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Kawasaki NINJA 650R Service Manual

Summary of NINJA 650R

  • Page 1

    Ninja 650r er-6f er-6f abs motorcycle service manual http://mototh.Com.

  • Page 2

    Http://mototh.Com.

  • 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 4

    Http://mototh.Com.

  • Page 5: Ninja 650R

    Ninja 650r er-6f er-6f abs motorcycle service manual all rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of qual...

  • 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 10

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  • Page 11: General Information

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

  • Page 12

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

  • Page 13

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

  • Page 14

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

  • Page 15

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

  • Page 16

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

  • Page 17

    General information 1-7 model identification ex650c9f (eur models) left side view ex650c9f (eur models) right side view http://mototh.Com.

  • Page 18

    1-8 general information model identification ex650c9f (us, ca models) left side view ex650c9f (us, ca models) right side view http://mototh.Com.

  • Page 19

    General information 1-9 model identification ex650d9f left side view ex650d9f right side view frame number engine number http://mototh.Com.

  • Page 20

    1-10 general information general specifications items ex650c9f, ex650d9f dimensions overall length 2 100 mm (82.68 in.) overall width 760 mm (29.9 in.) overall height 1 200 mm (47.24 in.) wheelbase 1 410 mm (55.51 in.) road clearance 145 mm (5.71 in.) seat height 790 mm (31.1 in.) curb mass: ex650c ...

  • Page 21

    General information 1-11 general specifications items ex650c9f, ex650d9f exhaust: open 50° bbdc close 30° atdc duration 260° lubrication system forced lubrication (semi-dry sump) engine oil: grade api se, sf or sg api sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity sae 10w-40 capacity 2.4 l (2.5...

  • Page 22

    1-12 general information general specifications items ex650c9f, ex650d9f rear suspension: type swingarm wheel travel 125 mm (4.92 in.) brake type: front dual discs rear single disc electrical equipment battery 12 v 10 ah headlight: type semi-sealed beam bulb: high 12 v 55 w + 55 w (quartz-halogen) l...

  • Page 23

    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 24

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  • Page 25: Periodic Maintenance

    Periodic maintenance 2-1 2 periodic maintenance table of contents periodic maintenance chart .............. 2-2 torque and locking agent................. 2-5 specifications .................................... 2-11 special tools ..................................... 2-13 periodic maintenance procedu...

  • Page 26

    2-2 periodic maintenance 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 27

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

  • Page 28

    2-4 periodic maintenance periodic maintenance chart periodic replacement parts frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) item every 1 (0.6) 12 (7.5) 24 (15) 36 (22.5) 48 (30) see page air cleaner element # - replace 2 years 2-44 fuel hose - replace 4 years • 2-44 c...

  • Page 29

    Periodic maintenance 2-5 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 30

    2-6 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks throttle body assy holder bolts 12 1.2 106 in·lb cylinder bolt (m8) 27.5 2.8 20 mo, s cylinder nut 49 5.0 36 mo, s cylinder bolts (m6) 12 1.2 106 in·lb s exhaust pipe manifold holder nuts 17 1.7 13 muffler body...

  • Page 31

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks crankshaft/transmission breather plate bolts 9.8 1.0 87 in·lb l race holder screw 4.9 0.50 43 in·lb l connecting rod big end nuts see text ← ← mo crankcase bolt (m8, l = 110 mm) 27.5 2.8 20 s crankcase bolt (m6...

  • Page 32

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks brakes caliper bleed valve 7.8 0.80 69 in·lb brake hose banjo bolts 25 2.5 18 brake lever pivot bolt 1.0 0.10 9 in·lb si brake lever pivot bolt locknut 5.9 0.60 52 in·lb brake disc mounting bolts 27 2.8 20 l fr...

  • Page 33

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks electrical system tail/brake light mounting bolts 8.8 0.90 78 in·lb license plate light mounting screws 1.2 0.12 11 in·lb alternator cover bolts 9.8 1.0 87 in·lb alternator lead holding plate bolt 9.8 1.0 87 in...

  • Page 34

    2-10 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 35

    Periodic maintenance 2-11 specifications item standard service limit fuel system (dfi) throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 1 300 ±50 r/min (rpm) – – – bypass screws (turn out) 0 ∼ 2 1/2 (for reference) – – – engine vacuum 35.3 ±1.3 kpa (265 ±10 mmhg) – – – air cleaner...

  • Page 36

    2-12 periodic maintenance specifications item standard service limit rear up to 180 kg (397 lb) load: 250 kpa (2.50 kgf/cm², 36 psi) – – – final drive drive chain slack 25 ∼ 35 mm (1.0 ∼ 1.4 in.) – – – chain 20-link length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) standard chain: make d...

  • Page 37

    Periodic maintenance 2-13 special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 oil filter wrench: 57001-1249 vacuum gauge: 57001-1369 throttle sensor setting adapter: 57001-1538 extension tube: 57001-1578 pilot screw adjuster, e: 57001-1603 http://mototh.Com.

  • Page 38

    2-14 periodic maintenance periodic maintenance procedures fuel system (dfi) air cleaner element cleaning note ○ in dusty areas, the element should be cleaned more frequently than the recommended interval. ○ after riding through rain or on muddily roads, the ele- ment should be cleaned immediately. W...

  • Page 39

    Periodic maintenance 2-15 periodic maintenance procedures 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 grip does not retur...

  • Page 40

    2-16 periodic maintenance periodic maintenance procedures • connect a vacuum gauge (special tool) and hoses [a] to the fittings of the throttle body as shown in the figure. Special tool - vacuum gauge: 57001-1369 • connect a highly accurate tachometer to one of the stick coil primary leads. • start ...

  • Page 41

    Periodic maintenance 2-17 periodic maintenance procedures • remove the bypass screw [a], spring [b], washer [c] and o-ring [d]. • check the bypass screw and its hole for carbon deposits. If any carbon accumulates, wipe the carbon off from the bypass screw and the hole, using a cotton pad penetrated ...

  • Page 42

    2-18 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 43

    Periodic maintenance 2-19 periodic maintenance procedures • check the liquid/vapor separator as follows. ○ remove the canister cover on the left side of the frame. ○ disconnect the hoses from the separator, and remove the separator [a]. ○ visually inspect the separator for cracks and other dam- age....

  • Page 44

    2-20 periodic maintenance periodic maintenance procedures water hose damage and installation condition inspection ○ the high pressure inside the water hose can cause coolant to leak [a] or the hose to burst if the line is not properly maintained. • visually inspect the hoses for signs of deteriorati...

  • Page 45

    Periodic maintenance 2-21 periodic maintenance procedures • using the thickness gauge [a], measure the valve clear- ance between cam and valve lifter. Valve clearance standard: exhaust 0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.) inlet 0.15 ∼ 0.21 mm (0.0059 ∼ 0.0083 in.) ○ each piston has two inlet and two...

  • Page 46

    2-22 periodic maintenance periodic maintenance procedures valve clearance adjustment chart inlet 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 th...

  • Page 47

    Periodic maintenance 2-23 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 48

    2-24 periodic maintenance periodic maintenance procedures air suction system damage inspection • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) fuel hose (see fuel hose replacement) • connect the following parts temporary. Fuel pump lead connector [a] fuel level sensor le...

  • Page 49

    Periodic maintenance 2-25 periodic maintenance procedures • remove the right upper fairing cover (see upper fairing cover removal in the frame chapter). • open the clamp [a]. • slide the dust cover [b] out of place. • loosen the locknut [c]. • turn the adjusting nut [d] until the free play is correc...

  • Page 50

    2-26 periodic maintenance periodic maintenance procedures tire tread wear, abnormal wear inspection as the tire tread wears down, the tire becomes more sus- ceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn). So ...

  • Page 51

    Periodic maintenance 2-27 periodic maintenance procedures • raise the rear wheel off the ground with the stand (see rear wheel removal in the wheels/tires chapter). • inspect the roughness of the rear wheel bearing by push- ing and pulling [a] the wheel. • spin [b] the rear wheel lightly, and check ...

  • Page 52

    2-28 periodic maintenance periodic maintenance procedures drive chain slack inspection note ○ check the slack with the motorcycle setting on its side- stand. ○ clean the chain if it is dirty, and lubricate it if it appears dry. • check the wheel alignment (see wheel alignment inspec- tion). • rotate...

  • Page 53

    Periodic maintenance 2-29 periodic maintenance procedures • bend the cotter pin [a] over the nut. Warning if the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condi- tion may result. Wheel alignment inspection • check that the edge [a] on the left wheel...

  • Page 54

    2-30 periodic maintenance periodic maintenance procedures drive chain wear inspection • remove the chain cover (see swingarm removal in the suspension chapter). • rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace t...

  • Page 55

    Periodic maintenance 2-31 periodic maintenance procedures brake system brake fluid leak (brake hose and pipe) inspection • for models equipped with an abs, remove the battery case (see battery case removal in the frame chapter). • apply the brake lever or pedal, and inspect the brake fluid leak from...

  • Page 56

    2-32 periodic maintenance periodic maintenance procedures brake fluid level inspection • check that the brake fluid level in the front brake reservoir [a] is above the lower level line [b]. Note ○ hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid le...

  • Page 57

    Periodic maintenance 2-33 periodic maintenance procedures brake pad wear inspection • check the lining thickness [a] of the pads in each caliper. If the lining thickness of either pad is less than the service limit [b], replace both pads in the caliper as a set. Pad lining thickness standard: front ...

  • Page 58

    2-34 periodic maintenance periodic maintenance procedures if it does not go on, inspect or replace the following items. Battery (see charging condition inspection in the elec- trical system chapter) brake light (led) (see tail/brake light (led) removal in the electrical system chapter) main fuse 30 ...

  • Page 59

    Periodic maintenance 2-35 periodic maintenance procedures rear shock absorber oil leak inspection • visually inspect the shock absorber [a] for oil leakage. If the oil leakage is found on it, replace the shock absorber with a new one. Steering system steering play inspection • raise the front wheel ...

  • Page 60

    2-36 periodic maintenance periodic maintenance procedures • install the claw washer [a] so that its bent side [b] faces upward, and engage the bent claws with the grooves of stem locknut [c]. • hand tighten the stem locknut until it touches the claw washer. • tighten the stem locknut clockwise until...

  • Page 61

    Periodic maintenance 2-37 periodic maintenance procedures electrical system lights and switches operation inspection first step • set the gear position in the neutral position. • turn the ignition switch on. • the following lights should go on according to below table. City lights [a] goes on tailli...

  • Page 62

    2-38 periodic maintenance periodic maintenance procedures second step • turn the ignition switch to p (park) position. • the city light, taillight (led) and license plate light should go on. If the light does not go on, inspect or replace the following item. Ignition switch (see switch inspection in...

  • Page 63

    Periodic maintenance 2-39 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 64

    2-40 periodic maintenance periodic maintenance procedures note ○ for the united states model, the proper angle is 0.4 de- grees below horizontal. This is 50 mm (2.0 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 (2.0...

  • Page 65

    Periodic maintenance 2-41 periodic maintenance procedures if the sidestand switch operation does not work, inspect or replace the following item. Battery (see charging condition inspection in the elec- trical system chapter) main fuse 30 a (see fuse inspection in the electrical system chapter) ignit...

  • Page 66

    2-42 periodic maintenance periodic maintenance procedures others chassis parts lubrication • before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • lubricate the points listed below with indicated lubricant. Note ○ whenever the vehic...

  • Page 67

    Periodic maintenance 2-43 periodic maintenance procedures bolts, nuts and fasteners tightness inspection • check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. Note ○ for the engine fasteners, check the tightness of them wh...

  • Page 68

    2-44 periodic maintenance periodic maintenance procedures replacement parts air cleaner element replacement • refer to the air cleaner element cleaning. Fuel hose replacement caution when removing and installing the fuel hose joint, do not apply strong force to the outlet pipe on the fuel pump and d...

  • Page 69

    Periodic maintenance 2-45 periodic maintenance procedures coolant change warning to avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury. Immediat...

  • Page 70

    2-46 periodic maintenance periodic maintenance procedures • remove the radiator cap [a] in two steps. First turn the cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap. ○ the coolant will drain from the radiator and engine. • take off the r...

  • Page 71

    Periodic maintenance 2-47 periodic maintenance procedures • install the reserve tank. • fill the reserve tank up to the “f” (full) level line [a] with coolant and install the cap [b]. • start the engine, warm it up thoroughly until the radiator fan turns on and then stop the engine. • check the cool...

  • Page 72

    2-48 periodic maintenance periodic maintenance procedures • 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 replacement). Replace the drain bolt gasket [b] with a new one. • tighten the drain bolt. Torque - engi...

  • Page 73

    Periodic maintenance 2-49 periodic maintenance procedures brake hose and pipe replacement caution brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • remove the brake hose banjo bolts [a]. • remove the brake hoses [b] as note the foll...

  • Page 74

    2-50 periodic maintenance periodic maintenance procedures • install the brake hose as note the following. ○ replace the washers [a] that are on each side of hose fitting [b] with new ones. ○ avoid sharp bending, kinking, flattening or twisting, and route the hoses according to cable, wire, and hose ...

  • Page 75

    Periodic maintenance 2-51 periodic maintenance procedures • follow the procedure below to install the rear brake fluid reservoir cap correctly. ○ first, tighten the rear brake fluid reservoir cap [b] clock- wise [c] by hand until slight resistance is felt indicating that the cap is seated on the res...

  • Page 76

    2-52 periodic maintenance periodic maintenance procedures master cylinder assembly • before assembly, clean all parts including the master cylinder with brake fluid or alcohol. Caution except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brak...

  • Page 77

    Periodic maintenance 2-53 periodic maintenance procedures note ○ if compressed air is not available, do as follows with the brake hose connected to the caliper. ○ prepare a container for brake fluid, and perform the work above it. ○ remove the brake pads (see front brake pad removal in the brakes ch...

  • Page 78

    2-54 periodic maintenance periodic maintenance procedures rear caliper disassembly • remove: rear caliper (see rear caliper removal in the brakes chapter) brake pads (see rear brake pad removal in the brakes chapter) pad spring • using compressed air, remove the piston. ○ cover the piston area with ...

  • Page 79

    Periodic maintenance 2-55 periodic maintenance procedures • replace the fluid seal [a] with a new one. ○ apply brake fluid to the fluid seal, and install it into the cylinder by hand. • replace the dust seal [b] with a new one if it is damaged. ○ apply brake fluid to the dust seal, and install it in...

  • Page 80

    2-56 periodic maintenance periodic maintenance procedures • replace the spark plug with a new one. Standard spark plug type: ngk cr9eia-9 • insert the spark plug [a] into the plug wrench [b]. • install the spark plug into the plug hole, and hand-tighten it first. Caution the insulator of the spark p...

  • Page 81: Fuel System (Dfi)

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

  • Page 82

    3-2 fuel system (dfi) subthrottle sensor (service code 32).................................................................................... 3-64 subthrottle sensor removal/adjustment .......................................................................... 3-64 subthrottle sensor input voltage i...

  • Page 83

    Fuel system (dfi) 3-3 fuel injector output voltage inspection ............................................................................ 3-96 fuel injector fuel line inspection ..................................................................................... 3-97 throttle grip and cables ........

  • Page 84

    3-4 fuel system (dfi) exploded view http://mototh.Com.

  • Page 85

    Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 timing rotor bolt 40 4.1 30 2 crankshaft sensor bolts 6.0 0.61 53 in·lb 3 water temperature sensor 12 1.2 106 in·lb 4 speed sensor bolt 7.8 0.80 69 in·lb l 5 speed sensor bracket bolts 9.8 1.0 87 in·lb 6 oxygen sensor ...

  • Page 86

    3-6 fuel system (dfi) exploded view http://mototh.Com.

