remove the right lower fairing (see lower fairing re- moval in the frame chapter). • remove the oil passage plug [a]. • attach the adapter [a] and gauge [b] to the plug hole. Special tools - oil pressure gauge, 10 kgf...

  • Page 332

    7-16 engine lubrication system oil pressure switch oil pressure switch removal • remove: left lower fairing assembly (see lower fairing assem- bly removal in the frame chapter) engine oil (drain, see engine oil change in the periodic maintenance chapter) switch cover [a] switch terminal bolt [b] oil...

  • Page 333

    Engine lubrication system 7-17 oil pipe oil pipe removal • remove: oil pan (see oil pan removal) oil pipe [a] oil pipe installation • replace the o-rings [a] with new ones. • apply grease to the o-rings, and install them..

  • Page 335: Engine Removal/installation

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

  • Page 336

    8-2 engine removal/installation exploded view.

  • Page 337

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper engine bracket bolts 44 4.5 32 s 2 lower engine bracket bolts 59 6.0 44 s 3 upper adjusting collar 9.8 1.0 87 in·lb s 4 upper engine mounting bolt (l = 65) 44 4.5 32 s 5 upper adjusting collar locknut 4...

  • Page 338

    8-4 engine removal/installation special tool engine mount nut wrench: 57001-1450

  • Page 339

    Engine removal/installation 8-5 engine removal/installation engine removal • support the rear part of the swingarm with a stand. • squeeze the brake lever slowly and hold it with a band [a]. Warning motorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to hold the front b...

  • Page 340

    8-6 engine removal/installation engine removal/installation • remove the connector [a] from the bracket on the air suc- tion valve cover. • disconnect the connector. • disconnect: starter motor cable (see starter motor removal in the electrical system chapter) alternator lead connector (see alternat...

  • Page 341

    Engine removal/installation 8-7 engine removal/installation • remove: (right side) coolant reserve tank (see coolant change in the peri- odic maintenance chapter) upper engine bracket bolts [a] lower engine bracket bolt [b] and washer engine bracket [c] • support the engine with a suitable stand [a]...

  • Page 342

    8-8 engine removal/installation engine removal/installation engine installation • support the engine with a suitable stand. ○ put a plank onto the suitable stand for engine balance. • screw the adjusting collars [a] to the frame. • install the engine mounting bolts and nuts, following the specified ...

  • Page 343

    Engine removal/installation 8-9 engine removal/installation • run the leads, cables and hoses correctly (see cable, wire, and hose routing section in the appendix chapter). • install the removed parts (see appropriate chapters). Torque - engine ground cable terminal bolt: 9.8 n·m (1.0 kgf·m, 87 in·l...

  • Page 344

    8-10 engine removal/installation engine removal/installation • fill the engine with engine oil (see engine oil change in the periodic maintenance chapter). • fill the engine with coolant (see coolant change in the periodic maintenance chapter)..

  • Page 345: Crankshaft/transmission 9-1

    Crankshaft/transmission 9-1 9 crankshaft/transmission table of contents exploded view................................... 9-2 specifications .................................... 9-6 special tools and sealants ............... 9-8 crankcase splitting............................ 9-9 crankcase splitting ...

  • Page 346: 9-2 Crankshaft/transmission

    9-2 crankshaft/transmission exploded view.

  • Page 347: Crankshaft/transmission 9-3

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 balancer shaft clamp bolt 9.8 1.0 87 in·lb 2 balancer shaft lever bolt 25 2.5 18 l 3 breather side plate bolt 5.9 0.60 52 in·lb l 4 connecting rod big end nuts see the text ← ← mo 5 breather plate bolts 9.8 1.0 8...

  • Page 348: 9-4 Crankshaft/transmission

    9-4 crankshaft/transmission exploded view.

  • Page 349: Crankshaft/transmission 9-5

    Crankshaft/transmission 9-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 gear positioning lever bolt 12 1.2 106 in·lb 2 shift drum cam bolt 12 1.2 106 in·lb l 3 neutral switch 15 1.5 11 4 shift shaft return spring pin 39 4.0 29 l 5 shift pedal mounting bolt 25 2.5 18 eo: apply engine ...

  • Page 350: 9-6 Crankshaft/transmission

    9-6 crankshaft/transmission specifications item standard service limit crankcase, crankshaft, connecting rods connecting rod bend – – – tir 0.2/100 mm (0.008/3.94 in.) connecting rod twist – – – tir 0.2/100 mm (0.008/3.94 in.) connecting rod big end side clearance 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in....

  • Page 351: Crankshaft/transmission 9-7

    Crankshaft/transmission 9-7 specifications item standard service limit crankshaft main bearing insert thickness: brown 1.491 ∼ 1.495 mm (0.0587 ∼ 0.0589 in.) – – – black 1.495 ∼ 1.499 mm (0.0589 ∼ 0.0590 in.) – – – blue 1.499 ∼ 1.503 mm (0.0590 ∼ 0.0592 in.) – – – transmission shift fork ear thickne...

  • Page 352: 9-8 Crankshaft/transmission

    9-8 crankshaft/transmission special tools and sealants bearing puller: 57001-135 outside circlip pliers: 57001-144 bearing puller adapter: 57001-317 bearing driver, 32: 57001-382 bearing driver set: 57001-1129 flywheel holder: 57001-1313 liquid gasket, tb1216b: 92104-1064 liquid gasket, tb1207b: 921...

  • Page 353: Crankshaft/transmission 9-9

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

  • Page 354

    9-10 crankshaft/transmission crankcase splitting • remove the lower crankcase bolts, following the specified sequence. ○ first, loosen the m7 bolts [a]. ○ lastly, loosen the m9 bolts as shown sequence [1 ∼ 10] in the figure. • tap lightly around the crankcase mating surface with a plastic mallet, an...

  • Page 355

    Crankshaft/transmission 9-11 crankcase splitting • apply a non-permanent locking agent to the threads of the breather plate bolts [a] and tighten them. Torque - breather plate bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install the breather side plate [a] so that the plate hole [b] fit the projection [c]...

  • Page 356

    9-12 crankshaft/transmission crankcase splitting • apply a non-parmanent locking agent to the oil passage plugs [a], and tighten them. Torque - oil passage plugs: 20 n·m (2.0 kgf·m, 15 ft·lb) • install the oil passage plug [b] in the lower crankcase, and tighten it. Torque - oil passage plug: 9.8 n·...

  • Page 357

    Crankshaft/transmission 9-13 crankcase splitting • apply liquid gasket [a] to the mating surface of the lower crankcase half. ○ 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. Sealant - liquid gasket, tb1216b: 92...

  • Page 358

    9-14 crankshaft/transmission crankcase splitting • apply molybdenum disulfide oil solution to the lower seating surface [a] on the copper plated washer [b] and threads [c] of the m9 bolts [d]. • tighten the lower crankcase bolts using the following steps. ○ following the sequence numbers on the lowe...

  • Page 359

    Crankshaft/transmission 9-15 crankcase splitting • after tightening all crankcase bolts, check the following items. ○ wipe up the liquid gasket that seeps out around the crankcase mating surface. ○ crankshaft and transmission shafts turn freely. ○ while spinning the output shaft, gears shift smoothl...

  • Page 360

    9-16 crankshaft/transmission crankshaft and connecting rods crankshaft removal • split the crankcase (see crankcase splitting). • remove: balancer (see balancer removal) crankshaft [a] crankshaft installation notice if the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, ...

  • Page 361

    Crankshaft/transmission 9-17 crankshaft and connecting rods • apply molybdenum disulfide oil solution [a] to the inner surfaces of upper and lower bearing inserts. • do not apply any grease or oil to the cap inside and cap insert outside [b]. • install the inserts so that their nails [c] are on the ...

  • Page 362

    9-18 crankshaft/transmission crankshaft and connecting rods (1) bolt length measurement method • be sure to clean the bolts, nuts, and connecting rods thoroughly with a high-flash point solvent, because the new connecting rods, bolts, and nuts are treated with an anti-rust solution. Warning clean th...

  • Page 363

    Crankshaft/transmission 9-19 crankshaft and connecting rods (2) rotation angle method if you do not have a point micrometer, you may tighten the nuts using the “rotation angle method”. • be sure to clean the bolts, nuts and connecting rods thor- oughly with a high-flash point solvent, because the ne...

  • Page 364

    9-20 crankshaft/transmission crankshaft and connecting rods crankshaft/connecting rod cleaning • after removing the connecting rods from the crankshaft, clean them with a high-flash point solvent. • blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that ...

  • Page 365

    Crankshaft/transmission 9-21 crankshaft and connecting rods connecting rod big end bearing insert/crankpin wear inspection • measure the bearing insert/crankpin [a] clearance with plastigage [b]. • tighten the big end nuts to the specified torque (see con- necting rod installation). Note ○ do not mo...

  • Page 366

    9-22 crankshaft/transmission crankshaft and connecting rods • measure the connecting rod big end inside diameter, and mark each connecting rod big end in accordance with the inside diameter. • tighten the connecting rod big end nuts to the specified torque (see connecting rod installation). Note ○ t...

  • Page 367

    Crankshaft/transmission 9-23 crankshaft and connecting rods crankshaft runout inspection • measure the crankshaft runout. If the measurement exceeds the service limit, replace the crankshaft. Crankshaft runout standard: tir 0.02 mm (0.0008 in.) or less service limit: tir 0.05 mm (0.0020 in.) cranksh...

  • Page 368

    9-24 crankshaft/transmission crankshaft and connecting rods • measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. Crankcase main bearing inside diameter marks: “ ○ ” or no mark. • tighten the crankcase bolts to the specified torque (s...

  • Page 369

    Crankshaft/transmission 9-25 balancer balancer removal • split the crankcase (see crankcase splitting). • unscrew: balancer shaft clamp bolt [a] balancer shaft lever [b] oil seal [c] • remove the balancer [d] from the upper crankcase half. Balancer installation • check that the rubber dampers [a] ar...

  • Page 370

    9-26 crankshaft/transmission balancer • assemble the crankcase (see crankcase assembly). • fill the oil seal lips with grease. • install the new oil seal [a] so that its surface is flush with the surface of the crankcase. • turn the balancer shaft so that its mark [b] faces down- ward (this photo is...

  • Page 371

    Crankshaft/transmission 9-27 starter motor clutch starter motor clutch removal/installation • refer to the alternator rotor removal/installation in the electrical system chapter. Starter motor clutch inspection • remove: alternator cover (see alternator cover removal in the electrical system chapter...

  • Page 372

    9-28 crankshaft/transmission external shift mechanism shift pedal removal • remove: shift lever bolt [a] shift lever [b] shift pedal mounting bolt [c] shift pedal [d] with tie-rod [e] shift pedal installation • tighten: torque - shift pedal mounting bolt [a]: 25 n·m (2.5 kgf·m, 18 ft·lb) shift pedal...

  • Page 373

    Crankshaft/transmission 9-29 external shift mechanism • pull out the shift shaft assembly [a]. • remove: gear positioning lever bolt [a] gear positioning lever [b] collar and spring [c] • remove: shift drum cam bolt [a] shift drum cam [b] external shift mechanism installation • be sure to install th...

  • Page 374

    9-30 crankshaft/transmission external shift mechanism • while prying the gear positioning lever [a], tighten the gear positioning lever bolt [b]. Torque - gear positioning lever bolt: 12 n·m (1.2 kgf·m, 106 in·lb) • install the shift shaft [a] so that the return spring pin [b] fits between the sprin...

  • Page 375

    Crankshaft/transmission 9-31 external shift mechanism • check the gear positioning lever [a] and its spring for breaks or distortion. If the lever or spring are damaged in any way, replace them. • visually inspect the shift drum cam [b]. If it is badly worn or shows any damage, replace it..

  • Page 376

    9-32 crankshaft/transmission transmission transmission shaft removal • split the crankcase (see crankcase splitting). • remove the drive shaft [a] and output shaft [b]. Transmission shaft installation • check to see that the set pins [a] and set rings [b] are in place. • install the drive shaft and ...

  • Page 377

    Crankshaft/transmission 9-33 transmission • remove the ball bearing [a] from each shafts. Special tools - bearing puller [c]: 57001-135 bearing puller adapter [d]: 57001-317 • discard the bearing. ○ for output shaft, remove the collar [b] together with the ball bearing. Transmission shaft assembly •...

  • Page 378

    9-34 crankshaft/transmission transmission • the drive shaft gears can be recognized by size: the gear with the smallest diameter is 1st gear, and the largest one is 6th gear. Be sure that all parts are put back in the cor- rect sequence and all circlips and washers are properly in place. • install t...

  • Page 379

    Crankshaft/transmission 9-35 transmission this page intentionally left blank..

  • Page 380

    9-36 crankshaft/transmission transmission.

