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Kawasaki NINJA ZX-6R - Service Manual

Summary of NINJA ZX-6R -

  • Page 1

    Ninja zx-6r motorcycle service manual.

  • Page 3: Quick Reference Guide

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

  • Page 5: Ninja Zx-6R

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

  • Page 6

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

  • Page 7

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

  • Page 8

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

  • Page 9: Foreword

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

  • Page 11: General Information

    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 zx600r9f (us and ca models) left side view zx600r9f (us and ca models) right side view.

  • Page 18

    1-8 general information model identification zx600r9f (eur models) left side view zx600r9f (eur models) right side view frame number engine number.

  • Page 19

    General information 1-9 general specifications items zx600r9f dimensions overall length 2 090 mm (82.3 in.) overall width 710 mm (28.0 in.) overall height 1 115 mm (43.9 in.) wheelbase 1 400 mm (55.1 in.) road clearance 120 mm (4.72 in.) seat height 815 mm (32.1 in.) curb mass: 191 kg (421 lb) front...

  • Page 20

    1-10 general information general specifications items zx600r9f lubrication system forced lubrication (wet sump with oil cooler) 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 3.6 l (3.8 us qt) drive train primary reduction system: type g...

  • Page 21

    General information 1-11 general specifications items zx600r9f brake type: front dual discs rear single disc electrical equipment battery 12 v 8 ah headlight: type semi-sealed beam bulb: high 12 v 55 w + 65 w (quartz-halogen) low 12 v 55 w (quartz-halogen) tail/brake light led alternator: type three...

  • Page 22

    1-12 general information unit conversion table prefixes for units: prefix symbol power mega m × 1 000 000 kilo k × 1 000 centi c × 0.01 milli m × 0.001 micro µ × 0.000001 units of mass: kg × 2.205 = lb g × 0.03527 = oz units of volume: l × 0.2642 = gal (us) l × 0.2200 = gal (imp) l × 1.057 = qt (us)...

  • Page 23: Periodic Maintenance

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

  • Page 24

    2-2 periodic maintenance steering damper oil leak inspection ............................................................................... 2-40 electrical system ................................................................................................................. 2-41 lights and switch...

  • Page 25

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

  • Page 26

    2-4 periodic maintenance periodic maintenance chart frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) 1 6 12 18 24 30 36 item every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) see page wheel bearing damage - inspect year • • • 2-30 final drive drive chain lubrication co...

  • Page 27

    Periodic maintenance 2-5 periodic maintenance chart frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) 1 6 12 18 24 30 36 item every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) see page engine stop switch operation - inspect year • • • 2-45 others chassis parts - lubrica...

  • Page 28

    2-6 periodic maintenance 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 29

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks radiator bracket mounting bolt 9.8 1.0 87 in·lb radiator lower bolt 6.9 0.70 61 in·lb radiator upper bolts 9.8 1.0 87 in·lb thermostat housing cover bolts 5.9 0.60 52 in·lb water hose clamp screws 2.0 0.20 18 i...

  • Page 30

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks clutch cover plate bolts 9.8 1.0 87 in·lb l clutch hub nut 135 13.8 99.6 r clutch lever clamp bolts 7.8 0.80 69 in·lb s clutch spring bolts 8.8 0.90 78 in·lb oil filler plug – – – hand-tighten sub clutch hub bo...

  • Page 31

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks gear positioning lever bolt 12 1.2 106 in·lb idle gear cover bolts 9.8 1.0 87 in·lb oil jet nozzles 2.9 0.30 26 in·lb oil passage nozzle 4.9 0.50 43 in·lb oil passage plug 17 1.7 13 oil passage plugs (taper) 20...

  • Page 32

    2-10 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks front master cylinder bleed valve 5.4 0.55 48 in·lb front master cylinder clamp bolts 11 1.1 97 in·lb s rear brake disc mounting bolts 27 2.8 20 l rear caliper mounting bolts 25 2.5 18 rear master cylinder mou...

  • Page 33

    Periodic maintenance 2-11 torque and locking agent torque fastener n·m kgf·m ft·lb remarks alternator lead holding plate bolt 9.8 1.0 87 in·lb l alternator rotor bolt 155 15.8 114 s crankshaft sensor bolts 5.9 0.60 52 in·lb engine ground cable terminal bolt 9.8 1.0 87 in·lb front brake light switch ...

  • Page 34

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

  • Page 35

    Periodic maintenance 2-13 specifications item standard service limit fuel system (dfi) throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 1 300 ±50 r/min (rpm) – – – throttle body vacuum 30.6 ±1.3 kpa (230 ±10 mmhg) at idle speed – – – bypass screws (turn out) 0 ∼ 2 1/2 (for referen...

  • Page 36

    2-14 periodic maintenance specifications item standard service limit final drive drive chain slack 30 ∼ 40 mm (1.2 ∼ 1.6 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 enuma – – – type ek 520mvxl2 – – – link 112 links – – – br...

  • Page 37

    Periodic maintenance 2-15 special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 jack: 57001-1238 oil filter wrench: 57001-1249 pilot screw adjuster, c: 57001-1292 vacuum gauge: 57001-1369 throttle sensor setting adapter: 57001-1538 extension tube: 57001-1578 jack attach...

  • Page 38

    2-16 periodic maintenance periodic maintenance procedures fuel system (dfi) throttle control system inspection • check the throttle grip free play [a]. If the free play is incorrect, adjust the throttle cables. Throttle grip free play standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) • check that the throttle gr...

  • Page 39

    Periodic maintenance 2-17 periodic maintenance procedures • pull off the rubber caps [a] and vacuum hose [b] from the fittings of each throttle body. • for the california, southeast asia and thailand models, pull off the vacuum hose. • connect a vacuum gauge (special tool) and hoses [a] to the fitti...

  • Page 40

    2-18 periodic maintenance periodic maintenance procedures • start the engine and warm it up thoroughly. • check the idle speed, using a highly accurate tachometer [a]. Idle speed standard: 1 300 ±50 r/min (rpm) if the idle speed is out of the specified range, adjust it with the adjusting screw (see ...

  • Page 41

    Periodic maintenance 2-19 periodic maintenance procedures if any one vacuum measurement is out of the standard measurement after left and right synchronization, turn in the bypass screws [a] until it seats fully but not tightly. Rear view [b] special tool - pilot screw adjuster, c [c]: 57001-1292 ca...

  • Page 42

    2-20 periodic maintenance periodic maintenance procedures • remove the vacuum gauge hoses and install the rubber caps and vacuum hose on the original position. • for the california, southeast asia and thailand models, install the vacuum hose. ○ run the vacuum hose according to cable, wire, and hose ...

  • Page 43

    Periodic maintenance 2-21 periodic maintenance procedures • check that the fuel hoses [a] are routed according to cable, wire, and hose routing section in the appendix chapter. Replace the hose if it has been sharply bent or kinked. • check that the fuel hose joints are securely connected. ○ push an...

  • Page 44

    2-22 periodic maintenance periodic maintenance procedures • check the liquid/vapor separator as follows. ○ remove the upper fairing assembly (see upper fairing assembly removal in the frame chapter). ○ disconnect the hoses from the separator, and remove the separator [a] from the motorcycle left sid...

  • Page 45

    Periodic maintenance 2-23 periodic maintenance procedures radiator hose and pipe inspection (coolant leak, damage, installation condition) ○ the high pressure inside the radiator hose can cause coolant to leak [a] or the hose to burst if the line is not properly maintained. • visually inspect the ho...

  • Page 46

    2-24 periodic maintenance periodic maintenance procedures note ○ thickness gauge is horizontally inserted on the valve lifter. Appropriateness [a] inadequacy [b] thickness gauge [c] horizontally inserts [d] cam [e] valve lifter [f] hits the valve lifter ahead [g] ○ when positioning #1 piston tdc at ...

  • Page 47

    Periodic maintenance 2-25 periodic maintenance procedures • clean the shim to remove any dust or oil. • measure the thickness of the removed shim [a]. • select a new shim thickness calculation as follows. A + b – c = d [a] present shim thickness [b] measured valve clearance [c] specified valve clear...

  • Page 48

    2-26 periodic maintenance periodic maintenance procedures adjustment shims thickness part number mark 1.300 92180-0108 130 1.325 92180-0109 132 1.350 92180-0110 135 1.375 92180-0111 138 1.400 92180-0112 140 1.425 92180-0113 142 1.450 92180-0114 145 1.475 92180-0115 148 1.500 92180-0116 150 1.525 921...

  • Page 49

    Periodic maintenance 2-27 periodic maintenance procedures caution be sure to remeasure the clearance after selecting a shim. The clearance can be out of the specified range because of the shim tolerance. ○ if there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valv...

  • Page 50

    2-28 periodic maintenance periodic maintenance procedures • start the engine and run it at idle speed. • plug the air switching valve hose end [a] with your finger and feel vacuum pulsing in the hose. If there is no vacuum pulsation, check the hose line for leak. If there is no leak, check the air s...

  • Page 51

    Periodic maintenance 2-29 periodic maintenance procedures • push the release lever [a] toward the front of the motor- cycle until it becomes hard to turn. ○ at this time, the release lever should have the proper an- gle shown. 60° [b] if the angle is wrong, check the clutch and release parts for wea...

  • Page 52

    2-30 periodic maintenance periodic maintenance procedures tread depth standard: front 3.6 mm (0.14 in.) rear 5.3 mm (0.21 in.) service limit: front 1 mm (0.04 in.) (at, ch, de) 1.6 mm (0.06 in.) rear 2 mm (0.08 in.) (up to 130 km/h (80 mph)) 3 mm (0.12 in.) (over 130 km/h (80 mph)) warning to ensure...

  • Page 53

    Periodic maintenance 2-31 periodic maintenance procedures final drive drive chain lubrication condition inspection • if a special lubricant is not available, a heavy oil such as sae 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. • if the cha...

  • Page 54

    2-32 periodic maintenance periodic maintenance procedures drive chain slack adjustment • remove the cotter pin [a], and loosen the rear axle nut [b]. • loosen the both chain adjuster locknuts [c]. If the chain is too loose, turn out the left and right chain adjusters [d] evenly. If the chain is too ...

  • Page 55

    Periodic maintenance 2-33 periodic maintenance procedures wheel alignment inspection • check that the notch [a] on the left alignment indicator [b] aligns with the same swingarm mark or position [c] that the right alignment indicator notch aligns with. If they do not, adjust the chain slack and alig...

  • Page 56

    2-34 periodic maintenance periodic maintenance procedures chain guide wear inspection • remove the swingarm (see swingarm removal in the suspection chapter). • visually inspect the chain guide [a]. Replace the chain guide if it shows any signs of abnormal wear or damage. Brakes brake fluid leak (bra...

  • Page 57

    Periodic maintenance 2-35 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 58

    2-36 periodic maintenance periodic maintenance procedures brake pad wear inspection • remove the brake pads (see front/rear brake pad re- moval in the brakes chapter). • check the lining thickness of the pads in each caliper. If the lining thickness of either pad is less than the service limit, repl...

  • Page 59

    Periodic maintenance 2-37 periodic maintenance procedures if it does not go on, inspect or replace the following parts. Battery (see charging condition inspection in the elec- trical system chapter) brake light (led) (see tail/brake light (led) removal installation in the electrical system chapter) ...

  • Page 60

    2-38 periodic maintenance 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. Rocker arm operation inspection • pump the seat down and up 4 or ...

  • Page 61

    Periodic maintenance 2-39 periodic maintenance procedures steering play adjustment • remove: steering stem head with handlebars (see handlebar removal in the steering chapter). Fuel tank (see fuel tank removal in the fuel system (dfi) chapter) • bend the claws [a] of the claw washer [b] straighten. ...

  • Page 62

    2-40 periodic maintenance periodic maintenance procedures steering stem bearing lubrication • remove the steering stem (see stem, stem bearing re- moval in the steering chapter). • using a high-flash point solvent, wash the upper and lower ball bearings [a] in the cages, and wipe the upper and lower...

  • Page 63

    Periodic maintenance 2-41 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] go on tailligh...

  • Page 64

    2-42 periodic maintenance periodic maintenance procedures • turn the ignition switch off. • the all lights should go off (for models equipped with an immobilizer system, warning indicator light (led) will blinks. Refer to the immobilizer system (equipped mod- els) section in the electrical system ch...

  • Page 65

    Periodic maintenance 2-43 periodic maintenance procedures fourth step • set the dimmer switch [a] to low beam position. • start the engine. • the low beam headlight should go on. If the low beam headlight does not go on, inspect or re- place the following parts. Headlight low beam bulb (see headligh...

  • Page 66

    2-44 periodic maintenance periodic maintenance procedures note ○ on high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper an- gle according to local regulations. Note ○ for the united states mode...

  • Page 67

    Periodic maintenance 2-45 periodic maintenance procedures if the sidestand switch operation does not work, inspect or replace the following parts. Battery (see charging condition inspection in the elec- trical system chapter) main fuse 30 a (see fuse inspection in the electrical system chapter) igni...

  • Page 68

    2-46 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 69

    Periodic maintenance 2-47 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 70

    2-48 periodic maintenance periodic maintenance procedures replacement parts air cleaner element replacement note ○ in dusty areas, the element should be replaced more frequently than the recommended interval. ○ after riding through rain or on muddy roads, the element should be replaced immediately. ...

  • Page 71

    Periodic maintenance 2-49 periodic maintenance procedures for primary fuel hose (fuel tank ∼ throttle body assy) • be sure to place a piece of cloth [a] around the fuel hose joint. • insert a thin blade screwdriver [b] into the slit [c] on the joint lock [d]. • turn [a] the driver to disconnect the ...

  • Page 72

    2-50 periodic maintenance periodic maintenance procedures • turn [a] the driver to disconnect the joint lock [b]. • pull the fuel hose joint [c] out of the delivery pipe. Warning be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnect...

  • Page 73

    Periodic maintenance 2-51 periodic maintenance procedures • insert [a] the fuel hose joint [b] straight onto the delivery pipe until the hose joint clicks. • push [c] the joint lock [d]. Caution when inserting the fuel hose joint, do not apply strong force to the delivery pipe [e] on the nozzle assy...

  • Page 74

    2-52 periodic maintenance periodic maintenance procedures • place a container under the drain bolt [a] of the water pump cover. • drain the coolant from the radiator by removing the drain bolt. • remove: coolant reserve tank mounting bolts [a] cap [b] • pour the coolant into a container. • tighten: ...

  • Page 75

    Periodic maintenance 2-53 periodic maintenance procedures • bleed the air from the cooling system as follows. ○ start the engine with the radiator cap removed and run it until no more air bubbles [a] can be seen in the coolant. ○ tap the radiator hoses to force any air bubbles caught inside. ○ stop ...

  • Page 76

    2-54 periodic maintenance periodic maintenance procedures radiator hose and o-ring replacement • drain the coolant (see coolant change). • remove: upper fairing assembly (see upper fairing assembly removal in the frame chapter) thermostat housing cover [a] (see thermostat housing removal in the cool...

  • Page 77

    Periodic maintenance 2-55 periodic maintenance procedures engine oil change • situate the motorcycle so that it is vertical after warming up the engine. • remove the engine oil drain bolt [a] to drain the oil. ○ the oil in the oil filter can be drained by removing the filter (see oil filter replacem...

  • Page 78

    2-56 periodic maintenance periodic maintenance procedures oil filter replacement • drain the engine oil (see engine oil change). • remove the oil filter [a] with the oil filter wrench [b]. Special tool - oil filter wrench: 57001-1249 • replace the filter with a new one. • apply grease to the gasket ...

  • Page 79

    Periodic maintenance 2-57 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: upper fairing assembly (see upper fairing assembly removal in the frame chap...

  • Page 80

    2-58 periodic maintenance periodic maintenance procedures • level the brake fluid reservoir. • remove: screw [a] stopper [b] front brake reservoir cap [c] diaphragm plate diaphragm • remove the rubber cap [a] from the bleed valve on the caliper. • attach a clear plastic hose [b] to the bleed valve, ...

  • Page 81

    Periodic maintenance 2-59 periodic maintenance procedures • install the stopper on the reservoir. • tighten: torque - front brake reservoir cap stopper screw: 1.2 n·m (0.12 kgf·m, 11 in·lb) • tighten the bleed valve, and install the rubber cap. Torque - bleed valves: 7.8 n·m (0.80 kgf·m, 69 in·lb) •...

  • Page 82

    2-60 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 83

    Periodic maintenance 2-61 periodic maintenance procedures warning to avoid serious injury, never place your fingers or palm in front of the piston. If you apply compressed air into the caliper, the piston may crush your hand or fingers. ○ pull out the pistons by hand. • remove the dust seals [a] and...

  • Page 84

    2-62 periodic maintenance periodic maintenance procedures • install the pads (see front brake pad installation in the brakes chapter). • wipe up any spilled brake fluid on the caliper with wet cloth. Rear caliper disassembly • remove the rear caliper (see rear caliper removal in the brakes chapter)....

  • Page 85

    Periodic maintenance 2-63 periodic maintenance procedures • replace the fluid seal [a] with a new one. ○ apply silicone grease to the fluid seal, and install it into the cylinder by hand. • replace the dust seal [b] with a new one. ○ apply silicone grease to the dust seal, and install it into the cy...

  • Page 87: Fuel System (Dfi)

    Fuel system (dfi) 3-1 3 fuel system (dfi) table of contents exploded view................................... 3-4 dfi system........................................ 3-10 dfi parts location............................. 3-16 specifications .................................... 3-19 special tools and sea...

  • Page 88

    3-2 fuel system (dfi) subthrottle sensor input voltage inspection.................................. 3-76 subthrottle sensor output voltage inspection.................................. 3-77 subthrottle sensor resistance inspection.................................. 3-78 oxygen sensor - not activated (...

  • Page 89

    Fuel system (dfi) 3-3 secondary fuel injector removal/installation.................. 3-120 fuel injector audible inspection... 3-120 fuel injector resistance inspection.................................. 3-121 fuel injector power source voltage inspection..................... 3-122 fuel injector outp...

  • Page 90

    3-4 fuel system (dfi) exploded view.

  • Page 91

    Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air cleaner housing assembly screws 1.2 0.12 11 in·lb 2 air cleaner housing clamp bolts 2.0 0.20 18 in·lb 3 air cleaner housing mounting bolt 6.9 0.70 61 in·lb 4 air inlet duct mounting bolts 9.8 1.0 87 in·lb l 5. Cal,...