  • Page 87

    Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 switch housing screws 3.5 0.36 31 in·lb 2 fuel level sensor bolts 6.9 0.70 61 l 3 fuel pump bolts 9.8 1.0 87 in·lb l, s 4 clutch cover bolt 9.8 1.0 87 in·lb 5. Throttle cable (accelerator) 6. Throttle cable (decelerato...

  • Page 88

    3-8 fuel system (dfi) exploded view cal and sea models http://mototh.Com.

  • Page 89

    Fuel system (dfi) 3-9 exploded view 1. Separator 2. Canister 3. Tube (blue) 4. Tube (red) 5. Tube (white) 6. Tube (green) http://mototh.Com.

  • Page 90

    3-10 fuel system (dfi) dfi system dfi system http://mototh.Com.

  • Page 91

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

  • Page 92

    3-12 fuel system (dfi) dfi system dfi system wiring diagram http://mototh.Com.

  • Page 93

    Fuel system (dfi) 3-13 dfi system part name 1. Ignition switch 2. Engine stop switch 3. Starter button 4. Fan motor 5. Stick coils 6. Air switching valve 7. Speed sensor 8. Subthrottle valve actuator 9. Subthrottle sensor 10. Main throttle sensor 11. Inlet air pressure sensor 12. Water-proof joint d...

  • Page 94

    3-14 fuel system (dfi) dfi system terminal numbers of ecu connectors terminal names 1. Subthrottle valve actuator: bk/bl 2. Subthrottle valve actuator: g/y 3. Water temperature warning indicator light: bl/w 4. Oxygen sensor: bl/y 5. Speed sensor: lg/r 6. Main throttle sensor: y/w 7. Inlet air pressu...

  • Page 95

    Fuel system (dfi) 3-15 dfi parts location ignition switch [a] fi indicator light (led) [b] main throttle sensor [a] subthrottle sensor [b] subthrottle valve actuator [c] fuel injectors #1, #2 [d] water temperature sensor [a] air switching valve [a] inlet air temperature sensor [b] inlet air pressure...

  • Page 96

    3-16 fuel system (dfi) dfi parts location relay box (ecu main relay, fan relay, fuel pump re- lay) [a] battery 12v 10ah [b] fuse box (oxygen sensor heater fuse 10a, fan fuse 15a, ecu fuse 15a, ignition fuse 10a) [c] ecu [a] kawasaki diagnostic system connector [b] self-diagnosis terminal [c] cranksh...

  • Page 97

    Fuel system (dfi) 3-17 dfi parts location oxygen sensor (equipped models) [a] http://mototh.Com.

  • Page 98

    3-18 fuel system (dfi) specifications item standard digital fuel injection system idle speed 1 300 ±50 r/min (rpm) throttle body assy: type two barrel type bore 38 mm (1.5 in.) bypass screws (turn out) 0 ∼ 2 1/2 (for reference) ecu (electronic control unit): make denso type digital memory type, with...

  • Page 99

    Fuel system (dfi) 3-19 specifications item standard output voltage with the sensor tilted 60 ∼ 70° or more: 0.65 ∼ 1.35 v with the sensor arrow mark pointed up: 3.55 ∼ 4.45 v subthrottle sensor: non-adjustable and non-removable input voltage dc 4.75 ∼ 5.25 v output voltage dc 0.4 ∼ 0.6 v at idle thr...

  • Page 100

    3-20 fuel system (dfi) special tools and sealant oil pressure gauge, 5 kgf/cm²: 57001-125 fork oil level gauge: 57001-1290 vacuum gauge: 57001-1369 hand tester: 57001-1394 throttle sensor setting adapter #1: 57001-1400 peak voltage adapter: 57001-1415 needle adapter set: 57001-1457 throttle sensor s...

  • Page 101

    Fuel system (dfi) 3-21 special tools and sealant oxygen sensor measuring adapter: 57001-1682 measuring adapter: 57001-1700 kawasaki bond (silicone sealant): 56019-120 http://mototh.Com.

  • Page 102

    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 103

    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 104

    3-24 fuel system (dfi) troubleshooting the dfi system outline when an abnormality in the dfi system occurs, the fi indicator light (led) goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ecu (electronic control unit). With the eng...

  • Page 105

    Fuel system (dfi) 3-25 troubleshooting the dfi system ○ the dfi part connectors [a] have seals [b], including the ecu. • join the connector and insert the needle adapters [c] inside the seals [b] from behind the connector until the adapter reaches the terminal. Special tool - needle adapter set: 570...

  • Page 106

    3-26 fuel system (dfi) 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 107

    Fuel system (dfi) 3-27 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 108

    3-28 fuel system (dfi) 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 109

    Fuel system (dfi) 3-29 troubleshooting the dfi system □ other □ spark plug loose (tighten it) □ spark plug dirty, broken, or gap maladjusted (remedy it) □ spark plug incorrect (replace it) □ knocking (fuel poor quality or incorrect, → use high-octane gasoline) □ brake dragging □ clutch slipping □ en...

  • Page 110

    3-30 fuel system (dfi) 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 111

    Fuel system (dfi) 3-31 dfi system troubleshooting guide symptoms or possible causes actions fuel pressure regulator trouble inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged inspect and repair (see chapter 3). Inlet air pressure sensor trouble inspect (see chapter 3). Wa...

  • Page 112

    3-32 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions water temperature sensor trouble inspect (see chapter 3). Inlet air temperature sensor trouble inspect (see chapter 3). Spark plug dirty, broken or gap maladjusted inspect and replace (see chapter 2). Stick c...

  • Page 113

    Fuel system (dfi) 3-33 dfi system troubleshooting guide poor running or no power at high speed symptoms or possible causes actions firing incorrect: stick coil shorted or not in good contact inspect or reinstall (see chapter 16). Stick coil trouble inspect (see chapter 16). Spark plug dirty, broken ...

  • Page 114

    3-34 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions engine overheating - water temperature sensor, crankshaft sensor or speed sensor trouble (see overheating of troubleshooting guide in chapter 17) air switching valve trouble inspect and replace (see chapter 1...

  • Page 115

    Fuel system (dfi) 3-35 self-diagnosis self-diagnosis outline the self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User mode the ecu notifies the rider of troubles in dfi system and ignition system by lighting the fi indicator when df...

  • Page 116

    3-36 fuel system (dfi) self-diagnosis • to enter the self-diagnosis dealer mode 2, open [a] and ground [b] the lead more than five times [c] within 2 sec- onds [d] after the lead is first grounded, and then keep it grounded continuously [e] for more than 2 seconds. ○ count the blinks of the light (l...

  • Page 117

    Fuel system (dfi) 3-37 self-diagnosis http://mototh.Com.

  • Page 118

    3-38 fuel system (dfi) self-diagnosis how to read service codes ○ service codes are shown by a series of long and short blinks of the fi indicator light (led) as shown below. ○ read 10th digit and unit digit as the fi indicator light (led) blinks. ○ when there are a number of problems, all the servi...

  • Page 119

    Fuel system (dfi) 3-39 self-diagnosis service code table service code fi indicator light (led) problems 11 main throttle sensor malfunction, wiring open or short 12 inlet air pressure sensor malfunction, wiring open or short 13 inlet air temperature sensor malfunction, wiring open or short 14 water ...

  • Page 120

    3-40 fuel system (dfi) self-diagnosis backups ○ the ecu takes the following measures to prevent engine damage when the dfi or the ignition system parts have troubles. Service codes parts output signal usable range or criteria backups by ecu 11 main throttle sensor main throttle sensor output voltage...

  • Page 121

    Fuel system (dfi) 3-41 self-diagnosis service codes parts output signal usable range or criteria backups by ecu 51 stick coil #1* the stick coil primary winding must send signals continuously to the ecu. If the stick coil #1 primary winding has failures (no signal, wiring short or open), the ecu shu...

  • Page 122

    3-42 fuel system (dfi) main throttle sensor (service code 11) main throttle sensor removal/adjustment caution do not remove or adjust the main throttle sensor [a] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface. Such a...

  • Page 123

    Fuel system (dfi) 3-43 main throttle sensor (service code 11) main throttle sensor output voltage inspection • measure the output voltage at the main throttle sensor in the same way as input voltage inspection, note the following. ○ disconnect the main throttle sensor connector and con- nect the har...

  • Page 124

    3-44 fuel system (dfi) main throttle sensor (service code 11) if the output voltage is normal, check the wiring for conti- nuity. ○ disconnect the ecu and sensor connectors. Wiring continuity inspection ecu connector [a] ←→ main throttle sensor connector [b] y/w lead (ecu terminal 6) [c] br/bk lead ...

  • Page 125

    Fuel system (dfi) 3-45 inlet air pressure sensor (service code 12) caution never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Inlet air pressure sensor removal • remove the upper fairing (see upper fairing removal in the frame chapter). • disconnect the inle...

  • Page 126

    3-46 fuel system (dfi) inlet air pressure sensor (service code 12) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main harness connectors. Special tool - hand tester: 57001-1394 ○ disconnect the ecu and sensor connectors. Wiring continuity inspectio...

  • Page 127

    Fuel system (dfi) 3-47 inlet air pressure sensor (service code 12) if the reading is within the usable range, remove the ecu and check the wiring for continuity between main harness connector. Special tool - hand tester: 57001-1394 ○ disconnect the ecu and sensor connectors. Wiring continuity inspec...

  • Page 128

    3-48 fuel system (dfi) inlet air pressure sensor (service code 12) suppose: pg: vacuum pressure (gauge) to sensor pl: local atmospheric pressure (absolute) measured by a barometer pv: vacuum pressure (absolute) to sensor vv: sensor output voltage (v) then pv = pl – pg for example, suppose the follow...

  • Page 129

    Fuel system (dfi) 3-49 inlet air pressure sensor (service code 12) pv = 55 ∼ 86 cmhg id: idling ps: standard atmospheric pressure (absolute) pv: throttle vacuum pressure (absolute) st: standard of sensor output voltage (v) to: throttle full open ur: usable range of sensor output voltage (v) vv: inle...

  • Page 130

    3-50 fuel system (dfi) inlet air pressure sensor (service code 12) inlet air pressure sensor circuit 1. Ecu 2. Water-proof joint d 3. Inlet air pressure sensor 4. Water-proof joint e http://mototh.Com.

  • Page 131

    Fuel system (dfi) 3-51 inlet air temperature sensor (service code 13) inlet air temperature sensor removal/installation caution never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove the fuel tank (see fuel tank removal). • disconnect the connector [a...

  • Page 132

    3-52 fuel system (dfi) inlet air temperature sensor (service code 13) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main harness side connectors. Special tool - hand tester: 57001-1394 ○ disconnect the ecu and sensor connectors. Wiring continuity i...

  • Page 133

    Fuel system (dfi) 3-53 inlet air temperature sensor (service code 13) inlet air temperature sensor circuit 1. Ecu 2. Water-proof joint e 3. Inlet air temperature sensor http://mototh.Com.

  • Page 134

    3-54 fuel system (dfi) water temperature sensor (service code 14) water temperature sensor removal/installation caution never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • drain the coolant (see coolant change in the periodic maintenance chapter). • disco...

  • Page 135

    Fuel system (dfi) 3-55 water temperature sensor (service code 14) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main harness connectors. Special tool - hand tester: 57001-1394 ○ disconnect the ecu and sensor connectors. Wiring continuity inspection...

  • Page 136

    3-56 fuel system (dfi) crankshaft sensor (service code 21) start the engine and switch the diagnosis mode to dealer 1 mode to know all the problem that the dfi system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of ...

  • Page 137

    Fuel system (dfi) 3-57 crankshaft sensor (service code 21) crankshaft sensor circuit 1. Ecu 2. Crankshaft sensor http://mototh.Com.

  • Page 138

    3-58 fuel system (dfi) speed sensor (service code 24, 25) speed sensor removal/installation • refer to the speed sensor removal/installation in the electrical system chapter. Speed sensor inspection • refer to the speed sensor inspection in the electrical system chapter. Speed sensor input voltage i...

  • Page 139

    Fuel system (dfi) 3-59 speed sensor (service code 24, 25) speed sensor output voltage inspection • before this inspection, inspect the input voltage (see speed sensor input voltage inspection). Note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the left upper fairi...

  • Page 140

    3-60 fuel system (dfi) speed sensor (service code 24, 25) speed sensor circuit 1. Ecu 2. Speed sensor 3. Frame ground 4. Meter unit http://mototh.Com.

  • Page 141

    Fuel system (dfi) 3-61 vehicle-down sensor (service code 31) vehicle-down sensor removal caution never drop the vehicle-down sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove: right frame cover (see frame cover removal in the frame chapter) connector [a] vehicl...

  • Page 142

    3-62 fuel system (dfi) vehicle-down sensor (service code 31) • remove the vehicle-down sensor (see vehicle-down sensor removal). ○ do not disconnect the sensor connector. • connect a digital meter [a] to the connector with needle adapter set [b]. Special tool - needle adapter set: 57001-1457 vehicle...

  • Page 143

    Fuel system (dfi) 3-63 vehicle-down sensor (service code 31) vehicle-down sensor circuit 1. Ecu 2. Water-proof joint d 3. Vehicle-down sensor 4. Water-proof joint e http://mototh.Com.

  • Page 144

    3-64 fuel system (dfi) subthrottle sensor (service code 32) subthrottle sensor removal/adjustment caution do not remove or adjust the subthrottle sensor [a] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface. Such a shock...

  • Page 145

    Fuel system (dfi) 3-65 subthrottle sensor (service code 32) subthrottle sensor output voltage inspection • remove the air cleaner housing (see air cleaner housing removal). • measure the output voltage at the subthrottle sensor in the same way as input voltage inspection. Note the fol- lowing. ○ dis...

  • Page 146

    3-66 fuel system (dfi) subthrottle sensor (service code 32) subthrottle sensor resistance inspection • turn the ignition switch off. • disconnect the subthrottle sensor connector. • connect a digital meter [a] to the subthrottle sensor con- nector [b]. • measure the subthrottle sensor resistance. Th...

  • Page 147

    Fuel system (dfi) 3-67 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. • turn...

  • Page 148

    3-68 fuel system (dfi) oxygen sensor-not activated (service code 33) (equipped models) if the reading is out of the standard (with plug: dc 0.7 v or more, without plug: dc 0.2 v or less), remove the ecu and check the wiring for continuity between main harness connectors. Special tool - hand tester: ...

  • Page 149

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

  • Page 150

    3-70 fuel system (dfi) stick coils #1, #2: (service code 51, 52) stick coil circuit 1. Ignition switch 2. Engine stop switch 3. Stick coils 4. Ecu 5. Frame ground 6. Main fuse 30 a 7. Battery 12 v 10 ah 8. Fuse box 9. Ignition fuse 10 a 10. Water-proof joint c 11. Frame ground http://mototh.Com.

  • Page 151

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

  • Page 152

    3-72 fuel system (dfi) subthrottle valve actuator (service code 62) subthrottle valve actuator removal caution 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 sh...

  • Page 153

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

  • Page 154

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

  • Page 155

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

  • Page 156

    3-76 fuel system (dfi) oxygen sensor heater (service code 67) (equipped models) oxygen sensor heater removal/installation the oxygen sensor heater is bult in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see oxygen sensor removal in the electrical system ch...

  • Page 157

    Fuel system (dfi) 3-77 oxygen sensor heater (service code 67) (equipped models) if the fuse and wiring are good, remove the ecu and check the wiring for continuity between main harness con- nectors. Special tool - hand tester: 57001-1394 ○ disconnect the ecu and sensor connectors. Wiring continuity ...

  • Page 158

    3-78 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 sta...

  • Page 159

    Fuel system (dfi) 3-79 oxygen sensor-incorrect output voltage (service code 94) (equipped models) oxygen sensor circuit 1. Ignition switch 2. Water-proof joint e 3. Oxygen sensor 4. Ecu 5. Frame ground 6. Main fuse 30 a 7. Battery 12 v 10 ah 8. Fuse box 9. Oxygen sensor heater fuse 10 a 10. Water-pr...