  • Page 381

    Crankshaft/transmission 9-37 transmission 1. Output shaft 2. Collar 3. Bearing 4. Bushing 5. 2nd gear (39 t) 6. Washer ( 34 × 28.1) 7. Circlips ( 33 × 25.9) 8. Top gear (25 t) 9. Toothed washer ( 34) 10. 4th/3rd gear (25 t/24 t) 11. Bushing 12. Toothed washer ( 40.5) 13. Toothed washer ( 37) 14. Ste...

  • Page 382

    9-38 crankshaft/transmission transmission shift drum and fork removal • remove: lower crankcase half (see crankcase splitting) transmission shafts (see transmission shaft removal) gear positioning lever (see external shift mechanism removal) bolts [a] shift drum bearing holder [b] • pull out the shi...

  • Page 383

    Crankshaft/transmission 9-39 transmission shift fork/gear groove wear inspection • measure the thickness of the shift fork ears [a], and mea- sure the width of the gear grooves [b]. If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced. Shift fork ear t...

  • Page 384

    9-40 crankshaft/transmission ball bearing, needle bearing, and oil seal ball and needle bearing replacement notice do not remove the ball or needle bearings unless it is necessary. Removal may damage them. • using a press or puller, remove the ball bearing and/or needle bearings. Note ○ in the absen...

  • Page 385: Wheels/tires 10-1

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

  • Page 386: 10-2 Wheels/tires

    10-2 wheels/tires exploded view.

  • Page 387: Wheels/tires 10-3

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front axle clamp bolt 20 2.0 15 al 2 front axle 108 11.0 79.7 3 rear axle nut 98 10 72 al: tighten the two clamp bolts alternately two times to ensure even tightening torque. Hg: apply high-temperature grease. R: replaceme...

  • Page 388: 10-4 Wheels/tires

    10-4 wheels/tires specifications item standard service limit wheels (rims) rim runout: axial tir 0.5 mm (0.02 in.) or less tir 1.0 mm (0.04 in.) radial tir 0.8 mm (0.03 in.) or less tir 1.0 mm (0.04 in.) axle runout/100 mm (3.94 in.) tir 0.1 mm (0.004 in.) or less tir 0.2 mm (0.008 in.) wheel balanc...

  • Page 389: Wheels/tires 10-5

    Wheels/tires 10-5 special tools inside circlip pliers: 57001-143 bearing driver set: 57001-1129 jack: 57001-1238 attachment jack: 57001-1252 bearing remover head, 20 × 22: 57001-1293 bearing remover shaft, 13: 57001-1377 jack attachment: 57001-1608.

  • Page 390: 10-6 Wheels/tires

    10-6 wheels/tires wheels (rims) front wheel removal • remove: front caliper mounting bolts [a] (both sides) front calipers [b] (both sides) lower fairing (see lower fairing removal in the frame chapter) front fender (see front fender removal in the frame chapter) • for the abs equipped models, remov...

  • Page 391: Wheels/tires 10-7

    Wheels/tires 10-7 wheels (rims) • apply high-temperature grease to the grease seal lips. • fit the collars [a] on the both sides of the hub. ○ the collars are identical. • insert the front axle. • tighten: torque - front axle: 108 n·m (11.0 kgf·m, 79.7 ft·lb) • before tightening the axle clamp bolts...

  • Page 392: 10-8 Wheels/tires

    10-8 wheels/tires wheels (rims) • loosen the torque link nuts [a] lightly for chain adjuster turn easily. • remove: rear caliper mounting bolts [a] rear caliper [b] • for abs equipped models, remove the bolt [a], clamp [b] and rear wheel rotation sensor [c]. • loosen the chain adjuster clamp bolts [...

  • Page 393: Wheels/tires 10-9

    Wheels/tires 10-9 wheels (rims) • remove the drive chain [a] from the rear sprocket toward the left. • move the rear wheel back and remove it. Notice do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not...

  • Page 394: 10-10 Wheels/tires

    10-10 wheels/tires wheels (rims) wheel inspection • raise the front/rear wheel off the ground. Special tools - jack: 57001-1238 jack attachment: 57001-1608 attachment jack: 57001-1252 • spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bear...

  • Page 395: Wheels/tires 10-11

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

  • Page 396: 10-12 Wheels/tires

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

  • Page 397: Wheels/tires 10-13

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

  • Page 398: 10-14 Wheels/tires

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

  • Page 399: Wheels/tires 10-15

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

  • Page 400: 10-16 Wheels/tires

    10-16 wheels/tires hub bearing hub bearing removal • remove the wheels (see front/rear wheel removal), and take out the following. Collars [a] coupling [b] (out of rear hub) grease seals [c] circlip [d] special tool - inside circlip pliers: 57001-143 • use the bearing remover to remove the hub beari...

  • Page 401: Wheels/tires 10-17

    Wheels/tires 10-17 hub bearing • replace the circlip with a new one. Special tool - inside circlip pliers: 57001-143 • replace the grease seals with new ones. • press in the grease seals [a] so that the seal surface flush [b] with the end of the hole. ○ apply high-temperature grease to the grease se...

  • Page 403: Final Drive 11-1

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

  • Page 404: 11-2 Final Drive

    11-2 final drive exploded view.

  • Page 405: Final Drive 11-3

    Final drive 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine sprocket nut 125 12.7 92.2 mo 2 drive chain guide bolts 9.8 1.0 87 in·lb 3 speed sensor mounting bolt 6.9 0.70 61 in·lb l 4 chain adjuster clamp bolts 64 6.5 47 5 rear sprocket nuts 59 6.0 44 hg: apply high-temperatu...

  • Page 406: 11-4 Final Drive

    11-4 final drive specifications item standard service limit drive chain drive chain slack 20 ∼ 30 mm (0.8 ∼ 1.2 in.) – – – drive chain wear (20-link length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 319 mm (12.56 in.) standard chain: make enuma – – – type ek525zx – – – link 112 links – – – link pin outsi...

  • Page 407: Final Drive 11-5

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

  • Page 408: 11-6 Final Drive

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

  • Page 409: Final Drive 11-7

    Final drive 11-7 drive chain drive chain installation • install the drive chain to the engine sprocket. • install: swingarm (see swingarm installation in the suspension chapter) rear wheel (see rear wheel installation in the wheels/tires chapter) engine sprocket cover (see engine sprocket cover in- ...

  • Page 410: 11-8 Final Drive

    11-8 final drive drive chain • screw the pin holder until it touches chain pin. • be sure that the cutting pin hits center of chain pin. • screw the handlebar [a] into body. • turn the pin holder with wrench [b] clockwise to extract chain pin. • replace the link pin, link plate and grease seals. • a...

  • Page 411: Final Drive 11-9

    Final drive 11-9 drive chain • turn the pin holder [a] by wrench clockwise until two pins of link come into groove of plate holders [b]. • take off the plate holder. • set the plate holder (b) [a] and cutting and riveting pin [b] as shown in the figure. • turn the pin holder until riveting pin touch...

  • Page 412: 11-10 Final Drive

    11-10 final drive drive chain • after staking, check the staked area of the link pin for cracks. • measure the outside diameter [a] of the link pin and link plates width [b]. Link pin outside diameter standard: 5.6 ∼ 6.0 mm (0.22 ∼ 0.24 in.) link plates outside width standard: 20.35 ∼ 20.55 mm (0.80...

  • Page 413: Final Drive 11-11

    Final drive 11-11 sprocket, coupling engine sprocket cover removal • remove: right lower fairing (see lower fairing removal in the frame chapter) engine sprocket inner cover bolts [a] engine sprocket inner and outer cover [b] • remove the engine sprocket outer cover screws [a] to sparate the outer a...

  • Page 414: 11-12 Final Drive

    11-12 final drive sprocket, coupling engine sprocket removal • remove: left lower fairing (see lower fairing removal in the frame chapter) engine sprocket cover (see engine sprocket cover re- moval) • flatten out the bended washer [a]. • remove the engine sprocket nut [b] and washer. Note ○ when loo...

  • Page 415: Final Drive 11-13

    Final drive 11-13 sprocket, coupling rear sprocket installation • install the sprocket facing the tooth number marking [a] outward. • replace the rear sprocket nuts with new ones. • tighten: torque - rear sprocket nuts: 59 n·m (6.0 kgf·m, 44 ft·lb) • install the rear wheel (see rear wheel installati...

  • Page 416: 11-14 Final Drive

    11-14 final drive sprocket, coupling coupling bearing installation • replace the bearing with a new one. • press in the bearing [a] until it is bottomed. Special tool - bearing driver set [b]: 57001-1129 • pack the bearing with high-temperature grease. • replace the circlip with a new one. Special t...

  • Page 417: Final Drive 11-15

    Final drive 11-15 sprocket, coupling sprocket wear inspection • visually inspect the engine and rear sprocket teeth for wear and damage. If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see drive chain wear inspection in the periodic maintenance chapter)....

  • Page 419: Brakes 12-1

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

  • Page 420: 12-2 Brakes

    12-2 brakes abs servicing precautions ............................................................................................... 12-33 abs troubleshooting outline............................................................................................ 12-35 inquiries to rider...................

  • Page 421: Brakes 12-3

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

  • Page 422: 12-4 Brakes

    12-4 brakes exploded view.

  • Page 423: Brakes 12-5

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front master cylinder reservoir cap stopper screw 1.2 0.12 11 in·lb 2 brake lever pivot bolt 1.0 0.10 8.8 in·lb si 3 front master cylinder bleed valve 5.4 0.55 48 in·lb 4 front master cylinder clamp bolts 11 1.1 97 in·lb s 5 bra...

  • Page 424: 12-6 Brakes

    12-6 brakes exploded view.

  • Page 425: Brakes 12-7

    Brakes 12-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake hose banjo bolts 25 2.5 18 2 rear master cylinder mounting bolts 25 2.5 18 3 brake pedal bolt 8.8 0.90 78 in·lb l 4 bleed valve 7.8 0.8 69 in·lb 5 rear master cylinder push rod locknut 17 1.7 12 6 rear brake disc mounting ...

  • Page 426: 12-8 Brakes

    12-8 brakes exploded view abs equipped models.

  • Page 427: Brakes 12-9

    Brakes 12-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front brake disc mounting bolts 27 2.8 20 l 2 brake hose banjo bolts 25 2.5 18 3 brake pipe joint nuts 18 1.8 13 4 rear brake disc mounting bolts 27 2.8 20 l 5. Front wheel rotation sensor 6. Rear wheel rotation sensor 7. Abs hy...

  • Page 428: 12-10 Brakes

    12-10 brakes specifications item standard service limit brake lever, brake pedal brake lever position 6-way adjustable (to suit rider) – – – brake lever free play non-adjustable – – – pedal free play non-adjustable – – – pedal position about 62 mm (2.4 in.) below footpeg top – – – brake pads lining ...

  • Page 429: Brakes 12-11

    Brakes 12-11 special tools jack: 57001-1238 attachment jack: 57001-1252 jack attachment: 57001-1608.

  • Page 430: 12-12 Brakes

    12-12 brakes brake lever, brake pedal brake lever position adjustment the brake lever adjuster has 6 positions so that the brake lever position can be adjusted to suit the operator’s hand. • push the lever forward and turn the adjuster [a] to align the number with the arrow mark [b] on the lever hol...

  • Page 431: Brakes 12-13

    Brakes 12-13 brake lever, brake pedal • remove: cotter pin [a] joint pin [b] rear brake light switch spring [c] return spring [d] brake pedal bolt [e] brake pedal [f] brake pedal installation • apply grease to the footpeg pivot shaft [a]. • install: washer [b] brake pedal [c] washer [d] • apply a no...

  • Page 432: 12-14 Brakes

    12-14 brakes calipers front caliper removal • loosen the banjo bolt [a] at the brake hose lower end, and tighten it loosely. • unscrew the caliper mounting bolts [b], and detach the caliper [c] from the disc. Notice do not loosen the caliper assembly bolts [d]. Take out only the caliper mounting bol...

  • Page 433: Brakes 12-15

    Brakes 12-15 calipers caliper installation • install the caliper and brake hose lower end. ○ for the front caliper, install the collars [a] on the fork leg and fit the holes [b] of the front caliper to the collars. ○ replace the washers on each side of hose fitting with new ones. • tighten: torque -...

  • Page 434: 12-16 Brakes

    12-16 brakes calipers caliper fluid seal damage the fluid seal (piston seal) [a] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- perature of ...

  • Page 435: Brakes 12-17

    Brakes 12-17 calipers rear caliper holder shaft wear the caliper body must slide smoothly on the caliper holder shafts [a]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and con- stant drag on the disc will raise brake and brake fluid tem- peratu...

  • Page 436: 12-18 Brakes

    12-18 brakes brake pads front brake pad removal • loosen the pad pins [a]. • remove the front caliper with the hose installed (see front caliper removal). • remove: pad pins [a] brake pads [b] front brake pad installation • check that the pad spring [a] is in place on the caliper. • push the caliper...

  • Page 437: Brakes 12-19

    Brakes 12-19 brake pads rear brake pad removal • remove the rear caliper with the hose installed (see rear caliper removal). • remove: clip [a] pad pin [b] • remove the brake pad [c] of the jaw side from the holder shaft [d], then remove the other pad [e]. Rear brake pad installation • check that th...