  • Page 92

    3-6 fuel system (dfi) exploded view.

  • Page 93

    Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 delivery pipe assy mounting screws (nozzle assy) 3.43 0.35 30 in·lb 2 delivery pipe assy mounting screws (throttle body assy) 3.43 0.35 30 in·lb 3 inlet air temperature sensor screw 0.80 0.081 7.1 in·lb 4 nozzle assy m...

  • Page 94

    3-8 fuel system (dfi) exploded view.

  • Page 95

    Fuel system (dfi) 3-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 canister bracket screws 1.2 0.12 11 in·lb 2 crankshaft sensor bolts 5.9 0.60 52 in·lb 3 exhaust butterfly valve actuator mounting screws 4.3 0.44 38 in·lb 4 exhaust butterfly valve actuator pulley bolt 4.9 0.50 43 in·l...

  • Page 96

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

  • Page 97

    Fuel system (dfi) 3-11 dfi system 1. Ecu 2. Battery 12 v 8 ah 3. Main throttle sensor 4. Inlet air temperature sensor 5. Subthrottle valve actuator 6. Subthrottle sensor 7. Fuel injectors 8. Vehicle-down sensor 9. Delivery pipe assy 10. Fuel filter 11. Pressure regulator 12. Fuel pump 13. Speed sens...

  • Page 98

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

  • Page 99

    Fuel system (dfi) 3-13 dfi system part names 1. Gear position switch 2. Ecu 3. Joint connector c 4. Immobilizer (equipped models)/kawasaki diagnostic system connector 5. Vehicle-down sensor 6. Fuel pump 7. Joint connector d 8. Exhaust butterfly valve actuator 9. Fuse box 10. Ignition fuse 15 a 11. E...

  • Page 100

    3-14 fuel system (dfi) dfi system terminal numbers of ecu connectors terminal names 1. Subthrottle valve actuator: r/y 2. Subthrottle valve actuator: r/w 3. Exhaust battery valve actuator (–): gy 4. Exhaust butterfly valve actuator (+): g/r 5. Exhaust butterfly valve actuator sensor: r/bk 6. Speed s...

  • Page 101

    Fuel system (dfi) 3-15 dfi system 35. Primary fuel injector #4: bl/y 36. Secondary fuel injector #4: o/y 37. Engine stop switch: r 38. Starter lockout switch: r/g 39. Ground: p 40. Unused 41. Secondary fuel injector #2: o/g 42. Primary fuel injector #2: bl/g 43. Secondary fuel injector #1: o/r 44. P...

  • Page 102

    3-16 fuel system (dfi) dfi parts location main throttle sensor [a] subthrottle sensor [b] subthrottle valve actuator [c] inlet air pressure sensor [d] stick coils #1, #2, #3, #4 [e] air switching valve [f] atmospheric pressure sensor [g] water temperature sensor [a] primary fuel injectors #1, #2, #3...

  • Page 103

    Fuel system (dfi) 3-17 dfi parts location secondary fuel injectors #1, #2, #3, #4 [a] inlet air temperature sensor [b] crankshaft sensor [a] speed sensor [a] gear position switch [a] ignition key [a] (transponder, immobilizer system equipped models) immobilizer antenna [b] (equipped models) ignition...

  • Page 104

    3-18 fuel system (dfi) dfi parts location immobilizer amplifier [a] (equipped models) oxygen sensor [a] (equipped models).

  • Page 105

    Fuel system (dfi) 3-19 specifications item standard digital fuel injection system idle speed 1 300 ±50 r/min (rpm) throttle body assy: type four oval type bore 38 mm (1.5 in.) throttle body vacuum 30.6 ±1.3 kpa (230 ±10 mmhg) bypass screws (turn out) 0 ∼ 2 1/2 (for reference) ecu: make denso type di...

  • Page 106

    3-20 fuel system (dfi) specifications item standard vehicle-down sensor: input voltage dc 4.75 ∼ 5.25 v output voltage with sensor tilted 60 ∼ 70° or more right or left: dc 0.65 ∼ 1.35 v with sensor arrow mark pointed up: dc 3.55 ∼ 4.45 v subthrottle sensor: input voltage dc 4.75 ∼ 5.25 v output vol...

  • Page 107

    Fuel system (dfi) 3-21 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 108

    3-22 fuel system (dfi) special tools and sealant fuel hose: 57001-1607 measuring adapter: 57001-1700 kawasaki bond (silicone sealant): 56019-120

  • Page 109

    Fuel system (dfi) 3-23 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 110

    3-24 fuel system (dfi) 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. Primary fuel hose [a] secondary fuel hose [b] repl...

  • Page 111

    Fuel system (dfi) 3-25 troubleshooting the dfi system the warning indicator light (led) [a] is used for the fi indicator, immobilizer indicator (immobilizer models) and oil pressure warning indicator. Outline when a problem occurs with dfi system, the warning in- dicator light (led) [a] and fi warni...

  • Page 112

    3-26 fuel system (dfi) troubleshooting the dfi system when the service code [a] is displayed, for first ask the rider about the conditions [b] of trouble, and then start to determine the cause [c] of problem. As a pre-diagnosis inspection, check the ecu for ground and power supply, the fuel line for...

  • Page 113

    Fuel system (dfi) 3-27 troubleshooting the dfi system • when checking the dfi parts, use a digital meter which can be read two decimal place voltage or resistance. ○ the dfi part connectors [a] have seals [b], including the ecu. When measuring the input or output voltage with the connector joined, u...

  • Page 114

    3-28 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 115

    Fuel system (dfi) 3-29 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 116

    3-30 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 117

    Fuel system (dfi) 3-31 troubleshooting the dfi system □ spark plug loose (tighten it). □ spark plug dirty, broken, or gap maladjusted (remedy it). □ spark plug incorrect (replace it). □ knocking (fuel poor quality or incorrect, → use high-octane gasoline). □ brake dragging. □ clutch slipping. □ engi...

  • Page 118

    3-32 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 119

    Fuel system (dfi) 3-33 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). At...

  • Page 120

    3-34 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions subthrottle sensor trouble inspect (see chapter 3). Subthrottle valve actuator trouble inspect (see chapter 3). Inlet air pressure sensor trouble inspect (see chapter 3). Atmospheric pressure sensor trouble i...

  • Page 121

    Fuel system (dfi) 3-35 dfi system troubleshooting guide symptoms or possible causes actions other: intermittent any dfi fault and its recovery check that dfi connectors are clean and tight, and examine leads for signs of burning or fraying (see chapter 3). Poor running or no power at high speed symp...

  • Page 122

    3-36 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions inlet air temperature sensor trouble inspect (see chapter 3). Miscellaneous: subthrottle sensor trouble inspect (see chapter 3). Subthrottle valve actuator trouble inspect (see chapter 3). Speed sensor troubl...

  • Page 123

    Fuel system (dfi) 3-37 self-diagnosis the warning indicator light (led) [a] is used for the fi indicator, immobilizer indicator (equipped models) and oil pressure warning indicator. Self-diagnosis outline the self-diagnosis system has two modes and can be switched to another mode by operating the me...

  • Page 124

    3-38 fuel system (dfi) self-diagnosis dealer mode the lcd (liquid crystal display) display the service code(s) [a] to show the problem(s) which the dfi system, ignition system and immobilizer system has at the moment of diagnosis. Immobilizer models [b] self-diagnosis procedures ○ when a problem occ...

  • Page 125

    Fuel system (dfi) 3-39 self-diagnosis • turn the ignition switch on. • push the mode button [a] to display the odometer. Immobilizer models [b] • push the mode button [a] for more than two seconds. • the service code [b] is displayed on the lcd by the num- ber of two digits. Immobilizer models [c] •...

  • Page 126

    3-40 fuel system (dfi) self-diagnosis self-diagnosis flow chart.

  • Page 127

    Fuel system (dfi) 3-41 self-diagnosis service code reading ○ the service code(s) is displayed on the lcd by the number of two digits. ○ when there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical or...

  • Page 128

    3-42 fuel system (dfi) self-diagnosis service code table service code 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 temperature sensor malfun...

  • Page 129

    Fuel system (dfi) 3-43 self-diagnosis backups ○ the ecu takes the following measures to prevent engine damage when the dfi, ignition or immo- bilizer system parts have troubles. Service codes parts output signal usable range or criteria backups by ecu 11 main throttle sensor output voltage 0.2 ∼ 4.8...

  • Page 130

    3-44 fuel system (dfi) self-diagnosis service codes parts output signal usable range or criteria backups by ecu 34 exhaust butterfly valve actuator sensor output voltage 0.1 ∼ 4.8 v if the exhaust butterfly valve actuator sensor system fails (the output voltage is out of the usable range, wiring sho...

  • Page 131

    Fuel system (dfi) 3-45 self-diagnosis service codes parts output signal usable range or criteria backups by ecu 67 oxygen sensor heater (equipped models) the oxygen sensor heater raise temperature of the sensor for its earlier activation. If the oxygen sensor heater fails (wiring short or open), the...

  • Page 132

    3-46 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 133

    Fuel system (dfi) 3-47 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 follow- ing. ○ disconnect the main throttle sensor connector and con- nect the h...

  • Page 134

    3-48 fuel system (dfi) main throttle sensor (service code 11) if the reading is within the standard, 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 inspection e...

  • Page 135

    Fuel system (dfi) 3-49 inlet air pressure sensor (service code 12) inlet air pressure sensor removal caution never drop the inlet air pressure sensor especially on a hard surface. Such a shock to the sensor can damage it. • remove: air cleaner housing (see air cleaner housing removal) inlet air pres...

  • Page 136

    3-50 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 137

    Fuel system (dfi) 3-51 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 138

    3-52 fuel system (dfi) inlet air pressure sensor (service code 12) then pv = pl – pg for example, suppose the following data is obtained: pg = 8 cmhg (vacuum gauge reading) pl = 70 cmhg (barometer reading) vv = 3.2 v (digital meter reading) then pv = 70 – 8 = 62 cmhg (absolute) plot this pv (62 cmhg...

  • Page 139

    Fuel system (dfi) 3-53 inlet air pressure sensor (service code 12) id: idling ps: standard atmospheric pressure (absolute) pv: throttle vacuum pressure (absolute) st: standard of sensor output voltage (v) to: throttle full open ur: usable range of sensor output voltage (v) vv: inlet air pressure sen...

  • Page 140

    3-54 fuel system (dfi) inlet air pressure sensor (service code 12) inlet air pressure sensor circuit 1. Inlet air pressure sensor 2. Ecu.

  • Page 141

    Fuel system (dfi) 3-55 inlet air temperature sensor (service code 13) inlet air temperature sensor removal/installation caution never drop the inlet air temperature sensor espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove the fuel tank (see fuel tank removal). • disc...

  • Page 142

    3-56 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 connectors. Special tool - hand tester: 57001-1394 ○ disconnect the ecu and sensor connectors. Wiring continuity inspec...

  • Page 143

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

  • Page 144

    3-58 fuel system (dfi) water temperature sensor (service code 14) water temperature sensor removal/installation caution never drop the water temperature sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove the throttle body assy (see throttle body assy removal)....

  • Page 145

    Fuel system (dfi) 3-59 water temperature sensor (service code 14) • turn the ignition switch off. If the reading is within the standard, check the ecu for its ground and power supply (see ecu power supply in- spection). If the ground and power supply are good, replace the ecu (see ecu removal/instal...

  • Page 146

    3-60 fuel system (dfi) atmospheric pressure sensor (service code 16) atmospheric pressure sensor removal caution never drop the atmospheric pressure sensor espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove the air cleaner housing (see air cleaner housing removal). • ...

  • Page 147

    Fuel system (dfi) 3-61 atmospheric pressure sensor (service code 16) 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 inspect...

  • Page 148

    3-62 fuel system (dfi) atmospheric pressure sensor (service code 16) 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 insp...

  • Page 149

    Fuel system (dfi) 3-63 atmospheric pressure sensor (service code 16) atmospheric pressure/altitude relationship.

  • Page 150

    3-64 fuel system (dfi) atmospheric pressure sensor (service code 16) atmospheric pressure sensor circuit 1. Atmospheric pressure sensor 2. Ecu.

  • Page 151

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

  • Page 152

    3-66 fuel system (dfi) crankshaft sensor (service code 21) crankshaft sensor circuit 1. Crankshaft sensor 2. Ecu.

  • Page 153

    Fuel system (dfi) 3-67 speed sensor (service code 24) 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 inspe...

  • Page 154

    3-68 fuel system (dfi) speed sensor (service code 24) speed sensor output voltage inspection • raise the rear wheel off the ground with the stand. • measure the output voltage at the speed sensor in the same way as input voltage inspection, note the following. ○ disconnect the speed sensor connector...

  • Page 155

    Fuel system (dfi) 3-69 speed sensor (service code 24) speed sensor circuit 1. Meter unit 2. Speed sensor 3. Ecu 4. Frame ground.

  • Page 156

    3-70 fuel system (dfi) gear position switch (service code 25) gear position switch removal/installation • refer to the gear position switch removal/installation in the electrical system chapter. Gear position switch resistance inspection • refer to the gear position switch inspection in the elec- tr...

  • Page 157

    Fuel system (dfi) 3-71 gear position switch (service code 25) gear position switch circuit 1. Meter unit 2. Gear position switch 3. Ecu 4. Frame ground.

  • Page 158

    3-72 fuel system (dfi) vehicle-down sensor (service code 31) this sensor has a weight [a] with two magnets inside, and sends a signal to the ecu. But when the motorcycle banks 60 ∼ 70° or more to either side (in fact falls down), the weight turns and the signal changes. The ecu senses this change, a...

  • Page 159

    Fuel system (dfi) 3-73 vehicle-down sensor (service code 31) vehicle-down sensor input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • disconnect the vehicle-down sensor connector and con- nect the harness adapter [a] between these connectors as show...

  • Page 160

    3-74 fuel system (dfi) vehicle-down sensor (service code 31) vehicle-down sensor output voltage inspection • remove the vehicle-down sensor (see vehicle-down sensor removal). • connect the harness adapter [a] to the vehicle-down sen- sor connectors as shown in the figure. Special tool - measuring ad...

  • Page 161

    Fuel system (dfi) 3-75 vehicle-down sensor (service code 31) if the reading is within the standard, 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 inspection ec...

  • Page 162

    3-76 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 163

    Fuel system (dfi) 3-77 subthrottle sensor (service code 32) subthrottle sensor output voltage inspection • measure the output voltage at the subthrottle sensor in the same way as input voltage inspection, note the fol- lowing. ○ disconnect the subthrottle sensor connector and connect the harness ada...

  • Page 164

    3-78 fuel system (dfi) subthrottle sensor (service code 32) if the reading is within the standard, 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 inspection ecu...

  • Page 165

    Fuel system (dfi) 3-79 oxygen sensor - not activated (service code 33 (equipped models)) oxygen sensor removal/installation • refer to the oxygen sensor removal/installation (equipped models) in the electrical system chapter. Oxygen sensor inspection • warm up the engine thoroughly until the radiato...

  • Page 166

    3-80 fuel system (dfi) oxygen sensor - not activated (service code 33 (equipped models)) • install the suitable plugs [a] on the fitting of the air suction valve covers, and shut off the secondary air. • connect the following parts temporarily. Fuel pump lead connector [a] extension tube [b] air cle...

  • Page 167

    Fuel system (dfi) 3-81 oxygen sensor - not activated (service code 33 (equipped models)) oxygen sensor circuit 1. Ignition switch 2. Oxygen sensor 3. Ecu 4. Fuse box 5. Oxygen sensor heater fuse 10 a 6. Battery 12 v 8 ah 7. Main fuse 30 a.

  • Page 168

    3-82 fuel system (dfi) exhaust butterfly valve actuator sensor (service code 34) exhaust butterfly valve actuator sensor removal/installation the exhaust butterfly valve actuator sensor is built in the exhaust butterfly valve actuator. So, the sensor itself can not be removed. Remove the exhaust but...

  • Page 169

    Fuel system (dfi) 3-83 exhaust butterfly valve actuator sensor (service code 34) exhaust butterfly valve actuator sensor output voltage inspection note ○ before this inspection, confirm the pulley [a] is original position (see exhaust butterfly valve actuator installa- tion). • disconnect: 2 pins co...

  • Page 170

    3-84 fuel system (dfi) exhaust butterfly valve actuator sensor (service code 34) exhaust butterfly valve actuator sensor resistance inspection • turn the ignition switch off. • disconnect the exhaust butterfly valve actuator sensor connector (3 pins connector) [a]. • connect a digital meter [b] to t...

  • Page 171

    Fuel system (dfi) 3-85 immobilizer amplifier (service code 35 (equipped models)) antenna resistance inspection • turn the ignition switch off. • remove the air cleaner housing (see air cleaner housing removal). • disconnect the antenna lead connector [a]. • measure the antenna resistance. Antenna re...

  • Page 172

    3-86 fuel system (dfi) blank key detection (service code 36 (equipped models)) • this code appears in the following conditions. ○ the transponder [a] in the master and/or user key is mal- function. ○ when the spare key of unregistration is used. ○ when the master key is registered in the registered ...

  • Page 173

    Fuel system (dfi) 3-87 blank key detection (service code 36 (equipped models)) immobilizer system circuit 1. Ignition switch 2. Ecu 3. Immobilizer/kawasaki diagnostic system connector 4. Fuse box 5. Ignition fuse 15 a 6. Frame ground 7. Battery 12 v 8 ah 8. Main fuse 30 a 9. Meter unit 10. Immobiliz...

  • Page 174

    3-88 fuel system (dfi) ecu communication error (service code 39) ecu communication line inspection ○ when the data is not sent from the ecu to the meter unit for more than about 10 seconds, the service code 39 is displayed. ○ the service code 39 is detected with meter unit. • remove the ecu and mete...

  • Page 175

    Fuel system (dfi) 3-89 stick coils #1, #2, #3, #4 (service code 51, 52, 53, 54) stick coil #1: service code 51 stick coil #2: service code 52 stick coil #3: service code 53 stick coil #4: service code 54 stick coil removal/installation • refer to the stick coil removal/installation in the electri- c...

  • Page 176

    3-90 fuel system (dfi) stick coils #1, #2, #3, #4 (service code 51, 52, 53, 54) • turn the ignition switch off. If the input voltage is out of the standard, check the wiring for continuity (see wiring diagram in this section). Special tool - hand tester: 57001-1394 if the wiring is good, check the e...