  • Page 160

    3-80 fuel system (dfi) fi indicator light (led) fi indicator light (led) inspection • refer to the electronic combination meter unit inspection in the electrical system chapter. Fi indicator light (led) circuit 1. Ecu 2. Frame ground 3. Battery 12v 10 ah 4. Main fuse 30 a 5. Fuse box 6. Ignition fus...

  • Page 161

    Fuel system (dfi) 3-81 ecu caution never drop the ecu, especially on a hard surface. Such a shock to the ecu can damage it. Ecu removal • remove: seat covers (see seat cover removal in the frame chapter) • remove the nuts [a] and washers to lower the rear fender. • remove the bolts [a]. • disconnect...

  • Page 162

    3-82 fuel system (dfi) ecu ecu power supply inspection • remove the seat (see seat removal in the frame chap- ter). • 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 termina...

  • Page 163

    Fuel system (dfi) 3-83 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 connectors. • connect a digital meter [a] to the connector [b] with the needle adapter set. Special tool - needle adapter set: 57001-1457 ecu po...

  • Page 164

    3-84 fuel system (dfi) ecu ecu power source circuit 1. Ecu 2. Joint connector 3. Frame ground 4. Main fuse 30 a 5. Battery 12 v 10ah 6. Ecu main relay 7. Relay box 8. Ecu main fuse 15 a 9. Fuse box 10. Water-proof joint b 11. Water-proof joint c 12. Frame ground 13. Ignition switch http://mototh.Com.

  • Page 165

    Fuel system (dfi) 3-85 dfi power source ecu fuse removal • refer to the 15 a ecu fuse removal in the electrical system chapter. Ecu fuse installation if a fuse fails during operation, inspect the dfi system to determine the cause, and then replace it with a new fuse of proper amperage. • refer to th...

  • Page 166

    3-86 fuel system (dfi) fuel line fuel pressure inspection note ○ be sure the battery is fully charged. • remove: fuel tank (see fuel tank removal) fuel hose (see fuel hose replacement in the periodic maintenance chapter) ○ be sure to place a piece of cloth around the fuel supply pipes of the fuel pu...

  • Page 167

    Fuel system (dfi) 3-87 fuel line note ○ the gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. • turn the ignition switch off. If the fuel pressure is much higher than specified, the fuel pressure regulator in the fuel pump have been clogged or stuc...

  • Page 168

    3-88 fuel system (dfi) fuel line • connect the prepared fuel hose [a] to the fuel supply pipe of the fuel pump. • secure the fuel hose with a clamp. • insert the fuel hose into the measuring cylinder [b]. Warning wipe off spilled out fuel immediately. Be sure to hold the measuring cylinder vertical....

  • Page 169

    Fuel system (dfi) 3-89 fuel pump fuel pump removal warning gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the igniti...

  • Page 170

    3-90 fuel system (dfi) fuel pump • replace the fuel pump gasket [a] with a new one. • apply a non-permanent locking agent to the threads of the fuel pump bolts. • tighten the fuel pump bolts to a snug fit following the tight- ening sequence shown. Front [a] • following the tightening sequence, tight...

  • Page 171

    Fuel system (dfi) 3-91 fuel pump fuel pump operating voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the left side cover (see side cover removal in the frame chapter). • disconnect the fuel pump lead connector and connect the harness adapter [...

  • Page 172

    3-92 fuel system (dfi) fuel pump pressure regulator removal ○ the pressure regulator [a] is built into the fuel pump [b] and cannot be removed. Pump screen, fuel filter cleaning ○ the pump screen [a] and fuel filter [b] are built into the pump and cannot be cleaned or checked. If the pump screen or ...

  • Page 173

    Fuel system (dfi) 3-93 fuel pump fuel pump circuit 1. Ignition switch 2. Engine stop switch 3. Ecu 4. Joint connector 5. Fuel pump 6. Frame ground 7. Main fuse 30 a 8. Battery 12 v10 ah 9. Ecu main relay 10. Fuel pump relay 11. Relay box 12. Ecu fuse 15 a 13. Ignition fuse 10 a 14. Fuse box 15. Wate...

  • Page 174

    3-94 fuel system (dfi) fuel injectors fuel injector removal/installation • refer to the throttle body assy disassembly/assembly. Fuel injector audible inspection • start the engine, and let it to idle. • apply the tip of a screwdriver [a] to the fuel injector [b]. Put the grip end onto your ear, and...

  • Page 175

    Fuel system (dfi) 3-95 fuel injectors fuel injector power source voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • disconnect the injector connector and connect the har- ness adapter [a] between these connectors as shown in the figure. Main harness [b]...

  • Page 176

    3-96 fuel system (dfi) 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 a digital meter [a] to the connector [b] with the needle ada...

  • Page 177

    Fuel system (dfi) 3-97 fuel injectors fuel injector fuel line inspection • remove: fuel tank (see fuel tank removal) fuel hose (see fuel hose replacement in the periodic maintenance chapter) ○ be sure to place a piece of cloth around the fuel supply pipes of the fuel pump and the throttle body assy....

  • Page 178

    3-98 fuel system (dfi) fuel injectors fuel injector circuit 1. Ignition switch 2. Engine stop switch 3. Fuel injectors 4. Ecu 5. Joint connector 6. Frame ground 7. Main fuse 30 a 8. Battery 12 v10 ah 9. Ecu main relay 10. Fuel pump relay 11. Relay box 12. Ecu fuse 15 a 13. Ignition fuse 10 a 14. Fus...

  • Page 179

    Fuel system (dfi) 3-99 throttle grip and cables throttle grip free play inspection • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Throttle grip free play adjustment • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Thro...

  • Page 180

    3-100 fuel system (dfi) throttle body assy idle speed inspection/adjustment • refer to the idle speed inspection/adjustment in the pe- riodic maintenance chapter. Synchronization inspection/adjustment • refer to the engine vacuum synchronization inspection in the periodic maintenance chapter. Thrott...

  • Page 181

    Fuel system (dfi) 3-101 throttle body assy • loosen the throttle body assy holder clamp bolts [a] on both sides. • remove the throttle case [a] to make a throttle cable slack. • free the idle adjusting screw [a] from the bracket. • remove the right upper fairing cover (see upper fairing cover remova...

  • Page 182

    3-102 fuel system (dfi) throttle body assy throttle body assy installation if the air cleaner duct [a] was removed, install it. ○ install the duct clamp screws [b] in the direction as shown. Bolt heads [c] • install the throttle body assy holder clamp bolts [a] in the direction as shown. Bolt heads ...

  • Page 183

    Fuel system (dfi) 3-103 throttle body assy throttle body assy disassembly caution do not remove, disassemble or adjust the main throttle sensor [a], subthrottle sensor [b], sub- throttle valve actuator [c], throttle link mechanism [d] and throttle body assy [e], because they are adjusted or set at t...

  • Page 184

    3-104 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 185

    Fuel system (dfi) 3-105 air cleaner • unscrew the bolts [a] and remove the air cleaner housing [b]. Air cleaner housing installation • install the clamp on the breather hose [a] as shown in the figure. Pinch heads [b] viewed from top [c] front [d] ○ insert the breather hose [a] into the crankcase as...

  • Page 186

    3-106 fuel system (dfi) fuel tank fuel tank removal warning gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignit...

  • Page 187

    Fuel system (dfi) 3-107 fuel tank • disconnect: fuel pump lead connector [a] fuel level sensor lead connector [b] • remove the fuel tank breather hose and the fuel drain hose from the fuel tank. • be sure to place a piece of cloth around the fuel hose joint. • insert a minus screwdriver [a] into the...

  • Page 188

    3-108 fuel system (dfi) fuel tank fuel tank installation • note the warning on the previous page (see fuel tank removal). • route the hoses correctly (see cable, wire, and hose routing section in the appendix chapter). • check that the rubber dampers [a] are on the frame and the fuel tank. If the da...

  • Page 189

    Fuel system (dfi) 3-109 fuel tank fuel tank and cap inspection • visually inspect the gasket [a] on the tank cap for any damage. Replace the gasket if it is damaged. • check to see if the water drain pipe [b] and fuel breather pipe [c] in the tank is not clogged. Check the tank cap breather also. If...

  • Page 190

    3-110 fuel system (dfi) evaporative emission control system (cal and sea 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 thorough...

  • Page 191

    Fuel system (dfi) 3-111 evaporative emission control system (cal and sea models) separator operation test warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Do not smoke. Turn the ignition switch off. Make sure the area is well-ventilated and free from any sourc...

  • Page 192

    Http://mototh.Com.

  • Page 193: Cooling System

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

  • Page 194

    4-2 cooling system exploded view http://mototh.Com.

  • Page 195

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 baffle plate bolts 5.9 0.60 52 in·lb 2 radiator bolt 15 1.5 11 3 water hose clamp screws 2.0 0.20 18 in·lb 4 thermostat housing bolts 9.8 1.0 87 in·lb 5 water pump cover bolts 9.8 1.0 87 in·lb 6 water pump drain bolt 9.8 ...

  • Page 196

    4-4 cooling system coolant flow chart http://mototh.Com.

  • Page 197

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

  • Page 198

    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 199

    Cooling system 4-7 special tools bearing driver set: 57001-1129 oil seal driver: 57001-1660 http://mototh.Com.

  • Page 200

    4-8 cooling system coolant coolant deterioration inspection • remove the upper fairing (see upper fairing removal 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 the coolan...

  • Page 201

    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 202

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

  • Page 203

    Cooling system 4-11 water pump • install the two dowel pins [a]. • install the water pump cover. • tighten: torque - water pump cover bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • align the line [a] of the water pump cover and the white paint mark [b] of the water hose. • install the water hose clamp [c] s...

  • Page 204

    4-12 cooling system water pump water pump housing assembly • apply grease [a] to the new oil seal [b]. • press the oil seal into the housing with a bearing driver so that the seal surface is flush [c] with the end of the hole. ○ apply high-temperature grease to the outer circum- ference [d] of the o...

  • Page 205

    Cooling system 4-13 radiator radiator and radiator fan removal • drain the coolant (see coolant change in the periodic maintenance chapter). • open the clamp [a]. • disconnect the radiator fan lead connector [b]. • remove the water hose [c]. • remove: water hose [a] reserve tank hose [b] radiator bo...

  • Page 206

    4-14 cooling system radiator radiator and radiator fan installation if the radiator guard [a] was removed, install it. • install the radiator fan [b]. • install the rubber dampers [c] and collar [d] to the radiator and frame. • align the projections [e] on the frame with the holes [f] on the dampers...

  • Page 207

    Cooling system 4-15 radiator radiator inspection • remove the radiator (see radiator and radiator fan re- moval). • 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 cor...

  • Page 208

    4-16 cooling system radiator radiator filler neck inspection • remove the radiator cap (see coolant change in the pe- riodic maintenance chapter). • 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 be smoo...

  • Page 209

    Cooling system 4-17 thermostat thermostat removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: water hose [a] thermostat housing bolts [b] thermostat housing [c] • pull the thermostat [a] out of the cylinder head. Thermostat installation • install the therm...

  • Page 210

    4-18 cooling system thermostat • align the line [a] of the thermostat housing and the white paint mark [b] of the water hose [c]. • install the water hose clamp [d] as shown. • tighten: torque - water hose clamp screws: 2.0 n·m (0.20 kgf·m, 18 in·lb) • fill the radiator with coolant (see coolant cha...

  • Page 211

    Cooling system 4-19 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 212

    4-20 cooling system water temperature sensor caution 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- lat...

  • Page 213: Engine Top End

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

  • Page 214

    5-2 engine top end exploded view http://mototh.Com.

  • Page 215

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 baffle plate bolts 5.9 0.60 52 in·lb 2 air suction valve cover bolts 9.8 1.0 87 in·lb 3 cylinder head cover bolts 9.8 1.0 87 in·lb 4 camshaft cap bolts 12 1.2 106 in·lb s 5 spark plugs 15 1.5 11 6 throttle body assy holde...

  • Page 216

    5-4 engine top end exploded view http://mototh.Com.

  • Page 217

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 cylinder bolt (m8) 27.5 2.8 20 mo,s 2 cylinder bolts (m6) 12 1.2 106 in·lb s 3 cylinder nut 49 5.0 36 mo, s 4 exhaust pipe manifold holder nuts 17 1.7 13 5 muffler body mounting bolt (front) 20 2.0 15 6 muffler body mount...

  • Page 218

    5-6 engine top end exhaust system identification exhaust system manifold mark position [a] muffler body mark position [b] honeycomb type catalyst position [c] muffler body with hole [d] for oxygen sensor [e] http://mototh.Com.

  • Page 219

    Engine top end 5-7 specifications item standard service limit camshafts cam height: exhaust 35.843 ∼ 35.957 mm (1.4111 ∼ 1.4156 in.) 35.74 mm (1.407 in.) inlet 36.543 ∼ 36.657 mm (1.4387 ∼ 1.4432 in.) 36.44 mm (1.435 in.) camshaft journal, camshaft cap clearance 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in....

  • Page 220

    5-8 engine top end specifications item standard service limit valve spring free length: exhaust 41.91 mm (1.650 in.) 40.5 mm (1.59 in.) inlet 41.91 mm (1.650 in.) 40.5 mm (1.59 in.) cylinder, pistons cylinder inside diameter 82.994 ∼ 83.006 mm (3.2675 ∼ 3.2679 in.) 83.09 mm (3.271 in.) piston diamet...

  • Page 221

    Engine top end 5-9 special tools and sealant compression gauge, 20 kgf/cm²: 57001-221 valve spring compressor assembly: 57001-241 valve seat cutter, 45° - 35: 57001-1116 valve seat cutter, 32° - 30: 57001-1120 valve seat cutter, 32° - 35: 57001-1121 valve seat cutter, 60° - 30: 57001-1123 valve seat...

  • Page 222

    5-10 engine top end special tools and sealant compression gauge adapter, m10 × 1.0: 57001-1317 valve seat cutter holder, 4.5: 57001-1330 valve guide arbor, 4.5: 57001-1331 valve guide reamer, 4.5: 57001-1333 piston pin puller: 57001-1568 piston pin puller adapter, 12: 57001-1657 kawasaki bond (silic...

  • Page 223

    Engine top end 5-11 clean air system air suction valve removal • remove: air switching valve (see air switching valve removal) air suction valve cover bolts [a] clamp [b] air suction valve cover [c] • remove the air suction valve [a]. Air suction valve installation • install the air suction valve [a...

  • Page 224

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

  • Page 225

    Engine top end 5-13 clean air system air switching valve unit test • refer to the air switching valve unit test in the electrical system chapter. 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 cl...

  • Page 226

    5-14 engine top end cylinder head cover cylinder head cover removal • remove: air suction valve (see air suction valve removal) stick coils (see stick coil removal in the electrical sys- tem chapter). Throttle cables (see throttle body assy removal in the fuel system (dfi) chapter) inlet air pressur...

  • Page 227

    Engine top end 5-15 cylinder head cover • replace the plug hole gaskets [a] with new ones. • be sure to install the following parts. Dowel pins [b] plug hole gaskets • install the rubber washers [a] with metal side faces up- ward. • tighten: torque - cylinder head cover bolts: 9.8 n·m (1.0 kgf·m, 87...

  • Page 228

    5-16 engine top end camshaft chain tensioner camshaft chain tensioner removal caution this is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: when removing the ten...

  • Page 229

    Engine top end 5-17 camshaft chain tensioner • install the tensioner body so that the stopper [a] faces upward. • tighten the tensioner mounting bolts. Torque - camshaft chain tensioner mounting bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install: spring [a] washer [b] • tighten: torque - camshaft chain ...