  • Page 438: 12-20 Brakes

    12-20 brakes master cylinder front master cylinder removal • remove the rear view mirror (see rear view mirror re- moval in the frame chapter). • remove the banjo bolt [a] to disconnect the brake hose from the master cylinder (see brake hose removal/in- stallation). • unscrew the clamp bolts [b], an...

  • Page 439: Brakes 12-21

    Brakes 12-21 master cylinder rear master cylinder installation • replace the cotter pin [a] with a new one. • insert the cotter pin and bend the pin ends [b]. • replace the washers on each side of hose fitting with new ones. • depress the brake pedal [a] to align the holes of the mas- ter cylinder, ...

  • Page 440: 12-22 Brakes

    12-22 brakes master cylinder master cylinder inspection (visual inspection) • remove the master cylinders (see front/rear master cylinder removal). • disassemble the front and rear master cylinders (see master cylinder rubber parts replacement in the peri- odic maintenance chapter). • check that the...

  • Page 441: Brakes 12-23

    Brakes 12-23 brake disc brake disc removal • remove the wheels (see front/rear wheel removal in the wheels/tires chapter). • unscrew the mounting bolts [a], and take off the disc [b]. • remove the gaskets. Brake disc installation • replace the gaskets with new ones. • install the brake disc on the w...

  • Page 442: 12-24 Brakes

    12-24 brakes brake fluid brake fluid level inspection • refer to the brake fluid level inspection in the periodic maintenance chapter. Brake fluid change • refer to the brake fluid change in the periodic mainte- nance chapter. Brake line bleeding the brake fluid has a very low compression coefficien...

  • Page 443: Brakes 12-25

    Brakes 12-25 brake fluid • remove the rubber cap from the bleed valve on the front master cylinder. • attach a clear plastic hose [a] to the bleed valve, and run the other end of the hose into a container. • bleed the brake line and the master cylinder. ○ repeat this operation until no more air can ...

  • Page 444: 12-26 Brakes

    12-26 brakes brake fluid • bleed the brake line and the caliper. ○ repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [a]. 2. Quickly open and close [b] the bleed valve while hold- ing...

  • Page 445: Brakes 12-27

    Brakes 12-27 brake fluid warning when working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types and brands of fluid for use in th...

  • Page 446: 12-28 Brakes

    12-28 brakes brake hose brake hose removal/installation • refer to the brake hose replacement in the periodic maintenance chapter. Brake hose and pipe inspection • refer to the brake hose and pipe damage and instal- lation condition inspection in the periodic maintenance chapter..

  • Page 447: Brakes 12-29

    Brakes 12-29 anti-lock brake system (equipped models) parts location front wheel rotation sensor [a] front wheel rotation sensor rotor [b] rear wheel rotation sensor [a] rear wheel rotation sensor rotor [b] abs indicator light [a] abs hydraulic unit [a] fuse box 1 [a] (abs fuses and accessory fuse).

  • Page 448: 12-30 Brakes

    12-30 brakes anti-lock brake system (equipped models) abs kawasaki diagnostic system connector [a] abs self-diagnosis terminal [b].

  • Page 449: Brakes 12-31

    Brakes 12-31 anti-lock brake system (equipped models) abs system wiring diagram 1. Abs self-diagnosis terminal 2. Fuse box 1 3. Abs motor relay fuse 30 a 4. Abs solenoid valve relay fuse 20 a 5. Abs ecu fuse 10 a 6. Fuse box 2 7. Ignition fuse 10 a 8. Front brake light switch 9. Meter ground 10. Fra...

  • Page 450: 12-32 Brakes

    12-32 brakes anti-lock brake system (equipped models) abs hydraulic unit terminal names 1. Power supply to abs motor 2. Power supply to abs solenoid valve relay 3. Ground 4. Ground 5. Abs self-diagnosis terminal 6. Unused 7. Unused 8. Front and rear brake light switch 9. Unused 10. Unused 11. Unused...

  • Page 451: Brakes 12-33

    Brakes 12-33 anti-lock brake system (equipped models) abs servicing precautions there are a number of important precautions that should be followed servicing the abs system. ○ this abs system is designed to be used with a 12 v sealed battery as its power source. Do not use any other battery except f...

  • Page 452: 12-34 Brakes

    12-34 brakes anti-lock brake system (equipped models) warning air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If any of the brake line fittings, including the abs hydraulic unit joint nuts, or the bleed valve is opened at any time, the air ...

  • Page 453: Brakes 12-35

    Brakes 12-35 anti-lock brake system (equipped models) ○ the abs indicator light (led) may come on if the engine is run with the motorcycle on its stand and the transmis- sion in gear. If the indicator light comes on, just turn the ignition switch off, then clear service code 42, which in- dicates a ...

  • Page 454: 12-36 Brakes

    12-36 brakes anti-lock brake system (equipped models) even when the abs is operating normally, the abs indi- cator light (led) may light up under the conditions listed be- low. Turn the ignition switch off to stop the indicator light. If the motorcycle runs without erasing the service code, the ligh...

  • Page 455: Brakes 12-37

    Brakes 12-37 anti-lock brake system (equipped models) abs diagnosis flow chart.

  • Page 456: 12-38 Brakes

    12-38 brakes anti-lock brake system (equipped models) inquiries to rider ○ each rider reacts to problems in different ways, so it is important to confirm what kind of condition the rider is dissatisfied with. ○ try to find out exactly what problem occurs under exactly what conditions by asking the r...

  • Page 457: Brakes 12-39

    Brakes 12-39 anti-lock brake system (equipped models) pre-diagnosis inspection 1.

  • Page 458: 12-40 Brakes

    12-40 brakes anti-lock brake system (equipped models) pre-diagnosis inspection 2 self-diagnosis outline when the indicator light has blinked or come on, the abs hydraulic unit memorizes and stores the service code (17 codes including “normal code”) for the service person to troubleshoot easily. The ...

  • Page 459: Brakes 12-41

    Brakes 12-41 anti-lock brake system (equipped models) • remove the rear seat (see rear seat removal in the frame chapter). • turn on the ignition switch. • ground the self-diagnosis terminal [a] (gray) to the bat- tery (–) terminal, using a suitable lead. ○ count the blinks of the light to read the ...

  • Page 460: 12-42 Brakes

    12-42 brakes anti-lock brake system (equipped models).

  • Page 461: Brakes 12-43

    Brakes 12-43 anti-lock brake system (equipped models) self-diagnosis flow chart.

  • Page 462: 12-44 Brakes

    12-44 brakes anti-lock brake system (equipped models) how to read service codes ○ service codes are shown by a series of long and short blinks of the abs indicator light (led) as shown below. ○ read 10th digit and unit digit as the abs indicator light (led) blinks. ○ when there are a number of fault...

  • Page 463: Brakes 12-45

    Brakes 12-45 anti-lock brake system (equipped models) service code table service code abs indicator light (led) problems light state 11 rise in heat of solenoid coil by abs continuousness operation on 12 start code (not fault) after starts, turn off 13 rear inlet solenoid valve trouble (shorted or o...

  • Page 464: 12-46 Brakes

    12-46 brakes anti-lock brake system (equipped models) abs indicator light (led) inspection ○ in this model, the abs indicator light (led) [a] goes on or blinks by the control of the abs hydraulic unit. • turn the ignition switch on. If the abs indicator light (led) lights, it is normal. If the abs i...

  • Page 465: Brakes 12-47

    Brakes 12-47 anti-lock brake system (equipped models) abs solenoid valve relay inspection (service code 19) • remove: front seat (see front seat removal in the frame chap- ter) • check the abs solenoid valve relay fuse (20 a) [a] (see fuse inspection in the electrical system chapter). If the fuse is...

  • Page 466: 12-48 Brakes

    12-48 brakes anti-lock brake system (equipped models) if the abs indicator light (led) [a] lights, the abs hy- draulic unit has trouble. Replace the abs hydraulic unit. If the abs indicator light (led) does not light, abs system is normal (service code is not stored; temporary failure.). Abs motor r...

  • Page 467: Brakes 12-49

    Brakes 12-49 anti-lock brake system (equipped models) • check that there is iron or other magnetic deposits be- tween the sensor [a] and sensor rotor [b], and the sensor rotor slots for obstructions. • check the installation condition of the sensor for loose- ness. • check the sensor rotor tip for d...

  • Page 468: 12-50 Brakes

    12-50 brakes anti-lock brake system (equipped models) rear wheel rotation sensor signal abnormal (service code 44) • measure the air gap between the rear wheel rotation sen- sor and sensor rotor (see wheel rotation sensor air gap inspection). • check the rear wheel rotation sensor (see rear wheel ro...

  • Page 469: Brakes 12-51

    Brakes 12-51 anti-lock brake system (equipped models) • recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the abs indicator light (led) [a] lights, replace the rear wheel rotation sensor (see rear wheel rotati...

  • Page 470: 12-52 Brakes

    12-52 brakes anti-lock brake system (equipped models) ecu inspection (service code 55) • recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the abs indicator light (led) [a] lights, the abs hy- draulic unit has...

  • Page 471: Brakes 12-53

    Brakes 12-53 anti-lock brake system (equipped models) • remove: battery case (see battery case removal in the frame chapter) brake hose (see brake hose replacement in the peri- odic maintenance chapter) • clean the abs hydraulic unit. Notice clean all fittings on the abs hydraulic unit and the rear ...

  • Page 472: 12-54 Brakes

    12-54 brakes anti-lock brake system (equipped models) • remove: bolts [a] abs hydraulic unit [b] notice the abs hydraulic unit [a] has been adjusted and set with precision at the factory. Do not try to dis- assemble and repair the abs hydraulic unit. Abs hydraulic unit installation • install the abs...

  • Page 473: Brakes 12-55

    Brakes 12-55 anti-lock brake system (equipped models) • visually inspect the connector terminals [a]. Replace the abs hydraulic unit or main harness if either of the terminals are cracked, bent, or otherwise damaged. If the abs hydraulic unit connector is clogged with mud or dust, blow it off with c...

  • Page 474: 12-56 Brakes

    12-56 brakes anti-lock brake system (equipped models) rear wheel rotation sensor removal notice the wheel rotation sensor should be handled care- fully, never struck sharply, as with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made. Be careful not ...

  • Page 475: Brakes 12-57

    Brakes 12-57 anti-lock brake system (equipped models) wheel rotation sensor inspection • remove the front wheel rotation sensor [a] from the front fork. • remove the rear wheel rotation sensor [b] from the caliper bracket. • visually inspect the wheel rotation sensors. Replace the wheel rotation sen...

  • Page 476: 12-58 Brakes

    12-58 brakes anti-lock brake system (equipped models) wheel rotation sensor rotor inspection • remove: wheels (see front/rear wheel removal in the wheels/tires chapter) brake disc mounting bolts [a] sensor rotor [b] front wheel [c] rear wheel [d] • visually inspect the wheel rotation sensor rotor. I...

  • Page 477: Brakes 12-59

    Brakes 12-59 anti-lock brake system (equipped models) fuse installation • if a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage (see fuse installation in the electrical system chapter). Fuse inspection • remov...

  • Page 479: Suspension 13-1

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

  • Page 480: 13-2 Suspension

    13-2 suspension exploded view.

  • Page 481: Suspension 13-3

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper front fork clamp bolts 20 2.0 15 2 lower front fork clamp bolts 25 2.5 18 al 3 piston rod nuts 20 2.0 15 4 front fork top plugs 34 3.5 25 5 front axle clump bolts 20 2.0 15 al 6 front fork bottom allen bolts 35 3.6 26 ...

  • Page 482: 13-4 Suspension

    13-4 suspension exploded view.

  • Page 483: Suspension 13-5

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear shock absorber bolt (upper) 34 3.5 25 2 tie-rod nuts 34 3.5 25 r 3 rear shock absorber nut (lower) 34 3.5 25 r 4 rocker arm nut 34 3.5 25 r 5 swingarm pivot adjusting collar locknut 98 10 72 6 swingarm pivot shaft nut 1...

  • Page 484: 13-6 Suspension

    13-6 suspension specifications item standard front fork (per one unit) fork inner tube diameter 41 mm (1.6 in.) air pressure atmospheric pressure (non-adjustable) rebound damper setting 2 turns out from the fully clockwise position (usable range: 0 ←→ 3 1/2 turns out) compression damper setting (rig...

  • Page 485: Suspension 13-7

    Suspension 13-7 special tools inside circlip pliers: 57001-143 oil seal & bearing remover: 57001-1058 bearing driver set: 57001-1129 jack: 57001-1238 bearing remover head, 15 × 17: 57001-1267 fork oil seal driver, 41: 57001-1288 fork piston rod puller, m12 × 1.25: 57001-1289 fork oil level gauge: 57...