  • Page 177

    Fuel system (dfi) 3-91 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 178

    3-92 fuel system (dfi) radiator fan relay (service code 56) radiator fan relay circuit 1. Ignition switch 2. Fan motor 3. Water temperature sensor 4. Ecu 5. Fuse box 6. Fan fuse 15 a 7. Frame ground 8. Battery 12 v 8 ah 9. Main fuse 30 a 10. Relay box 11. Fan relay.

  • Page 179

    Fuel system (dfi) 3-93 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 sho...

  • Page 180

    3-94 fuel system (dfi) subthrottle valve actuator (service code 62) subthrottle valve actuator input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • disconnect the subthrottle valve actuator connector and connect the harness adapter [a] between these...

  • Page 181

    Fuel system (dfi) 3-95 subthrottle valve actuator (service code 62) subthrottle valve actuator circuit 1. Subthrottle valve actuator 2. Ecu.

  • Page 182

    3-96 fuel system (dfi) exhaust butterfly valve actuator (service code 63) exhaust butterfly valve actuator removal caution never drop the exhaust butterfly valve actuator es- pecially on a hard surface. Such a shock to the ac- tuator can damage it. • remove: exhaust butterfly valve cable upper ends ...

  • Page 183

    Fuel system (dfi) 3-97 exhaust butterfly valve actuator (service code 63) • after tightening the pulley bolt, confirm whether pulley [a] is an angle shown in the figure. 41.7° ±0.7° [b] ○ this position is original position of the pulley. Note ○ correct the position electrically after confirming use ...

  • Page 184

    3-98 fuel system (dfi) exhaust butterfly valve actuator (service code 63) exhaust butterfly valve actuator inspection note ○ be sure the battery is fully charged. • remove the front seat (see front seat removal in the frame chapter). • turn the ignition switch on. • check to see the pulley [a] turns...

  • Page 185

    Fuel system (dfi) 3-99 exhaust butterfly valve actuator (service code 63) exhaust butterfly valve actuator circuit 1. Exhaust butterfly valve actuator 2. Ecu.

  • Page 186

    3-100 fuel system (dfi) air switching valve (service code 64) air switching valve removal/installation • refer to the air switching valve removal/installation in the engine top end chapter. Air switching valve inspection • refer to the air switching valve unit test in the electrical system chapter. ...

  • Page 187

    Fuel system (dfi) 3-101 oxygen sensor heater (service code 67 (equipped models)) oxygen sensor heater removal/installation the oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see oxygen sensor removal (equipped mod- els) in th...

  • Page 188

    3-102 fuel system (dfi) oxygen sensor heater (service code 67 (equipped models)) oxygen sensor heater power source voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • disconnect the oxygen sensor lead connector and con- nect the harness adapter [a] betwe...

  • Page 189

    Fuel system (dfi) 3-103 oxygen sensor heater (service code 67 (equipped models)) oxygen sensor circuit 1. Ignition switch 2. Oxygen sensor 3. Ecu 4. Fuse box 5. Oxygen sensor heater fuse 10 a 6. Battery 12 v 8 ah 7. Main fuse 30 a.

  • Page 190

    3-104 fuel system (dfi) oxygen sensor - incorrect output voltage (service code 94 (equipped models)) oxygen sensor removal/installation • refer to the oxygen sensor removal/installation (equipped models) in the electrical system chapter. Oxygen sensor inspection • warm up the engine thoroughly until...

  • Page 191

    Fuel system (dfi) 3-105 oxygen sensor - incorrect output voltage (service code 94 (equipped models)) • install the suitable plugs [a] on the fitting of the air suction valve covers, and shut off the secondary air. • connect the following parts temporarily. Fuel pump lead connector [a] extension tube...

  • Page 192

    3-106 fuel system (dfi) oxygen sensor - incorrect output voltage (service code 94 (equipped models)) oxygen sensor circuit 1. Ignition switch 2. Oxygen sensor 3. Ecu 4. Fuse box 5. Oxygen sensor heater fuse 10 a 6. Battery 12 v 8 ah 7. Main fuse 30 a.

  • Page 193

    Fuel system (dfi) 3-107 warning indicator light (led) light (led) inspection ○ the warning indicator light (led) [a] is used for the fi indicator, immobilizer indicator (equipped models) and oil pressure warning indicator. ○ in this model, the warning indicator light (led) (fi/immo- bilizer) blinks ...

  • Page 194

    3-108 fuel system (dfi) ecu ecu identification ○ most countries have their own regulations, so each ecu has different characteristic. So, do not confuse ecu with each other and use only the ecu for your model. Other- wise, the motorcycle can not clear the regulation. Ecu identification part number [...

  • Page 195

    Fuel system (dfi) 3-109 ecu ecu installation • install: ecu [a] (in rubber protector [b]) ecu connectors [c] • insert the slits of the rubber protector [a] to the projections [b] of the rear fender. Ecu power supply inspection • remove the front seat cover (see seat cover removal in the frame chapte...

  • Page 196

    3-110 fuel system (dfi) ecu if the wiring is good, check the power source voltage of the ecu. Note ○ be sure the battery is fully charged. • connect the ecu connectors. • connect a digital meter [a] to the connector [b] with the needle adapter set. Special tool - needle adapter set: 57001-1457 ecu p...

  • Page 197

    Fuel system (dfi) 3-111 ecu ecu power source circuit 1. Ignition switch 2. Ecu 3. Joint connector c 4. Joint connector d 5. Fuse box 6. Ecu fuse 10 a 7. Frame ground 8. Battery 12 v 8 ah 9. Main fuse 30 a 10. Relay box 11. Ecu main relay.

  • Page 198

    3-112 fuel system (dfi) dfi power source ecu fuse removal • refer to the 10 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 t...

  • Page 199

    Fuel system (dfi) 3-113 fuel line fuel pressure inspection note ○ be sure the battery is fully charged. • remove: fuel tank bolts [a] primary fuel hose (see fuel hose replacement in the periodic maintenance chapter) ○ be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and...

  • Page 200

    3-114 fuel system (dfi) 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, replace the fuel pump because the fuel pressure regulator in the fuel...

  • Page 201

    Fuel system (dfi) 3-115 fuel line • open the fuel tank cap [a] to lower the pressure in the tank. • remove the primary fuel hose from the fuel pump (see fuel tank removal). ○ be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump. Warning be prepared for fuel spillage; any sp...

  • Page 202

    3-116 fuel system (dfi) 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 ignit...

  • Page 203

    Fuel system (dfi) 3-117 fuel pump fuel pump installation • remove dirt or dust from the fuel pump [a] by lightly ap- plying compressed air. • replace the fuel pump gasket with a new one. • check that the fuel pump terminal [a] and band [b] are in place. • apply a non-permanent locking agent to the t...

  • Page 204

    3-118 fuel system (dfi) fuel pump fuel pump operating voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the front seat (see front seat removal in the frame chapter). • disconnect the fuel pump lead connector and connect the harness adapter [a] b...

  • Page 205

    Fuel system (dfi) 3-119 fuel pump pressure regulator removal ○ the pressure regulator [a] is built into the fuel pump and can not be removed. Fuel filter cleaning ○ the fuel filter [a] is built into the fuel pump and can not be cleaned or checked. If the fuel filter is suspected of clogging or being...

  • Page 206

    3-120 fuel system (dfi) fuel injectors primary fuel injector removal/installation • refer to the throttle body assy disassembly/assembly. Secondary fuel injector removal/installation • refer to the nozzle assy disassembly/assembly. Fuel injector audible inspection note ○ be sure the battery is fully...

  • Page 207

    Fuel system (dfi) 3-121 fuel injectors fuel injector resistance inspection for primary fuel injectors • remove the air cleaner housing (see air cleaner housing removal). • disconnect the primary fuel injector connector [a]. • connect a digital meter to the terminals in each primary fuel injector [a]...

  • Page 208

    3-122 fuel system (dfi) fuel injectors fuel injector power source voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. For primary fuel injectors • remove the air cleaner housing (see air cleaner housing removal). • disconnect the injector connector and con...

  • Page 209

    Fuel system (dfi) 3-123 fuel injectors for secondary fuel injectors • remove the fuel tank (see fuel tank removal). • disconnect the injector connector and connect the har- ness adapter [a] between these connectors as shown in the figure. Main harness [b] secondary fuel injector #1 [c] special tool ...

  • Page 210

    3-124 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 ad...

  • Page 211

    Fuel system (dfi) 3-125 fuel injectors if the reading is out of the specification, remove the ecu and check the wiring for continuity between main harness connectors. Special tool - hand tester: 57001-1394 ○ disconnect the ecu and injector connector. Wiring continuity inspection (primary fuel inject...

  • Page 212

    3-126 fuel system (dfi) fuel injectors fuel injector fuel line inspection • remove: fuel tank (see fuel tank removal) air cleaner housing (see air cleaner housing removal) primary and secondary fuel hoses (see fuel hose re- placement in the periodic maintenance chapter) ○ do not remove the nozzle as...

  • Page 213

    Fuel system (dfi) 3-127 fuel injectors fuel injector circuit 1. Ignition switch 2. Engine stop switch 3. Primary fuel injector #1 4. Primary fuel injector #2 5. Primary fuel injector #3 6. Primary fuel injector #4 7. Secondary fuel injector #1 8. Secondary fuel injector #2 9. Secondary fuel injector...

  • Page 214

    3-128 fuel system (dfi) throttle grip and cables free play inspection • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Free play adjustment • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Cable installation • install th...

  • Page 215

    Fuel system (dfi) 3-129 throttle body assy idle speed inspection/adjustment • refer to the idle speed inspection/adjustment in the pe- riodic maintenance chapter. Synchronization inspection/adjustment • refer to the engine vacuum synchronization inspection in the periodic maintenance chapter. Thrott...

  • Page 216

    3-130 fuel system (dfi) throttle body assy • remove the adjusting screw [a] from the clamp. • remove the throttle body assy from the throttle body assy holders. • remove: bolt [a] holder plate [b] throttle cable lower ends • after removing the throttle body assy, stuff pieces of lint -free, clean cl...

  • Page 217

    Fuel system (dfi) 3-131 throttle body assy throttle body assy disassembly 1. Throttle body assy 2. Subthrottle valve actuator 3. Main throttle sensor 4. Subthrottle sensor 5. Primary fuel injectors 6. Delivery pipe assy caution do not remove, disassemble or adjust the main throttle sensor, subthrott...

  • Page 218

    3-132 fuel system (dfi) throttle body assy • pull out the primary fuel injectors [a] from the delivery pipe assy [b]. Note ○ do not damage the insertion portions of the injectors when they are pulled out from the delivery pipe assy. Caution never drop the primary fuel injector especially on a hard s...

  • Page 219

    Fuel system (dfi) 3-133 nozzle assy nozzle assy removal • remove the fuel tank (see fuel tank removal). • disconnect the secondary fuel hose [a] from the delivery pipe of the nozzle assy [b] (see fuel hose replacement in the periodic maintenance chapter). • disconnect the secondary fuel injector con...

  • Page 220

    3-134 fuel system (dfi) nozzle assy nozzle assy disassembly • remove the nozzle assy (see nozzle assy removal). • remove the screws [a] to pull out the secondary fuel in- jectors [b] from the stay plate [c] together with the delivery pipe assy [d]. Note ○ do not damage the insertion portions of the ...

  • Page 221

    Fuel system (dfi) 3-135 nozzle assy • replace the o-rings [a] of each secondary fuel injector [b] with new ones. • apply engine oil to the new o-rings, and insert them to the delivery pipe assy [c] and confirm whether the injectors turn smoothly or not. • replace the dust seals [a] with new ones. • ...

  • Page 222

    3-136 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 223

    Fuel system (dfi) 3-137 air cleaner • remove the caps [a]. • loosen the air cleaner housing clamp bolts [a]. • remove: air cleaner drain hose [a] breather hose [b] • separate the air switching valve hose [a] from the air cleaner housing [b]..

  • Page 224

    3-138 fuel system (dfi) air cleaner air cleaner housing installation • install the air switching valve hose to the air cleaner hous- ing. • install the air cleaner housing on the throttle body assy. ○ install the clamp bolt heads [a] outside as shown in the figure. ○ push in the ducts [b] touch the ...

  • Page 225

    Fuel system (dfi) 3-139 air cleaner air cleaner housing assembly • fit the projections [a] of the duct into the slits [b] on the air cleaner housing. • do not twist the ducts [c]. • install: air cleaner frame gasket [a] pads [b] air cleaner element gasket [c] air cleaner element [d] air cleaner case...

  • Page 226

    3-140 fuel system (dfi) air line air inlet duct removal • remove: upper fairing assembly (see upper fairing assembly removal in the frame chapter) immobilizer amplifier [a] (equipped models) (see immo- bilizer system parts replacement in the electrical sys- tem chapter) lead [b] (free) air inlet duc...

  • Page 227

    Fuel system (dfi) 3-141 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 228

    3-142 fuel system (dfi) fuel tank • disconnect: battery (–) terminal [a] fuel pump lead connector [b] • remove: fuel tank bolt [c] fuel tank drain hose [d] fuel tank breather hose [e] • for the california, southeast asia and thailand models, remove the following. Fuel return hose • be sure to place ...

  • Page 229

    Fuel system (dfi) 3-143 fuel tank • for the california, southeast asia and thailand models, note the following. Caution for the california, southeast asia and thailand models, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor ab- sorbing capacity is greatly re...

  • Page 230

    3-144 fuel system (dfi) fuel tank • install the pads [a] and trim [b] as shown in the figure. Hook [c] 8 mm (0.31 in.) [d] view a [e] view b [f] fuel tank bracket [g] weld [h] view upper side [i] • for the california, southeast asia and thailand models, note the following. ○ to prevent the gasoline ...

  • Page 231

    Fuel system (dfi) 3-145 fuel tank • push and pull [a] the fuel hose joint [b] back and forth more than two times, and make sure it is locked and does not come off. Warning make sure the hose joint is installed correctly on the delivery pipe or the fuel could leak. If it comes off, reinstall the hose...

  • Page 232

    3-146 fuel system (dfi) evaporative emission control system (cal, sea and th 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 thor...

  • Page 233

    Fuel system (dfi) 3-147 evaporative emission control system (cal, sea and th 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 s...

  • Page 234

    3-148 fuel system (dfi) evaporative emission control system (cal, sea and th models) 1. Green hose (purge) 2. Band (for canister) 3. Canister 4. White hose (vacuum) 5. Throttle body assy 6. Fuel tank 7. Red hose (return) 8. Blue hose (breather) 9. Bracket (for separator) 10. Separator 11. Blue hose ...

  • Page 235: Cooling System

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

  • Page 236

    4-2 cooling system exploded view.

  • Page 237

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 coolant by-pass fitting bolt 8.8 0.90 78 in·lb l 2 coolant drain bolt (cylinder) 9.8 1.0 87 in·lb 3 coolant drain bolt (water pump) 8.8 0.90 78 in·lb 4 coolant reserve tank mounting bolts 6.9 0.70 61 in·lb 5 heat insulati...

  • Page 238

    4-4 cooling system coolant flow chart.

  • Page 239

    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 240

    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 241

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

  • Page 242

    4-8 cooling system coolant coolant deterioration inspection • remove the upper fairing assembly (see upper fairing assembly removal in the frame chapter). • visually inspect the coolant in the reserve tank [a]. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corro...

  • Page 243

    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 244

    4-10 cooling system water pump water pump removal • refer to the oil pump removal in the engine lubrication system chapter. Water pump installation • refer to the oil pump installation in the engine lubrica- tion system chapter. Water pump inspection • remove the left lower fairing (see lower fairin...

  • Page 245

    Cooling system 4-11 water pump • take the oil seal [a] out of the housing [b] with a hook [c]. Water pump housing assembly caution do not reuse the mechanical seal and oil seal. • apply high-temperature grease to the oil seal lips [a]. • press the new oil seal into the housing with a bearing driver ...

  • Page 246

    4-12 cooling system radiator radiator and radiator fan removal • remove: upper fairing assembly (see upper fairing assembly removal in the frame chapter) coolant (drain, see coolant change in the periodic maintenance chapter) air cleaner housing (see air cleaner housing removal in the fuel system (d...

  • Page 247

    Cooling system 4-13 radiator radiator and radiator fan installation if the radiator bracket [a] was removed, install it. Torque - radiator bracket mounting bolt [b]: 9.8 n·m (1.0 kgf·m, 87 in·lb) • run the radiator fan motor lead correctly (see cable, wire, and hose routing section in the appendix c...

  • Page 248

    4-14 cooling system radiator caution when cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage: keep the steam gun [a] away more than 0.5 m (1.6 ft) [b] from the radiator core. Hold the steam gun perpendicular [c] (not oblique [d]) to the core surface. Run...

  • Page 249

    Cooling system 4-15 thermostat thermostat removal • remove: oil cooler (see oil cooler removal in the engine lubri- cation system chapter) thermostat housing cover bolts [a] thermostat housing cover [b] thermostat thermostat installation • install the thermostat [a] in the housing so that the air bl...

  • Page 250

    4-16 cooling system thermostat • to check valve opening temperature, suspend the ther- mostat [a] in a container of water and raise the tempera- ture of the water. ○ the thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [b] in...

  • Page 251

    Cooling system 4-17 hoses 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 ne...

  • Page 252

    4-18 cooling system water temperature sensor water temperature sensor removal/installation • refer to the water temperature sensor removal/instal- lation in the fuel system (dfi) chapter. Water temperature sensor inspection • refer to the water temperature sensor inspection in the electrical system ...

  • Page 253: 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 .................................... 5-8 special tools and sealant ................. 5-9 clean air system..............................

  • Page 254

    5-2 engine top end exploded view.

  • Page 255

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air suction valve cover bolts 9.8 1.0 87 in·lb l 2 breather hose fitting 15 1.5 11 l 3 camshaft cap bolts 12 1.2 106 in·lb s 4 camshaft chain tensioner cap bolt 20 2.0 15 5 camshaft chain tensioner mounting bolts 11 1.1 9...

  • Page 256

    5-4 engine top end exploded view.

  • Page 257

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 exhaust butterfly valve cable adjuster locknuts 6.9 0.70 61 in·lb 2 exhaust butterfly valve cable locknuts 7.0 0.71 62 in·lb 3 exhaust pipe clamp bolt 17 1.7 13 4 exhaust pipe guard bolts 6.9 0.70 61 in·lb 5 exhaust pipe ...