  • Page 230

    5-18 engine top end camshaft, camshaft chain camshaft removal • remove: cylinder head cover (see cylinder head cover re- moval) lower fairing (see lower fairing removal in the frame chapter) timing inspection cap [a] timing rotor bolt cap [b] • using a wrench on the timing rotor bolt, turn the crank...

  • Page 231

    Engine top end 5-19 camshaft, camshaft chain • remove the camshaft chain tensioner (see camshaft chain tensioner removal). • loosen the camshaft cap bolts as shown sequence [1 ∼ 12 ] in the figure, and remove them. • remove: camshaft caps [a] camshafts [b] caution the crankshaft may be turned while ...

  • Page 232

    5-20 engine top end camshaft, camshaft chain camshaft installation • replace the plug hole gaskets [a] with new ones. • be sure to install the following parts. Plug hole gaskets dowel pins [b] • install the cam sprockets so that the marked (“in" and “ex”) side faces to the outward. ○ the inlet [a] a...

  • Page 233

    Engine top end 5-21 camshaft, camshaft chain • using a wrench on the timing rotor bolt, turn the crank- shaft clockwise until the 2/t mark line [a] on the timing rotor is aligned with the notch [b] in the edge of the timing inspection hole [c] in the clutch cover. Caution the crankshaft may be turne...

  • Page 234

    5-22 engine top end camshaft, camshaft chain • before installing the camshaft caps, install the camshaft chain tensioner body temporally (see camshaft chain tensioner installation). • install the camshaft caps as shown. Note ○ the exhaust cap has a “ex” mark [a] and the inlet cap has a “in” mark [b]...

  • Page 235

    Engine top end 5-23 camshaft, camshaft chain camshaft, camshaft cap wear • remove the camshaft caps (see camshaft removal). • cut strips of plastigage (press gauge) to journal width. Place a strip on each journal parallel to the camshaft in- stalled in the correct position. • tighten the camshaft ca...

  • Page 236

    5-24 engine top end camshaft, camshaft chain camshaft chain removal • split the crankcase (see crankcase splitting in the crank- shaft/transmission chapter). • remove the camshaft chain [a] from the crankshaft sprocket. Http://mototh.Com.

  • Page 237

    Engine top end 5-25 cylinder head cylinder compression measurement note ○ use the battery which is fully charged. • warm up the engine thoroughly. • stop the engine. • remove: spark plugs (see spark plug replacement in the peri- odic maintenance chapter) • attach the compression gauge [a] and adapte...

  • Page 238

    5-26 engine top end cylinder head cylinder head removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: exhaust pipes (see exhaust pipe removal) camshafts (see camshaft removal) throttle body assy holders (see throttle body assy holder removal) water hose [a] ...

  • Page 239

    Engine top end 5-27 cylinder head • apply molybdenum disulfide oil solution [a] to both sides of washers and the threads of bolts and nut. M10 cylinder head bolts [b] m10 cylinder nut [c] m8 cylinder bolt [d] • tighten the all bolts and nut following the tightening se- quence [1 ∼ 8]. Torque - cylin...

  • Page 240

    5-28 engine top end cylinder head • install the front camshaft chain guide [a]. ○ insert the end [b] of front camshaft chain guide into the hollow on the lower crankcase half. • install the removed parts (see appropriate chapters). Cylinder head warp inspection • clean the cylinder head. • lay a str...

  • Page 241

    Engine top end 5-29 valves valve clearance inspection • refer to the valve clearance inspection in the periodic maintenance chapter. Valve clearance adjustment • refer to the valve clearance adjustment in the periodic maintenance chapter. Valve removal • remove cylinder head (see cylinder head remov...

  • Page 242

    5-30 engine top end valves valve guide installation • apply engine oil to the valve guide outer surface before installation. • heat the area around the valve guide hole to about 120 ∼ 150°c (248 ∼ 302°f). • drive the valve guide in from the top of the head using the valve guide arbor. The flange sto...

  • Page 243

    Engine top end 5-31 valves valve seat inspection • remove the valve (see valve removal). • check the valve seating surface [a] between the valve [b] and valve seat [c]. ○ measure the outside diameter [d] of the seating pattern on the valve seat. If the outside diameter is too large or too small, rep...

  • Page 244

    5-32 engine top end valves seat cutter operation care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. 3. Do not fai...

  • Page 245

    Engine top end 5-33 valves • measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range. Widened width [a] of engagement by machining with 45° cutter ...

  • Page 246

    5-34 engine top end valves if the seat width is too wide, make the 60° or 55° [a] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. • grind the seat at a 60° or 55° angle until the seat width is within the specified range. ○ to make...

  • Page 247

    Engine top end 5-35 valves http://mototh.Com.

  • Page 248

    5-36 engine top end cylinder, pistons cylinder removal • remove: cylinder head (see cylinder head removal) engine mounting bolts (left and right) [a] (see engine removal in the engine removal/installation chapter) engine brackets (left and right) [b] (see engine re- moval in the engine removal/insta...

  • Page 249

    Engine top end 5-37 cylinder, pistons • remove the piston pins. Special tools - piston pin puller [a]: 57001-1568 piston pin puller adapter, 12 [d]: 57001 -1657 center bolt [b] shell of piston [c] • remove the pistons. • carefully spread the ring opening with your thumbs and then push up on the oppo...

  • Page 250

    5-38 engine top end cylinder, pistons note ○ if a new piston is used, use new piston ring. • install the piston with its marking hollow [a] facing forward. • fit a new piston pin snap ring into the side of the piston so that the ring opening [a] does not coincide with the slit [b] of the piston pin ...

  • Page 251

    Engine top end 5-39 cylinder, pistons piston ring, piston ring groove wear inspection • check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. • with the piston rings in their gro...

  • Page 252

    5-40 engine top end cylinder, pistons piston ring end gap inspection • place the piston ring [a] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. • measure the gap [b] between the ends of the ring wi...

  • Page 253

    Engine top end 5-41 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 • be sure to install the new o-rin...

  • Page 254

    5-42 engine top end muffler muffler body removal warning to avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. • remove: right footpeg stay (see footpeg stay removal in the frame chapter) lower fairing brackets (see lower fairing bracket r...

  • Page 255

    Engine top end 5-43 muffler • loosen the muffler body clamp bolt [a]. • remove the exhaust pipe to forward. Http://mototh.Com.

  • Page 256

    5-44 engine top end muffler muffler body and exhaust pipe installation • replace the exhaust pipe gaskets [a] and muffler body gasket [b] with new ones and install them. ○ install the muffler body gasket until it is bottomed so that the chamfer side [c] feces exhaust pipe [d]. • install: muffler bod...

  • Page 257: Clutch

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

  • Page 258

    6-2 clutch exploded view http://mototh.Com.

  • Page 259

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

  • Page 260

    6-4 clutch specifications item standard service limit clutch lever free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – clutch friction plate thickness 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) 2.8 mm (0.110 in.) friction plate warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.012 in.) steel plate warp 0.2 mm (0.008 in.) ...

  • Page 261

    Clutch 6-5 special tool and sealant clutch holder: 57001-1243 kawasaki bond (silicone sealant): 92104-0004 http://mototh.Com.

  • Page 262

    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 263

    Clutch 6-7 clutch lever and cable clutch cable lubrication • refer to the chassis parts lubrication in the periodic maintenance chapter. Clutch lever installation • install the clutch lever so that the mating surface [a] of the clutch lever clamp is aligned with the punch mark [b]. • tighten the upp...

  • Page 264

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

  • Page 265

    Clutch 6-9 clutch cover release shaft installation • apply grease to the oil seal lips on the upper ridge of the clutch cover. • apply molybdenum disulfide grease to the pusher-holding portion [a] on the release shaft. • install the washer [b] and spring [c]. • insert the release shaft straight into...

  • Page 266

    6-10 clutch clutch cover • apply water to the rubber of the oil gauge [a] and press [b] it so that the ring [c] face outside. • replace the o-rings of the following parts with new ones. Timing inspection cap timing rotor bolt cap oil filler plug • apply grease to the new o-rings. • tighten: torque -...

  • Page 267

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

  • Page 268

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

  • Page 269

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

  • Page 270

    6-14 clutch clutch • apply engine oil to the sliding surfaces of the bearing [a]. • install the spring plate [b] on the clutch hub [c]. • install the clutch springs, and tighten the clutch spring bolts. Torque - clutch spring bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install the clutch cover (see clutc...

  • Page 271

    Clutch 6-15 clutch clutch housing finger inspection • visually inspect the clutch housing fingers [a] where the friction plate tangs [b] hit them. If they are badly worn or if there are groove cuts where the tangs hit, replace the housing. Also, replace the friction plates if their tangs are damaged...

  • Page 272

    Http://mototh.Com.

  • Page 273: Engine Lubrication System

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

  • Page 274

    7-2 engine lubrication system exploded view http://mototh.Com.

  • Page 275

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oil filter 17.5 1.8 13 eo, r 2 holder mounting bolt 25 2.5 18 l 3 oil passage plug (m6) 3.9 0.40 35 in·lb 4 oil passage plug 20 2.0 15 l 5 oil pressure switch 15 1.5 11 ss 6 oil plate bolts 9.8 1.0 87 in·lb l 7...

  • Page 276

    7-4 engine lubrication system engine oil flow chart http://mototh.Com.

  • Page 277

    Engine lubrication system 7-5 engine oil flow chart http://mototh.Com.

  • Page 278

    7-6 engine lubrication system specifications item standard engine oil type api se, sf or sg api sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity sae 10w-40 capacity: 1.7 l (1.8 us gt) (when filter is not removed) 1.9 l (2.0 us gt) (when filter is removed) 2.4 l (2.5 us gt) (when engine is complet...

  • Page 279

    Engine lubrication system 7-7 special tools and sealant oil pressure gauge, 10 kgf/cm²: 57001-164 oil pressure gauge adapter, pt3/8: 57001-1233 kawasaki bond (silicone sealant): 56019-120 http://mototh.Com.

  • Page 280

    7-8 engine lubrication system engine oil and oil filter warning motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil level inspection • check that the engine oil le...

  • Page 281

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

  • Page 282

    7-10 engine lubrication system oil pan oil pan installation • replace the o-rings with new ones. • apply grease to the o-rings on the oil pipes [a]. • install the oil pipe plate [b] so that its guide portion fits the oil pipe as shown in the figure. • apply a non-permanent locking agent to the oil p...

  • Page 283

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

  • Page 284

    7-12 engine lubrication system oil pump oil pump removal • remove: clutch (see clutch removal in the clutch chapter) oil pump cover bolts [a] • temporarily install the oil pump sprocket bolt [a]. Note ○ the oil pump sprocket bolt has a left-hand threads. • using the oil pump sprocket bolt [a], pull ...

  • Page 285

    Engine lubrication system 7-13 oil pump • remove: inner rotor [a] for scavenge pump outer rotor [b] for scavenge pump • remove the pin [a]. • remove: pin [a] inner rotor for feed pump [b] oil pump shaft [c] oil pump installation • apply molybdenum disulfide oil solution to the portion [a] of the oil...

  • Page 286

    7-14 engine lubrication system oil pump • install: dowel pin [a] outer rotor [b] for feed pump • fit the pin of the crankcase into the hole [c] in the oil pump body. ○ turn the oil pump shaft so that the inner rotor [d] fits into the outer rotor. • fit the pin [a] into the hole [b] on the oil pump c...

  • Page 287

    Engine lubrication system 7-15 oil pressure measurement oil pressure measurement • remove: right lower fairing bracket (see lower fairing bracket removal in the frame chapter) oil passage plug [a] • attach the adapter [a] and gauge [b] to the plug hole. Special tools - oil pressure gauge, 10 kgf/cm²...

  • Page 288

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

  • Page 289: Engine Removal/installation

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

  • Page 290

    8-2 engine removal/installation exploded view http://mototh.Com.

  • Page 291

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

  • Page 292

    8-4 engine removal/installation engine removal/installation engine removal • support the rear part of the swingarm with a stand. • squeeze the brake lever slowly and hold it with a band [a]. Warning be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It could c...

  • Page 293

    Engine removal/installation 8-5 engine removal/installation • remove the baffle plate bolts [a], and take off the baffle plate [b]. • slide out the rubber cap [a]. • disconnect the oil pressure switch lead terminal [b]. • disconnect: crankshaft sensor lead connector [a] starter motor cable terminal ...

  • Page 294

    8-6 engine removal/installation engine removal/installation • support the engine using a suitable stand or jack [a]. ○ put planks [b] to balance the engine. • remove the engine mounting bolt [a] on both sides. • remove the bracket bolts [b] on both sides. • remove the engine mounting bolts [c], and ...

  • Page 295

    Engine removal/installation 8-7 engine removal/installation • by the following specified sequence, tighten the engine mounting bolts and nuts. ○ tighten: torque - engine mounting nut (lower) [a]: 44 n·m (4.5 kgf·m, 32 ft·lb) ○ tighten: torque - engine mounting nut (rear) [b]: 44 n·m (4.5 kgf·m, 32 f...

  • Page 296

    8-8 engine removal/installation engine removal/installation • run the leads, cables, and hoses correctly (see cable, wire, and hose routing section in the appendix chapter). • tighten: torque - engine ground lead terminal bolt: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install the removed parts (see appropria...

  • Page 297: Crankshaft/transmission

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

  • Page 298

    9-2 crankshaft/transmission exploded view http://mototh.Com.

  • Page 299

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

  • Page 300

    9-4 crankshaft/transmission exploded view http://mototh.Com.

  • Page 301

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

  • Page 302

    9-6 crankshaft/transmission specifications item standard service limit crankshaft, connecting rods connecting rod bend – – – tir 0.2/100 mm (0.008/3.94 in.) connecting rod twist – – – tir 0.2/100 mm (0.008/3.94 in.) connecting rod big end side clearance 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.) 0.58 mm (...

  • Page 303

    Crankshaft/transmission 9-7 specifications item standard service limit crankshaft runout tir 0.02 mm (0.0008 in.) or less tir 0.05 mm (0.002 in.) crankshaft main bearing insert/journal clearance 0.012 ∼ 0.036 mm (0.0005 ∼ 0.0014 in.) 0.07 mm (0.003 in.) crankshaft main journal diameter: 37.984 ∼ 38....

  • Page 304

    9-8 crankshaft/transmission specifications item standard service limit crankcase bearing bore diameter: 31.000 ∼ 31.016 mm (1.2205 ∼ 1.2211 in.) – – – marking: ○ 31.000 ∼ 31.008 mm (1.2205 ∼ 1.2208 in.) – – – none 31.009 ∼ 31.016 mm (1.2208 ∼ 1.2211 in.) – – – balancer shaft bearing insert thickness...

  • Page 305

    Crankshaft/transmission 9-9 special tools and sealants outside circlip pliers: 57001-144 bearing driver set: 57001-1129 kawasaki bond (silicone sealant): 92104-0004 kawasaki bond (liquid gasket - black): 92104-1064 http://mototh.Com.

  • Page 306

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

  • Page 307

    Crankshaft/transmission 9-11 crankcase splitting • remove the oil pan, oil screen and oil pipes (see oil pan removal in the engine lubrication system chapter). • remove the lower crankcase bolts, following the specified sequence. ○ firstly, loosen the m6 bolts [a]. ○ secondly, loosen the m8 bolts [b...

  • Page 308

    9-12 crankshaft/transmission crankcase splitting crankcase assembly caution the upper and lower crankcase halves are ma- chined at the factory in the assembled state, so the crankcase halves must be replaced as a set. • with a high-flash point solvent, clean off the mating sur- faces of the crankcas...

  • Page 309

    Crankshaft/transmission 9-13 crankcase splitting • apply silicone sealant to the breather plate mating surface [a] 1 mm (0.04 in.) or more thick, and then install the breather plate. Sealant - three bond: tb1207b note ○ make the application finish within 7 minutes when the liquid gasket to the matin...