  • Page 486: 13-8 Suspension

    13-8 suspension special tools hook wrench t=3.2 r37: 57001-1539 fork spring compressor: 57001-1587 swingarm pivot nut wrench: 57001-1597 jack attachment: 57001-1608 needle bearing driver, 17/ 18: 57001-1609 needle bearing driver, 28: 57001-1610 clamp: 57001-1693 bar: 57001-1751.

  • Page 487: Suspension 13-9

    Suspension 13-9 front fork rebound damping force adjustment • to adjust the rebound damping force, turn the rebound damping adjuster [a] until you feel a click. ○ the standard adjuster setting is the 2 turns out from the fully clockwise position. Warning if both adjusters are not adjusted equally, h...

  • Page 488: 13-10 Suspension

    13-10 suspension front fork compression damping force adjustment (right side only) • to adjust the compression damping force, turn the com- pression damping adjuster [a] until you feel a click. ○ the standard adjuster setting is the 1 1/4 turns out from the fully clockwise position. Warning if both ...

  • Page 489: Suspension 13-11

    Suspension 13-11 front fork front fork installation • install the fork so that the top end [a] of the outer tube as shown in the figure. 28 mm (1.10 in.) [b] • tighten: torque - lower front fork clamp bolts : 25 n·m (2.5 kgf·m, 18 ft·lb) front fork top plugs: 34 n·m (3.5 kgf·m, 25 ft·lb) upper front...

  • Page 490: 13-12 Suspension

    13-12 suspension front fork • install the clamps [a] as shown in the figure. Note ○ set the cutout [b] of the clamp to the groove [c] of collar [d], pull up the outer tube [e] to hold it by the clamps, and then tighten the two bolts [f]. The outer tube is used as a guide. Special tools - fork spring...

  • Page 491: Suspension 13-13

    Suspension 13-13 front fork • set the holder bar [a] and compression shafts [b]. • screw in the nuts [a] until the piston rod nut comes out. • while holding up the top plug [a], insert the fork spring stopper [b] between the piston rod nut [c] and the slider. Special tool - fork spring stopper: 5700...

  • Page 492: 13-14 Suspension

    13-14 suspension front fork • drain the fork oil into a suitable container. ○ pump the piston rod [a] up and down at least ten times to expel the oil from the fork. Special tool - fork piston rod puller, m12 × 1.25 [b]: 57001-1289 • hold the fork tube upright, press the outer tube [a] and the piston...

  • Page 493: Suspension 13-15

    Suspension 13-15 front fork oil level (fully compressed, without spring) standard: 91 ±2 mm (3.58 ±0.08 in.) (from the top of the outer tube) note ○ fork oil level may also be measured using the fork oil level gauge. Special tool - fork oil level gauge [a]: 57001-1290 ○ with the fork fully compresse...

  • Page 494: 13-16 Suspension

    13-16 suspension front fork • check the distance between the upper end [a] of the spring preload adjuster [b] and rebound damping adjuster [c] with a pair of vernier caliper. 1.5 mm (0.059 in.) [d] • set the fork spring compressor on the slider [a] using the outer tube as a guide. Special tools - fo...

  • Page 495: Suspension 13-17

    Suspension 13-17 front fork front fork disassembly • remove the front fork (see front fork removal). • drain the fork oil (see fork oil change). • install the suitable pipe ( 26 ∼ 32) [a] into the cylinder unit. • set the fork leg inverted. • while pushing down [b] the fork leg, loosen the bottom al...

  • Page 496: 13-18 Suspension

    13-18 suspension front fork front fork assembly • replace the following parts with new one. Oil seal [a] outer tube guide bushing [b] inner tube guide bushing [c] dust seal [d] retaining ring [e] bottom allen bolt gasket • install the following parts onto the inner tube. Dust seal retaining ring oil...

  • Page 497: Suspension 13-19

    Suspension 13-19 front fork inner tube, outer tube inspection • visually inspect the inner tube [a], and repair any dam- age. • nick or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage. If the damage is not repairable, replace t...

  • Page 498: 13-20 Suspension

    13-20 suspension rear shock absorber rebound damping force adjustment • to adjust the rebound damping force, turn the lower damping adjuster [a] to the desired position, until you feel a click. ○ the standard adjuster setting is the 1 1/4 turns out from the fully clockwise position. Rebound damping ...

  • Page 499: Suspension 13-21

    Suspension 13-21 rear shock absorber rear shock absorber removal • support the motorcycle with the stand. • remove: bolts [a] sidestand bracket [b] with the sidestand • squeeze the brake lever slowly and hold it with a band [a]. • raise the rear wheel off the ground with the jack. Special tools - ja...

  • Page 500: 13-22 Suspension

    13-22 suspension rear shock absorber rear shock absorber inspection • remove the rear shock absorber (see rear shock ab- sorber removal). • visually inspect the following items. Smooth stroke oil leakage crack or dent if there is any damage to the rear shock absorber, replace it. • visually inspect ...

  • Page 501: Suspension 13-23

    Suspension 13-23 swingarm swingarm removal • remove: rear brake hose lower end (see rear caliper removal in the brakes chapter) rear wheel (see rear wheel removal in the wheels/tires chapter) mud guard (see mad guard removal in the frame chapter) rocker arm (see rocker arm removal) • remove: cotter ...

  • Page 502: 13-24 Suspension

    13-24 suspension swingarm • turn the swingarm pivot shaft [a] counterclockwise to free the adjusting collar from the swingarm. ○ make the gap between the adjusting collar and swingarm. • pull out the pivot shaft to the right side and remove the swingarm. Swingarm installation • visually inspect the ...

  • Page 503: Suspension 13-25

    Suspension 13-25 swingarm • tighten the swingarm pivot shaft nut. Torque - swingarm pivot shaft nut: 108 n·m (11.0 kgf·m, 79.7 ft·lb) • move the swingarm up and down to check for abnormal friction. • install the removed parts (see appropriate chapters). Swingarm bearing removal • remove: swingarm (s...

  • Page 504: 13-26 Suspension

    13-26 suspension swingarm swingarm bearing, sleeve inspection notice do not remove the bearings for inspection. Re- moval may damage them. • inspect the needle bearings [a] and ball bearing [b] in- stalled in the swingarm. ○ the rollers and ball in a bearing normally wear very little, and wear is di...

  • Page 505: Suspension 13-27

    Suspension 13-27 tie-rod, rocker arm tie-rod removal • remove: mud guard (see mud guard removal in the frame chapter) • squeeze the brake lever slowly and hold it with a band [a]. • raise the rear wheel off the ground with the jack (see rear shock absorber removal). Special tools - jack: 57001-1238 ...

  • Page 506: 13-28 Suspension

    13-28 suspension tie-rod, rocker arm tie-rod and rocker arm bearing removal • remove: tie-rods (see tie-rod removal) rocker arm (see rocker arm removal) sleeves [a] oil seals [b] swingarm [c] (see swingarm removal) • remove the needle bearings [d], using the bearing re- mover head and bearing remove...

  • Page 507: Suspension 13-29

    Suspension 13-29 tie-rod, rocker arm rocker arm/tie-rod bearing, sleeve inspection notice do not remove the bearings for inspection. Re- moval may damage them. • visually inspect the rocker arm, or tie-rod sleeves [a] and needle bearings [b]. • the rollers in a needle bearing normally wear very litt...

  • Page 509: Steering 14-1

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

  • Page 510: 14-2 Steering

    14-2 steering exploded view.

  • Page 511: Steering 14-3

    Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 left switch housing screws 3.5 0.36 31 in·lb 2 upper front fork clamp bolts 25 2.5 18 3 handlebar holder bolts 25 2.5 18 4 handlebar bolts 34 3.5 25 l 5 right switch housing screws 3.5 0.36 31 in·lb 6 steering stem head bolt 1...

  • Page 512: 14-4 Steering

    14-4 steering special tools head pipe outer race press shaft: 57001-1075 head pipe outer race driver, 54.5: 57001-1077 steering stem nut wrench: 57001-1100 steering stem bearing driver, 42.5: 57001-1344 steering stem bearing driver adapter, 41.5: 57001-1345 head pipe outer race driver, 55: 57001-144...

  • Page 513: Steering 14-5

    Steering 14-5 steering steering inspection • refer to the steering play inspection in the periodic main- tenance chapter. Steering adjustment • refer to the steering play adjustment in the periodic maintenance chapter..

  • Page 514: 14-6 Steering

    14-6 steering steering stem stem, stem bearing removal • remove: upper fairing (see upper fairing removal in the frame chapter) upper fairing bracket (see upper fairing bracket re- moval in the frame chapter) meter unit (see meter unit removal in the electrical sys- tem chapter) handlebar (see handl...

  • Page 515: Steering 14-7

    Steering 14-7 steering stem • remove the lower ball bearing inner race (with its oil seal) [a] which is pressed onto the steering stem with a suitable commercially available chisel [b]. Stem, stem bearing installation • replace the bearing outer races with new ones. • drive them into the head pipe a...

  • Page 516: 14-8 Steering

    14-8 steering steering stem • settle the bearings in place as follows. ○ tighten the steering stem nut with 55 n·m (5.6 kgf·m, 41 ft·lb) of torque first, and loosen it a fraction of a turn until it turns lightly. Afterward tighten it again with specified torque using a steering stem nut wrench [a]. ...

  • Page 517: Steering 14-9

    Steering 14-9 steering stem steering stem warp • whenever the steering stem is removed, or if the steering can not be adjusted for smooth action, check the steering stem for straightness. If the steering stem [a] is bent, replace the steering stem. Stem cap deterioration, damage replace the stem cap...

  • Page 518: 14-10 Steering

    14-10 steering handlebar handlebar removal • remove: clutch lever clamp bolts [a] clutch lever assembly [b] left switch housing [c] handlebar weight [d] • remove: front master cylinder [a] (see front master cylinder re- moval in the brakes chapter) right switch housing [b] throttle case [c] handleba...

  • Page 519: Steering 14-11

    Steering 14-11 handlebar • apply adhesive cement to the inside of the left handlebar grip. • fit the pin [a] of the handlebar to the recess [b] of the handlebar holder. • apply a non-permanent locking agent to the threads of the handlebar bolts. • tighten: torque - handlebar bolts: 34 n·m (3.5 kgf·m...

  • Page 521: Frame 15-1

    Frame 15-1 15 frame table of contents exploded view................................... 15-2 seats ................................................. 15-8 rear seat removal...................... 15-8 rear seat installation................... 15-8 front seat removal ..................... 15-8 front sea...

  • Page 522: 15-2 Frame

    15-2 frame exploded view.

  • Page 523: Frame 15-3

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 lower fairing upper assembly screws 1.2 0.12 11 in·lb 2 lower fairing lower assembly screws 1.2 0.12 11 in·lb 3 front fender mounting bolts 3.9 0.40 35 in·lb 4 stay assembly mounting bolts 6.9 0.70 61 in·lb 5 stopper mounting bol...

  • Page 524: 15-4 Frame

    15-4 frame exploded view.

  • Page 525: Frame 15-5

    Frame 15-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear frame bracket bolts 44 4.5 32 2 front footpeg bracket bolts 25 2.5 18 3 rear footpeg bracket bolts 25 2.5 18 4 rear frame bolts 25 2.5 18 l 5 sidestand switch bolt 8.8 0.90 78 in·lb l 6 sidestand bracket bolts 49 5.0 36 l 7 ...

  • Page 526: 15-6 Frame

    15-6 frame exploded view.

  • Page 527: Frame 15-7

    Frame 15-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 grab rail mounting bolts 25 2.5 18 ft·lb 2. At model 3. Us, ca, and cal models r: replacement parts.

  • Page 528: 15-8 Frame

    15-8 frame seats rear seat removal • insert the ignition switch key [a] into the seat lock, turning the key clockwise, pulling the front part of the seat [b] up, and pull the seat forward. Rear seat installation • insert the rear seat hook [a] under the rear frame [b]. • insert the seat hook [c] int...

  • Page 529: Frame 15-9

    Frame 15-9 fairings lower fairing removal • remove: quick rivets [a] • remove: quick rivets [a] (both sides) • remove: bolts [a] right side [b] left side [c] • pull out the lower fairing [d] outward to clear the projec- tions [e]. • pull out the lower fairing upward to clear the projection [f] (righ...

  • Page 530: 15-10 Frame

    15-10 frame fairings • disconnect the turn signal light lead connector [a] (both sides). Lower fairing installation • be sure to install the dampers [a] and pad [b] (right side only). Right lower fairing [c] left lower fairing [d] • connect the turn signal light lead connector [a] (both sides). • in...

  • Page 531: Frame 15-11

    Frame 15-11 fairings • insert the hook portions [a] into the slits [b] on the lower fairing (both sides). • insert the stoppers [a] into the dampers [b] on the lower fairing (both sides). • for left lower fairing installation, insert the stopper [a] into the damper [b] on the left lower side fairing...

  • Page 532: 15-12 Frame

    15-12 frame fairings • remove: quick rivet [a] screws [b] inner fairing [c] • remove: screws [a] slat fairing [b] lower fairing upper [c] lower fairing assembly • installation is the reverse of disassembly, note the follow- ing. ○ insert the projection [a] into the hole [b]. ○ tighten: torque - lowe...