  • Page 258

    5-6 engine top end exhaust system identification exhaust pipe mark position [a] premuffler chamber mark position [a].

  • Page 259

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

  • Page 260

    5-8 engine top end specifications item standard service limit camshafts cam height: exhaust 33.143 ∼ 33.257 mm (1.3048 ∼ 1.3093 in.) 33.04 mm (1.301 in.) inlet 34.543 ∼ 34.657 mm (1.3600 ∼ 1.3644 in.) 34.44 mm (1.356 in.) camshaft journal/camshaft cap clearance 0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.)...

  • Page 261

    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° - 24.5: 57001-1113 valve seat cutter, 32° - 25: 57001-1118 valve seat cutter, 32° - 30: 57001-1120 valve seat cutter holder bar: 57001-1128 valve s...

  • Page 262

    5-10 engine top end special tools and sealant valve seat cutter holder, 4: 57001-1275 valve seat cutter, 60° - 25: 57001-1328 valve seat cutter, 60° - 27: 57001-1409 valve guide driver: 57001-1564 compression gauge adapter, m10 × 1.0: 57001-1601 l-shape hose: 57001-1606 attachment c: 57001-1624 kawa...

  • Page 263

    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] (both sides) air suction valve covers [b] (both sides) • remove the air suction valves [a] on both sides. Air suction valve installation • ...

  • Page 264

    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 265

    Engine top end 5-13 clean air system air switching valve operation test • refer to the air suction system damage inspection in the periodic maintenance chapter. Air switching valve unit test • refer to the air switching valve unit test in the electrical system chapter. Clean air system hose inspecti...

  • Page 266

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

  • Page 267

    Engine top end 5-15 cylinder head cover • tighten the cover bolts following the specified tightening sequence. Torque - cylinder head cover bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install the removed parts (see appropriate chapters)..

  • Page 268

    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 269

    Engine top end 5-17 camshaft chain tensioner camshaft chain tensioner installation • replace the o-ring [a] with a new one. • apply grease to the new o-ring. • release the stopper [b] and push the push rod [c] into the interior of the tensioner body [d]. • install the tensioner body so that the stop...

  • Page 270

    5-18 engine top end camshaft, camshaft chain camshaft removal • remove the cylinder head cover (see cylinder head cover removal). • remove the timing inspection cap [a] and starter clutch bolt cap [b] on the starter clutch cover [c]. • using a wrench on the starter clutch bolt [a], turn the cranksha...

  • Page 271

    Engine top end 5-19 camshaft, camshaft chain • remove the camshaft chain tensioner (see camshaft chain tensioner removal). • loosen the upper camshaft chain guide bolts and camshaft cap bolts as shown sequence [1 ∼ 20] in the figure, and remove them. • remove: upper camshaft chain guide [a] camshaft...

  • Page 272

    5-20 engine top end camshaft, camshaft chain • install the camshaft sprockets as shown in the figure. #4 cam positions [a] inlet camshaft sprocket [b] exhaust camshaft sprocket [c] ○ the inlet camshaft sprocket and exhaust camshaft sprocket are identical. • apply a non-permanent locking agent to the...

  • Page 273

    Engine top end 5-21 camshaft, camshaft chain • pull the tension side (exhaust side) [a] of the chain taut to install the chain. • engage the camshaft chain with the sprockets so that tim- ing marks on the sprockets are positioned as shown in the figure. ○ the timing marks must be aligned with the cy...

  • Page 274

    5-22 engine top end camshaft, camshaft chain • install: o-rings [a] dowel pins [b] o-rings [c] dowel pins [d] • install the camshaft caps and upper camshaft chain guide [a] as shown in the figure. “r” mark [b] “l” mark [c] • first tighten the all camshaft cap bolts evenly to seat the camshaft in pla...

  • Page 275

    Engine top end 5-23 camshaft, camshaft chain • install the camshaft chain tensioner (see camshaft chain tensioner installation). • turn the crankshaft 2 turns clockwise to allow the ten- sioner to expand and recheck the camshaft chain timing. • replace the o-ring of the timing inspection cap and sta...

  • Page 276

    5-24 engine top end camshaft, camshaft chain camshaft runout inspection • remove the camshafts (see camshaft removal). • set the camshaft in a camshaft alignment jig or on v blocks. • measure the runout with a dial gauge at the specified place as shown in the figure. If the runout exceeds the servic...

  • Page 277

    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 the spark plugs (see spark plug replacement in the periodic maintenance chapter). • attach the compression gauge [a] and adap...

  • Page 278

    5-26 engine top end cylinder head cylinder head removal • drain: coolant (see coolant change in the periodic mainte- nance chapter) engine oil (see engine oil change in the periodic main- tenance chapter) • remove: engine (see engine removal in the engine removal/in- stallation chapter) cylinder hea...

  • Page 279

    Engine top end 5-27 cylinder head cylinder head installation note ○ the camshaft cap is machined with the cylinder head, so if a new cylinder head is installed, use the cap that is supplied with the new head. • install the dowel pins. • replace the cylinder head gasket with a new one. • replace the ...

  • Page 280

    5-28 engine top end cylinder head cylinder head warp inspection • clean the cylinder head. • lay a straightedge across the lower surface of the cylinder head at several positions. • use a thickness gauge [a] to measure the space between the straightedge [b] and the head. Cylinder head warp standard:...

  • Page 281

    Engine top end 5-29 valves valve clearance inspection • refer to the valve clearance inspection in the periodic maintenance chapter. Valve removal • remove the cylinder head (see cylinder head removal). • remove the valve lifter and shim. ○ mark and record the valve lifter and shim locations so they...

  • Page 282

    5-30 engine top end valves • using the valve guide driver and attachment [a], press and insert the valve guide in until the attachment surface [b] touches the head surface [c]. 13.3 ∼ 13.5 mm (0.52 ∼ 0.53 in.) [d] special tools - valve guide driver: 57001-1564 attachment c: 57001-1624 • ream the val...

  • Page 283

    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 284

    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 285

    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 286

    5-34 engine top end valves if the seat width is too wide, make the 60° [a] grind de- scribed 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° angle until the seat width is within the specified range. ○ to make the 60° gri...

  • Page 287

    Engine top end 5-35 valves.

  • Page 288

    5-36 engine top end throttle body assy holder throttle body assy holder removal • remove: throttle body assy (see throttle body assy removal in the fuel system (dfi) chapter) clamps [a] throttle body assy holder bolts [b] throttle body assy holders [c] throttle body assy holder installation • be sur...

  • Page 289

    Engine top end 5-37 muffler warning to avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. Muffler body removal • remove the front seat (see front seat removal in the frame chapter). • open the clamp [a] and free the cables. • slide the dus...

  • Page 290

    5-38 engine top end muffler muffler body installation • replace the muffler body gasket [a] with a new one. • install the muffler body gasket to the premuffler chamber [b] until it is bottomed so that the chamfer side [c] faces muffler body [d]. About 4.0 mm (0.16 in.) [e] • install the muffler body...

  • Page 291

    Engine top end 5-39 muffler • install the muffler body cover, and tighten the bolts. Torque - muffler body cover bolts: 7.0 n·m (0.71 kgf·m, 62 in·lb) • install the damper [a] on the muffler body cover [b]. • install the muffler body rear cover, and tighten the bolts. Torque - muffler body rear cove...

  • Page 292

    5-40 engine top end muffler premuffler chamber installation • replace the exhaust pipe gasket [a] with a new one. • install the exhaust pipe gasket to the exhaust pipe [b] until it is bottomed so that the chamfer side [c] faces premuffler chamber [d]. About 4.0 mm (0.16 in.) [e] • install the exhaus...

  • Page 293

    Engine top end 5-41 muffler • install the muffler body (see muffler body installation). • thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts. Exhaust pipe removal • remove: radiator (see radiator and radiator fan removal in the cooling system chapter) oxygen sen...

  • Page 294

    5-42 engine top end muffler • remove the exhaust pipe holder nuts [a], and pull out the exhaust pipe forward from the premuffler chamber. Exhaust pipe installation • replace the exhaust pipe gaskets [a] [b] with new ones. • install the exhaust pipe gasket [b] to the exhaust pipe [c] until it is bott...

  • Page 295

    Engine top end 5-43 muffler • install the removed parts (see appropriate chapters). • thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts and nuts. Exhaust butterfly valve cable removal • remove the front seat (see front seat removal in the frame chapter). • open...

  • Page 296

    5-44 engine top end muffler • loosen the locknuts [a], and turn the adjusters [b] to give the cable plenty of play. • remove the clamp [a]. • remove the upper ends [b] of the exhaust butterfly valve cables from the pulley [c]. • remove the muffler body cover (see muffler body re- moval). • loosen th...

  • Page 297

    Engine top end 5-45 muffler • run the exhaust butterfly valve cables correctly (see cable, wire, and hose routing section in the appendix chapter). • install the lower ends of the exhaust butterfly valve cables to the pulley of the muffler body as shown in the figure. Open cable (white) [a] close ca...

  • Page 298

    5-46 engine top end muffler • install the upper ends of the exhaust butterfly valve ca- bles to the pulley of the exhaust butterfly valve actuator, following the specified installing sequence. ○ first, install the close cable (black) [a]. ○ second, install the open cable (white) [b]. ○ third, stretc...

  • Page 299: Clutch

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

  • Page 300

    6-2 clutch exploded view.

  • Page 301

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 clutch cover bolts (m6, l = 40 mm) 9.8 1.0 87 in·lb 2 clutch cover bolts (m6, l = 25 mm) 9.8 1.0 87 in·lb 3 clutch cover plate bolts 9.8 1.0 87 in·lb l 4 clutch hub nut 135 13.8 99.6 r 5 clutch lever clamp bolts 7.8 0.80 69 in·lb...

  • Page 302

    6-4 clutch specifications item standard service limit clutch lever free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – clutch spring plate free play (usable range) 0.05 ∼ 0.70 mm (0.002 ∼ 0.028 in.) – – – clutch plate assembly length (reference) 40.6 mm (1.60 in.) – – – friction plate thickness: 13088-0003/0...

  • Page 303

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

  • Page 304

    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. Cable removal • remove: air cleaner ho...

  • Page 305

    Clutch 6-7 clutch cover clutch cover removal • remove the bolt [a]. • remove the cover [b] from the frame. • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: right lower fairing (see lower fairing removal in the frame chapter) clutch cable lower end [a] (...

  • Page 306

    6-8 clutch clutch cover release shaft removal caution do not remove the clutch release lever and shaft assembly unless it is absolutely necessary. If re- moved, the oil seal replacement may be required. • remove the clutch cover (see clutch cover removal). • pull the release lever and shaft assembly...

  • Page 307

    Clutch 6-9 clutch cover • remove: bolts [a] plate [b] pads needle bearings [c] oil level gauge [d] clutch cover assembly • replace the needle bearings and oil seal with new ones. Note ○ install the needle bearings so that the manufacture’s mark face out. • install the needle bearings [a] and oil sea...

  • Page 308

    6-10 clutch clutch cover • install: pads [a] plate [b] • apply a non-permanent locking agent to the threads of the clutch cover plate bolts [c], and tighten them. Torque - clutch cover plate bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb).

  • Page 309

    Clutch 6-11 clutch clutch removal • remove: clutch cover (see clutch cover removal) clutch spring bolts [a] clutch springs (with clutch spring holders) clutch spring plate [b] (with shim, bearing, pusher [c], spring and washer) • remove: friction plates (8) [a] steel plates (7) [b] spring [c] spring...

  • Page 310

    6-12 clutch clutch • remove: torque limiter springs [a] sub clutch hub [b] clutch hub [c] spacer [d] ○ remove the sub clutch hub bolts [e] as necessary. • using the two 4 mm (0.16 in.) screws [a], pull out the sleeve [b], needle bearing [c] and clutch housing [d]. • remove the spacer. Clutch install...

  • Page 311

    Clutch 6-13 clutch • install: needle bearing [a] sleeve [b] ○ apply engine oil to the sleeve and needle bearing. • install the spacer [c] so that the stepped side [d] faces outward. If the sub clutch hub bolts were removed, install them as follows. ○ apply a non-permanent locking agent to the thread...

  • Page 312

    6-14 clutch clutch ○ fourth torque limiter spring [a] tang [b] • replace the clutch hub nut [a] with a new one. • hold the sub 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: 135 n·m (13.8 kgf·m, 99.6...

  • Page 313

    Clutch 6-15 clutch • apply molybdenum disulfide grease to the pusher end [a]. • install the washer [b], spring [c], bearing [d] and shim [e] to the pusher. • install the pusher to the drive shaft [f] direction as shown in the figure. • align the projections [a] of the spring plate [b] to the grooves...

  • Page 314

    6-16 clutch clutch • engage the clutch hub with the sub clutch hub. • to measure the free play, set a dial gauge [a] against the raised center [b] of the clutch spring plate. • move the clutch housing gear back and forth [c]. The dif- ference between the highest and lowest gauge readings is the amou...

  • Page 315

    Clutch 6-17 clutch clutch plate assembly length (reference information) • assemble the following parts. Clutch hub [a] spring seat [b] spring [c] sub clutch hub [d] sub clutch hub bolts [e] new friction plates [f] steel plates [g] spring plate [h] clutch springs [i] clutch spring holders [j] clutch ...

  • Page 316

    6-18 clutch clutch clutch spring free length measurement • measure the free length of the clutch springs [a]. If any spring is shorter than the service limit, it must be replaced. Clutch spring free length standard: 41.6 mm (1.64 in.) service limit: 40.1 mm (1.58 in.) clutch housing finger inspectio...

  • Page 317: Engine Lubrication System

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

  • Page 318

    7-2 engine lubrication system exploded view.

  • Page 319

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air bleed bolt 9.8 1.0 87 in·lb 2 engine oil drain bolt 29 3.0 21 3 impeller bolt 9.8 1.0 87 in·lb 4 oil cooler mounting bolts 20 2.0 15 5 oil cooler/oil filter case mounting bolts 20 2.0 15 l 6 oil filter 17 1...

  • Page 320

    7-4 engine lubrication system engine oil flow chart.

  • Page 321

    Engine lubrication system 7-5 engine oil flow chart.

  • Page 322

    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 2.8 l (3.0 us qt) (when filter is not removed) 3.1 l (3.3 us qt) (when filter is removed) 3.6 l (3.8 us qt) (when engine is complete...

  • Page 323

    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 outside circlip pliers: 57001-144 kawasaki bond (silicone sealant): 56019-120

  • Page 324

    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 325

    Engine lubrication system 7-9 oil pan oil pan removal • remove: engine oil (drain, see engine oil change in the periodic maintenance chapter) exhaust pipe (see exhaust pipe removal in the engine top end chapter) oil pan bolts [a] clamps [b] oil pan [c] oil pan installation • replace the oil pan gask...

  • Page 326

    7-10 engine lubrication system oil pressure relief valve oil pressure relief valve removal • remove: oil pan (see oil pan removal) oil screen [a] • remove the oil pressure relief valve [a]. Oil pressure relief valve installation • apply a non-permanent locking agent to the threads of the oil pressur...

  • Page 327

    Engine lubrication system 7-11 oil pressure relief valve oil pressure relief valve inspection • remove the oil pressure relief valve (see oil pressure relief valve removal). • check to see if the valve [a] slides smoothly when push- ing it in with a wooden or other soft rod, and see if it comes back...

  • Page 328

    7-12 engine lubrication system oil pump oil pump removal • remove: coolant (drain, see coolant change in the periodic maintenance chapter) engine oil (drain, see engine oil change in the periodic maintenance chapter) water pump cover bolts [a] water pump cover [b] water hose clamp screw [c] (loosen)...

  • Page 329

    Engine lubrication system 7-13 oil pump oil pump installation • install the outer rotor [a] into the crankcase. • install the pin [b] and inner rotor [c] to the oil (water) pump shaft [d], and install the assy. ○ turn the pump shaft so that the slot [e] in its shaft fits onto the projection [f] of t...

  • Page 330

    7-14 engine lubrication system oil pump • align the line [a] of the water pump cover and the white mark [b] of the water hose [c]. • install the water hose clamp [d] as shown in the figure. • tighten: torque - water hose clamp screws: 2.0 n·m (0.20 kgf·m, 18 in·lb) oil pump drive gear removal • remo...

  • Page 331

    Engine lubrication system 7-15 oil pump oil pump drive gear shaft installation • apply molybdenum disulfide oil solution to the journal por- tions [a] on the oil pump drive gear shaft. • install the oil pump drive gear shaft and washer [b] as shown in the figure. • install the new circlip [c] into t...

  • Page 332

    7-16 engine lubrication system oil cooler oil cooler removal • remove: coolant (drain, see coolant change in the periodic maintenance chapter) engine oil (drain, see engine oil change in the periodic maintenance chapter) starter motor (see starter motor removal in the electri- cal system chapter) wa...

  • Page 333

    Engine lubrication system 7-17 oil cooler • remove the bolts [a]. • remove: bolts [a] oil cooler/oil filter case [b] ○ remove the oil filter holder bolt [c] as necessary. Oil cooler/oil filter case installation if the crankcase was disassembled, pour the engine oil into the oil passage [a] until o-r...

  • Page 334

    7-18 engine lubrication system oil cooler • replace the o-rings [a] with new ones. • apply grease to the new o-rings. • install the oil cooler/oil filter case. • apply a non-permanent locking agent to the threads of the oil cooler/oil filter case mounting bolts, and tighten them. Torque - oil cooler...

  • Page 335

    Engine lubrication system 7-19 oil pressure measurement oil pressure measurement • remove: right lower fairing (see lower fairing 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: 57001-164 oil ...

  • Page 336

    7-20 engine lubrication system oil pressure switch oil pressure switch removal • remove: right lower fairing (see lower fairing removal in the frame chapter) engine oil (drain, see engine oil change in the periodic maintenance chapter) switch cover [a] switch terminal bolt [b] oil pressure switch [c...

  • Page 337: Engine Removal/installation

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

  • Page 338

    8-2 engine removal/installation exploded view.

  • Page 339

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 adjusting collar locknuts 49 5.0 36 s 2 adjusting collars 9.8 1.0 87 in·lb s 3 left front engine mounting bolt 44 4.5 32 s 4 lower engine mounting nut 44 4.5 32 s 5 middle engine mounting nut 44 4.5 32 s 6 ri...