  • Page 310

    9-14 crankshaft/transmission crankcase splitting • install the crankshaft and the balancer shaft on the upper crankcase half. ○ apply molybdenum disulfide oil solution to the following items. Crankshaft main bearing insert balancer shaft bearing insert ○ align [a] the timing mark on the balancer gea...

  • Page 311

    Crankshaft/transmission 9-15 crankcase splitting • apply liquid gasket [a] to the mating surface of the lower crankcase half. Sealant - kawasaki bond (liquid gasket-black): 92104 -1064 note ○ especially, apply a liquid gasket carefully so that it shall be filled up on the grooves. Caution do not app...

  • Page 312

    9-16 crankshaft/transmission crankcase splitting • fit the lower crankcase half to the upper crankcase half. ○ insert [a] the breather pipe [b] on the upper crankcase half through the hole [c] on the lower crankcase half. Note ○ make the application finish within 20 minutes when the liquid gasket to...

  • Page 313

    Crankshaft/transmission 9-17 crankcase splitting • tighten the lower crankcase bolts using the following steps. ○ following the sequence numbers on the lower crankcase half, tighten the m9 bolts [1, 2] l= 113 mm (4.45 in.) with washers. Torque - crankcase bolts (m9): 44 n·m (4.5 kgf·m, 32 ft·lb) ○ t...

  • Page 314

    9-18 crankshaft/transmission crankshaft and connecting rods crankshaft removal • split the crankcase (see crankcase splitting). • remove: camshaft chain [a] crankshaft [b] crankshaft installation note ○ if the crankshaft is replaced with a new one, refer to the connecting rod big end bearing/cranksh...

  • Page 315

    Crankshaft/transmission 9-19 crankshaft and connecting rods connecting rod installation caution to minimize vibration, the connecting rods should have the same weight mark. Big end cap [a] connecting rod [b] weight mark, alphabet [c] diameter mark [d]: “ ○ ” or no mark caution if the connecting rods...

  • Page 316

    9-20 crankshaft/transmission crankshaft and connecting rods ○ the connecting rod big end is bolted using the “plastic region fastening method”. ○ this method precisely achieves the needed clamping force without exceeding it unnecessarily, allowing the use of thinner, lighter bolts further decreasing...

  • Page 317

    Crankshaft/transmission 9-21 crankshaft and connecting rods • install new bolts in reused connecting rods. • dent both bolt head and bolt tip with a punch as shown. • before tightening, use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt st...

  • Page 318

    9-22 crankshaft/transmission crankshaft and connecting rods • install new bolts in reused connecting rods. • apply a small amount of molybdenum disulfide oil solution to the following. Threads [a] of nuts and bolts seating surfaces [b] of nuts and connecting rods • first, tighten the nuts to the spe...

  • Page 319

    Crankshaft/transmission 9-23 crankshaft and connecting rods connecting rod twist • with the big-end arbor [a] still on v block [c], hold the connecting rod horizontally and measure the amount that the arbor [b] varies from being paralleled with the surface plate over a 100 mm (3.94 in.) length of th...

  • Page 320

    9-24 crankshaft/transmission crankshaft and connecting rods if the clearance is within the standard, no bearing replace- ment is required. If the clearance is between 0.042 mm (0.00165 in.) and the service limit (0.08 mm, 0.003 in.), replace the bear- ing inserts [a] with inserts painted blue [b]. C...

  • Page 321

    Crankshaft/transmission 9-25 crankshaft and connecting rods • select the proper bearing insert [a] in accordance with the combination of the connecting rod and crankshaft coding. Size color [b] bearing insert connecting rod big end inside diameter marking crankpin diameter marking size color part nu...

  • Page 322

    9-26 crankshaft/transmission crankshaft and connecting rods crankshaft main bearing insert/journal wear • using a plastigage (press gauge) [a], measure the bear- ing insert/journal [b] clearance. Note ○ tighten the crankcase bolts to the specified torque (see crankcase assembly). ○ do not turn the c...

  • Page 323

    Crankshaft/transmission 9-27 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 324

    9-28 crankshaft/transmission balancer balancer removal • split the crankcase (see crankcase splitting). • pull the balancer shaft [a] with the balancer gear out of the crankcase. Balancer installation • apply molybdenum disulfide oil solution to the inside of the balancer shaft bearing insert. • ali...

  • Page 325

    Crankshaft/transmission 9-29 balancer note ○ do not turn the balancer shaft during clearance mea- surement. ○ remove the lower crankcase half and measure the plas- tigage width [a] to determine the bearing insert/journal [b] clearance. Balancer shaft bearing insert/journal clearance standard: 0.011 ...

  • Page 326

    9-30 crankshaft/transmission balancer • put the lower crankcase half on the upper crankcase half without bearing inserts, and tighten the case bolts to the specified torque and sequence (see crankcase assem- bly). • measure the crankcase bearing bore diameter for the bal- ancer shaft, and mark the u...

  • Page 327

    Crankshaft/transmission 9-31 external shift mechanism shift pedal removal • remove: shift pedal bolt [a] shift pedal [b] shift pedal installation • align the punch mark [a] on the shift shaft with the punch mark [b] on the shift pedal. • tighten the shift pedal bolt securely. Torque - shift pedal bo...

  • Page 328

    9-32 crankshaft/transmission external shift mechanism • remove: clutch (see clutch removal in the clutch chapter) gear positioning lever bolt [a] spacer [b] gear positioning lever [c] washer and spring external shift mechanism installation • install the gear positioning lever [a] as shown in the fig...

  • Page 329

    Crankshaft/transmission 9-33 external shift mechanism • replace the shift shaft cover gasket with a new one. • install the shift shaft cover. • apply a non-permanent locking agent to the shift shaft cover screw [a] and bolts [b, c]. ○ do not apply a non-permanent locking agent to the shift shaft cov...

  • Page 330

    9-34 crankshaft/transmission transmission transmission assy removal • remove: shift shaft assembly (see external shift mechanism re- moval) neutral switch holder screw [a] neutral switch holder [b] and pin shift drum holder [c] and pin • remove the collar [a] and the o-ring [b] from the output shaft...

  • Page 331

    Crankshaft/transmission 9-35 transmission if the gear positioning lever [a] was removed, install it (see external shift mechanism installation). If the shift rod plate [b] was removed, install it. ○ apply a non-permanent locking agent to the shift rod plate bolt, and tighten it. Torque - shift rod p...

  • Page 332

    9-36 crankshaft/transmission transmission • remove: shift drum cam bolt [a] shift drum [b] and pin shift drum [c] transmission assy assembly • when the new ball bearing [a] and new race [b] are in- stalled in the transmission case [c], press and insert them until they are bottomed. Special tool - be...

  • Page 333

    Crankshaft/transmission 9-37 transmission • install the following on the transmission case [a]. Shift drum [b] pin [c] shift drum cam [d] ○ align the pin with the hole on the shift drum cam. • apply a non-permanent locking agent to the shift drum cam bolt [e] and tighten it. Torque - shift drum cam ...

  • Page 334

    9-38 crankshaft/transmission transmission transmission shaft disassembly • remove the transmission shafts (see transmission assy disassembly). • remove the circlips, disassemble the transmission shafts. Special tool - outside circlip pliers: 57001-144 • the 5th gear [a] on the output shaft has three...

  • Page 335

    Crankshaft/transmission 9-39 transmission • fit the steel balls into the 5th gear holes in the output shaft, aligning oil hole as shown in the figure. 5th gear [a] output shaft [b] steel balls [c] oil holes [d] caution do not apply grease to the balls to hold them in place. This will cause the posit...

  • Page 336

    9-40 crankshaft/transmission transmission 1. Drive shaft 2. 1st gear 3. 2nd gear 4. 3rd gear 5. 4th gear 6. 5th gear 7. 6th (top) gear 8. Bushing 9. Toothed washer, 34 mm (1.34 in.) 10. Circlip 11. Bushing 12. Thrust washer, 30 mm (1.18 in.) 13. Needle bearing 14. Circlip 15. Output shaft 16. Spacer...

  • Page 337

    Crankshaft/transmission 9-41 transmission shift drum and fork removal • refer to the transmission assy disassembly. Shift drum and fork installation • refer to the transmission assy assembly. Shift drum disassembly • refer to the transmission assy disassembly. Shift drum assembly • refer to the tran...

  • Page 338

    9-42 crankshaft/transmission transmission gear dog and gear dog hole damage • visually inspect the gear dogs [a] and gear dog holes [b]. Replace any damaged gears or gears with excessively worn dogs or dog holes. Http://mototh.Com.

  • Page 339

    Crankshaft/transmission 9-43 ball bearing, needle bearing, and oil seal ball and needle bearing replacement caution 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 abse...

  • Page 340

    Http://mototh.Com.

  • Page 341: Wheels/tires

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

  • Page 342

    10-2 wheels/tires exploded view http://mototh.Com.

  • Page 343

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front axle 108 11.0 80 2 front axle clamp bolt 34 3.5 25 3 rear axle nut 108 11.0 80 4. Ex650d models g: apply grease. Hg: apply high-temperature grease. R: replacement parts wl: apply soap and water solution or rubber lub...

  • Page 344

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

  • Page 345

    Wheels/tires 10-5 special tools bearing driver set: 57001-1129 jack: 57001-1238 bearing remover head, 20 × 22: 57001-1293 bearing remover shaft, 13: 57001-1377 jack attachment: 57001-1608 http://mototh.Com.

  • Page 346

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

  • Page 347

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

  • Page 348

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

  • Page 349

    Wheels/tires 10-9 wheels (rims) • bend the cotter pin [a] over the nut [b]. Warning if the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condi- tion may result. • install the rear caliper (see caliper installation in the brakes chapter). • for models eq...

  • Page 350

    10-10 wheels/tires wheels (rims) axle inspection • remove the front and rear axles (see front/rear wheel removal). • visually inspect the front and rear axles for damages. If the axle is damaged or bent, replace it. • measure the axle runout. ○ place the axle in v blocks that are 100 mm (3.94 in.) [...

  • Page 351

    Wheels/tires 10-11 wheels (rims) balance weight removal • insert a regular tip screwdrivers [a] [b] between the rib [c] and the weight [d] as shown in the figure. • pry the balance weight with two screwdrivers and remove the balance weight. • discard the used balance weight. Caution do not tap the s...

  • Page 352

    10-12 wheels/tires wheels (rims) • be sure to install the balance weight. ○ check that the blade [a] and clip [b] are fully seated on the rim [c] and that the clip is hooked over the rib [d]. Left side [e] right side [f] http://mototh.Com.

  • Page 353

    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 354

    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. Caution do not use engine oil or petroleum dis...

  • Page 355

    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 356

    10-16 wheels/tires hub bearing hub bearing removal • remove the wheels (see front/rear wheel removal), and take out the following. Collars coupling (out of rear hub) grease seals • use the bearing remover to remove the hub bearings [a]. Caution do not lay the wheel on the ground with the disc facing...

  • Page 357

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

  • Page 358

    Http://mototh.Com.

  • Page 359: Final Drive

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

  • Page 360

    11-2 final drive exploded view http://mototh.Com.

  • Page 361

    Final drive 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine sprocket nut 125 12.7 92 mo 2 rear axle nut 108 11.0 80 3 rear sprocket nuts 59 6.0 44 4 speed sensor bolt 7.8 0.80 69 in·lb l 5 speed sensor bracket bolts 9.8 1.0 87 in·lb g: apply grease. Hg: apply high-temperature...

  • Page 362

    11-4 final drive specifications item standard service limit drive chain drive chain slack 25 ∼ 35 mm (1.0 ∼ 1.4 in.) – – – drive chain wear (20-link length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) standard chain: make daido – – – type did 520vp2-t – – – link 114 links – – – sprockets ...

  • Page 363

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

  • Page 364

    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 365

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

  • Page 366

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

  • Page 367

    Final drive 11-9 drive chain • after riveting, check the ends of the riveted pins for cracks. • measure the outside diameter [a] of the link pin and width [b] of the link plates. Link pin outside diameter standard: 5.7 ∼ 6.0 mm (0.22 ∼ 0.24 in.) link plate outside width standard: 17.25 ∼ 17.55 mm (0...

  • Page 368

    11-10 final drive sprocket, coupling engine sprocket removal • remove: left frame cover (see frame cover removal in the frame chapter) engine sprocket cover bolts [a] engine sprocket cover [b] • remove: speed sensor bracket bolts [a] speed sensor bracket [b] • flatten out the bended washer [a]. • re...

  • Page 369

    Final drive 11-11 sprocket, coupling engine sprocket installation • replace the sprocket washer with a new one. • install the engine sprocket [a] so that “outside” letters face outward. • apply molybdenum disulfide oil solution to the threads of the output shaft and seating surface of the engine spr...

  • Page 370

    11-12 final drive sprocket, coupling coupling installation • apply high-temperature grease to the coupling grease seal lips [a]. • apply grease to the coupling internal surface [b]. • apply grease to the following. Wheel flange portion [a] o-ring [b] • install the collar [c]. Coupling bearing remova...

  • Page 371

    Final drive 11-13 sprocket, coupling • replace the grease seal with a new one. • press in the grease seal so that the seal surface is flush with the end of the hole. ○ apply high-temperature grease to the grease seal lips. Special tool - bearing driver set: 57001-1129 coupling bearing inspection sin...

  • Page 372

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

  • Page 373: Brakes

    Brakes 12-1 12 brakes table of contents exploded view........................................................................................................................ 12-4 specifications .............................................................................................................

  • Page 374

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

  • Page 375

    Brakes 12-3 dummy page http://mototh.Com.

  • Page 376

    12-4 brakes exploded view ex650c models http://mototh.Com.

  • Page 377

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

  • Page 378

    12-6 brakes exploded view ex650c models http://mototh.Com.

  • Page 379

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

  • Page 380

    12-8 brakes exploded view ex650d models http://mototh.Com.

  • Page 381

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

  • Page 382

    12-10 brakes exploded view ex650d models http://mototh.Com.

  • Page 383

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

  • Page 384

    12-12 brakes specifications item standard service limit brake lever, brake pedal lever position 5-way adjustable (to suit rider) – – – lever free play non-adjustable – – – pedal position about 40 mm (1.6 in.) below top of footpeg – – – pedal free play non-adjustable – – – brake pads lining thickness...

  • Page 385

    Brakes 12-13 special tools jack: 57001-1238 hand tester: 57001-1394 jack attachment: 57001-1608 http://mototh.Com.

  • Page 386

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

  • Page 387

    Brakes 12-15 brake lever, brake pedal brake pedal installation • apply grease to the pivot shaft [a]. • install: washer [b] brake pedal [c] washer [d] • tighten: torque - brake pedal bolt [e]: 8.8 n·m (0.90 kgf·m, 78 in·lb) • install the following parts as shown in the figure. Return spring [a] rear...

  • Page 388

    12-16 brakes calipers caliper removal caution immediately wipe up any brake fluid that spilled. Note ○ if the caliper is to be disassembled after removal and compressed air is not available, disassemble the caliper before brake hose removal (see caliper rubber parts replacement in the periodic maint...

  • Page 389

    Brakes 12-17 calipers • check the fluid level in the brake reservoirs (see brake fluid level inspection in the periodic maintenance chap- ter). • bleed the brake line (see brake line bleeding). • check the brake for good braking power, no brake drag, and no fluid leakage. Warning do not attempt to d...

  • Page 390

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

  • Page 391

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

  • Page 392

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

  • Page 393

    Brakes 12-21 master cylinder front master cylinder removal • remove the banjo bolt [a] to disconnect the brake hose from the master cylinder [b]. • disconnect the front brake light switch connectors [a]. • unscrew the clamp bolts [b], and take off the master cylin- der as an assembly with the reserv...

  • Page 394

    12-22 brakes master cylinder rear master cylinder removal • unscrew the brake hose banjo bolt [a] on the master cylin- der. • unscrew the master cylinder mounting bolts [a]. • remove the cotter pin [b]. • pull off the joint pin [c] while pressing down the brake pedal. • pull off the reservoir hose l...