  • Page 533: Frame 15-13

    Frame 15-13 fairings rear lower fairing removal • remove the bolt [a]. • pull out the rear lower fairing [b] outward to clear the pro- jections [c]. Rear lower fairing installation • insert the projection [a] into the damper [b] on the right lower fairing. • insert the projection [c] into the damper...

  • Page 534: 15-14 Frame

    15-14 frame fairings • remove: bolts [a] with washers windshield bracket cover [b] • remove: nuts [a] (both sides) rear view mirror [b] (both sides) • remove: bolt [a] (both sides) clamp [b] (left side only) • disconnect: headlight lead connectors [a] city light lead connectors [b] • remove the uppe...

  • Page 535: Frame 15-15

    Frame 15-15 fairings upper fairing disassembly • remove: upper fairing (see upper fairing removal) screws [a] clamp [b] headlights [c] • remove: screw [a] • separate the upper fairing. Upper fairing assembly • fit the projections [a] into the slots [b]. Windshield bracket disassembly • remove: upper...

  • Page 536: 15-16 Frame

    15-16 frame fairings • remove: bolts [a] adjust knob [b] adjust knob bracket [c] • remove: bolts [a] stay shaft [b] lower stays [c] upper stays [d] stoppers [e] windshield bracket assembly • confirm that the upper fairing bracket has been firmly in- stalled by the mounting bolts [a]. • assemble the ...

  • Page 537: Frame 15-17

    Frame 15-17 fairings • apply grease to the dampers [a] and washers [b]. • apply a non-permanent locking agent to the threads of the adjust knob assembly bolts [c]. • install: adjust knob assembly [d] washers dampers collars [e] • install the stay assembly [a]. ○ fit the pis [b] of the adjust knob as...

  • Page 538: 15-18 Frame

    15-18 frame fairings • install: springs [a] • confirm that the position of the windshield stoppers [b] change smoothly and surely. ○ push the adjust knob [c] and change the positions of the windshield stoppers. If the windshield stoppers do not move smoothly re- assemble the windshield bracket. Wind...

  • Page 539: Frame 15-19

    Frame 15-19 side covers side cover removal • remove: lower fairing (see lower fairing removal) bolts [a] with washers • pull the side cover [b] outward to clear the stoppers [c]. Side cover installation • be sure to install the pads [a]. • hang the hooks [a] to the frame. • insert the projections [b...

  • Page 540: 15-20 Frame

    15-20 frame seat covers seat cover removal • remove: seats (see rear/front seat removal) bolts [a] with collars and washers (both sides) grab rail [b] (both sides) • remove: bolts [a] seat cover [b] seat cover installation • installation is the reverse of removal, note the following. ○ fit the craws...

  • Page 541: Frame 15-21

    Frame 15-21 fenders front fender removal • remove: brake hose clamps [a] (both sides) bolts [b] with washers (both sides) reflectors [c] (both sides, us, ca and cal models) front fender [d] front fender installation • installation is the reverse of removal, note the following. ○ install the front fe...

  • Page 542: 15-22 Frame

    15-22 frame fenders • remove: bolts [a] • push the rear fender [a] downward. • remove: relay box [b] ecu [c] • disconnect: turn signal light lead connectors [d] licence plate light lead connector [e] tali light lead connector [f] • remove the rear fender rearward. Flap and rear fender installation •...

  • Page 543: Frame 15-23

    Frame 15-23 frame frame inspection • visually inspect the frame for cracks, dents, bending, or warp. ○ if there is any damage to the frame, replace it. Warning a repaired frame may fail in use, possibly causing an accident resulting in injury or death. If the frame is bent, dented, cracked, or warpe...

  • Page 544: 15-24 Frame

    15-24 frame battery case battery case removal • remove: battery (see battery removal in the electrical system chapter) exhaust butterfly valve actuator [a] (see exhaust but- terfly valve actuator removal in the fuel system (dfi) chapter) seat bracket • disconnect: vehicle-down sensor connector [b] s...

  • Page 545: Frame 15-25

    Frame 15-25 guard mud guard removal • remove: rear lower fairing (see rear lower fairing removal) right front footpeg bracket bolts [a] • remove: bolts [a] • remove: quick rivets [a] mud guard [b] mud guard installation • installation is the reverse of removal, note the following. Torque - front foo...

  • Page 546: 15-26 Frame

    15-26 frame sidestand sidestand removal • raise the rear wheel off the ground with the stand. • remove: sidestand switch bolt [a] and nut [b] sidestand switch [c] • remove: spring [a] sidestand nut [b] sidestand bolt [c] sidestand [d] sidestand installation • apply grease to the sliding area [a] of ...

  • Page 547: Electrical System 16-1

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

  • Page 548: 16-2 Electrical System

    16-2 electrical system brush inspection ............................................................................................................... 16-54 commutator cleaning and inspection............................................................................... 16-54 armature inspection......

  • Page 549: Electrical System 16-3

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

  • Page 550: 16-4 Electrical System

    16-4 electrical system exploded view.

  • Page 551: Electrical System 16-5

    Electrical system 16-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 switch housing screws 3.5 0.36 31 in·lb 2 oxygen sensor (equipped models) 44 4.5 32 3 front brake light switch screw 1.2 0.12 11 in·lb 4 front turn signal light mounting screws 1.2 0.12 11 in·lb 5 licence plate light ...

  • Page 552: 16-6 Electrical System

    16-6 electrical system exploded view.

  • Page 553: Electrical System 16-7

    Electrical system 16-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 intake air temperature sensor mounting screw 1.2 0.12 11 in·ib 2 spark plugs 13 1.3 115 in·lb 3 crankshaft sensor cover bolts 12 1.2 106 in·lb 4 water temperature sensor 30 3.0 22 5 timing rotor bolt 39 4.0 29 6 crank...

  • Page 554: 16-8 Electrical System

    16-8 electrical system exploded view.

  • Page 555: Electrical System 16-9

    Electrical system 16-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 neutral switch 15 1.5 11 2 engine ground cable terminal bolt 9.8 1.0 87 in·lb 3 sidestand switch bolt 8.8 0.90 78 in·lb l 4 speed sensor mounting bolt 6.9 0.70 61 in·lb l 5. Air switching valve 6. Turn signal relay 7....

  • Page 556: 16-10 Electrical System

    16-10 electrical system specifications item standard battery type sealed battery model name ytx9-bs capacity 12 v 8 ah voltage 12.8 v or more charging system type three-phase ac alternator output voltage 43 v or more at 4 000 rpm stator coil resistance 0.18 ∼ 0.28 Ω at 20°c (68°f) charging voltage 1...

  • Page 557: Electrical System 16-11

    Electrical system 16-11 special tools and sealant hand tester: 57001-1394 peak voltage adapter: 57001-1415 lead wire - peak voltage adapter: 57001-1449 needle adapter set: 57001-1457 key registration unit: 57001-1582 grip: 57001-1591 flywheel & pulley holder: 57001-1605 flywheel puller assembly, m38...

  • Page 558: 16-12 Electrical System

    16-12 electrical system special tools and sealant key registration adapter: 57001-1746 rotor holder: 57001-1757 liquid gasket, tb1211f: 92104-0004.

  • Page 559: Electrical System 16-13

    Electrical system 16-13 parts location 1. Timing rotor 2. Crankshaft sensor 3. Oxygen sensor (equipped models) 4. Horn 5. Turn signal relay 6. Relay box 7. Ecu 8. Rear brake light switch 9. Regulator/rectifier.

  • Page 560: 16-14 Electrical System

    16-14 electrical system parts location 10. Water temperature sensor 11. Speed sensor 12. Alternator 13. Stator coil 14. Radiator fan motor 15. Neutral switch 16. Oil pressure switch 17. Sidestand switch 18. Fuse boxes 19. Battery 12 v 8 ah 20. Starter relay 21. Air switching valve 22. Stick coils 23...

  • Page 561: Electrical System 16-15

    Electrical system 16-15 parts location 25. Starter lockout switch 26. Ignition switch (immobilizer model: including immobi- lizer antenna) 27. Meter unit 28. Front brake light switch.

  • Page 562: 16-16 Electrical System

    16-16 electrical system wiring diagram (us, ca and cal models).

  • Page 563: Electrical System 16-17

    Electrical system 16-17 wiring diagram (us, ca and cal models).

  • Page 564: 16-18 Electrical System

    16-18 electrical system wiring diagram (other than us, ca and cal models).

  • Page 565: Electrical System 16-19

    Electrical system 16-19 wiring diagram (other than us, ca and cal models).

  • Page 566: 16-20 Electrical System

    16-20 electrical system wiring diagram (ca with abs models).

  • Page 567: Electrical System 16-21

    Electrical system 16-21 wiring diagram (ca with abs models).

  • Page 568: 16-22 Electrical System

    16-22 electrical system wiring diagram (other than ca with abs models).

  • Page 569: Electrical System 16-23

    Electrical system 16-23 wiring diagram (other than ca with abs models).

  • Page 570: 16-24 Electrical System

    16-24 electrical system precautions there are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○ always check battery con...

  • Page 571: Electrical System 16-25

    Electrical system 16-25 electrical wiring wiring inspection • visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clea...

  • Page 572: 16-26 Electrical System

    16-26 electrical system battery battery removal • turn off the ignition switch. • remove: front seat (see front seat removal in the frame chap- ter) • disconnect the negative (–) cable [a]. Notice be sure to disconnect the negative (–) cable first. • slide out the positive (+) terminal cap [b] and d...

  • Page 573: Electrical System 16-27

    Electrical system 16-27 battery notice do not remove the aluminum sealing sheet [a] from the filler ports [b] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. Danger sulfuric acid in battery electrolyte can cause severe burns. To prevent bur...

  • Page 574: 16-28 Electrical System

    16-28 electrical system battery • check the electrolyte flow. If no air bubbles [a] are coming up from the filler ports, or if the container cells have not emptied completely, tap the container [b] a few times. Note ○ be careful not to have the battery fall down. • keep the container in place. Don’t...

  • Page 575: Electrical System 16-29

    Electrical system 16-29 battery initial charge • newly activated sealed batteries require an initial charge. Standard charge: 0.9 a × 5 ∼ 10 hours if using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers: battery mate...

  • Page 576: 16-30 Electrical System

    16-30 electrical system battery danger batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri- ous injury and burns if ignited. Keep the battery away from sparks and open flames during charging. When using a battery charger, connect the battery to the charger before tu...

  • Page 577: Electrical System 16-31

    Electrical system 16-31 battery terminal voltage: 11.5 ∼ less than 12.8 v standard charge: 0.9 a × 5 ∼ 10 h (see following chart) quick charge: 4 a × 1 h notice if possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on. Terminal voltage: less than 11.5 v char...

  • Page 578: 16-32 Electrical System

    16-32 electrical system charging system alternator cover removal • remove: left lower fairing (see lower fairing removal in the frame chapter) • support the fuel tank with a suitable bar (see fuel tank removal in the fuel system (dfi) chapter). • pull up the connector bracket [a]. • remove the alter...

  • Page 579: Electrical System 16-33

    Electrical system 16-33 charging system stator coil removal • remove: alternator cover (see alternator cover removal) holding plate bolt [a] and plate alternator lead grommet [b] stator coil bolts [c] • remove the stator coil [d] from the alternator cover. Stator coil installation • apply a non-perm...

  • Page 580: 16-34 Electrical System

    16-34 electrical system charging system if using the rotor holder (57001-1757). • hold the alternator rotor steady with the rotor holder [a]. • remove the rotor bolt [b] and washer. Special tool - rotor holder: 57001-1757 • using the flywheel puller [a], remove the alternator rotor [b] from the cran...

  • Page 581: Electrical System 16-35

    Electrical system 16-35 charging system • using a cleaning fluid, clean off any oil or dirt on the washer [a] and dry it with a clean cloth. • install the washer. Note ○ confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque. • install the rotor bolt [b]...

  • Page 582: 16-36 Electrical System

    16-36 electrical system charging system • apply a thin coat of molybdenum disulfide grease to the shaft [a], and install it and starter idle gear [b]. • install the alternator cover (see alternator cover installa- tion). Alternator inspection there are three types of alternator failures: short, open...

  • Page 583: Electrical System 16-37

    Electrical system 16-37 charging system if there is more resistance than shown in the table, or no hand tester reading (infinity) for any two leads, the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced. • using the highest...

  • Page 584: 16-38 Electrical System

    16-38 electrical system charging system regulator circuit check to test the regulator out of circuit, use three 12 v batteries and a test light (12 v 3 ∼ 6 w bulb in a socket with leads). Notice the test light works as an indicator and also a cur- rent limiter to protect the regulator/rectifier from...

  • Page 585: Electrical System 16-39

    Electrical system 16-39 charging system charging voltage inspection • check the battery condition (see charging condition in- spection). • warm up the engine to obtain actual alternator operating conditions. • check that the ignition switch is turned off, and connect the hand tester [a] to the batte...