  • Page 340

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

  • Page 341

    Engine removal/installation 8-5 engine removal/installation engine removal • support the rear part of the swingarm with a stand. • squeeze the brake lever slowly and hold it with a band [a]. Warning be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It could c...

  • Page 342

    8-6 engine removal/installation engine removal/installation • remove the clamp [a]. • disconnect the sidestand switch lead connector [a]. • remove the engine ground cable terminal bolt [a]. • remove: bolt [a] heat insulation plate [b] ○ clear the projections [c] from the frame [d]. • support the eng...

  • Page 343

    Engine removal/installation 8-7 engine removal/installation • remove the left front engine mounting bolt [a]. • remove: right front engine mounting bolt [a] middle engine mounting nut [b] lower engine mounting nut • using the nut wrench [a], loosen the locknuts [b]. Special tool - engine mount nut w...

  • Page 344

    8-8 engine removal/installation engine removal/installation engine installation • install the adjusting collar [a] to crankcase backside until end of the threads. • install the adjusting collar [a] to the frame until end of the threads. • support the engine with a suitable stand. ○ put a plank onto ...

  • Page 345

    Engine removal/installation 8-9 engine removal/installation • install the engine mounting bolts and nuts, following the specified installing sequence. ○ first, tighten the following bolts and nuts temporarily. Lower engine mounting bolt [a] and nut [b] middle engine mounting bolt [c] and nut [d] lef...

  • Page 346

    8-10 engine removal/installation engine removal/installation ○ third, tighten the adjusting collar [a] with the lower engine mounting bolt [b] counterclockwise until the adjusting col- lar touches [c] the frame [d]. Torque - adjusting collars: 9.8 n·m (1.0 kgf·m, 87 in·lb) ○ fourth, tighten the adju...

  • Page 347: Crankshaft/transmission

    Crankshaft/transmission 9-1 9 crankshaft/transmission table of contents exploded view................................... 9-2 specifications .................................... 9-6 special tools and sealants ............... 9-9 crankcase ......................................... 9-11 crankcase split...

  • Page 348

    9-2 crankshaft/transmission exploded view.

  • Page 349

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bearing holder screws 4.9 0.50 43 in·lb l 2 breather hose fitting 15 1.5 11 l 3 breather plate bolts 9.8 1.0 87 in·lb l 4 connecting rod big end nuts see the text ← ← mo 5 crankcase bolt (m8, l = 90 mm) 27 2.8 20...

  • Page 350

    9-4 crankshaft/transmission exploded view.

  • Page 351

    Crankshaft/transmission 9-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 gear position switch screws 2.9 0.30 26 in·lb l 2 gear positioning lever bolt 12 1.2 106 in·lb 3 idle gear cover bolts 9.8 1.0 87 in·lb 4 shift drum cam holder bolt 12 1.2 106 in·lb l 5 shift lever bolt 6.9 0.70 ...

  • Page 352

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

  • Page 353

    Crankshaft/transmission 9-7 specifications item standard service limit crankshaft main bearing insert thickness: brown, yellow 1.491 ∼ 1.495 mm (0.0587 ∼ 0.0589 in.) – – – black, green 1.495 ∼ 1.499 mm (0.0589 ∼ 0.0590 in.) – – – blue, purple 1.499 ∼ 1.503 mm (0.0590 ∼ 0.0592 in.) – – – cylinder , p...

  • Page 354

    9-8 crankshaft/transmission specifications connecting rod big end bearing insert selection bearing insert con-rod big end inside diameter marking crankpin diameter marking size color part number none ○ brown 92139-0167 none none ○ ○ black 92139-0166 ○ none blue 92139-0165 crankshaft main bearing ins...

  • Page 355

    Crankshaft/transmission 9-9 special tools and sealants outside circlip pliers: 57001-144 piston pin puller assembly: 57001-910 piston ring compressor grip: 57001-1095 piston ring compressor belt, 67 ∼ 79: 57001-1097 bearing driver set: 57001-1129 grip: 57001-1591 rotor holder: 57001-1666 stopper: 57...

  • Page 356

    9-10 crankshaft/transmission special tools and sealants kawasaki bond (liquid gasket - black): 92104-1064.

  • Page 357

    Crankshaft/transmission 9-11 crankcase 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: crankshaft sensor (see crankshaft sensor removal in ...

  • Page 358

    9-12 crankshaft/transmission crankcase 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 crankcase halves a...

  • Page 359

    Crankshaft/transmission 9-13 crankcase • press and insert the fitting [a] in the upper crankcase [b] until it is bottomed. Special tool - bearing driver set: 57001-1129 • apply a non-permanent locking agent to the threads of the breather hose fitting [c] and tighten it. Torque - breather hose fittin...

  • Page 360

    9-14 crankshaft/transmission crankcase • press and insert the new needle bearing [a] for the shift shaft so that its marked side faces outside [b] and its sur- face [c] is flush with the end of the hole. • install the new oil seal [d] so that its surface [e] is flush with the end of the hole. • appl...

  • Page 361

    Crankshaft/transmission 9-15 crankcase • 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 sealant so that it shall be filled up on the groove [b]. ○ do not apply liquid gasket to the ins...

  • Page 362

    9-16 crankshaft/transmission crankcase • the m8 bolts [a] has a copper plated washer [b], replace it with a new one. • apply molybdenum disulfide oil solution to both sides [c] of the washers and threads [d] of m8 bolts. • tighten the lower crankcase bolts using the following steps. ○ following the ...

  • Page 363

    Crankshaft/transmission 9-17 crankshaft and connecting rods crankshaft removal • split the crankcase (see crankcase splitting). • remove: camshaft chain (see camshaft chain removal in the engine top end chapter) connecting rod big end caps (see connecting rod re- moval) crankshaft [a] • remove the t...

  • Page 364

    9-18 crankshaft/transmission crankshaft and connecting rods note ○ the thrust washer [a] has oil grooves [b] on the one side. ○ the thrust washers are identical. • apply molybdenum disulfide grease [c] to the oil groove side [d] of the thrust washers. • slide [e] the thrust washer of the one side in...

  • Page 365

    Crankshaft/transmission 9-19 crankshaft and connecting rods • remove: camshaft chain (see camshaft chain removal in the engine top end chapter) crankshaft [a] pistons (see piston removal) caution discard the connecting rod bolts and nuts. To pre- vent damage to the crankpin surfaces, do not al- low ...

  • Page 366

    9-20 crankshaft/transmission crankshaft and connecting rods • install each connecting rod on its original crankpin. ○ 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, allow...

  • Page 367

    Crankshaft/transmission 9-21 crankshaft and connecting rods • install new bolts and nuts in reused connecting rod. If the connecting rod assy was replaced, use the bolts and nuts attached to the new connecting rod assy. • apply a small amount of molybdenum disulfide oil solution to the following por...

  • Page 368

    9-22 crankshaft/transmission crankshaft and connecting rods • install new bolts and nuts in reused connecting rod. If the connecting rod assy was replaced, use the bolts and nuts attached to the new connecting rod assy. • apply a small amount of molybdenum disulfide oil solution to the following por...

  • Page 369

    Crankshaft/transmission 9-23 crankshaft and connecting rods connecting rod twist inspection • 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.) l...

  • Page 370

    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 0.082 mm (0.0032 in.) and the service limit (0.11 mm, 0.0043 in.), replace the bear- ing inserts [a] with inserts painted blue [b]. C...

  • Page 371

    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 con-rod big end inside diameter marking crankpin diameter marking size color part number no...

  • Page 372

    9-26 crankshaft/transmission crankshaft and connecting rods crankshaft main bearing insert/journal wear inspection • split the crankcase (see crankcase splitting). • cut strips of plastigage to journal width. Place a strip on each journal parallel to the crankshaft installed in the correct position....

  • Page 373

    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. [a]: crankcase main bearing inside diameter marks, “ ○ ” or no mark. • tighten the crankcase bolts to the specified torq...

  • Page 374

    9-28 crankshaft/transmission pistons piston removal • split the crankcase (see crankcase splitting). • remove the connecting rod big end nuts [a] and caps [b]. Note ○ mark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positio...

  • Page 375

    Crankshaft/transmission 9-29 pistons piston installation • apply molybdenum disulfide oil solution to the oil ring ex- pander, and install the oil ring expander [a] in the bottom piston ring groove so the ends [b] not butt together. • apply molybdenum disulfide oil solution to the oil ring steel rai...

  • Page 376

    9-30 crankshaft/transmission pistons • apply molybdenum disulfide oil solution to the cylinder bore and piston skirt. • install the piston with its marking hollow [a] facing exhaust side. • using the piston ring compressor assembly [b] to install the piston from the cylinder head side. Special tools...

  • Page 377

    Crankshaft/transmission 9-31 pistons piston ring groove width inspection • measure the piston ring groove width. ○ use a vernier caliper at several points around the piston. Piston ring groove width standard: top [a] 0.82 ∼ 0.84 mm (0.0323 ∼ 0.0331 in.) second [b] 0.82 ∼ 0.84 mm (0.0323 ∼ 0.0331 in....

  • Page 378

    9-32 crankshaft/transmission starter idle gear and starter clutch starter idle gear removal • remove: right fairing cover (see fairing cover removal in the frame chapter) bolts [a] idle gear cover [b] • pull out the idle gear (starter motor side) [a] with the shaft [b]. • remove: bolts [a] starter c...

  • Page 379

    Crankshaft/transmission 9-33 starter idle gear and starter clutch • install the idle gear (starter clutch side) [a] on the shaft. • engage the idle gear with the starter clutch gear. • apply silicone sealant to the following portion. Crankshaft sensor lead grommet [b] crankcase halves mating surface...

  • Page 380

    9-34 crankshaft/transmission starter idle gear and starter clutch starter clutch removal • remove: alternator cover (see alternator cover removal in the electrical system chapter) starter clutch cover (see starter idle gear removal) idle gear (starter clutch side) (see starter idle gear removal) • u...

  • Page 381

    Crankshaft/transmission 9-35 starter idle gear and starter clutch starter clutch assembly • install the one-way clutch [a] so that its circlip side [b] faces in. • install the new snap ring. • push [a] the starter clutch gear [b] in and turn it counter- clockwise [c] and install it. • apply molybden...

  • Page 382

    9-36 crankshaft/transmission starter idle gear and starter clutch ○ examine the starter clutch gear [a] as well. Replace the clutch gear if it is worn or damaged..

  • Page 383

    Crankshaft/transmission 9-37 transmission transmission assy removal • remove: engine sprocket (see engine sprocket removal in the final drive chapter) gear position switch (see gear position switch re- moval in the electrical system chapter) collar [a] o-ring [b] • remove: clutch (see clutch removal...

  • Page 384

    9-38 crankshaft/transmission transmission • press and insert the ball bearing [a] in the transmission case [b] so that the stepped side faces outside until it is bottomed. • install the bearing holder [c] as shown in the figure. • apply a non-permanent locking agent to the threads of the bearing hol...

  • Page 385

    Crankshaft/transmission 9-39 transmission • install the drive shaft [a] and output shaft [b] as a set in the transmission case [c]. • install the shift forks as shown in the figure. ○ the shift fork [d] for drive shaft gears has the short ears. ○ the shift forks [e] [f] for output shaft gears have t...

  • Page 386

    9-40 crankshaft/transmission transmission • install the gear positioning lever (see external shift mech- anism installation). • set the gear positioning lever to the neutral position [a]. • check that the drive and output shaft turn freely. • apply grease to the o-ring [a] and install it to its posi...

  • Page 387

    Crankshaft/transmission 9-41 transmission • replace any circlips removed with new ones. • install the circlip [a] on the drive shaft [b] so that the punch mark [c] faces the washer [d] and position the opening [e] as shown in the figure. • install the circlip [a] on the output shaft [b] so that the ...

  • Page 388

    9-42 crankshaft/transmission 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 389

    Crankshaft/transmission 9-43 transmission 1. 1st gear 2. 2nd gear 3. 3rd gear 4. 4th gear 5. 5th gear 6. 6th (top) gear 7. Ball bearing 8. Bushing 9. Washer, 34 mm (1.34 in.) 10. Circlip 11. Toothed washer, 34 mm (1.34 in.) 12. Bushing 13. Washer, 32 mm (1.26 in.) 14. Needle bearing 15. Circlip 16. ...

  • Page 390

    9-44 crankshaft/transmission 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 • remove the shift drum (see transmission assy disas- sembly). • while holding the sh...

  • Page 391

    Crankshaft/transmission 9-45 transmission shift fork guide pin/drum groove wear inspection • measure the diameter of each shift fork guide pin [a], and measure the width [b] of each shift drum groove. If the guide pin on any shift fork is less than the service limit, the fork must be replaced. Shift...

  • Page 392

    9-46 crankshaft/transmission external shift mechanism shift pedal removal • remove: shift lever bolt [a] shift lever [b] if the tie-rod is removed from the shift pedal and shift lever, note the following. ○ the following portions have left-hand threads. Shift lever side of tie-rod (the shift lever s...

  • Page 393

    Crankshaft/transmission 9-47 external shift mechanism external shift mechanism removal • remove: shift lever (see shift pedal removal) clutch (see clutch removal in the clutch chapter) circlip [a] washer [b] special tool - outside circlip pliers: 57001-144 • remove the shift shaft assembly [a] while...

  • Page 394

    9-48 crankshaft/transmission external shift mechanism external shift mechanism inspection • examine the shift shaft [a] for any damage. If the shaft is bent, replace it. If the serration [b] are damaged, replace the shaft. If the springs [c] are damaged in any way, replace them. If the shift mechani...

  • Page 395: Wheels/tires

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

  • Page 396

    10-2 wheels/tires exploded view.

  • Page 397

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front axle clamp bolts 20 2.0 15 al 2 front axle nut 127 13.0 93.7 3 rear axle nut 127 13.0 93.7 al: tighten the two clamp bolts alternately two times to ensure even tightening torque. Hg: apply high-temperature grease. R:...

  • Page 398

    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 (0.0012 in.) or less tir 0.2 mm (0.008 in.) wheel bala...

  • Page 399

    Wheels/tires 10-5 special tools bearing driver set: 57001-1129 jack: 57001-1238 bearing remover head, 25 × 28: 57001-1346 bearing remover shaft, 13: 57001-1377 jack attachment: 57001-1608.

  • Page 400

    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 bolts [a] (right side) front axle [b] • remove the lower fairings (see lower fairing removal in the frame chapter). • raise the front ...

  • Page 401

    Wheels/tires 10-7 wheels (rims) front wheel installation note ○ the direction of the wheel rotation [a] is shown by an arrow [b] on the wheel spoke. • check the wheel rotation mark on the front wheel and install it. • apply high-temperature grease to the grease seal lips. • fit the collars [a] on th...

  • Page 402

    10-8 wheels/tires wheels (rims) rear wheel removal • raise the rear wheel off the ground with the stand [a]. • remove: rear caliper mounting bolts [a] rear caliper [b] • remove: cotter pin [a] axle nut [b] washer [c] axle [d] (from right side) • remove the drive chain [a] from the rear sprocket towa...

  • Page 403

    Wheels/tires 10-9 wheels (rims) • engage the drive chain with the rear sprocket. • install the caliper bracket [a] onto the stopper [b] of the swingarm. • insert the axle from the right side of the wheel. • install the washer and axle nut. • adjust the drive chain slack before tightening the axle nu...

  • Page 404

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

  • Page 405

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

  • Page 406

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

  • Page 407

    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 408

    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 409

    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 410

    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 411

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

  • Page 413: Final Drive

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

  • Page 414

    11-2 final drive exploded view.

  • Page 415

    Final drive 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 chain guide bolts 9.8 1.0 87 in·lb l 2 engine sprocket cover bolts 9.8 1.0 87 in·lb 3 engine sprocket cover plate mounting bolts 9.8 1.0 87 in·lb l 4 engine sprocket nut 125 13.0 92.2 mo 5 rear axle nut 127 13.0 93.7 6 rear...

  • Page 416

    11-4 final drive specifications item standard service limit drive chain drive chain slack 30 ∼ 40 mm (1.2 ∼ 1.6 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 enuma – – – type ex520mvxl2 – – – link 112 links – – – sprockets re...

  • Page 417

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

  • Page 418

    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 419

    Final drive 11-7 drive chain body [a] handlebar [b] cutting and riveting pin [c] for cutting [d] for riveting [e] plate holder (a) [f] plate holder (b) [g] gauge [h] • grind [a] the pin head to make it flat. • set the cutting and riveting pin [b] as shown in the figure. • screw the pin holder until ...

  • Page 420

    11-8 final drive drive chain • set the plate holder (a) [a] and plate holder (b) [b] on the body. • fit the plate holder (a) to the link plate. • turn the pin holder by hand until the plate holder (b) touches the other link plate. • turn the pin holder by a wrench clockwise until two pins of link co...

  • Page 421

    Final drive 11-9 drive chain • turn the wrench clockwise until the tip of riveting pin hits of the link pin. • rivet it. • same work for the other link pin. • after staking, check the staked area of the link pin for cracks. • measure the outside diameter [a] of the link pin and link plates width [b]...

  • Page 422

    11-10 final drive sprocket, coupling engine sprocket removal • remove: speed sensor bolt [a] speed sensor [b] engine sprocket cover bolts [c] engine sprocket cover [d] • flatten out the bended washer [a]. • remove the engine sprocket nut [b] and washer. Note ○ when loosening the engine sprocket nut,...

  • Page 423

    Final drive 11-11 sprocket, coupling if the chain guide and engine sprocket cover plate re- moved, install the as follows. • install: pad [a] engine sprocket cover plate [b] ○ insert the groove of the pad into the rib of the engine sprocket cover. ○ apply a non-permanent locking agent to the threads...

  • Page 424

    11-12 final drive sprocket, coupling rear sprocket installation • install the sprocket facing the tooth number marking [a] outward. • tighten: torque - rear sprocket nuts: 59 n·m (6.0 kgf·m, 44 ft·lb) • install the rear wheel (see rear wheel installation in the wheels/tires chapter). Coupling instal...

  • Page 425

    Final drive 11-13 sprocket, coupling coupling bearing installation • replace the bearing with a new one. • press in the bearing [a] until it is bottomed. Special tool - bearing driver set [b]: 57001-1129 • pack the bearing with high-temperature grease. • replace the circlip with a new one. Special t...

  • Page 426

    11-14 final drive sprocket, coupling sprocket wear inspection • visually inspect the engine and rear sprocket teeth for wear and damage. If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see drive chain wear inspection in the periodic maintenance chapter)....