  • Page 395

    Brakes 12-23 master cylinder master cylinder inspection • remove the master cylinders (see front/rear master cylinder removal). • disassemble the front and rear master cylinders. • check that there are no scratches, rust or pitting on the inner wall [a] of each master cylinder and on the outside of ...

  • Page 396

    12-24 brakes brake disc brake disc removal • remove the wheel (see front/rear wheel removal in the wheels/tires chapter). • unscrew the mounting bolts [a], and take off the disc. • for front brake disc, remove the gaskets. Brake disc installation • for front brake disc, replace the gaskets with new ...

  • Page 397

    Brakes 12-25 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 398

    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 399

    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 400

    12-28 brakes brake hose brake hose removal/installation • refer to the brake hose and pipe replacement in the periodic maintenance chapter. Brake hose inspection • refer to the brake hose damage and installation condi- tion inspection in the periodic maintenance chapter. Http://mototh.Com.

  • Page 401

    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] abs solenoid valve relay fuse 25a [a] abs moto...

  • Page 402

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

  • Page 403

    Brakes 12-31 anti-lock brake system (equipped models) abs system wiring diagram 1. Ignition switch 2. Abs hydraulic unit 3. Abs self-diagnosis terminal 4. Abs kawasaki diagnostic system connec- tor 5. Front wheel rotation sensor 6. Rear wheel rotation sensor 7. Abs solenoid valve relay fuse 25 a 8. ...

  • Page 404

    12-32 brakes anti-lock brake system (equipped models) terminal names 1. Ground to motor 2. Power supply to abs motor relay 3. Power supply to abs solenoid valve relay 4. Ground 5. Front wheel rotation sensor signal 6. Unused 7. Power supply to rear wheel rotation sensor 8. Unused 9. Unused 10. Unuse...

  • Page 405

    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 406

    12-34 brakes anti-lock brake system (equipped models) ○ the abs indicator light (led) [a] may light if the tire pres- sure is incorrect, a non-recommended tire is installed, or the wheel is deformed. If the indicator light lights, remedy the problem and clear the service code. Warning use of non-rec...

  • Page 407

    Brakes 12-35 anti-lock brake system (equipped models) abs troubleshooting outline when an abnormality in the system occurs, the abs in- dicator light (led) lights up to alert the rider. In addition, the nature of the fault is stored in the memory of the abs hydraulic unit and when in the self-diagno...

  • Page 408

    12-36 brakes anti-lock brake system (equipped models) • visually inspect the wiring for signs of burning or fraying. If any wiring is poor, replace the damaged wiring. • pull each connector [a] apart and inspect it for corrosion, dirt and damage. If the connector is corroded or dirty, clean it caref...

  • Page 409

    Brakes 12-37 anti-lock brake system (equipped models) abs diagnosis flow chart http://mototh.Com.

  • Page 410

    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 411

    Brakes 12-39 anti-lock brake system (equipped models) pre-diagnosis inspection 1 http://mototh.Com.

  • Page 412

    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 (15 codes including “normal code”) for the service person to troubleshoot easily. The ...

  • Page 413

    Brakes 12-41 anti-lock brake system (equipped models) • remove the seat (see seat removal in the frame chap- ter). • ground the self-diagnosis terminal [a] (gray) to the bat- tery (–) terminal or battery (–) cable connector, using a lead [b]. • turn on the ignition switch. ○ count the blinks of the ...

  • Page 414

    12-42 brakes anti-lock brake system (equipped models) self-diagnosis flow chart http://mototh.Com.

  • Page 415

    Brakes 12-43 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 416

    12-44 brakes anti-lock brake system (equipped models) service code table service code abs indicator light (led) problems light state 12 start code (not fault) after starts, turn off 13 rear inlet solenoid valve trouble (open, temperature abnormal) on 14 rear outlet solenoid valve trouble (open, temp...

  • Page 417

    Brakes 12-45 anti-lock brake system (equipped models) abs indicator light (led) inspection • turn the ignition switch on. If the abs indicator light (led) [a] lights, it is normal. If the abs indicator light (led) does not light, check the meter unit (see electronic combination meter unit inspection...

  • Page 418

    12-46 brakes anti-lock brake system (equipped models) • do the 2nd step test. ○ disconnect the abs hydraulic unit connector [a]. ○ check for continuity between the white/red and black/yel- low lead terminals of the abs hydraulic unit connector. If there is the continuity in the lead, replace the abs...

  • Page 419

    Brakes 12-47 anti-lock brake system (equipped models) front, rear wheel rotation difference abnormal (service code 25) • do the 1st step test. ○ check the following and correct the faulty part. Incorrect the tire pressure. Tires not recommended for the motorcycle were installed (incorrect tire size)...

  • Page 420

    12-48 brakes anti-lock brake system (equipped models) • do the 4th step test. ○ check the battery terminal voltage between the red/white lead terminal of the fuse box [a] and ground. Special tool - hand tester: 57001-1394 battery terminal voltage standard: battery voltage if the battery terminal vol...

  • Page 421

    Brakes 12-49 anti-lock brake system (equipped models) • do the 2nd step test. ○ 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 th...

  • Page 422

    12-50 brakes anti-lock brake system (equipped models) • do the 3rd step test. ○ 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] lit, faulty ecu in the abs hydraulic unit. Re...

  • Page 423

    Brakes 12-51 anti-lock brake system (equipped models) rear wheel rotation sensor wiring inspection (service code 45) • do the 1st step test. ○ disconnect the abs hydraulic unit connector and rear wheel rotation sensor connector. ○ short the red and green lead terminals of the main har- ness side con...

  • Page 424

    12-52 brakes anti-lock brake system (equipped models) • do the 2nd step test. ○ connect the abs kawasaki diagnostic system connector and abs hydraulic unit connector. ○ check the battery terminal voltage, connect the hand tester to the brown terminal of abs kawasaki diagnostic system connector [a] a...

  • Page 425

    Brakes 12-53 anti-lock brake system (equipped models) • do the 2nd step test. ○ connect the abs kawasaki diagnostic system connector and abs hydraulic unit connector. ○ check the battery terminal voltage, connect the hand tester to the brown terminal of abs kawasaki diagnostic system connector [a] a...

  • Page 426

    12-54 brakes anti-lock brake system (equipped models) abs hydraulic unit removal caution the abs hydraulic unit [a] has been adjusted and set with precision at the factory. Therefore, it should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface. Be car...

  • Page 427

    Brakes 12-55 anti-lock brake system (equipped models) • remove the brake pipe joint nuts [a]. • tape the brake line opening to prevent brake fluid leakage or contamination by foreign matter. Caution brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed awa...

  • Page 428

    12-56 brakes anti-lock brake system (equipped models) abs hydraulic unit inspection • remove the abs hydraulic unit (see abs hydraulic unit removal). • visually inspect the abs hydraulic unit. Replace the abs hydraulic unit if any of them are cracked, or otherwise damaged. • visually inspect the con...

  • Page 429

    Brakes 12-57 anti-lock brake system (equipped models) • disconnect the connector [a]. • remove: bolt [a] front wheel rotation sensor [b] • free the sensor lead from the clamps. Front wheel rotation sensor installation • installation is the reverse of removal. ○ route the lead correctly (see cable, w...

  • Page 430

    12-58 brakes anti-lock brake system (equipped models) • remove: bolt [a] rear wheel rotation sensor [b] • free the sensor lead from the clamps. Rear wheel rotation sensor installation • installation is the reverse of removal. ○ route the lead correctly (see cable, wire, and hose routing section in t...

  • Page 431

    Brakes 12-59 anti-lock brake system (equipped models) wheel rotation sensor rotor inspection • remove the front/rear brake discs (see brake disc re- moval). • visually inspect the wheel rotation sensor rotor. If the rotor is deformed or damaged (chipped teeth [a]), replace the sensor rotor with the ...

  • Page 432

    12-60 brakes anti-lock brake system (equipped models) fuse inspection • remove the fuse (see abs solenoid valve relay fuse 25 a/abs motor relay fuse 30 a removal). • inspect the fuse element. If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affect...

  • Page 433: Suspension

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

  • Page 434

    13-2 suspension exploded view http://mototh.Com.

  • Page 435

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fork bottom allen bolts 30 3.1 22 l 2 front fork clamp bolts (lower) 21 2.1 15 al 3 front fork clamp bolts (upper) 20 2.0 15 4 front fork top plugs 25 2.5 18 5 front axle clamp bolt 34 3.5 25 al: tighten the two clamp ...

  • Page 436

    13-4 suspension exploded view http://mototh.Com.

  • Page 437

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear shock absorber bolts 59 6.0 44 2 swingarm pivot shaft nut 108 11.0 80 g: apply grease. R: replacement parts 2t: apply 2-stroke oil. Http://mototh.Com.

  • Page 438

    13-6 suspension specifications item standard front fork (per one unit) fork inner tube outside diameter 41 mm (1.6 in.) air pressure atmospheric pressure (non-adjustable) fork spring setting non-adjustable damper setting non-adjustable fork oil: viscosity kayaba khl34-g10 or equivalent amount: ex650...

  • Page 439

    Suspension 13-7 special tools inside circlip pliers: 57001-143 fork cylinder holder handle: 57001-183 fork cylinder holder adapter: 57001-1057 oil seal & bearing remover: 57001-1058 bearing driver set: 57001-1129 jack: 57001-1238 front fork oil seal driver: 57001-1219 fork oil level gauge: 57001-129...

  • Page 440

    13-8 suspension special tools spacer, 28: 57001-1663 http://mototh.Com.

  • Page 441

    Suspension 13-9 front fork front fork removal • remove: upper fairing (see upper fairing removal in the frame chapter) front wheel (see front wheel removal in the wheels/tires chapter) front fender (see front fender removal in the frame chapter) front wheel rotation sensor (abs equipped models, see ...

  • Page 442

    13-10 suspension front fork • compress [a] the fork [b] upside down to draw out the oil into the suitable container [c]. • hold the fork tube upright, pour in the type and amount of fork oil specified. Fork oil viscosity: kayaba khl34-g10 or equivalent amount (per side): when changing oil: ex650c mo...

  • Page 443

    Suspension 13-11 front fork • repeat the same procedure for adjusting the other fork. • install: fork spring [a] fork spring seat [b] spacer [c] • replace the top plug o-ring with a new one. • install: top plug front fork (see front fork installation) front fork disassembly • remove the front fork (...

  • Page 444

    13-12 suspension front fork • separate the inner tube [a] from the outer tube [b]. Note ○ from the compressed state, firmly pull down the outer tube a few times towards the direction of elongation. • remove the following from the inner tube. Inner guide bushing [a] outer guide bushing [b] washer [c]...

  • Page 445

    Suspension 13-13 front fork • install the new guide bushing [a] with a use one [b] on it by tapping the use one with the fork oil seal driver [c]. ○ the split [d] of the bushing should face toward the side of the motorcycle. Special tool - front fork oil seal driver: 57001-1219 • install the washer ...

  • Page 446

    13-14 suspension front fork inner tube, outer tube inspection • visually inspect the inner tube [a], and repair any dam- age. • nicks 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 ...

  • Page 447

    Suspension 13-15 rear shock absorber spring preload adjustment • using the hook wrench [a], turn the adjusting nut [b] to adjust the spring preload. ○ the standard adjuster setting for average-build rider of 68 kg (150 ib) with no passenger and no accessories is 4th position. Spring preload setting ...

  • Page 448

    13-16 suspension rear shock absorber • remove: rear shock absorber bolt (upper) [a] rear shock absorber bolt (lower) [b], nut and washer • remove the shock absorber [c] backward. Rear shock absorber installation • installation is the reverse of removal. • replace the o-ring of the rear shock absorbe...

  • Page 449

    Suspension 13-17 swingarm swingarm removal • remove: chain cover bolts [a] quick rivet [b] chain cover [c] • free the brake hose [a] from the clamps [b]. • for models equipped with an abs, remove the rear wheel rotation sensor (see rear wheel rotation sensor re- moval in the brakes chapter). • remov...

  • Page 450

    13-18 suspension swingarm swingarm installation • installation is the reverse of removal. ○ apply grease to the lip of the oil seals. ○ be sure to install the oil seal and collar to the swingarm. • tighten the pivot shaft nut. Torque - swingarm pivot shaft nut: 108 n·m (11.0 kgf·m, 80 ft·lb) • insta...

  • Page 451

    Suspension 13-19 swingarm • install the needle bearings [a], ball bearing [b] and oil seals [c] position as shown. Circlip [d] 25 mm (0.98 in.) [e] 17 mm (0.67 in.) [f] 1 mm (0.04 in.) [g] 1 mm (0.04 in.) [h] 1 mm (0.04 in.) [i] 23.5 mm (0.93 in.) [j] 5.5 mm (0.22 in.) [k] left side [l] right side [...

  • Page 452

    13-20 suspension swingarm • turn the bearing in the swingarm back and forth [a] while checking for plays, roughness, or binding. If bearing play, roughness, or binding is found, replace the bearing. • examine the bearing seal [b] for tears or leakage. If the seal is torn or is leaking, replace the b...

  • Page 453: Steering

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

  • Page 454

    14-2 steering exploded view http://mototh.Com.

  • Page 455

    Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fork clamp bolts (lower) 21 2.1 15 al 2 front fork clamp bolts (upper) 20 2.0 15 3 handlebar holder bolts 25 2.5 18 s 4 handlebar holder mounting nuts 34 3.5 25 5 switch housing screws 3.5 0.36 31 in·lb 6 steering stem h...

  • Page 456

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

  • Page 457

    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. Http://mototh.Com.

  • Page 458

    14-6 steering steering stem stem, stem bearing removal • remove: upper fairing (see upper fairing removal in the frame chapter) front fender (see front fender removal in the frame chapter) front wheel (see front wheel removal in the wheels/tires chapter) handlebar (see handlebar removal) under brack...

  • Page 459

    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. • apply grease to the outer races...

  • Page 460

    14-8 steering steering stem • install the steering stem [a] through the head pipe, and install the ball bearing [b] and inner race [c] on it. • apply grease to the stem cap [d]. • install: stem cap steering stem nut [e] • settle the bearings in place as follows. ○ tighten the steering stem nut with ...

  • Page 461

    Steering 14-9 steering stem steering stem bearing lubrication • refer to the steering stem bearing lubrication in the pe- riodic maintenance chapter. Steering stem warp inspection • whenever the steering stem is removed, or if the steering can not be adjusted for smooth action, check the steering st...

  • Page 462

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

  • Page 463

    Steering 14-11 handlebar • align the punch mark [a] on the handlebar and the corner edge [b] on the lower handlebar holder. • tighten the front holder bolts first, and then the rear holder bolts. There will be a gap [a] at the rear part of the holder after tightening. Torque - handlebar holder bolts...

  • Page 464

    Http://mototh.Com.

  • Page 465: Frame

    Frame 15-1 15 frame table of contents exploded view................................... 15-2 seat ................................................... 15-8 seat removal .............................. 15-8 seat installation ........................... 15-8 fairings.........................................

  • Page 466

    15-2 frame exploded view http://mototh.Com.

  • Page 467

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

  • Page 468

    15-4 frame exploded view http://mototh.Com.

  • Page 469

    Frame 15-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 lower fairing mounting bolts 8.8 0.90 78 in·lb 2 lower fairing bracket bolts 12 1.2 106 in·lb l 3 front turn signal light mounting screws 1.2 0.12 11 in·lb l: apply a non-permanent locking agent. Http://mototh.Com.

  • Page 470

    15-6 frame exploded view http://mototh.Com.