  • Page 586: 16-40 Electrical System

    16-40 electrical system charging system charging system circuit 1. Regulator/rectifier 2. Alternator 3. Ignition switch 4. Load 5. Main fuse 30 a 6. Battery 12 v 8 ah.

  • Page 587: Electrical System 16-41

    Electrical system 16-41 ignition system warning the ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. Notice do not disconnect the battery cables or any ot...

  • Page 588: 16-42 Electrical System

    16-42 electrical system ignition system • remove: crankshaft sensor bolts [a] crankshaft sensor [b] crankshaft sensor installation • tighten: torque - crankshaft sensor bolts: 5.9 n·m (0.60 kgf·m, 52 in·lb) • apply silicone sealant [a] to the crankshaft sensor lead grommet and crankcase halves matin...

  • Page 589: Electrical System 16-43

    Electrical system 16-43 ignition system crankshaft sensor inspection • remove: crankshaft sensor lead connector [a] (see crankshaft sensor removal) • set the hand tester [b] to the × 100 Ω range and connect (+) lead to the yellow lead and (–) lead to the black lead in the connector. Special tools - ...

  • Page 590: 16-44 Electrical System

    16-44 electrical system ignition system timing rotor removal • remove the crankshaft sensor (see crankshaft sensor removal). • remove the timing rotor [a]. ○ holding the timing rotor with the flywheel & pulley holder [b] and remove the rotor bolt [c]. Special tool - flywheel & pulley holder: 57001-1...

  • Page 591: Electrical System 16-45

    Electrical system 16-45 ignition system stick coil inspection • remove the stick coils (see stick coil removal). • measure the primary winding resistance [a] as follows. ○ connect the hand tester between the coil terminals. ○ set the tester to the × 1 Ω range, and read the tester. • measure the seco...

  • Page 592: 16-46 Electrical System

    16-46 electrical system ignition system warning to avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • turn the ignition switch and the engine stop switch on. • pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measur...

  • Page 593: Electrical System 16-47

    Electrical system 16-47 ignition system 2nd check • start the engine to the following conditions. Condition: transmission gear → 1st position clutch lever → pulled in sidestand → up ○ turn the ignition switch on and push the starter button. ○ then the starter motor should turn when the starter sys- ...

  • Page 594: 16-48 Electrical System

    16-48 electrical system ignition system.

  • Page 595: Electrical System 16-49

    Electrical system 16-49 ignition system ignition system circuit 1. Ignition switch 2. Fuse box 2 3. Ignition fuse 15 a 4. Engine stop switch 5. Stick coils 6. Spark plugs 7. Subthrottle sensor 8. Main throttle sensor 9. Oxygen sensor (equipped models) 10. Speed sensor 11. To meter unit 12. Frame gro...

  • Page 596: 16-50 Electrical System

    16-50 electrical system electric starter system starter motor removal notice do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: left lower fairing (see lower fairing rem...

  • Page 597: Electrical System 16-51

    Electrical system 16-51 electric starter system starter motor installation notice do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • when installing the starter motor, clean the starter mo- tor legs [a] and crankcase [b] where the starter motor is grounde...

  • Page 598: 16-52 Electrical System

    16-52 electrical system electric starter system • remove the starter motor terminal locknut [a]. • pull out the brushes from the brush holder [a]. • remove: brush springs [b] starter motor terminal [c] positive brush assy [d] screw [e] negative brush assy [f] brush holder starter motor assembly • al...

  • Page 599: Electrical System 16-53

    Electrical system 16-53 electric starter system • replace the o-ring [a] with a new one. • install the following parts to the starter motor terminal [b]. New o-ring collar [c] washer [d] starter motor terminal locknut [e] ○ install the collar so that stepped side faces outward. • tighten: torque - s...

  • Page 600: 16-54 Electrical System

    16-54 electrical system electric starter system • align the marks [a] to assemble the yoke and the end cover [b]. • tighten: torque - starter motor through bolts [a]: 4.9 n·m (0.50 kgf·m, 43 in·lb) brush inspection • measure the length of each brushes [a]. If any is worn down to the service limit, r...

  • Page 601: Electrical System 16-55

    Electrical system 16-55 electric starter system armature inspection • using the × 1 Ω hand tester range, measure the resis- tance between any two commutator segments [a]. Special tool - hand tester: 57001-1394 if there is a high resistance or no reading ( ∞) between any two segments, a winding is op...

  • Page 602: 16-56 Electrical System

    16-56 electrical system electric starter system • remove the cable terminal cover [a]. • disconnect: connector [a] cable terminals [b] • remove: starter relay [c] • connect the hand tester [a] and 12 v battery [b] to the starter relay [c] as shown in the figure. Special tool - hand tester: 57001-139...

  • Page 603: Electrical System 16-57

    Electrical system 16-57 electric starter system electric starter circuit 1. Ignition switch 2. Fuse box 2 3. Ignition fuse 15 a 4. Engine stop switch 5. Starter button 6. Frame ground 7. Sidestand switch 8. Neutral switch 9. Starter lockout switch 10. Relay box 11. Starter circuit relay 12. Starter ...

  • Page 604: 16-58 Electrical System

    16-58 electrical system lighting system this motorcycle adopt the daylight system and have a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays o...

  • Page 605: Electrical System 16-59

    Electrical system 16-59 lighting system • fit the projection [a] of the bulb in the hollow [b] of the headlight. • install the hook [a]. • fit the dust cover [a] firmly onto the bulb so that the top mark [b] is aligned with the arrow mark [c] on the head- light. • be sure to fit the dust cover [a] o...

  • Page 606: 16-60 Electrical System

    16-60 electrical system lighting system city light bulb replacement • remove: meter cover (see upper fairing removal in the frame chapter) • pull out the socket [a] and remove it with the bulb. • pull out the bulb [a] straight from the socket. Notice do not turn the bulb. Pull the bulb out to preven...

  • Page 607: Electrical System 16-61

    Electrical system 16-61 lighting system license plate light bulb replacement • remove: screws [a] license plate light cover [b] and lens • pull out the bulb [a]. • replace the bulb with a new one. • insert the new bulb into the socket. • fit the projections [a] on the lens to the cover grooves [b]. ...

  • Page 608: 16-62 Electrical System

    16-62 electrical system lighting system headlight/tail light circuit 1. Fuse box 2 2. Turn signal relay fuse 10 a 3. Headlight fuse 10 a 4. Alternator 5. Meter ground 6. Frame ground 7. Ignition switch 8. Meter unit 9. High beam indicator light (led) 10. City light 12 v 5 w 11. Headlight (high) 12 v...

  • Page 609: Electrical System 16-63

    Electrical system 16-63 lighting system turn signal light bulb replacement front turn signal light • remove: lower fairing (see lower fairing removal in the frame chapter) inner fairings (see inner fairing removal in the frame chapter) • turn the socket [a] counterclockwise and pull out the socket t...

  • Page 610: 16-64 Electrical System

    16-64 electrical system lighting system • push and turn the bulb [a] counterclockwise and remove it. • insert the new bulb [a] by aligning its upper and lower pins [b] with the upper and lower grooves [c] in the socket, and turn the bulb clockwise. ○ turn the bulb about 15°. • fit the projection [a]...

  • Page 611: Electrical System 16-65

    Electrical system 16-65 lighting system • connect one 12 v battery and turn signal lights as indi- cated in the figure, and count how many times the lights flash for one minute. Turn signal relay [a] turn signal lights [b] 12 v battery [c] if the lights do not flash as specified, replace the turn si...

  • Page 612: 16-66 Electrical System

    16-66 electrical system lighting system turn signal light circuit 1. Fuse box 2 2. Turn signal relay fuse 10 a 3. Meter ground 4. Frame ground 5. Ignition switch 6. Meter unit 7. Right turn signal indicator light (led) 8. Left turn signal indicator light (led) 9. Front right turn signal light 12 v 2...

  • Page 613: Electrical System 16-67

    Electrical system 16-67 air switching valve air switching valve operation test • refer to the air suction system damage inspection in the periodic maintenance chapter. Air switching valve unit test • remove the air switching valve (see air switching valve removal in the engine top end chapter). • se...

  • Page 614: 16-68 Electrical System

    16-68 electrical system air switching valve air switching valve circuit 1. Ignition switch 2. Fuse box 2 3. Ignition fuse 15 a 4. Engine stop switch 5. Air switching valve 6. Frame ground 7. Ecu 8. Relay box 9. Ecu main relay 10. Fuel pump relay 11. Fi fuse 15 a 12. Main fuse 30 a 13. Battery 12 v 8...

  • Page 615: Electrical System 16-69

    Electrical system 16-69 radiator fan system fan motor inspection • remove the left lower fairing (see lower fairing removal in the frame chapter). • remove the rubber band [a]. • slide the dust cover [a]. • disconnect the connector [b]. • using an auxiliary leads, supply battery power to the fan mot...

  • Page 616: 16-70 Electrical System

    16-70 electrical system radiator fan system radiator fan circuit 1. Radiator fan motor 2. Fuse box 2 3. Fan fuse 15 a 4. Meter ground 5. Frame ground 6. Water temperature sensor 7. Ecu 8. Ignition switch 9. Water-proof joint a 10. Relay box 11. Radiator fan relay 12. Fi fuse 15 a 13. Main fuse 30 a ...

  • Page 617: Electrical System 16-71

    Electrical system 16-71 meter, gauge, indicator unit meter unit removal/installation • remove: windshield bracket cover (see upper fairing removal in the frame chapter) • slide the dust cover [a] and disconnect the connector. • pull the meter unit [b] forward to remove it from the bracket [c]. Notic...

  • Page 618: 16-72 Electrical System

    16-72 electrical system meter, gauge, indicator unit electronic combination meter unit inspection • remove the meter unit [a]. [1] neutral indicator light (led) ground (–) [2] right turn signal indicator light (led) (+) [3] high beam indicator light (led) (+) [4] water temperature sensor [5] unused ...

  • Page 619: Electrical System 16-73

    Electrical system 16-73 meter, gauge, indicator unit • connect the terminal [15] to the battery (+) terminal. • check the following items. ○ the tachometer needle momentarily points their last read- ings and back to the minimum position. ○ all the lcd (liquid crystal display) segments [a] and warnin...

  • Page 620: 16-74 Electrical System

    16-74 electrical system meter, gauge, indicator unit check 2: meter communication line (service code 39) check • connect the leads in the same circuit as check 1. • wait 10 seconds and the fi in the display and warning indicator light (led) flash. • set the odo mode [a] by pushing the mode button [b...

  • Page 621: Electrical System 16-75

    Electrical system 16-75 meter, gauge, indicator unit • by pushing the mode button [a] each time, check that the display [b] changes as follows. If the display function does not work, replace the meter assembly. Check 4: clock setting check • connect the leads in the same circuit as check 1. • set th...

  • Page 622: 16-76 Electrical System

    16-76 electrical system meter, gauge, indicator unit • by pushing the reset button, check that the hour and minute display start flashing. • by pushing the mode button, check that the hour and minute display decide. • when both hour and minute display is flashing, by push- ing the reset button, chec...

  • Page 623: Electrical System 16-77

    Electrical system 16-77 meter, gauge, indicator unit • push the mode [a] and reset [b] buttons more than 2 second, within 20 seconds after the terminal [15] discon- nected. • check that the warning indicator light (led) [c] goes on one second, and then the light starts flashing (immobilizer warning ...

  • Page 624: 16-78 Electrical System

    16-78 electrical system meter, gauge, indicator unit check 8: right turn signal indicator light (led) in- spection • connect the leads in the same circuit as check 1. • connect the terminal [9] to the battery (+) terminal. • check that the right turn signal indicator light (led) [a] goes on. If the ...

  • Page 625: Electrical System 16-79

    Electrical system 16-79 meter, gauge, indicator unit • check that the abs indicator light (led) [a] goes off. If the indicator light (led) does not go off, replace the meter assembly. Check 11: oil pressure warning indicator light (led) inspection • connect the leads in the same circuit as check 1. ...

  • Page 626: 16-80 Electrical System

    16-80 electrical system meter, gauge, indicator unit check 13: fuel gauge inspection • connect the leads in the same circuit as check 1. ○ the all segments of the fuel gauge in the display will flash. • connect the variable rheostat [a] to the terminal [16] and the battery (–) terminal. • check that...

  • Page 627: Electrical System 16-81

    Electrical system 16-81 meter, gauge, indicator unit check 16: trip a/b meter check • check the trip meter with the speedometer in the same way. If value indicated in the trip meter is not added, replace the meter unit. • check that when the reset button is pushed for more than two seconds, the figu...

  • Page 628: 16-82 Electrical System

    16-82 electrical system meter, gauge, indicator unit meter circuit 1. Meter unit 2. To turn signal switch (right) 3. To turn signal switch (left) 4. To dimmer switch and passing button (equipped models) 5. Ignition switch 6. Abs hydrauric unit (equipped models) 7. To france ground 8. Fuel level gaug...