  • Page 427: Brakes

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

  • Page 428

    12-2 brakes exploded view.

  • Page 429

    Brakes 12-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bleed valves 7.8 0.80 69 in·lb 2 brake hose banjo bolts 25 2.5 18 3 brake lever pivot bolt 1.0 0.10 8.9 in·lb si 4 brake lever pivot bolt locknut 5.9 0.60 52 in·lb 5 front brake disc mounting bolts 27 2.8 20 l 6 front brake ligh...

  • Page 430

    12-4 brakes exploded view.

  • Page 431

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bleed valve 7.8 0.80 69 in·lb 2 brake hose banjo bolts 25 2.5 18 3 brake pedal mounting bolt 34 3.5 25 l 4 rear brake disc mounting bolts 27 2.8 20 l 5 rear caliper mounting bolts 25 2.5 18 6 rear master cylinder mounting bolts ...

  • Page 432

    12-6 brakes specifications item standard service limit brake lever, brake pedal brake lever position 6-way adjustable (to suit rider) – – – brake lever free play non-adjustable – – – pedal free play non-adjustable – – – pedal position about 75 mm (2.95 in.) below top of footpeg – – – brake pads lini...

  • Page 433

    Brakes 12-7 special tools inside circlip pliers: 57001-143 jack: 57001-1238 jack attachment: 57001-1608.

  • Page 434

    12-8 brakes brake lever, brake pedal brake lever position adjustment the brake lever adjuster has 6 positions so that the brake lever position can be adjusted to suit the operator’s hand. • push the lever forward and turn the adjuster [a] to align the number with the arrow mark [b] on the lever hold...

  • Page 435

    Brakes 12-9 brake lever, brake pedal • remove: cotter pin [a] joint pin [b] rear brake light switch spring [c] return spring [d] • remove the brake pedal mounting bolt [e] and take out the brake pedal. Brake pedal installation • apply grease to the footpeg pivot shaft [a]. • install: bushing [b] bra...

  • Page 436

    12-10 brakes brake lever, brake pedal • install the front footpeg bracket. • tighten: torque - front footpeg bracket bolts: 25 n·m (2.5 kgf·m, 18 ft·lb) • install the rear master cylinder [a] and foot guard. Note ○ depress the brake pedal [b] and then align the holes of the master cylinder. ○ after ...

  • Page 437

    Brakes 12-11 calipers front caliper removal • loosen the banjo bolt [a] at the brake hose lower end, and tighten it loosely. • unscrew the caliper mounting bolts [b], and detach the caliper [c] from the disc. Caution do not loosen the caliper assembly bolts. Take out only the caliper mounting bolts ...

  • Page 438

    12-12 brakes calipers caliper installation • install the caliper and brake hose lower end. ○ replace the washers on each side of hose fitting with new ones. • tighten: torque - caliper mounting bolts: front: 34 n·m (3.5 kgf·m, 25 ft·lb) rear: 25 n·m (2.5 kgf·m, 18 ft·lb) brake hose banjo bolts: 25 n...

  • Page 439

    Brakes 12-13 calipers caliper fluid seal damage inspection the fluid seal (piston seal) [a] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- p...

  • Page 440

    12-14 brakes calipers caliper piston and cylinder damage inspection • visually inspect the pistons [a] and cylinder surfaces [b]. Replace the caliper if the cylinder and piston are badly scores or rusty. Rear caliper holder shaft wear inspection the caliper body must slide smoothly on the caliper ho...

  • Page 441

    Brakes 12-15 brake pads front brake pad removal • loosen the pad pins [a]. • remove: pad pins [a] pad springs [b] brake pads [c] front brake pad installation • push the caliper pistons in by hand as far as they will go. • install the outside pad [a] and insert the pad pin [b] as shown in the figure....

  • Page 442

    12-16 brakes brake pads rear brake pad removal • remove the rear caliper with the hose installed (see rear caliper removal). • remove: clip [a] pad pin [b] brake pads [c] rear brake pad installation • push the caliper piston in by hand as far as it will go. • install the pad spring in place. • insta...

  • Page 443

    Brakes 12-17 master cylinder front master cylinder removal • remove the reservoir mounting bolt and nut [a]. • unscrew the banjo bolt [a] and remove the brake hose from the master cylinder (see brake hose and pipe re- placement in the periodic maintenance chapter). • unscrew the clamp bolts [b], and...

  • Page 444

    12-18 brakes master cylinder • install the master cylinder clamp [a] so that the arrow mark [b] faces upward. • set the front master cylinder to match its mating surface [a] to the punch mark [b] of the handlebar. • tighten the upper clamp bolt first, and then the lower clamp bolt. Torque - front ma...

  • Page 445

    Brakes 12-19 master cylinder • remove: cotter pin [a] joint pin [b] • slide the reservoir hose lower end clamp [a]. • pull off the reservoir hose lower end [b], and drain the brake fluid into a container. Rear master cylinder installation • replace the cotter pin [a] with a new one. • insert the cot...

  • Page 446

    12-20 brakes master cylinder rear master cylinder disassembly • refer to the master cylinder rubber parts replacement in the periodic maintenance chapter. Master cylinder assembly • refer to the master cylinder rubber parts replacement in the periodic maintenance chapter. Master cylinder inspection ...

  • Page 447

    Brakes 12-21 brake disc brake disc removal • remove the wheels (see front/rear wheel removal in the wheels/tires chapter). • unscrew the mounting bolts [a], and take off the disc [b]. Brake disc installation • replace the gaskets with new ones. • install the brake disc on the wheel so that the marke...

  • Page 448

    12-22 brakes brake disc brake disc warp inspection • raise the wheel off the ground with jack. Special tools - jack: 57001-1238 jack attachment: 57001-1608 ○ for front disc inspection, turn the handlebar fully to one side. • set up a dial gauge against the disc [a] as shown in the figure and measure...

  • Page 449

    Brakes 12-23 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 450

    12-24 brakes brake fluid • release the clamps [a] and projection [b] of the cover from the rear brake reservoir. • remove the rear brake reservoir cap [a]. • remove: diaphragm plate diaphragm • fill the reservoir with fresh brake fluid to the upper level line in the reservoir. • slowly pump the brak...

  • Page 451

    Brakes 12-25 brake fluid • bleed the brake line and the master cylinder. ○ 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 h...

  • Page 452

    12-26 brakes brake fluid • follow the procedure below to install the front/rear brake fluid reservoir cap correctly. ○ first, tighten the brake fluid reservoir cap [b] clockwise [c] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap ...

  • Page 453

    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 454

    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 and pipe damage and instal- lation condition inspection in the periodic maintenance chapter..

  • Page 455: Suspension

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

  • Page 456

    13-2 suspension exploded view.

  • Page 457

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front axle clamp bolts 20 2.0 15 al 2 front fork top plugs 35 3.6 26 3 lower front fork clamp bolts 23 2.3 17 al 4 piston rod guide case 90 9.2 66 5 upper front fork clamp bolts 20 2.0 15 al: tighten the two clamp bolts alte...

  • Page 458

    13-4 suspension exploded view.

  • Page 459

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 lower rear shock absorber nut 34 3.5 25 2 rear shock absorber bracket nut 59 6.0 44 3 swingarm pivot adjusting collar locknut 98 10.0 72.3 4 swingarm pivot shaft 20 2.0 15 5 swingarm pivot shaft nut 108 11.0 79.7 6 tie-rod n...

  • Page 460

    13-6 suspension specifications item standard front fork (per one unit) fork inner tube diameter 41 mm (1.6 in.) air pressure atmospheric pressure (non-adjustable) rebound damper setting 4 turns out from the fully clockwise position (usable range: 0 ←→ 5 1/2 turns out) compression damper setting 5 1/...

  • Page 461

    Suspension 13-7 special tools inside circlip pliers: 57001-143 oil seal & bearing remover: 57001-1058 bearing driver set: 57001-1129 jack: 57001-1238 fork oil seal driver, 41: 57001-1288 fork oil level gauge: 57001-1290 bearing remover head, 20 × 22: 57001-1293 bearing remover shaft, 13: 57001-1377 ...

  • Page 462

    13-8 suspension special tools jack attachment: 57001-1608 needle bearing driver, 17/ 18: 57001-1609 needle bearing driver, 28: 57001-1610 spacer, 18: 57001-1636 spacer, 28: 57001-1637 hook wrench: 57001-1641 needle bearing driver, 20 & spacer, 28: 57001-1678 top plug wrench (45 mm): 57001-1741 box w...

  • Page 463

    Suspension 13-9 front fork rebound damping force adjustment • to adjust the rebound damping force, turn the rebound damping adjuster [a] until you feel a click. ○ the standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 4 turns out from ...

  • Page 464

    13-10 suspension front fork spring preload adjustment • to adjust the spring preload, turn the spring preload ad- juster [a] until you feel a click. ○ the standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 4 turns in from the fully cou...

  • Page 465

    Suspension 13-11 front fork front fork installation (each fork leg) • install the fork so that the top end [a] of the outer tube as shown in the figure. 5 mm (0.20 in.) [b] steering stem head [c] • tighten: torque - lower front fork clamp bolts: 23 n·m (2.3 kgf·m, 17 ft·lb) front fork top plugs: 35 ...

  • Page 466

    13-12 suspension front fork • using the wrench [a], unscrew the piston rod guide case out of the inner tube. Special tool - box wrench (27 mm): 57001-1742 • remove: piston rod assy [a] collar [b] fork spring [c] collar [d] • drain the fork oil into a suitable container [a]. ○ pump the inner tube up ...

  • Page 467

    Suspension 13-13 front fork • insert the piston rod assy into the inner tube. Note ○ lifting the outer tube, and insert the piston rod assy. Caution when inserting, be careful not to damage the piston ring [a]. • using the wrench [a], tighten the piston rod guide case to the inner tube. Special tool...

  • Page 468

    13-14 suspension front fork • measure the oil level as follows. ○ hold the inner tube vertically in a vise. ○ wait until the oil level settles. ○ with the fork fully compressed, insert a tape measure or rod into the piston rod guide case [a], and measure the distance [b] from the top [c] of the oute...

  • Page 469

    Suspension 13-15 front fork • remove the following parts from the inner tube. Slide bushing [a] guide bushing [b] washer [c] oil seal [d] retaining ring [e] dust seal [f] front fork assembly • replace the following parts with new ones. Slide bushing guide bushing oil seal • install the following par...

  • Page 470

    13-16 suspension front fork inner tube inspection • visually inspect the inner tube [a], and repair any dam- age. • nick or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage. If the damage is not repairable, replace the inner tub...

  • Page 471

    Suspension 13-17 rear shock absorber rebound damping force adjustment • to adjust the rebound damping force, turn the rebound damping adjuster [a] to the desired position, until you feel a click. ○ the standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no ac...

  • Page 472

    13-18 suspension rear shock absorber • to adjust the low speed compression damping force, turn the inside damping adjuster with a flat-head screwdriver to the desired position. ○ the standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 3...

  • Page 473

    Suspension 13-19 rear shock absorber • remove: bolts [a] quick rivet [b] chain cover [c] ○ push the central pin, and then remove the quick rivet. • to adjust the spring preload, turn in the adjusting nut to the desired position and tighten the locknut by using hook wrenches [a] with the rear shock a...

  • Page 474

    13-20 suspension rear shock absorber • remove: lower rear shock absorber nut and bolt [a] upper tie-rod nut and bolt [b] upper rear shock absorber nut and bolt [c] • remove the rear shock absorber [d] downward. Rear shock absorber installation • tighten: torque - rear shock absorber nuts: 34 n·m (3....

  • Page 475

    Suspension 13-21 swingarm swingarm removal • remove: rear wheel (see rear wheel removal in the wheels/tires chapter) chain cover (see drive chain removal in the final drive chapter) engine sprocket (see engine sprocket removal in the final drive chapter) mud guard (see mud guard removal in the frame...

  • Page 476

    13-22 suspension swingarm • apply plenty of grease to the lip of the oil seals [a]. • be sure to install the oil seals and sleeve [b] to the swingarm. • fit the collar [c] on the oil seal of the left side. • screw the adjusting collar [a] into the frame [b] so that the collar does not project the sw...

  • Page 477

    Suspension 13-23 swingarm • remove the ball bearing and needle bearings. Special tool - oil seal & bearing remover [a]: 57001-1058 swingarm bearing installation • replace the ball and needle bearings [a] with new ones. • install the ball and needle bearings so that the manufac- turer’s marks face ou...

  • Page 478

    13-24 suspension swingarm swingarm bearing, sleeve inspection caution do not remove the bearings for inspection. Re- moval may damage them. • inspect the needle bearings [a] and ball bearing installed in the swingarm. ○ the rollers and ball in a bearing normally wear very little, and wear is difficu...

  • Page 479

    Suspension 13-25 tie-rod, rocker arm tie-rod removal • remove: lower fairings (see lower fairing removal in the frame chapter) premuffler chamber (see premuffler chamber removal in the engine top end chapter) • squeeze the brake lever slowly and hold it with a band [a]. Warning be sure to hold the b...

  • Page 480

    13-26 suspension tie-rod, rocker arm • remove: lower rear shock absorber nut and bolt [a] lower tie-rod nut and bolt [b] rocker arm nut and bolt [c] rocker arm [d] rocker arm installation • apply grease to the inside of the oil seals [a]. • be sure to install the oil seals and sleeves [b] to the roc...

  • Page 481

    Suspension 13-27 tie-rod, rocker arm tie-rod and rocker arm bearing installation • replace the needle bearings and oil seals with new ones. • install the needle bearings and oil seals position as shown in the figure. ○ screw the needle bearing driver [a] into the driver holder [b]. ○ insert the need...

  • Page 482

    13-28 suspension tie-rod, rocker arm needle bearings [a] oil seals [b] front [c] right side [d] left side [e] rear shock absorber [f] tie-rods [g] rocker arm [h] 7.5 mm (0.30 in.) [i] 5.0 mm (0.20 in.) [j] 5.5 mm (0.22 in.) [k] 5.5 mm (0.22 in.) [l] tie-rod/rocker arm bearing, sleeve inspection caut...

  • Page 483: Steering

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

  • Page 484

    14-2 steering exploded view.

  • Page 485

    Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 handlebar clamp bolts 25 2.5 18 2 handlebar positioning bolts 9.8 1.0 87 in·lb l 3 left switch housing screws 3.5 0.36 31 in·lb 4 lower front fork clamp bolts 23 2.3 17 al 5 right switch housing screws 3.5 0.36 31 in·lb 6 stee...

  • Page 486

    14-4 steering specifications item standard steering damper damper setting 18th click from the first click of the fully clockwise position (usable range: 0 ←→ 18 clicks).

  • Page 487

    Steering 14-5 special tools bearing puller: 57001-135 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...

  • Page 488

    14-6 steering steering steering inspection • refer to the steering play inspection in the periodic main- tenance chapter. Steering adjustment • refer to the steering play adjustment in the periodic maintenance chapter..

  • Page 489

    Steering 14-7 steering damper damping force adjustment • to adjust the damping force, turn the damping adjuster [a] until you feel a click. ○ the standard adjuster setting is the 18th click from the 1st of the fully clockwise position. If the damping feels too soft or too stiff, adjust it in accorda...

  • Page 490

    14-8 steering steering stem stem, stem bearing removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) steering damper (see steering damper removal) upper fairing assembly (see upper fairing assembly removal in the frame chapter) front fender (see front fender removal in...

  • Page 491

    Steering 14-9 steering stem • remove the lower ball bearing [a] from the steering stem. • remove the lower bearing inner race (with its grease seal) [a] which is pressed onto the steering stem [b] with the bearing puller [c] and adapter [d]. Special tool - bearing puller: 57001-135 stem, stem bearin...

  • Page 492

    14-10 steering steering stem • install the steering stem [a] through the head pipe and install the upper bearing [b] and inner race [c] on it. • install: stem cap [d] steering stem nut [e] • settle the bearings in place as follows. ○ tighten the steering stem nut with 55 n·m (5.6 kgf·m, 41 ft·lb) of...

  • Page 493

    Steering 14-11 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 s...

  • Page 494

    14-12 steering handlebar handlebar removal • remove: steering damper (see steering damper removal) clutch lever clamp bolts [a] clutch lever assembly [b] left switch housing [c] handlebar weight [d] left handlebar grip [e] • remove: front master cylinder [a] (see front master cylinder re- moval in t...

  • Page 495

    Steering 14-13 handlebar handlebar installation • apply a non-permanent locking agent to the threads of the handlebar positioning bolts and tighten them. Torque - handlebar positioning bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install the steering stem head with handlebars. • install the washer [a] and...

  • Page 496

    14-14 steering handlebar • install: clutch lever assembly (see clutch lever installation in the clutch chapter) front master cylinder (see front master cylinder instal- lation in the brakes chapter) steering damper (see steering damper installation).

  • Page 497: Frame

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

  • Page 498

    15-2 frame exploded view.

  • Page 499

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front footpeg bracket bolts 25 2.5 18 2 rear footpeg bracket bolts 25 2.5 18 3 rear frame bolts (m10) 44 4.5 32 l 4 rear frame bolts (m8) 25 2.5 18 l 5 sidestand bolt 44 4.5 32 g 6 sidestand bracket bolts 49 5.0 36 l 7 sidestand ...

  • Page 500

    15-4 frame exploded view.

  • Page 501

    Frame 15-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fender mounting bolts 3.9 0.40 35 in·lb 2. Us, ca, cal and sea models l: apply a non-permanent locking agent..

  • Page 502

    15-6 frame exploded view.

  • Page 503

    Frame 15-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 windshield mounting bolts 0.42 0.043 3.7 in·lb 2. Other than cal, sea and th models.

  • Page 504

    15-8 frame seats front seat removal • remove: side covers (see side cover removal) bolts [a] (both sides) • remove the seat [b] forward while lifting up the front part of the seat. Front seat installation • installation is the reverse of removal, note the following. ○ slip the seat hook [a] under th...

  • Page 505

    Frame 15-9 fairings lower fairing removal • remove: lower inner fairing (see lower inner fairing removal) quick rivet [a] bolts [b] ○ pull up the core by the flat-head screwdriver, and then remove the quick rivet. • clear the hook portions [c] from the slots and remove the lower fairing [d]. • remov...