  • Page 471

    Frame 15-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fender mounting bolts 8.8 0.90 78 in·lb 2 grab rail mounting bolts 25 2.5 18 3 seat lock mounting screws 1.2 0.12 11 in·lb 4. Us, ca, cal, au and sea models 5. Us, ca, cal and au models 6. Abs equipped models http://mototh....

  • Page 472

    15-8 frame seat seat removal • insert the ignition switch key [a] into the seat lock. • turn the key clockwise, and pull up on the rear of the seat [b]. • remove the seat backward. Seat installation • slip the seat hook [a] to under the brace [b] of the fuel tank. • insert the seat hooks [c] into th...

  • Page 473

    Frame 15-9 fairings lower fairing removal • remove the quick rivets [a]. • remove the bolts [a] and washers. • pull the upper fairing outward to clear the stopper [b] and take off the lower fairing [c]. Lower fairing installation • installation is the reverse of removal; note the following. ○ insert...

  • Page 474

    15-10 frame fairings lower fairing bracket installation • for right side, hold the lead with the clamp. • apply a non-permanent locking agent to the threads of the lower fairing bracket bolts. • tighten: torque - lower fairing bracket bolts: 12 n·m (1.2 kgf·m, 106 in·lb) upper fairing cover removal ...

  • Page 475

    Frame 15-11 fairings • remove: windshield (see windshield removal) quick rivets [a] meter cover [b] • slide the dust cover [a] and disconnect the meter unit connector [b]. • remove the bolts [c]. • pull the upper fairing [a] outward to clear the stoppers [b] on both sides. • remove the upper fairing...

  • Page 476

    15-12 frame fairings • remove the quick rivet [a]. • separate the upper center fairing [b], upper fairings [c] and inner fairings [d]. • remove the inner fairings (see inner fairing removal). • remove the front turn signal light mounting screws [a] and washers, and then take off the turn signal ligh...

  • Page 477

    Frame 15-13 fairings ○ insert the tabs [a] to the slots and fit the projections [b] to the holes as shown in the figure. ○ install the grommets [a] to the holes [b] on both sides of the upper center fairing and bracket after rear view mirrors installation. Upper inner fairing removal • remove: quick...

  • Page 478

    15-14 frame fairings • remove the bolts [a], and take off the upper fairing bracket [b]. Upper fairing bracket installation • installation is the reverse of removal. ○ run the leads correctly (see cable, wire, and hose rout- ing section in the appendix chapter). Under bracket removal • remove the up...

  • Page 479

    Frame 15-15 fairings inner fairing installation • installation is the reverse of removal; note the following. ○ tighten: torque - front turn signal light mounting screw [a]: 1.2 n·m (0.12 kgf·m, 11 in·lb) ○ fit the ribs [a] to inside of the upper fairing [b]. ○ fit the ribs [c] to assemble the left ...

  • Page 480

    15-16 frame side covers side cover removal • remove the seat (see seat removal). • remove the quick rivet [a]. • pull the side cover [b] evenly outward to clear the stop- pers. Side cover installation • install the trim [a] securely. • install the side cover. ○ fit the rib [b] to inside of the trim....

  • Page 481

    Frame 15-17 seat covers seat cover removal • remove: seat (see seat removal) quick rivets [a] center seat cover [b] • remove: bolts [a] grab rail [b] (equipped models) • remove: screw [a] and washer • remove: quick rivets [a] seat cover [b] seat cover installation • install the damper [a] to the sea...

  • Page 482

    15-18 frame seat covers • install the seat cover. ○ fit the projection [a] into the grommet [b]. ○ insert the ribs [c] into the inside of the rear fender. • install: screw quick rivets grab rail (equipped models) • tighten: torque - grab rail mounting bolts: 25 n·m (2.5 kgf·m, 18 ft·lb) • install th...

  • Page 483

    Frame 15-19 fenders front fender removal • remove: front fender bolts [a] (both sides) front fender [b] front fender installation • install the front fender [a] together with the brake hose clamp [b] on both sides. • tighten torque - front fender mounting bolts [c]: 8.8 n·m (0.90 kgf·m, 78 in·lb) fl...

  • Page 484

    15-20 frame fenders rear fender removal • remove: seat cover (see seat cover removal) rear right turn signal light lead connector [a] rear left turn signal light lead connector [b] license plate light lead connector [c] tail/brake light lead connector [d] • clear the harness and leads from the clamp...

  • Page 485

    Frame 15-21 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. If the frame is bent, dented, cracked, or warped, replace it. Http://mototh.C...

  • Page 486

    15-22 frame battery case battery case removal • remove: seat cover (see seat cover removal) battery (see battery removal in the electrical system chapter) fuel tank (see fuel tank removal in the fuel system (dfi) chapter) • free the harness from the clamp [a]. • remove the bolts [b] and remove the f...

  • Page 487

    Frame 15-23 battery case • remove: clamp [a] fuse box [b] quick rivet [c] • remove the battery case [a]. Battery case installation • installation is the reverse of removal. • run the cables and harness correctly (see cable, wire, and hose routing section in the appendix chapter). Http://mototh.Com.

  • Page 488

    15-24 frame footpeg stay footpeg stay removal • remove: frame cover (see frame cover removal) bolts [a] footpeg stay guard [b] • remove: footpeg stay bolts [a] footpeg stay [b] rear master cylinder (right side, see rear master cylinder removal in the brakes chapter) brake pedal (right side, see brak...

  • Page 489

    Frame 15-25 windshield windshield removal • remove: bolts [a] and washers windshield [b] windshield installation • installation is the reverse of removal. Http://mototh.Com.

  • Page 490

    15-26 frame sidestand sidestand removal • raise the rear wheel off the ground using a stand [a]. • remove: left frame cover (see frame cover removal) left footpeg stay (see footpeg stay removal) • remove: sidestand switch bolt [a] with clamp [b] sidestand switch [c] • remove: spring [a] sidestand nu...

  • Page 491

    Frame 15-27 frame cover frame cover removal • remove the bolt [a]. • pull the frame cover [b] outward to clear the stoppers. Frame cover installation • fit the rib [a] to the inside of the footpeg stay. • insert the projections [b] into the grommets [c]. • tighten the bolt. Http://mototh.Com.

  • Page 492

    15-28 frame rear view mirrors rear view mirror removal • remove: center inner fairing together with meter unit (see meter unit removal in the electrical system chapter) nuts [a] rear view mirror [b] rear view mirror installation • installation is the reverse of removal. Http://mototh.Com.

  • Page 493: Electrical System

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

  • Page 494

    16-2 electrical system starter motor removal...................................................................................................... 16-47 starter motor installation................................................................................................... 16-47 starter motor d...

  • Page 495

    Electrical system 16-3 dummy page http://mototh.Com.

  • Page 496

    16-4 electrical system exploded view http://mototh.Com.

  • Page 497

    Electrical system 16-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 meter cover screws 1.2 0.12 11 in·lb 2 front turn signal light mounting screws 1.2 0.12 11 in·lb 3 license plate light mounting screws 1.2 0.12 11 in·lb 4 tail/brake light mounting bolts 8.8 0.90 78 in·lb http://motot...

  • Page 498

    16-6 electrical system exploded view http://mototh.Com.

  • Page 499

    Electrical system 16-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 switch housing screws 3.5 0.36 31 in·lb 2 front brake light switch screw 1.2 0.12 11 in·lb 3 starter motor terminal nut 6.0 0.61 53 in·lb 4 starter motor terminal locknut 11 1.1 97 in·lb 5 starter motor mounting bolts...

  • Page 500

    16-8 electrical system exploded view http://mototh.Com.

  • Page 501

    Electrical system 16-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 fuel level sensor bolts 6.9 0.70 61 in·lb l 2 fuel pump bolts 9.8 1.0 87 in·lb l, s 3 regulator/rectifier bolts 8.8 0.90 78 in·lb 4 sidestand switch bolt 8.8 0.90 78 in·lb l 5 spark plugs 15 1.5 11 6 water temperature...

  • Page 502

    16-10 electrical system specifications item standard battery type sealed battery model name ftx12-bs capacity 12 v 10 ah voltage 12.6 v or more charging system type three-phase ac alternator output voltage 42 v or more at 4 000 r/min (rpm) stator coil resistance 0.18 ∼ 0.27 Ω charging voltage 14.2 ∼...

  • Page 503

    Electrical system 16-11 special tools and sealant hand tester: 57001-1394 flywheel puller assembly, m38 × 1.5/m35 × 1.5: 57001-1405 peak voltage adapter: 57001-1415 lead wire - peak voltage adapter: 57001-1449 grip: 57001-1591 rotor holder: 57001-1567 rotor holder: 57001-1658 kawasaki bond (silicone...

  • Page 504

    16-12 electrical system parts location http://mototh.Com.

  • Page 505

    Electrical system 16-13 parts location 1. Air switching valve 2. Alternator 3. Battery 12 v 10 ah 4. Crankshaft sensor 5. Ecu 6. Radiator fan motor 7. Front brake light switch 8. Fuse box with ecu main fuse 9. Ignition switch 10. Meter unit 11. Neutral switch 12. Oil pressure switch 13. Rear brake l...

  • Page 506

    16-14 electrical system wiring diagram (other than us, ca and cal models) http://mototh.Com.

  • Page 507

    Electrical system 16-15 wiring diagram (other than us, ca and cal models) http://mototh.Com.

  • Page 508

    16-16 electrical system wiring diagram (us, ca and cal models) http://mototh.Com.

  • Page 509

    Electrical system 16-17 wiring diagram (us, ca and cal models) http://mototh.Com.

  • Page 510

    16-18 electrical system wiring diagram (ex650d models) http://mototh.Com.

  • Page 511

    Electrical system 16-19 wiring diagram (ex650d models) http://mototh.Com.

  • Page 512

    16-20 electrical system precautions there are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○ always check battery con...

  • Page 513

    Electrical system 16-21 electrical wiring wiring inspection • visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clea...

  • Page 514

    16-22 electrical system battery battery removal • turn off the ignition switch. • remove the seat (see seat removal in the frame chap- ter). • disconnect the negative (–) cable [a]. Caution be sure to disconnect the negative (–) cable first. • slide out the positive (+) terminal cap [b] and then dis...

  • Page 515

    Electrical system 16-23 battery caution 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. • place the battery on a level surface. • check to see that the sealing sheet has...

  • Page 516

    16-24 electrical system battery • gently remove the container from the battery. • let the battery sit for 30 minutes prior to charging to allow the electrolyte to permeate into the plates for optimum performance. Note ○ charging the battery immediately after filling can shorten service life. Let the...

  • Page 517

    Electrical system 16-25 battery note ○ to ensure maximum battery life and customer satisfac- tion, it is recommended the battery be load tested at three times its amp-hour rating for 15 seconds. Re-check voltage and if less than 12.6 v repeat the charging cycle and load test. If still below 12.6 v t...

  • Page 518

    16-26 electrical system battery charging condition inspection battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter [a]. • remove the battery (see battery removal). Caution be sure to disconnect the negative (−) lead first. • measure the battery ter...

  • Page 519

    Electrical system 16-27 battery note ○ increase the charging voltage to a maximum voltage of 25 v if the battery will not accept current initially. Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current. If the battery will accept current decrease the...

  • Page 520

    16-28 electrical system charging system alternator cover removal • remove: lower fairing (see lower fairing removal in the frame chapter) frame cover (see frame cover removal in the frame chapter) engine oil (drain, see engine oil change in the periodic maintenance chapter) bolts [a] engine sprocket...

  • Page 521

    Electrical system 16-29 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] • take off the stator coil [d] from the alternator cover. Stator coil installation • apply a non-pe...

  • Page 522

    16-30 electrical system charging system • using the flywheel puller [a], remove the alternator rotor from the crankshaft. Special tool - flywheel puller assembly, m38 × 1.5/m35 × 1.5: 57001-1405 caution do not attempt to strike the alternator rotor itself. Striking the rotor can cause the magnets to...

  • Page 523

    Electrical system 16-31 charging system • apply a thin coat of molybdenum disulfide grease to the shafts [a], and install them. • install the torque limiter [b] and starter idle gear [c]. • install the alternator cover (see alternator cover installa- tion). Alternator inspection there are three type...

  • Page 524

    16-32 electrical system 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 525

    Electrical system 16-33 charging system rectifier circuit check • check conductivity of the following pair of terminals. Rectifier circuit inspection w1-bk1, w1-bk2, w1-bk3 tester connection bk/y-bk1, bk/y-bk2, bk/y-bk3 the resistance should be low in one direction and more than ten times as much in...

  • Page 526

    16-34 electrical system charging system • do the 3rd step regulator circuit test. ○ connect the test light and the 12 v battery in the same manner as specified in the “regulator circuit test-1st step”. ○ momentarily apply 24 v to the voltage w2 terminal by adding a 12 v battery. ○ check the bk1, bk2...

  • Page 527

    Electrical system 16-35 charging system charging voltage inspection • check the battery condition (see charging condition in- spection). • warm up the engine to obtain actual alternator operating conditions. • remove the seat (see seat removal in the frame chap- ter). • check that the ignition switc...

  • Page 528

    16-36 electrical system charging system charging system circuit 1. Ignition switch 2. Load 3. Main fuse 30 a 4. Battery 12 v 10 ah 5. Frame ground 6. Alternator 7. Regulator/rectifier http://mototh.Com.

  • Page 529

    Electrical system 16-37 starter motor clutch starter motor clutch removal/installation • refer to the alternator rotor removal/installation. Starter motor clutch inspection • remove: alternator cover (see alternator cover removal) starter idle gear and torque limiter shafts • turn the starter motor ...

  • Page 530

    16-38 electrical system ignition system warning the ignition system produces extremely high volt- age. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock. Caution do not disconnect the battery cables or any other electrical connect...

  • Page 531

    Electrical system 16-39 ignition system crankshaft sensor installation • route the crankshaft sensor lead correctly (see cable, wire, and hose routing section in the appendix chapter). • tighten: torque - crankshaft sensor bolts [a]: 6.0 n·m (0.61 kgf·m, 53 in·lb) • apply silicone sealant to the cir...

  • Page 532

    16-40 electrical system ignition system • pushing the starter button, turn the engine 4 ∼ 5 sec- onds with the transmission gear in neutral to measure the crankshaft sensor peak voltage. • repeat the measurement 5 or more times. Crankshaft sensor peak voltage standard: 2.0 v or more special tools - ...

  • Page 533

    Electrical system 16-41 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 534

    16-42 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 535

    Electrical system 16-43 ignition system interlock operation inspection • raise the rear wheel off the ground with a stand. 1st check • start the engine to the following conditions. Condition transmission gear → 1st position clutch lever → release sidestand → down or up ○ turn the ignition switch on ...

  • Page 536

    16-44 electrical system ignition system ic igniter inspection ○ the ic igniter is built in the ecu [a]. • refer to the interlock operation inspection, ignition sys- tem troubleshooting chart and fuel system (dfi) chapter for ecu power supply inspection. Http://mototh.Com.

  • Page 537

    Electrical system 16-45 ignition system http://mototh.Com.

  • Page 538

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

  • Page 539

    Electrical system 16-47 electric starter system starter motor removal caution do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • remove: air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter) • slide out the rubber cap [a]....

  • Page 540

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

  • Page 541

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

  • Page 542

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

  • Page 543

    Electrical system 16-51 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 o...

  • Page 544

    16-52 electrical system electric starter system • disconnect: connector [a] starter motor cable [b] battery positive (+) cable [c] • remove the starter relay. Caution the battery positive (+) cable with the rubber cap is connected directly to the battery positive (+) termi- nal even when the ignitio...

  • Page 545

    Electrical system 16-53 electric starter system electric starter circuit 1. Ignition switch 2. Frame ground 3. Water-proof joint c 4. Starter lockout switch 5. Fuse box 6. Ignition fuse 10 a 7. Relay box 8. Starter circuit relay 9. Main fuse 30 a 10. Starter relay 11. Starter motor 12. Battery 12 v ...