  • Page 629: Electrical System 16-83

    Electrical system 16-83 immobilizer system (equipped models) this motorcycle is equipped with an immobilizer system to protect the motorcycle from theft. This system provides a theft proof device by means of matching a code between the inbuilt key transponder and ecu (electronic control unit). If th...

  • Page 630: 16-84 Electrical System

    16-84 electrical system immobilizer system (equipped models) • insert the registered ignition key into the ignition switch, and turn it to on. Verified ○ the warning indicator light (led) and the immobilizer warning symbol [a] blink to display the registration mode (go to the next step). Not verifie...

  • Page 631: Electrical System 16-85

    Electrical system 16-85 immobilizer system (equipped models) ○ if there is any problem in the registration, the warning indicator light (led) and the immobilizer warning symbol [a] blink to display the collation error. Immobilizer amplifier failure when registered ignition key is inserted. Ignition ...

  • Page 632: 16-86 Electrical System

    16-86 electrical system immobilizer system (equipped models) • insert the ignition key 2 to the ignition switch and turn it to on. ○ if there is any problem in the registration, the warning indicator light (led) and the immobilizer warning symbol [a] blink to display the collation error. Immobilizer...

  • Page 633: Electrical System 16-87

    Electrical system 16-87 immobilizer system (equipped models) • the warning indicator light (led) [a] goes off. • remove the key registration unit, key registration adapter and install the immobilizer/kawasaki diagnostic system connector cap. Note ○ turn the ignition switch to on with the registered ...

  • Page 634: 16-88 Electrical System

    16-88 electrical system immobilizer system (equipped models) spare ignition key registration flow chart.

  • Page 635: Electrical System 16-89

    Electrical system 16-89 immobilizer system (equipped models) case 2: when the ignition switch is faulty and has to be replaced. • prepare a new ignition switch [a] and two new ignition keys [b]. ○ these parts are available as a set. Prepare the current registered ignition key [c]. • remove: ignition...

  • Page 636: 16-90 Electrical System

    16-90 electrical system immobilizer system (equipped models) verified ○ the warning indicator light (led) and the immobilizer warning symbol [a] blink to display the ecu is in the registration mode (go to the next step). Not verified ○ the warning indicator light (led) and the immobilizer warning sy...

  • Page 637: Electrical System 16-91

    Electrical system 16-91 immobilizer system (equipped models) ○ if there is any problem in the registration, the warning indicator light (led) and the immobilizer warning symbol [a] blink to display the collation error. Immobilizer amplifier failure when registered ignition key is inserted. Ignition ...

  • Page 638: 16-92 Electrical System

    16-92 electrical system immobilizer system (equipped models) ○ if there is any problem in the registration, the warning indicator light (led) and the immobilizer warning symbol [a] blink to display the collation error. Immobilizer amplifier failure when registered ignition key is inserted. Ignition ...

  • Page 639: Electrical System 16-93

    Electrical system 16-93 immobilizer system (equipped models) • remove the key registration unit, key registration adapter and install the immobilizer/kawasaki diagnostic system connector cap. Note ○ turn the ignition switch to on with the registered ignition key. ○ check that the engine can be start...

  • Page 640: 16-94 Electrical System

    16-94 electrical system immobilizer system (equipped models) • the registered ignition key is successfully registered in the ecu. ○ the warning indicator light (led) and the immobilizer warning symbol [a] blink 1 time and stop for 1 second and then repeat this cycle. • turn to off the ignition switc...

  • Page 641: Electrical System 16-95

    Electrical system 16-95 immobilizer system (equipped models) ignition key collation error • the other remaining ignition key is registered in the ecu. ○ the warning indicator light (led) and the immobilizer warning symbol [a] blink 2 times and stop for 1 second and then repeat this cycle. • turn to ...

  • Page 642: 16-96 Electrical System

    16-96 electrical system immobilizer system (equipped models) when registered ignition key is inserted. Ignition key collation error • the ignition key 1 is successfully registered in the ecu. ○ the warning indicator light (led) and the immobilizer warning symbol [a] blink 3 times and stop for 1 seco...

  • Page 643: Electrical System 16-97

    Electrical system 16-97 immobilizer system (equipped models) case 4: when all registered ignition keys are faulty or lost. The all registered ignition keys replacement is considered very rare case. However if it is required, the following is necessary. Note ○ the ecu must be replaced with a new one ...

  • Page 644: 16-98 Electrical System

    16-98 electrical system immobilizer system (equipped models) • the first ignition key is successfully registered in the ecu. ○ the warning indicator light (led) and the immobilizer warning symbol [a] blink 1 time and stops for 1 second and the repeats this cycle to indicate successful registra- tion...

  • Page 645: Electrical System 16-99

    Electrical system 16-99 immobilizer system (equipped models) ignition key collation error • the second ignition key is registered in the ecu. ○ the warning indicator light (led) and the immobilizer warning symbol [a] blinks 2 time and stops for 1 second and the repeats this cycle to indicate success...

  • Page 646: 16-100 Electrical System

    16-100 electrical system immobilizer system (equipped models) all keys initial registration flow chart.

  • Page 647: Electrical System 16-101

    Electrical system 16-101 immobilizer system (equipped models) immobilizer system parts replacement ignition switch (immobilizer antenna) replacement • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) handlebar holder (see handlebar removal in the steer- ing chapter) left lo...

  • Page 648: 16-102 Electrical System

    16-102 electrical system immobilizer system (equipped models) ecu (electronic control unit) replacement (for immo- bilizer models) notice never drop the ecu, especially on a hard surface. Such a shock to the ecu can damage it. • remove: front seat (see front seat removal in the frame chap- ter) • us...

  • Page 649: Electrical System 16-103

    Electrical system 16-103 immobilizer system (equipped models) immobilizer system circuit 1. Fuse box 2 2. Ignition fuse 15 a 3. Meter ground 4. Frame ground 5. Ecu 6. Ignition switch 7. Immobilizer antenna 8. Immobilizer amplifier 9. Meter unit 10. Water temperature/oil pressure/fi/immobilizer warni...

  • Page 650: 16-104 Electrical System

    16-104 electrical system switches and sensors brake light timing inspection • refer to the brake light switch operation inspection in the periodic maintenance chapter. Brake light timing adjustment • refer to the brake light switch operation inspection in the periodic maintenance chapter. Switch ins...

  • Page 651: Electrical System 16-105

    Electrical system 16-105 switches and sensors water temperature sensor inspection • remove the water temperature sensor (see water tem- perature sensor removal/installation in the fuel system (dfi) chapter). • suspend the sensor [a] in a container of coolant so that the threaded portion is submerged...

  • Page 652: 16-106 Electrical System

    16-106 electrical system switches and sensors speed sensor installation • apply a non-parmanent locking agent to the speed sensor mounting bolt [a]. • install the speed sensor [b] to the inner engine sprocket cover. • tighten: torque - speed sensor mounting bolt: 6.9 n·m (0.70 kgf·m, 61 in·lb) • ins...

  • Page 653: Electrical System 16-107

    Electrical system 16-107 switches and sensors • clear the oxygen sensor lead from the clamp [a]. • remove the oxygen sensor [b]. Oxygen sensor installation (equipped models) notice never drop the oxygen sensor [a] especially on a hard surface. Such a shock to the unit can damage it. Do not touch the...

  • Page 654: 16-108 Electrical System

    16-108 electrical system relay box the relay box [a] has relays and diodes. The relays and diodes can not be removed. Relay box removal notice never drop the relay box especially on a hard sur- face. Such a shock to the relay box can damage it. • remove the rear fender from the battery case and rear...

  • Page 655: Electrical System 16-109

    Electrical system 16-109 relay box relay circuit inspection (with the battery connected) battery connection (+) (–) tester connection tester reading ( Ω) 2-11 1-3 0 ecu main relay 4-5 7-6 0 fuel pump relay 9-10 7-8 0 fan relay 18-19 17-20 0 battery connection (+) (–) tester connection dc 25 v range ...

  • Page 656: 16-110 Electrical System

    16-110 electrical system relay box relay box internal circuit a: headlight relay b: ecu main relay c: fuel pump relay d: starter circuit relay e: fan relay.

  • Page 657: Electrical System 16-111

    Electrical system 16-111 fuse 30 a main fuse removal • remove: starter cable terminal cover (see starter relay inspec- tion) • pull out the main fuse [a] from the starter relay with a needle nose pliers. Fuse box fuse removal • remove: front seat (see front seat removal in the frame chap- ter) • unl...

  • Page 658: 16-112 Electrical System

    16-112 electrical system fuse fuse inspection • remove the fuse. • inspect the fuse element. If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and relat...

  • Page 659: Appendix 17-1

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

  • Page 660: 17-2 Appendix

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

  • Page 661: Appendix 17-3

    Appendix 17-3 cable, wire, and hose routing 1. Headlight lead 2. Run the brake hose to the rear side of the headlight lead. 3. Brake hose 4. Run the front right turn signal light lead through the air switching valve. And run to the rear side of the light switch housing. 5. Air switching valve clamp ...

  • Page 662: 17-4 Appendix

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

  • Page 663: Appendix 17-5

    Appendix 17-5 cable, wire, and hose routing 1. Insert the clamp on the main harness to the rib of the frame as shown. 2. Run the headlight lead, right and left light switch housing lead, ignition switch lead, immobilizer amplifier lead (equipped models) and radiator fan motor lead to the front side ...

  • Page 664: 17-6 Appendix

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

  • Page 665: Appendix 17-7

    Appendix 17-7 cable, wire, and hose routing 1. Run the fuel pump lead to the upside of the exhaust butterfly valve cables, to the outside of the fuse box, and to under the fuel tank bracket. 2. Run the rear of main harness to inside of the battery case, to underside of the fuel pump lead, to rear of...

  • Page 666: 17-8 Appendix

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

  • Page 667: Appendix 17-9

    Appendix 17-9 cable, wire, and hose routing 1. Run the oxygen sensor lead (equipped models), crankshaft sensor lead and rear brake light switch lead to the outside of main harness. 2. Crankshaft sensor lead 3. Hold the rear brake light switch connector with the clamp. 4. Rear brake light switch lead...

  • Page 668: 17-10 Appendix

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

  • Page 669: Appendix 17-11

    Appendix 17-11 cable, wire, and hose routing 1. Kawasaki diagnostic system connector 2. Abs self-diagnosis connector (abs equipped models) 3. Relay box 4. Rear left turn signal light lead 5. Rear right turn signal light lead 6. Ecu 7. Run the leads to forward of the rear fender wall connect them. 8....

  • Page 670: 17-12 Appendix

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

  • Page 671: Appendix 17-13

    Appendix 17-13 cable, wire, and hose routing 1. Throttle cable (accelerator) 2. Throttle cable (decelerator) 3. Right switch housing lead 4. Brake hose 5. Clamp the brake hose, throttle cable (decelerator), throttle cable (accelerator) and right switch housing lead in order from the outside of frame...

  • Page 672: 17-14 Appendix

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

  • Page 673: Appendix 17-15

    Appendix 17-15 cable, wire, and hose routing 1. Run the exhaust butterfly valve cables to inside of the main harness. 2. Exhaust butterfly valve close cable 3. Exhaust butterfly valve open cable 4. Main harness.

  • Page 674: 17-16 Appendix

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

  • Page 675: Appendix 17-17

    Appendix 17-17 cable, wire, and hose routing 1. Bend the clamp upward to secure the harness at the portion of the taped. 2. Install the main harness clamp at the headlight bracket. 3. Bend the clamp reward to inside to secure the harness at the portion of the taped. 4. Main harness.

  • Page 676: 17-18 Appendix

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

  • Page 677: Appendix 17-19

    Appendix 17-19 cable, wire, and hose routing 1. Clamp 2. Run the clutch cable and left switch housing lead in order from the inside of clamp. 3. Clamp 4. Run the left switch housing leads, ignition switch lead, immobilizer antenna lead (equipped mod- els), and clutch cables to the inside of the fron...

  • Page 678: 17-20 Appendix

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

  • Page 679: Appendix 17-21

    Appendix 17-21 cable, wire, and hose routing 1. Insert the hole on the engine top heat protector into the slit on the radiator side pad. 2. Connect the left turn signal light lead at the rear of radiator side pad, and push its connector into the cutout on the pad. 3. Band 4. Cover the right switch h...

  • Page 680: 17-22 Appendix

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

  • Page 681: Appendix 17-23

    Appendix 17-23 cable, wire, and hose routing 1. Air cleaner drain hose 2. Neutral switch/oil pressure switch lead 3. Idle adjusting screw 4. Run the starter motor cable to the upside of the idle adjusting screw. 5. Sidestand switch lead 6. Speed sensor lead 7. Fuel tank breather hose (other than cal...