  • Page 506

    15-10 frame fairings lower inner fairing installation • installation is the reverse of removal, note the following. ○ insert the projection [a] into the hole [b]. Upper fairing assembly removal • remove: lower fairings (see lower fairing removal) upper inner fairings (see upper inner fairing removal...

  • Page 507

    Frame 15-11 fairings • remove: bolts [a] rear view mirror [b] bolt [c] • remove the bolts [a]. • clear the projections [b] from the holes and remove the upper fairing assembly [c]. Upper fairing assembly installation • installation is the reverse of removal, note the following. ○ run the hoses, lead...

  • Page 508

    15-12 frame fairings center fairing installation • installation is the reverse of removal, note the following. ○ check that the pads [a] are in place on the center fairing. Left center fairing [b] right center fairing [c] ○ insert the hook portions [a] into the slots [b]. Upper fairing removal • rem...

  • Page 509

    Frame 15-13 fairings upper center fairing installation • installation is the reverse of removal, note the following. ○ check that the pads [a] are in place on the upper center fairing [b]. ○ insert the slots [a] onto the hook portions. ○ tighten the screws [b]. Upper inner fairing removal • remove: ...

  • Page 510

    15-14 frame fairings center inner fairing removal • remove the bolt [a]. • clear the slots [b] from the hook portions and remove the center inner fairing. Center inner fairing installation • installation is the reverse of removal, note the following. ○ insert the hook portions [a] into the slots [b]...

  • Page 511

    Frame 15-15 fairings fairing cover removal • remove: upper fairing assembly (see upper fairing assembly removal) bolts [a] left fairing cover [b] right fairing cover [c] fairing cover installation • installation is the reverse of removal..

  • Page 512

    15-16 frame side covers side cover removal • remove the bolt [a]. • pull the side cover [b] evenly outward to clear the projec- tion [c] and hook fasteners [d], and remove it. Side cover installation • installation is the reverse of removal, note the following. ○ insert the projections [a] into the ...

  • Page 513

    Frame 15-17 seat covers seat cover removal • remove: seats (see front/rear seat removal) bolts [a] • pull the front seat cover [b] backward to clear the hook portions [c], and remove it upward. • remove the quick rivets [a]. ○ push the central pin, and then remove the quick rivet. • remove the quick...

  • Page 514

    15-18 frame seat covers • remove the bolt [a]. • clear the hook portion [b] from the slot. • remove the lower end [a] of the seat lock cable [b]. • remove: connector [a] bolt [b] rear seat cover [c] tail/brake light (led) (see tail/brake light (led) re- moval/installation in the electrical system ch...

  • Page 515

    Frame 15-19 seat covers ○ insert the hook portions [a] into the slots [b]. ○ check that the pad [a] is in place on the front seat cover [b]. ○ insert the hook portions [a] into the slots [b]. Upper seat cover removal (only on ninja zx-6r monster energy® model) • insert the ignition switch key [a] in...

  • Page 516

    15-20 frame fenders front fender removal • remove: clamps [a] (both sides) bolts [b] with washers (both sides) reflectors [c] (both sides, us, ca, cal and sea mod- els) front fender [d] front fender installation • tighten: torque - front fender mounting bolts: 3.9 n·m (0.40 kgf·m, 35 in·lb) flap and...

  • Page 517

    Frame 15-21 fenders flap and rear fender installation • installation is the reverse of removal, note the following. ○ check that the pad [a] is in place on the rear fender [b]. 5 mm (0.20 in.) [c] ○ run the harness, cables and leads correctly (see cable, wire, and hose routing section in the appendi...

  • Page 518

    15-22 frame frame rear frame rear removal • remove: rear seat cover (see seat cover removal) tool kit case (see flap and rear fender removal) bolts [a] (both sides) rear frame rear [b] rear frame rear installation • apply a non-permanent locking agent to the threads of the rear frame bolts (m8) and ...

  • Page 519

    Frame 15-23 windshield windshield removal • remove: bolts with washers [a] windshield [b] windshield installation • be sure that the wellnuts [a] are in position as shown in the figure. • tighten: torque - windshield mounting bolts: 0.42 n·m (0.043 kgf·m, 3.7 in·lb).

  • Page 520

    15-24 frame guard mud guard removal • remove: bolts [a] and brake hose clamp [b] mud guard [c] mud guard installation • installation is the reverse of removal, note the following. ○ apply a non-permanent locking agent to the threads of the mud guard mounting bolts, and tighten them securely..

  • Page 521

    Frame 15-25 sidestand sidestand removal • raise the rear wheel off the ground with the stand [a]. • remove: sidestand switch bolt [a] sidestand switch [b] • remove: spring [a] sidestand nut [b] sidestand bolt [c] sidestand [d] sidestand installation • apply grease to the sliding area [a] of the side...

  • Page 523: Electrical System

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

  • Page 524

    16-2 electrical system right-hand end cover assembly inspection .................................................................... 16-45 starter relay inspection.................................................................................................... 16-45 lighting system .................

  • Page 525

    Electrical system 16-3 dummy page.

  • Page 526

    16-4 electrical system exploded view.

  • Page 527

    Electrical system 16-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front turn signal light mounting screw 1.2 0.12 11 in·lb 2 license plate light cover screws 1.0 0.10 8.9 in·lb 3 license plate light mounting nuts 3.5 0.36 31 in·lb 4 meter unit mounting screws 1.2 0.12 11 in·lb 5 rea...

  • Page 528

    16-6 electrical system exploded view.

  • Page 529

    Electrical system 16-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 alternator cover bolts 9.8 1.0 87 in·lb 2 alternator lead holding plate bolt 9.8 1.0 87 in·lb l 3 alternator rotor bolt 155 15.8 114 s 4 crankshaft sensor bolts 5.9 0.60 52 in·lb 5 front brake light switch screw 1.2 0...

  • Page 530

    16-8 electrical system exploded view.

  • Page 531

    Electrical system 16-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine ground cable terminal bolt 9.8 1.0 87 in·lb 2 fuel pump bolts 9.8 1.0 87 in·lb l, s 3 gear position switch screws 2.9 0.30 26 in·lb l 4 oxygen sensor (equipped models) 25 2.5 18 5 regulator/rectifier bracket sc...

  • Page 532

    16-10 electrical system specifications item standard battery type sealed battery model name ytx9-bs capacity 12 v 8 ah voltage 12.8 v or more charging system type three-phase ac alternator output voltage 54 v or more at 4 000 r/min (rpm) stator coil resistance 0.11 ∼ 0.17 Ω at 20°c (68°f) charging v...

  • Page 533

    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 key registration unit: 57001-1582 grip: 57001-1591 rotor holder: 57001-1666 stopper: 57001...

  • Page 534

    16-12 electrical system parts location.

  • Page 535

    Electrical system 16-13 parts location 1. Immobilizer amplifier (equipped models) 2. Ignition switch 3. Immobilizer antenna (equipped models) 4. Starter lockout switch 5. Starter relay 6. Battery 12 v 8 ah 7. Immobilizer (equipped models)/kawasaki diagnostic system connector 8. Relay box 9. Ecu 10. ...

  • Page 536

    16-14 electrical system wiring diagram (us, cal and ca models).

  • Page 537

    Electrical system 16-15 wiring diagram (us, cal and ca models).

  • Page 538

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

  • Page 539

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

  • Page 540

    16-18 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 541

    Electrical system 16-19 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 542

    16-20 electrical system battery battery removal • turn off the ignition switch. • remove the front seat (see front seat removal in the frame chapter). • slide the red cap [a]. • disconnect the negative (–) cable [b] and then positive (+) cable [c]. Caution be sure to disconnect the negative (–) cabl...

  • Page 543

    Electrical system 16-21 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 544

    16-22 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 545

    Electrical system 16-23 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 12.8 v repeat the charging cycle and load test. If still below 12.8 v t...

  • Page 546

    16-24 electrical system battery precautions 1) no need of topping-up no topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that. 2) refreshing charge if an engine will not start, a horn sounds wea...

  • Page 547

    Electrical system 16-25 battery if the reading is 12.8 v or more, no refresh charge is re- quired, however, if the read is below the specified, refresh charge is required. Battery terminal voltage standard: 12.8 v or more terminal voltage (v) [a] battery charge rate (%) [b] good [c] refresh charge i...

  • Page 548

    16-26 electrical system charging system alternator cover removal • remove: upper fairing assembly (see upper fairing assembly removal in the frame chapter) air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter) clamps [a] • remove: bolts [a] alternator cover [b] alter...

  • Page 549

    Electrical system 16-27 charging system stator coil installation • apply a non-permanent locking agent to the threads of the stator coil bolts and tighten them. Torque - stator coil bolts: 12 n·m (1.2 kgf·m, 106 in·lb) • apply silicone sealant to the circumference of the alterna- tor lead grommet [a...

  • Page 550

    16-28 electrical system charging system • using a cleaning fluid, clean off any oil or dirt on the washer [a] and dry it with a clean cloth. • install the washer. Note ○ confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque. • install the rotor bolt [b]...

  • Page 551

    Electrical system 16-29 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 front seat (see front seat removal in the frame chapter). • check that the igni...

  • Page 552

    16-30 electrical system charging system • to check the alternator output voltage, do the following procedures. ○ turn the ignition switch off. ○ remove the right upper inner fairing (see upper inner fairing removal in the frame chapter). ○ disconnect the alternator lead connector [a]. ○ connect the ...

  • Page 553

    Electrical system 16-31 charging system regulator/rectifier inspection • remove: upper fairing assembly (see upper fairing assembly removal in the frame chapter) right inner fairing (see inner fairing removal in the frame chapter) bolts [a] regulator/rectifier [b] • set the hand tester to the × 1 k ...

  • Page 554

    16-32 electrical system charging system charging system circuit 1. Ignition switch 2. Load 3. Regulator/rectifier 4. Alternator 5. Frame ground 6. Battery 12 v 8 ah 7. Starter relay 8. Main fuse 30 a.

  • Page 555

    Electrical system 16-33 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 556

    16-34 electrical system ignition system crankshaft sensor inspection • disconnect the crankshaft sensor lead connector (see crankshaft sensor removal). • set the hand tester [a] to the × 10 Ω range and connect it to the crankshaft sensor lead connector [b]. Special tool - hand tester: 57001-1394 cra...

  • Page 557

    Electrical system 16-35 ignition system stick coil removal • remove the air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter). • disconnect the stick coil connectors [a]. • pull out the stick coils [b] upward. ○ first, turn the stick coil by 90 degrees, and then pull...

  • Page 558

    16-36 electrical system ignition system stick coil primary peak voltage inspection note ○ be sure the battery is fully charged. • remove the stick coils (see stick coil removal). ○ do not remove the spark plugs. • measure the primary peak voltage as follows. ○ install the new spark plug [a] into eac...

  • Page 559

    Electrical system 16-37 ignition system spark plug condition inspection • remove the spark plugs (see spark plug replacement in the periodic maintenance chapter). • visually inspect the spark plugs. If the spark plug center electrode [a] and/or side elec- trode [b] are corroded or damaged, or if the...

  • Page 560

    16-38 electrical system ignition system 3rd check • inspect the engine for its secure stop after the following operations are completed. • run the engine to the following conditions. Condition: transmission gear → 1st position clutch lever → release sidestand → up • set the sidestand on the ground, ...

  • Page 561

    Electrical system 16-39 ignition system.

  • Page 562

    16-40 electrical system ignition system ignition system circuit 1. Ignition switch 2. Engine stop switch 3. Stick coils 4. Spark plugs 5. Primary fuel injector 6. Secondary fuel injector 7. Crankshaft sensor 8. Gear position switch 9. Sidestand switch 10. Ecu 11. Vehicle-down sensor 12. Fuel pump 13...

  • Page 563

    Electrical system 16-41 electric starter system starter motor removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: throttle body assy (see throttle body assy removal in the fuel system (dfi) chapter) starter clutch cover (see starter idle gear removal in th...

  • Page 564

    16-42 electrical system electric starter system • install the starter motor cable [a] as shown in the figure. • tighten: torque - starter motor cable terminal bolt [b]: 2.9 n·m (0.30 kgf·m, 26 in·lb) • slide back the rubber cap to the original position. Starter motor disassembly • take off the start...

  • Page 565

    Electrical system 16-43 electric starter system • press the springs holding the brush leads with suitable clips [a] as shown in the figure. • put the armature [b] among the brushes. • install the new o-rings [a] as shown in the figure. • align the groove [a] in the right-hand end cover and the hollo...

  • Page 566

    16-44 electrical system electric starter system commutator cleaning and inspection • smooth the commutator surface [a] if necessary with fine emery cloth [b], and clean out the grooves. • measure the diameter [a] of the commutator [b]. If the commutator diameter is less than the service limit, repla...

  • Page 567

    Electrical system 16-45 electric starter system right-hand end cover assembly inspection • using the highest hand tester range, measure the resis- tance as shown in the figure. Terminal and right-hand end cover [a] special tool - hand tester: 57001-1394 if there is any reading, the right-hand end co...

  • Page 568

    16-46 electrical system electric starter system electric starter circuit 1. Ignition switch 2. Engine stop switch 3. Starter button 4. Gear position switch 5. Sidestand switch 6. Ecu 7. Fuse box 8. Ignition fuse 15 a 9. Frame ground 10. Battery 12 v 8 ah 11. Starter relay 12. Main fuse 30 a 13. Star...

  • Page 569

    Electrical system 16-47 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 570

    16-48 electrical system lighting system • turn the headlight bulb [a] clockwise. • connect the headlight connector. • after installation, adjust the headlight aim (see headlight aiming inspection in the periodic maintenance chapter). ○ other bulb: repeat the above steps. City light bulb replacement ...

  • Page 571

    Electrical system 16-49 lighting system tail/brake light (led) removal/installation • remove: rear seat cover (see seat cover removal in the frame chapter) bolts [a] tail/brake light (led) [b] • installation is the reverse of removal, note the following. ○ fit the projections [a] of the rear seat co...

  • Page 572

    16-50 electrical system lighting system headlight/tail light circuit 1. Ignition switch 2. Regulator/rectifier 3. Alternator 4. License plate light 12 v 5 w 5. Tail/brake light (led) 13.5 v 0.5/4.1 w 6. Joint connector c 7. Taillight fuse 10 a 8. Headlight fuse 15 a 9. Fuse box 10. Battery 12 v 8 ah...

  • Page 573

    Electrical system 16-51 lighting system turn signal light bulb replacement front turn signal light • remove the upper fairing assembly (see upper fairing assembly removal in the frame chapter). • turn the socket [a] counterclockwise and pull out the socket together with the bulb. • push and turn the...

  • Page 574

    16-52 electrical system lighting system • push and turn the rear turn signal light bulb [a] counter- clockwise and remove it. • insert the new bulb [a] by aligning its left and right pins [b] with the left and right grooves [c] in the socket, and turn the bulb clockwise. ○ turn the bulb about 15°. •...

  • Page 575

    Electrical system 16-53 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 light 21 w [b] turn signal light 10 w [c] 12 v battery [d] if the lights do not flash as ...

  • Page 576

    16-54 electrical system lighting system turn signal light circuit 1. Turn signal indicator light (led) 2. Ignition switch 3. Rear right turn signal light 12 v 10 w 4. Rear left turn signal light 12 v 10 w 5. Joint connector c 6. Turn signal relay 7. Fuse box 8. Turn signal relay fuse 10 a 9. Frame g...

  • Page 577

    Electrical system 16-55 air switching valve air switching valve operation test • refer to the air suction system damage inspection in the periodic maintenance chapter. Air switching valve unit test • remove the air switching valve (see air switching valve removal in the engine top end chapter). • se...

  • Page 578

    16-56 electrical system air switching valve air switching valve circuit 1. Ignition switch 2. Engine stop switch 3. Air switching valve 4. Ecu 5. Fuel pump 6. Fuse box 7. Ignition fuse 15 a 8. Frame ground 9. Battery 12 v 8 ah 10. Main fuse 30 a 11. Fuel pump relay 12. Relay box.

  • Page 579

    Electrical system 16-57 radiator fan system fan motor inspection • remove the air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter). • slide the dust cover [a]. • disconnect the connector [b]. • using an auxiliary leads, supply battery power to the fan motor. If the ...

  • Page 580

    16-58 electrical system meter, gauge, indicator unit meter unit removal/installation • remove the upper fairing assembly (see upper fairing assembly removal in the frame chapter). • slide back the dust cover and disconnect the meter unit connector [a]. • remove: screws [b] meter unit [c] caution pla...

  • Page 581

    Electrical system 16-59 meter, gauge, indicator unit electronic unit (combination meter) inspection • remove the meter unit [a] (see meter unit removal/in- stallation). [1] left turn signal indicator light (led) (+) [2] unused [3] unused [4] unused [5] stop watch (+) [6] lap time (+) [7] water tempe...

  • Page 582

    16-60 electrical system meter, gauge, indicator unit ○ when the terminals are connected, all the lcd segments [a] blinks 2 times, then appear for 1 seconds. ○ the fuel level warning indicator light (led) [b] goes on for 3 seconds. If the lcd segments do not appear, replace the meter unit. • disconne...

  • Page 583

    Electrical system 16-61 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 [b] change to the odo, trip, and stop watch displays ...

  • Page 584

    16-62 electrical system meter, gauge, indicator unit • in the minute setting mode, press the reset button to return to the hour/minute setting mode. • press the mode button to complete the time setting process. • indicate the odo mode. • check that the display [a] [b] change to the mile and °f, mile...

  • Page 585

    Electrical system 16-63 meter, gauge, indicator unit odometer check • check the odometer with the speedometer check in the same way. If value indicated in the odometer is not added, replace the meter unit. Note ○ the data is maintained even if the battery is discon- nected. ○ when the figures come t...

  • Page 586

    16-64 electrical system meter, gauge, indicator unit tachometer check • 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, the tachometer nee- dle momentary points to the last reading, a...

  • Page 587

    Electrical system 16-65 meter, gauge, indicator unit stop watch check • connect the 12 v battery and terminal in the same man- ner as specified in the “liquid crystal display (lcd) seg- ments check”. • press the mode button each time to set the stop watch mode. • connect the insulated auxiliary lead...

  • Page 588

    16-66 electrical system meter, gauge, indicator unit lights (led) inspection shift up indicator light (led) [a] illumination light (led) [b] fuel level warning indicator light (led) [c] high beam indicator light (led) [d] neutral indicator light (led) [e] turn signal indicator light (led) [f] warnin...