  • Page 546

    16-54 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 547

    Electrical system 16-55 lighting system • 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. • after installation, adjust the headlight aim (see headlight aiming inspection in the periodic maintenance chapter). City light bulb ...

  • Page 548

    16-56 electrical system lighting system tail/brake light (led) removal • remove: seat cover (see seat cover removal in the frame chapter) • disconnect the tail/brake light lead connector [a] • remove the nuts [a] and washers. • remove the tail/brake light mounting bolts [a], and take off the tail/br...

  • Page 549

    Electrical system 16-57 lighting system • pull the bulb [a] out of the socket [b]. Caution do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage then the specified valve. • replace the bulb with a new one. • install the license plate light c...

  • Page 550

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

  • Page 551

    Electrical system 16-59 lighting system • connect one 12 v battery and turn signal lights as indi- cated in the figure, and count how may times the lights 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 sig...

  • Page 552

    16-60 electrical system lighting system turn signal light circuit 1. Ignition switch 2. Frame ground 3. Meter unit 4. Water-proof joint b 5. Water-proof joint a 6. Front right turn signal light 7. Front left turn signal light 8. Turn signal relay 9. Hazard button 10. Turn signal switch 11. Fuse box ...

  • Page 553

    Electrical system 16-61 air switching valve air switching valve operation test • remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • pull the air switching valve hose [a] out of the air cleaner base. • take the air switching valve hose end outside of the frame. • reinsta...

  • Page 554

    16-62 electrical system air switching valve • blow the air to the inlet air duct [a], and make sure does not flow the blown air from the outlet air duct [b]. • disconnect the 12 v battery. • blow the air to the inlet air duct [a] again, and make sure flow the blown air from the outlet air duct [b]. ...

  • Page 555

    Electrical system 16-63 radiator fan system fan motor inspection • disconnect the connector [a]. • using an auxiliary leads, supply battery power to the fan motor. If the fan does not rotate, the fan motor is defective and must be replaced. Radiator fan circuit 1. Ignition switch 2. Frame ground 3. ...

  • Page 556

    16-64 electrical system meter, gauge, indicator unit meter unit removal/installation • remove: lower fairing (see lower fairing removal in the frame chapter) upper fairing covers (see upper fairing cover re- moval in the frame chapter) bolt [a] (both sides) • remove: windshield (see windshield remov...

  • Page 557

    Electrical system 16-65 meter, gauge, indicator unit meter, gauge disassembly • remove: meter unit (see meter unit removal) screws [a] lower meter cover [b] • separate the meter assembly [a] and upper meter cover [b]. Electronic combination meter unit inspection • remove the meter unit [a] (see mete...

  • Page 558

    16-66 electrical system meter, gauge, indicator unit liquid crystal display (lcd) segments check • using the auxiliary leads, connect the 12 v battery to the meter unit connector as follows. ○ connect the battery positive terminal to the terminal [7]. ○ connect the battery negative terminal to the t...

  • Page 559

    Electrical system 16-67 meter, gauge, indicator unit mode and reset button operation check • connect the 12 v battery and terminals in the same man- ner as specified in the “liquid crystal display (lcd) seg- ments check”. • check that the display change to the odo, trip a and trip b displays each ti...

  • Page 560

    16-68 electrical system meter, gauge, indicator unit • in the hour setting mode, press the reset button to effect the minute setting mode. ○ the minute display flashes on the display. • press the mode button to set the minute. • in the minute setting mode, press the reset button to return to the hou...

  • Page 561

    Electrical system 16-69 meter, gauge, indicator unit speed sensor electric source check • connect the 12 v battery and terminals in the same man- ner as specified in the “liquid crystal display (lcd) seg- ments check”. • set the hand tester to the dc 25 v range and connect it to the terminals [15] a...

  • Page 562

    16-70 electrical system meter, gauge, indicator unit • if the oscillator is not available, the tachometer can be checked as follows. ○ connect the 12 v battery and terminals in the same man- ner as specified in the "liquid crystal display (lcd) seg- ments check". ○ when the terminals are connected, ...

  • Page 563

    Electrical system 16-71 meter, gauge, indicator unit • check that one segment [a] in the fuel gauge starts flash- ing. • check that the fuel segments [b] flashes in the lcd. If the display function does not work, replace the meter assembly. Indicator lights inspection • connect the 12 v battery and ...

  • Page 564

    16-72 electrical system meter, gauge, indicator unit high beam indicator light (led) battery positive (+) terminal to terminal [1] neutral indicator light (led) battery negative (–) terminal to terminal [9] right and left turn signal indicator light (led) for right turn signal indicator light (led) ...

  • Page 565

    Electrical system 16-73 meter, gauge, indicator unit ex650d models abs indicator light (led) battery negative (–) terminal to terminal [5] if the light (led) keeps going on, replace the meter as- sembly. Meter circuit 1. Ignition switch 2. Abs hydraulic unit (abs equipped models) 3. Frame ground 4. ...

  • Page 566

    16-74 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 insp...

  • Page 567

    Electrical system 16-75 switches and sensors water temperature sensor inspection • remove the water temperature sensor (see water tem- perature sensor removal/installation in the fuel system (dfi) chapter). • suspend the sensor [a] in a container of coolant so that the temperature-sensing projection...

  • Page 568

    16-76 electrical system switches and sensors speed sensor inspection • remove the speed sensor (see speed sensor removal). • connect the speed sensor connector [a] with the battery [b], 10 k Ω resistor [c] and hand tester [d] as shown. • set the tester to the dc 25 v range. Special tool - hand teste...

  • Page 569

    Electrical system 16-77 switches and sensors • install a new gasket [a] on the fuel level sensor as shown. Hollows [b] • apply a non-permanent locking agent to the threads of the level sensor bolts and tighten it. Torque - fuel level sensor bolts: 6.9 n·m (0.70 kgf·m, 61 in·lb) oxygen sensor removal...

  • Page 570

    16-78 electrical system switches and sensors fuel reserve switch inspection • fill the fuel tank with fuel. • close the fuel tank cap surely. • remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • connect the test light [a] (12 v 3.4 w bulb a socket with leads) and the 12...

  • Page 571

    Electrical system 16-79 relay box the relay box [a] has relays and diodes. The relays and diodes can not be removed. Relay box removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) • take out the relay box [a] and disconnect the connectors [b]. Relay circuit inspection...

  • Page 572

    16-80 electrical system relay box relay circuit inspection (with the battery connected) battery connection (+) (–) tester connection tester reading ( Ω ) 2-11 1-3 0 ecu main relay 4-5 7-6 0 fuel pump relay 9-10 7-8 0 fan relay 18-19 17-20 0 battery connection (+) (–) tester connection dc 25 v range ...

  • Page 573

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

  • Page 574

    16-82 electrical system fuse 30 a main fuse removal • remove: bolt [a] cover [b] • take off the starter relay from the battery case. • remove the cover [a], and pull out the main fuse [b] with needle nose pliers. Fuse box fuse removal • remove: seat (see seat removal in the frame chapter) • open the...

  • Page 575

    Electrical system 16-83 fuse • pull the ecu fuse [a] straight out of the fuse box with needle nose pliers. 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. • install the fuse box fuse...

  • Page 576

    Http://mototh.Com.

  • Page 577: Appendix

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

  • Page 578

    17-2 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 579

    Appendix 17-3 cable, wire, and hose routing 1. Throttle cable (decelerator) 2. Throttle cable (accelerator) 3. Right switch housing lead 4. Clutch cable 5. Left switch housing lead http://mototh.Com.

  • Page 580

    17-4 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 581

    Appendix 17-5 cable, wire, and hose routing 1. Insert the clamp into the frame from the air cleaner side. 2. Clamp 3. Insert the clamp into the frame. 4. Insert the clamp into the fuel tank bracket. 5. Clamp (faces the stopper forward.) 6. Clamp (faces the stopper outward.) 7. Insert the clamp into ...

  • Page 582

    17-6 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 583

    Appendix 17-7 cable, wire, and hose routing 1. Run the band into the space of the frame gusset. 2. Clamp 3. Run the tail/brake light lead to outside of the rear fender mounting bracket. 4. Frame ground 5. Insert the kawasaki diagnostic system connector to the bracket. 6. Clamps http://mototh.Com.

  • Page 584

    17-8 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 585

    Appendix 17-9 cable, wire, and hose routing 1. Clamp 2. Frame pipe 3. Fuel tank bracket 4. Bands (hold the main harness between the frame pipe and fuel tank bracket.) 5. Band (hold the main harness in rear of the frame cross pipe.) 6. Clamp (tighten with the tail/brake light mounting bolt. Bend the ...

  • Page 586

    17-10 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 587

    Appendix 17-11 cable, wire, and hose routing 1. Place the turn signal light lead connectors and license plate light lead connector between the frame and rear fender. 2. Run the frame ground lead to outside of the other leads. 3. Insert the tail/brake light lead connector into the grab rail bracket. ...

  • Page 588

    17-12 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 589

    Appendix 17-13 cable, wire, and hose routing 1. Clamp (hold the main harness, and insert the clamp into the battery case.) 2. Battery negative (–) lead connector 3. Battery 12v 10ah 4. Relay box 5. Run the battery positive (+) cable, main harness and battery negative (–) cable in turn from left side...

  • Page 590

    17-14 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 591

    Appendix 17-15 cable, wire, and hose routing 1. Run the regulator/rectifier lead into the battery case opening. 2. Crankshaft sensor lead connector 3. Run the vehicle-down sensor lead and rear brake light switch lead in front of the frame cross pipe. 4. Regulator/rectifier lead connector 5. Rear bra...

  • Page 592

    17-16 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 593

    Appendix 17-17 cable, wire, and hose routing 1. Clamp 2. Clamp 3. Stick coil lead connectors 4. Subthrottle valve actuator lead 5. Clamp 6. Subthrottle sensor lead 7. Clamp 8. Clamp 9. Clamp (hold the stick coil leads.) 10. Clamp (install the clamp with the quick rivet onto the throttle body assy. H...

  • Page 594

    17-18 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 595

    Appendix 17-19 cable, wire, and hose routing 1. Meter unit connector (cover the connector with the cap securely.) 2. Throttle cable (accelerator) 3. Throttle cable (decelerator) 4. Right city light lead connector 5. Headlight (lo) lead connector 6. Front brake hose 7. Clamp (hold the front brake hos...

  • Page 596

    17-20 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 597

    Appendix 17-21 cable, wire, and hose routing 1. Clamp (hold the clutch cable.) 2. Clutch cable 3. Reserve tank over flow hose 4. Clamp (insert clamp into the frame. Hold the right switch housing lead.) 5. Right switch housing lead 6. Clamps (hold the right switch housing lead, front brake hose, thro...

  • Page 598

    17-22 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 599

    Appendix 17-23 cable, wire, and hose routing 1. Run the fuel tank breather tube and fuel tank drain tube between the main harness and air cleaner housing. 2. Air cleaner drain hose 3. Run the electrical leads into the upper space of the engine sprocket cover. 4. Run the fuel tank breather tube, fuel...

  • Page 600

    17-24 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 601

    Appendix 17-25 cable, wire, and hose routing 1. Run the harness into the clamp, and then bend the clamp. 2. Place the air cleaner drain hose end as shown in the figure. 3. Fuel tank drain tube 4. Clamps http://mototh.Com.

  • Page 602

    17-26 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 603

    Appendix 17-27 cable, wire, and hose routing 1. Engine ground lead 2. Starter motor cable 3. Starter relay lead 4. Battery positive (+) cable http://mototh.Com.

  • Page 604

    17-28 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 605

    Appendix 17-29 cable, wire, and hose routing 1. Align the white paint of the reserve tank over flow hose with the welding bead. 2. Align the paint of the reserve tank hose with the reserve tank projection. 3. Clamps (faces the clamp knobs downward.) 4. Run the reserve tank over flow hose under the t...

  • Page 606

    17-30 appendix cable, wire, and hose routing http://mototh.Com.

  • Page 607

    Appendix 17-31 cable, wire, and hose routing 1. Run the brake hose into the guide. 2. Clamps 3. Clamps 4. Clamp with damper 5. Viewed a 6. Faces the white paint upward. Http://mototh.Com.

  • Page 608

    17-32 appendix cable, wire, and hose routing ex650d models http://mototh.Com.

  • Page 609

    Appendix 17-33 cable, wire, and hose routing ex650d models 1. Run the brake hose into the guide. 2. Clamps 3. Abs hydraulic unit 4. Brake pipe (from front master cylinder) 5. Brake pipe (to front calipers) 6. Front wheel rotation sensor 7. Run the front wheel rotation sensor lead into the guide. 8. ...

  • Page 610

    17-34 appendix cable, wire, and hose routing ex650d models http://mototh.Com.

  • Page 611

    Appendix 17-35 cable, wire, and hose routing 1. Main harness 2. Run the abs hydraulic unit lead in front of the frame cross pipe. 3. Abs hydraulic unit 4. Run the battery positive (+) cable and abs fuse lead in turn from upper side. 5. Abs kawasaki diagnostic system connector (insert the connector i...

  • Page 612

    17-36 appendix cable, wire, and hose routing ex650d models http://mototh.Com.

  • Page 613

    Appendix 17-37 cable, wire, and hose routing 1. Rear wheel rotation sensor 2. Run the rear wheel rotation sensor lead into the clamps. 3. Clamp (hold the rear wheel rotation sensor lead with the brake hose under the rear shock ab- sorber lower end.) 4. Cover the connector with the cap securely. 5. R...

  • Page 614

    17-38 appendix cable, wire, and hose routing ex650d models http://mototh.Com.

  • Page 615

    Appendix 17-39 cable, wire, and hose routing 1. Regulator/rectifier lead 2. Place the rear rotation sensor connector over the frame cross pipe. 3. Run the regulator/rectifier lead in front of the abs hydraulic unit bracket. 4. Abs hydraulic unit bracket 5. Rear wheel rotation sensor lead 6. Rear res...

  • Page 616

    17-40 appendix cable, wire, and hose routing cal and sea models http://mototh.Com.

  • Page 617

    Appendix 17-41 cable, wire, and hose routing 1. Clamps 2. Canister 3. Tube (red) 4. Tube (blue) 5. Align the clamp knob with the red paint as shown in the figure. 6. Align the clamp knob with the blue paint as shown in the figure. 7. Tube (green) 8. Separator 9. Turn signal relay 10. Clamp (hold the...

  • Page 618

    17-42 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 619

    Appendix 17-43 troubleshooting guide compression low: spark plug loose cylinder head not sufficiently tightened down no valve clearance cylinder, piston worn piston ring bad (worn, weak, broken, or sticking) piston ring/groove clearance excessive cylinder head warped cylinder head gasket damaged val...

  • Page 620

    17-44 appendix troubleshooting guide engine oil viscosity too high drive train trouble brake dragging lubrication inadequate: engine oil level too low engine oil poor quality or incorrect gauge incorrect: water temperature gauge broken water temperature sensor broken coolant incorrect: coolant level...

  • Page 621

    Appendix 17-45 troubleshooting guide engine mount loose crankshaft bearing worn primary gear worn or chipped camshaft chain tensioner trouble camshaft chain, sprocket, guide worn air suction valve damaged air switching valve damaged alternator rotor loose catalytic converter melt down due to muffler...

  • Page 622

    17-46 appendix troubleshooting guide rear shock adjustment too soft front fork, rear shock absorber spring weak rear shock absorber oil leaking brake doesn’t hold: air in the brake line pad or disc worn brake fluid leakage disc warped contaminated pad brake fluid deteriorated primary or secondary cu...

  • Page 623

    Model application year model beginning frame no. 2009 ex650c9f jkaexec1 □ 9da19833 jkaex650ccda19835 2009 ex650d9f jkaex650cdda23433 □ :this digit in the frame number changes from one machine to another. Part no.99924-1419-01 printed in japan http://mototh.Com.