  • Page 682: 17-24 Appendix

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

  • Page 683: Appendix 17-25

    Appendix 17-25 cable, wire, and hose routing 1. Air cleaner drain hose 2. Idle adjusting screw 3. Run the idle adjusting screw to the under of the starter motor cable, outside of the air cleaner drain hose. 4. Starter motor cable 5. Run the fuel hose, starter motor cable, and alternator lead in orde...

  • Page 684: 17-26 Appendix

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

  • Page 685: Appendix 17-27

    Appendix 17-27 cable, wire, and hose routing 1. Air cleaner housing 2. Air switching valve hose 3. Air switching valve 4. Tighten the clamp bolt from left side. 5. Tighten the clamp bolt from right side. 6. Intake air temperature sensor 7. Install the clamp so that knob of the clamp faces rear side ...

  • Page 686: 17-28 Appendix

    17-28 appendix cable, wire, and hose routing.

  • Page 687: Appendix 17-29

    Appendix 17-29 cable, wire, and hose routing 1. Insert the subharness connector to the clamp on the air suction valve cover. 2. Run the subharness under the hose. 3. Hose 4. Subharness 5. Run the subharness between the #1 and #2 throttle body holders so as not to pinch the lead with the throttle bod...

  • Page 688: 17-30 Appendix

    17-30 appendix cable, wire, and hose routing.

  • Page 689: Appendix 17-31

    Appendix 17-31 cable, wire, and hose routing 1. Regulator/rectifier harness 2. Hold the regulator/rectifier harness with clamp. 3. Rear brake light switch lead 4. Exhaust butterfly valve open cable 5. Exhaust butterfly valve close cable 6. Oxygen sensor lead (equipped models) 7. Run the rear brake l...

  • Page 690: 17-32 Appendix

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

  • Page 691: Appendix 17-33

    Appendix 17-33 cable, wire, and hose routing 1. Install the clamps as shown in the direction. 2. Reserve tank hose 3. Radiator hose 4. Water hose 5. Water hose 6. Reserve tank 7. Reserve tank overflow hose 8. Thermostat 9. Radiator 10. Radiator hose 11. Water pipe 12. Oil cooler 13. Water hose 14. W...

  • Page 692: 17-34 Appendix

    17-34 appendix cable, wire, and hose routing.

  • Page 693: Appendix 17-35

    Appendix 17-35 cable, wire, and hose routing 1. Install the clamps so that its opening facing the direction indicated with arrow. 2. Clamp (for water hose) 3. Clamp (for radiator hose) 4. Hold the clutch cable with clamp. 5. Run the front right turn signal light lead to the upside of the reserve tan...

  • Page 694: 17-36 Appendix

    17-36 appendix cable, wire, and hose routing.

  • Page 695: Appendix 17-37

    Appendix 17-37 cable, wire, and hose routing 1. Run the reserve tank overflow hose to the inside of the frame. 2. Reserve tank overflow hose 3. Run the water hose, reserve tank overflow hose, water hose in order the outside of frame. 4. Water hose 5. Water hose 6. Connect the right turn signal light...

  • Page 696: 17-38 Appendix

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

  • Page 697: Appendix 17-39

    Appendix 17-39 cable, wire, and hose routing 1. Radiator hose 2. Install the clamps as shown, noting its screw head direction. 3. White paint mark (install the water hose so that the white paint mark faces upside of the engine.) 4. Water hose 5. White paint mark (install the water hose so that the w...

  • Page 698: 17-40 Appendix

    17-40 appendix cable, wire, and hose routing abs equipped models.

  • Page 699: Appendix 17-41

    Appendix 17-41 cable, wire, and hose routing 1. Front wheel rotation sensor lead 2. Clamps (for brake hose and front wheel rotation sensor lead) 3. Front wheel rotation sensor connector 4. Headlight lead 5. Run the front wheel rotation sensor lead to the outside of the headlight lead, and connect th...

  • Page 700: 17-42 Appendix

    17-42 appendix cable, wire, and hose routing abs equipped models.

  • Page 701: Appendix 17-43

    Appendix 17-43 cable, wire, and hose routing 1. Hold the brake hose inside the front wheel rotation sensor lead with clamp. Install the clamp with its closed side facing forward. 2. Hold the brake hose at the rubber portions with the clamp. 3. Run the front wheel rotation sensor lead to the rear sid...

  • Page 702: 17-44 Appendix

    17-44 appendix cable, wire, and hose routing abs equipped models.

  • Page 703: Appendix 17-45

    Appendix 17-45 cable, wire, and hose routing 1. Brake pipe 2. Brake pipe 3. Brake hose 4. Front 5. Clamp (hold the brake pipes) 6. Hold the brake pipes at the rubber portions with the clamps. 7. Rear wheel rotation sensor lead 8. Run the rear wheel rotation sensor lead to the outside of the main har...

  • Page 704: 17-46 Appendix

    17-46 appendix cable, wire, and hose routing abs equipped models.

  • Page 705: Appendix 17-47

    Appendix 17-47 cable, wire, and hose routing 1. Rear wheel rotation sensor 2. Run the rear wheel rotation sensor lead into the clamp. 3. Rear wheel rotation sensor lead 4. Run the rear wheel rotation sensor lead upper the brake hose, and hold the brake hose at the attaching mark with the clamp. 5. C...

  • Page 706: 17-48 Appendix

    17-48 appendix cable, wire, and hose routing abs equipped models.

  • Page 707: Appendix 17-49

    Appendix 17-49 cable, wire, and hose routing 1. Front 2. Rear wheel rotation sensor lead 3. Run the exhaust butterfly valve close cable, exhaust butterfly valve open cable, brake hose, brake light switch lead, rear wheel rotation sensor lead in order from the inside of frame. 4. Exhaust butterfly va...

  • Page 708: 17-50 Appendix

    17-50 appendix cable, wire, and hose routing abs equipped models.

  • Page 709: Appendix 17-51

    Appendix 17-51 cable, wire, and hose routing 1. Air cleaner drain hose 2. Breather hose 3. Run the breather hose and air cleaner drain hose through the front side of frame ground lead and outside of the starter motor cable. 4. Starter motor (+) cable 5. Run the brake pipe through the inside of the s...

  • Page 710: 17-52 Appendix

    17-52 appendix cable, wire, and hose routing abs equipped models.

  • Page 711: Appendix 17-53

    Appendix 17-53 cable, wire, and hose routing 1. Clamp (hold the each harness.) 2. Regulator/rectifier harness 3. Run the regulator/rectifier harness from the cutout on the battery case to underside of the battery case. 4. Abs hydraulic unit harness 5. Run the rear of main harness to upside of the ba...

  • Page 712: 17-54 Appendix

    17-54 appendix cable, wire, and hose routing abs equipped models.

  • Page 713: Appendix 17-55

    Appendix 17-55 cable, wire, and hose routing 1. Abs hydraulic unit 2. Clamps 3. Brake hose (between front master cylinder and abs hydraulic unit) 4. Brake hose (between abs hydraulic unit and right front caliper) 5. Clamp (hold the grommet of the brake hose only. For zx1000hb late model ∼ , face the...

  • Page 714: 17-56 Appendix

    17-56 appendix cable, wire, and hose routing abs equipped models.

  • Page 715: Appendix 17-57

    Appendix 17-57 cable, wire, and hose routing 1. Abs hydraulic unit 2. Clamps 3. Brake hose (between rear master cylinder and abs hydraulic unit) 4. Brake hose (between abs hydraulic unit and rear caliper) 5. Rear wheel rotation sensor 6. Rear wheel rotation sensor lead 7. Section a-a 8. Section b-b.

  • Page 716: 17-58 Appendix

    17-58 appendix cable, wire, and hose routing.

  • Page 717: Appendix 17-59

    Appendix 17-59 cable, wire, and hose routing 1. Brake hose 2. Headlight lead 3. Run the brake hose to the rear side of the headlight lead. 4. Run the brake hose to the most front side of the other leads and cables, and through it to the clamp. 5. Clamp 6. Front.

  • Page 718: 17-60 Appendix

    17-60 appendix cable, wire, and hose routing.

  • Page 719: Appendix 17-61

    Appendix 17-61 cable, wire, and hose routing 1. (zx1000gb early model) hold the brake hose with the clamp at the grommet of the brake hose, and insert it to the front fender. (zx1000gb late model ∼ ) hold the brake hose with the clamp at the grommet of the brake hose. Face the lock portion of the cl...

  • Page 720: 17-62 Appendix

    17-62 appendix cable, wire, and hose routing.

  • Page 721: Appendix 17-63

    Appendix 17-63 cable, wire, and hose routing 1. Clamp (for brake hose) 2. Brake hose 3. Clamp (for brake hose) 4. Front 5. Fit the brake pipe to the stopper of the caliper as shown, and tighten the brake hose banjo bolt to the specified torque. 6. Clamp (for brake hose).

  • Page 722: 17-64 Appendix

    17-64 appendix cable, wire, and hose routing.

  • Page 723: Appendix 17-65

    Appendix 17-65 cable, wire, and hose routing 1. Viewed from a 2. Fit the projection of the brake hose end to the stopper as shown, and tighten the brake hose banjo bolt to the specified torque. 3. Front.

  • Page 724: 17-66 Appendix

    17-66 appendix cable, wire, and hose routing 1. Brake hoses 2. Clamps (hold the grommet of the brake hose only. For zx1000gb late model ∼ , face the lock portion of the clamp backward.).

  • Page 725: Appendix 17-67

    Appendix 17-67 cable, wire, and hose routing 1. Brake hose 2. Clamps.

  • Page 726: 17-68 Appendix

    17-68 appendix cable, wire, and hose routing cal and sea-b1 models.

  • Page 727: Appendix 17-69

    Appendix 17-69 cable, wire, and hose routing 1. Run the purge hose to the inside of the sidestand switch lead and speed sensor lead, upside of the main harness and frame ground lead. 2. Sidestand switch lead 3. Speed sensor lead 4. Front 5. Main harness 6. Vacuum hose (between separator and throttle...

  • Page 728: 17-70 Appendix

    17-70 appendix cable, wire, and hose routing cal and sea-b1 models.

  • Page 729: Appendix 17-71

    Appendix 17-71 cable, wire, and hose routing 1. Run the water hose, reserve tank overflow hose, purge hose in order from the outside of frame. 2. Purge hose (between canister and fitting for air switching valve) 3. Front 4. Reserve tank overflow hose 5. Water hose 6. Air switching valve hose (betwee...

  • Page 730: 17-72 Appendix

    17-72 appendix cable, wire, and hose routing cal and sea-b1 models.

  • Page 731: Appendix 17-73

    Appendix 17-73 cable, wire, and hose routing 1. Canister 2. Install the canister hose clamps with its tabs facing upward. 3. Main relay lead 4. Run the breather hose and purge hose to the under the main relay lead. 5. Breather hose (between canister and separator) 6. Run the breather hose under the ...

  • Page 732: 17-74 Appendix

    17-74 appendix cable, wire, and hose routing cal and sea-b1 models.

  • Page 733: Appendix 17-75

    Appendix 17-75 cable, wire, and hose routing 1. Air switching valve 2. Hoses 3. Fitting 4. Install the purge hose as shown in the direction. 5. Run the vacuum hose to the front side of the vacuum hose. 6. Vacuum hose 7. Front.

  • Page 734: 17-76 Appendix

    17-76 appendix troubleshooting guide note ○ refer to the fuel system chapter for most of dfi trouble shooting guide. ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common di...

  • Page 735: Appendix 17-77

    Appendix 17-77 troubleshooting guide throttle body assy holder loose air cleaner duct loose compression low: spark plug loose cylinder head not sufficiently tightened down no valve clearance cylinder, piston worn piston ring bad (worn, weak, broken, or sticking) piston ring/groove clearance excessiv...

  • Page 736: 17-78 Appendix

    17-78 appendix troubleshooting guide air cleaner duct loose air cleaner poorly sealed, or missing air cleaner clogged compression high: carbon built up in combustion chamber engine load faulty: clutch slipping engine oil level too high engine oil viscosity too high drive train trouble brake dragging...

  • Page 737: Appendix 17-79

    Appendix 17-79 troubleshooting guide piston ring groove worn piston seizure, damage cylinder head gasket leaking exhaust pipe leaking at cylinder head con- nection crankshaft runout excessive engine mount loose crankshaft bearing worn primary gear worn or chipped camshaft chain tensioner trouble cam...

  • Page 738: 17-80 Appendix

    17-80 appendix troubleshooting guide shock absorption unsatisfactory: (too hard) front fork oil excessive front fork oil viscosity too high rear shock absorber adjustment too hard tire air pressure too high front fork bent (too soft) tire air pressure too low front fork oil insufficient and/or leaki...

  • Page 739: Model Application

    Model application year model beginning frame no. 2011 zx1000gb jkazxcg1 □ ba000001 jkazxt00gga000001 2011 zx1000hb jkazxch1 □ ba000001 jkazxt00gha000001 2012 zx1000gc jkazxcg1 □ ca013001 jkazxt00gga013001 2012 zx1000hc jkazxch1 □ ca003001 jkazxt00gha013001 □ :this digit in the frame number changes f...