  • Page 589

    Electrical system 16-67 meter, gauge, indicator unit left and right turn signal indicator light (led) • connect the 12 v battery and terminals in the same man- ner as specified in the “liquid crystal display (lcd) seg- ments check”. • using the insulated auxiliary leads, 12 v battery to the meter un...

  • Page 590

    16-68 electrical system meter, gauge, indicator unit ○ when the terminals are connected, the fuel level warning indicator light (led) [a] should go on and the fuel seg- ments [b] appears in the display. ○ the fuel segments is flashing. If the fuel level warning indicator light (led) does not go on a...

  • Page 591

    Electrical system 16-69 meter, gauge, indicator unit meter unit circuit 1. Ignition switch 2. Stop watch button 3. Speed sensor 4. Water temperature sensor 5. Oil pressure switch 6. Gear position switch 7. Ecu 8. Fuel reserve switch 9. Fuse box 10. Ignition fuse 15 a 11. Ecu fuse 10 a 12. Frame grou...

  • Page 592

    16-70 electrical system immobilizer system (equipped models) this motorcycle is equipped with an immobilizer system to protect the motorcycle from theft. This system provides a theft proof device by means of matching a code between the inbuilt key transponder and ecu. If the code does not match, ign...

  • Page 593

    Electrical system 16-71 immobilizer system (equipped models) • insert the master key to the ignition switch and turn it on. Verified ○ the warning indicator light (led) and immobilizer warning symbol [a] blinks to display the registration mode (go to the next step). Not verified ○ the warning indica...

  • Page 594

    16-72 electrical system immobilizer system (equipped models) ○ if there is any problem in the registration, the warning indicator light (led) and immobilizer warning symbol [a] blinks to display the collation error. Immobilizer amplifier failure when registered user key is inserted. User key collati...

  • Page 595

    Electrical system 16-73 immobilizer system (equipped models) ○ if there is any problem in the registration, the warning indicator light and immobilizer warning symbol [a] blinks to display the collation error. Immobilizer amplifier failure when registered user key is inserted. User key collation err...

  • Page 596

    16-74 electrical system immobilizer system (equipped models) • the warning indicator light (led) goes off [a]. • remove the key registration unit and connect the immo- bilizer/kawasaki diagnostic system connector. Note ○ turn the ignition switch on with the registered user key. ○ check that the engi...

  • Page 597

    Electrical system 16-75 immobilizer system (equipped models) spare user key registration flow chart.

  • Page 598

    16-76 electrical system immobilizer system (equipped models) case 2: when the ignition switch is faulty and to be replaced. • prepare a new ignition switch [a] and two new user keys [b]. ○ these parts are available as a set. Prepare the current master key [c]. • remove: ignition switch and immobiliz...

  • Page 599

    Electrical system 16-77 immobilizer system (equipped models) verified ○ the warning indicator light (led) and immobilizer warning symbol [a] blinks to display the ecu is in the registration mode (go to the next step). Not verified ○ the warning indicator light (led) and immobilizer warning symbol [a...

  • Page 600

    16-78 electrical system immobilizer system (equipped models) ○ if there is any problem in the registration, the warning indicator light (led) and immobilizer warning symbol [a] blinks to display the collation error. Immobilizer amplifier failure when registered user key is inserted. User key collati...

  • Page 601

    Electrical system 16-79 immobilizer system (equipped models) ○ if there is any problem in the registration, the warning indicator light (led) and immobilizer warning symbol [a] blinks to display the collation error. Immobilizer amplifier failure when registered user key is inserted. User key collati...

  • Page 602

    16-80 electrical system immobilizer system (equipped models) • remove the key registration unit and connect the immo- bilizer/kawasaki diagnostic system connector. Note ○ turn the ignition switch on with the registered user key. ○ check that the engine can be started using all regis- tered user keys...

  • Page 603

    Electrical system 16-81 immobilizer system (equipped models) master key collation error • the master key is registered in the ecu. ○ the warning indicator light (led) and immobilizer warning symbol [a] blinks 1 time and stops for 1 second and the repeats this cycle to indicate successful registratio...

  • Page 604

    16-82 electrical system immobilizer system (equipped models) when registered user key is inserted. User key collation error • the user key 1 is registered in the ecu. ○ the warning indicator light (led) and immobilizer warn- ing symbol [a] blinks 2 times and stops for 1 second and then repeats this ...

  • Page 605

    Electrical system 16-83 immobilizer system (equipped models) ○ if there is any problem in the registration, the warning indicator light (led) and immobilizer warning symbol [a] blinks to display the collation error code. Immobilizer amplifier failure when registered user key is inserted. User key co...

  • Page 606

    16-84 electrical system immobilizer system (equipped models) case 4: when master key is faulty or lost. The master key replacement is considered very rare case. However if it is required, the following is necessary. Note ○ the ecu must be replaced with a new one because the master key code that is r...

  • Page 607

    Electrical system 16-85 immobilizer system (equipped models) all keys initial registration flow chart.

  • Page 608

    16-86 electrical system immobilizer system (equipped models) immobilizer system parts replacement immobilizer antenna • remove: upper fairing assembly (see upper fairing assembly removal in the frame chapter) air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter) • di...

  • Page 609

    Electrical system 16-87 immobilizer system (equipped models) immobilizer amplifier replacement • remove the upper fairing assembly (see upper fairing assembly removal in the frame chapter). • disconnect the connector [a]. • pull out the immobilizer amplifier [b] together with the rub- ber protector ...

  • Page 610

    16-88 electrical system immobilizer system (equipped models) immobilizer system circuit 1. Ignition switch 2. Ecu 3. Immobilizer/kawasaki diagnostic system connector 4. Fuse box 5. Ignition fuse 15 a 6. Frame ground 7. Battery 12 v 8 ah 8. Main fuse 30 a 9. Meter unit 10. Immobilizer amplifier 11. I...

  • Page 611

    Electrical system 16-89 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 612

    16-90 electrical system switches and sensors water temperature sensor inspection • remove the water temperature sensor (see water tem- perature sensor removal/installation in the fuel system (dfi) chapter). • suspend the sensor [a] in a container of coolant so that the threaded portion is submerged....

  • Page 613

    Electrical system 16-91 switches and sensors • remove: bolt [a] lead [b] (free) speed sensor [c] speed sensor installation • run the lead [a] as shown in the figure. • apply a non-permanent locking agent to the threads of the speed sensor bolt, and tighten it. Torque - speed sensor bolt: 6.9 n·m (0....

  • Page 614

    16-92 electrical system switches and sensors • connect the test light [a] (12 v 3.4 w bulb in a socket with leads) and the 12 v battery [b] to the fuel pump lead connector [c]. Connections: battery (+) → 12 v 3.4 w bulb (one side) 12 v 3.4 w bulb (other side) → r/bk lead [d] battery (–) → bk/w lead ...

  • Page 615

    Electrical system 16-93 switches and sensors oxygen sensor installation (equipped models) caution never drop the oxygen sensor [a] especially on a hard surface. Such a shock to the unit can damage it. Do not touch the sensing part [b] to prevent oil contact. Oil contamination from hands can reduce s...

  • Page 616

    16-94 electrical system switches and sensors gear position switch installation • securely place the springs [a] and pins [b] into the holes [c] of the shift drum. • apply grease to the new o-ring [d]. • install the gear position switch [e] and holding plate [f]. • apply a non-permanent locking agent...

  • Page 617

    Electrical system 16-95 switches and sensors • set the hand tester [a] to the × 1 k Ω or × 100 Ω range and connect it to the terminals in the connector [b] and ground. ○ when changing the gear position from lower gear to higher gear, raise the rear wheel off the ground with the stand and rotate the ...

  • Page 618

    16-96 electrical system relay box relay box removal • remove the front seat cover (see seat cover removal in the frame chapter). • disconnect the connectors [a]. • pull out the relay box [b] from the rubber protector [c]. Note ○ the relay box has relays and diodes. The relays and diodes can not be r...

  • Page 619

    Electrical system 16-97 relay box diode circuit inspection • remove the relay box (see relay box removal). • check conductivity of the following pairs of terminals (see relay box internal circuit in this section). Diode circuit inspection tester connection 1-11, 2-11, 12-13, 12-15, 12-16, 13-14, 13-...

  • Page 620

    16-98 electrical system fuse 30 a main fuse removal • remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • disconnect the connector [a]. • pull out the main fuse [a] from the starter relay with needle nose pliers. Fuse box fuse removal • remove the front seat (see front s...

  • Page 621

    Electrical system 16-99 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 fuses ...

  • Page 623: Appendix

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

  • Page 624

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

  • Page 625

    Appendix 17-3 cable, wire, and hose routing 1. Attach the clamp on each marking of the clutch cable and throttle cable (accelerator) with the clutch cable positioned on the upper side. Clamp (larger diameter) → clutch cable clamp (smaller diameter) → throttle cable (accelerator) 2. Throttle cable (a...

  • Page 626

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

  • Page 627

    Appendix 17-5 cable, wire, and hose routing 1. Be careful not to press the throttle cables by the fuel tank. 2. Run the clutch cable near the engine side. 3. Run the clutch cable under the inlet air temperature sensor lead. 4. Run the secondary injector lead to the inside of the air cleaner housing ...

  • Page 628

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

  • Page 629

    Appendix 17-7 cable, wire, and hose routing 1. Fuel tank drain hose 2. Run the fuel tank breather hose as shown in the figure. 3. Run the fuel tank breather hose over the gear position switch lead and fuel pump lead. 4. Run the fuel tank drain hose and fuel tank breather hose over the battery negati...

  • Page 630

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

  • Page 631

    Appendix 17-9 cable, wire, and hose routing 1. Gear position switch lead 2. Sidestand switch lead 3. Make sure that each end of the fuel tank drain hose and fuel tank breather hose is out of the lower fairing. Keep each hose end away from the exhaust pipe. 4. Run the fuel tank drain hose and fuel ta...

  • Page 632

    17-10 appendix cable, wire, and hose routing 1. Run the reserve tank overflow hose under the alternator lead. 2. Run the reserve tank overflow hose into the clamp. 3. Run the reserve tank overflow hose to the inside of the frame..

  • Page 633

    Appendix 17-11 cable, wire, and hose routing 1. Reserve tank overflow hose 2. Air bleeder hose 3. Clamp 4. Clamp 5. 40° or more 6. Water hose 7. Run the reserve tank overflow hose, oxygen sensor lead (equipped models) and oil pressure switch lead into the clamp. 8. Clamp 9. Radiator overflow hose 10...

  • Page 634

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

  • Page 635

    Appendix 17-13 cable, wire, and hose routing 1. Install the water hose so that white paint mark faces left side. 2. Install the water hose so that white paint mark faces left side. 3. Install the clamp as shown in the figure. 4. Install the outlet hose as shown in the figure. 5. Water hose 6. Instal...

  • Page 636

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

  • Page 637

    Appendix 17-15 cable, wire, and hose routing 1. Air bleeder hose (straight side) 2. Install the air bleeder hose as shown in the figure. 3. Install the water hose as shown in the figure. 4. Install the clamp as shown in the figure. 5. Water hose 6. Install the clamp as shown in the figure. 7. Run th...

  • Page 638

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

  • Page 639

    Appendix 17-17 cable, wire, and hose routing 1. Install the engine ground terminal so that it touches to the stopper. 2. Install the engine ground cable as shown in the figure. 3. Rivet (fix the heat insulation rubber plate to the frame.) 4. Air cleaner drain hose 5. Breather hose 6. Water temperatu...

  • Page 640

    17-18 appendix cable, wire, and hose routing 1. Main harness side 2. Regulator/rectifier 3. Hold the idle adjusting screw cable end. 4. Hold the air cleaner drain hose. 5. Canister (california, southeast asia and thailand models).

  • Page 641

    Appendix 17-19 cable, wire, and hose routing 1. Run the oil pressure switch lead/crankshaft sensor lead to the inside of the water hose. 2. Run the oil pressure switch lead/crankshaft sensor lead into the clamp. 3. Oil pressure switch lead/crankshaft sensor lead 4. To heat insulation rubber plate.

  • Page 642

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

  • Page 643

    Appendix 17-21 cable, wire, and hose routing 1. Throttle cable (decelerator) 2. Throttle cable (accelerator) 3. Throttle body assy 4. Hold the alternator lead. 5. Run the gear position switch lead to the right side of the outlet hose. 6. Run the gear position switch lead between the water hoses. 7. ...

  • Page 644

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

  • Page 645

    Appendix 17-23 cable, wire, and hose routing 1. Meter unit lead 2. Hold the meter unit lead. 3. Left switch housing lead 4. Ignition switch lead 5. Immobilizer antenna lead (equipped models) 6. Left city light lead connector 7. Hold the left city light lead and front left turn signal light lead, ben...

  • Page 646

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

  • Page 647

    Appendix 17-25 cable, wire, and hose routing 1. Hang the front left turn signal lead on the bracket. 2. Immobilizer antenna lead (equipped models) 3. Ignition switch lead 4. Front left turn signal light lead 5. Hold the meter unit lead. 6. Hold the meter unit lead to the hook of the air inlet duct. ...

  • Page 648

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

  • Page 649

    Appendix 17-27 cable, wire, and hose routing 1. Speed sensor lead 2. Run the speed sensor lead to the hook of the engine sprocket cover. 3. Run the gear position switch lead to the inside of the fuel tank drain hose, fuel tank breather hose and water hose. 4. Run the air cleaner drain hose to the in...

  • Page 650

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

  • Page 651

    Appendix 17-29 cable, wire, and hose routing 1. Inlet air temperature sensor lead 2. Hold the right switch housing lead, radiator fun motor lead and alternator lead. 3. Stick coil 4. Subthrottle sensor lead connector 5. Main throttle sensor lead connector 6. Secondary fuel injector 7. Alternator lea...

  • Page 652

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

  • Page 653

    Appendix 17-31 cable, wire, and hose routing 1. Oxygen sensor lead connector (equipped models) 2. Hold the main harness and fix the clamp to the frame. 3. Battery negative (–) cable 4. Speed sensor lead 5. Hold the primary injector lead and water temperature sensor lead. 6. Fuel injector lead 7. Run...

  • Page 654

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

  • Page 655

    Appendix 17-33 cable, wire, and hose routing 1. Run the main harness between the exhaust butterfly valve actuator and rear fender. 2. Immobilizer (equipped models)/kawasaki diagnostic system connector 3. Relay box 4. Turn signal relay 5. Ecu 6. Fuse box 7. Exhaust butterfly valve actuator lead conne...

  • Page 656

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

  • Page 657

    Appendix 17-35 cable, wire, and hose routing 1. Run the rear left and right turn signal light leads and license plat light lead into the hole. 2. Hold the rear left and right turn signal light lead and license plat light lead. 3. Run the rear brake light switch lead to the outside of the exhaust but...

  • Page 658

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

  • Page 659

    Appendix 17-37 cable, wire, and hose routing 1. Exhaust butterfly valve cable (open) 2. Exhaust butterfly valve cable (close) 3. Run the exhaust butterfly valve cables into the clamp. 4. Run the exhaust butterfly valve cables to the inside of the rear brake light switch lead. 5. Align the exhaust bu...

  • Page 660

    17-38 appendix cable, wire, and hose routing 1. Clamp 2. Exhaust butterfly valve cable (open) 3. Exhaust butterfly valve cable (close) 4. Clamp 5. Clamp 6. Clamp 7. Front 8. View right side.

  • Page 661

    Appendix 17-39 cable, wire, and hose routing 1. Seat lock cable 2. Run the seat lock cable into the hole of the seat lock cover..

  • Page 662

    17-40 appendix cable, wire, and hose routing 1. Brake hoses 2. Clamps.

  • Page 663

    Appendix 17-41 cable, wire, and hose routing 1. Brake hose 2. Face the white paint mark outside. 3. View from b 4. Clamp 5. Section a-a.

  • Page 664

    17-42 appendix cable, wire, and hose routing california, southeast asia and thailand models.

  • Page 665

    Appendix 17-43 cable, wire, and hose routing 1. Green hose (from canister to air switching valve) 2. Red hose (from separator to fuel tank) 3. White hose (from separator to throttle body assy #2) 4. Blue hose (from separator to fuel tank) 5. Blue hose (from separator to canister) 6. Hang the front l...

  • Page 666

    17-44 appendix cable, wire, and hose routing california, southeast asia and thailand models.

  • Page 667

    Appendix 17-45 cable, wire, and hose routing 1. Run the blue hose and red hose under each lead in this position. 2. Run the white hose over each lead. 3. Run the blue hose and red hose under each lead. 4. Run the blue hose and red hose over the main harness, and under the inlet air temperature senso...

  • Page 668

    17-46 appendix cable, wire, and hose routing california, southeast asia and thailand models 1. Canister 2. Blue hose 3. Green hose 4. Hose 5. Fitting 6. Heat insulation plate 7. Protector side 8. Red hose 9. Blue hose 10. To fuel tank: red 11. To fuel tank: blue 12. White hose (to throttle body assy...

  • Page 669

    Appendix 17-47 cable, wire, and hose routing california, southeast asia and thailand models 1. Clamp 2. Clamps 3. Canister 4. Fuel tank 5. Throttle body assy 6. Throttle body assy #2 7. To air cleaner housing 8. Hose 9. To air switching valve 10. Hose 11. Green hose 12. White hose 13. Clamp 14. Sepa...

  • Page 670

    17-48 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 671

    Appendix 17-49 troubleshooting guide 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 gasket damaged cylinder head warped valve spring broken or weak valve not...

  • Page 672

    17-50 appendix troubleshooting guide compression high: carbon built up in combustion chamber engine load faulty: clutch slipping engine oil level too high engine oil viscosity too high drive train trouble brake dragging lubrication inadequate: engine oil level too low engine oil poor quality or inco...

  • Page 673

    Appendix 17-51 troubleshooting guide exhaust pipe leaking at cylinder head con- nection crankshaft runout excessive engine mounting portions loose crankshaft bearing worn primary gear worn or chipped camshaft chain tensioner trouble camshaft chain, sprocket, guide worn air suction valve damaged air ...

  • Page 674

    17-52 appendix troubleshooting guide tire air pressure too low front fork oil insufficient and/or leaking front fork oil viscosity too low 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 ...

  • Page 675

    Model application year model beginning frame no. 2009 zx600r9f jkazx4r1 □ 9a000001 or jkazx600rra000001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1417-01 printed in japan.