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Kawasaki VERSYS - Service Manual

Other manuals for VERSYS -: Brochure, Owner's Manual, Service Manual

Summary of VERSYS -

  • Page 1

    Versys 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: Versys

    Versys 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 division/consume...

  • Page 6

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

  • Page 7: Foreword

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

  • Page 9: General Information

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

  • Page 10

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

  • Page 11

    General information 1-3 before servicing 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 12

    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 13

    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 14

    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 15

    General information 1-7 model identification kle650b7f left side view kle650b7f right side view frame number engine number.

  • Page 16

    1-8 general information general specifications items kle650a7f, kle650b7f dimensions overall length 2 125 mm (83.7 in.) overall width 840 mm (33.1 in.) overall height 1 315 mm (51.8 in.) wheelbase 1 415 mm (55.7 in.) road clearance 180 mm (7.1 in.) seat height 840 mm (33.1 in.) dry mass: kle650a7f 1...

  • Page 17

    General information 1-9 general specifications items kle650a7f, kle650b7f valve timing: inlet: open 25° (btdc) close 54° (abdc) duration 260° exhaust: open 47° (bbdc) close 25° (atdc) duration 252° lubrication system forced lubrication (sem-dry sump) engine oil: type api se, sf or sg api sh, sj or s...

  • Page 18

    1-10 general information general specifications items kle650a7f, kle650b7f rim size: front 17 × 3.50 rear 17 × 4.50 front suspension: type telescopic fork (upside-down) wheel travel 150 mm (5.9 in.) rear suspension: type swingarm (uni-trak) wheel travel 145 mm (5.7 in.) brake type: front dual discs ...

  • Page 19

    General information 1-11 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 21: Periodic Maintenance

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

  • Page 22

    2-2 periodic maintenance lights and switches operation inspection........................................................................ 2-37 headlight aiming inspection ............................................................................................. 2-39 sidestand switch operation ins...

  • Page 23

    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 24

    2-4 periodic maintenance periodic maintenance chart frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) inspection every 1 (0.6) 6 (4) 12 (7.5) 18 (12) 24 (15) 30 (20) 36 (24) see page brake hose and pipe damage - inspect year • • • • • • • 2-31 brake hose and pipe installat...

  • Page 25

    Periodic maintenance 2-5 periodic maintenance chart periodic replacement parts frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) change/replace item every 1 (0.6) 12 (7.5) 24 (15) 36 (24) 48 (30) see page air cleaner element # 2 years 2-44 fuel hose 4 years • 2-44 coolant ...

  • Page 26

    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 27

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks throttle body assy holder bolts 12 1.2 106 in·lb cylinder bolt (m8) 27.5 2.8 20 mo,s cylinder nut (m10) 49 5.0 36 mo, s cylinder bolts (m6) 12 1.2 106 in·lb exhaust pipe manifold holder nuts 17 1.7 12 muffler b...

  • Page 28

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks crankcase bolt (m6, l = 32 mm) 19.6 2.0 14 s crankcase bolts (m6, l = 38 mm) 19.6 2.0 14 s crankcase bolts (m6, l = 45 mm) 19.6 2.0 14 s crankcase bolts (m8, l = 50 mm) 27.5 2.8 20 s crankcase bolts (m8, l = 60...

  • Page 29

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks front brake reservoir cap screws 1.5 0.15 13 in·lb front caliper mounting bolts 34 3.5 25 front master cylinder clamp bolts 8.8 0.90 78 in·lb bleed valve 7.8 0.80 69 in·lb brake hose banjo bolts 25 2.5 18 brake...

  • Page 30

    2-10 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks turn signal light lens screws 1.0 0.10 9 in·lb alternator cover bolts 9.8 1.0 87 in·lb alternator lead holding plate bolt 9.8 1.0 87 in·lb l alternator rotor bolt 155 15.8 114 mo engine ground cable terminal b...

  • Page 31

    Periodic maintenance 2-11 specifications item standard service limit fuel system (dfi) throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 1 300 ±50 r/min (rpm) – – – bypass screws (turn out) 0 ∼ 2 1/2 (for reference) – – – engine vacuum 37.9 ±1.3 kpa (285 ±10 mmhg) – – – air cleaner...

  • Page 32

    2-12 periodic maintenance specifications item standard service limit final drive drive chain slack 25 ∼ 35 mm (1.0 ∼ 1.4 in.) – – – drive chain wear (20-link length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) standard chain: make enuma – – – type ek520mvxl1 – – – link 114 links – – – bra...

  • Page 33

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

  • Page 34

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

  • Page 35

    Periodic maintenance 2-15 periodic maintenance procedures warning clean the element in a well-ventilated area, and make sure that there are no sparks or flame any- where near the working area. Because of the danger of highly flammable liquids, do not use gasoline or a low-flash point solvent to clea...

  • Page 36

    2-16 periodic maintenance periodic maintenance procedures • loosen the locknut [a] at the middle of the decelerator cable. • turn the adjuster [b] until there is no play when the throttle grip is completely closed. • tighten the locknut. • turn the accelerator cable adjuster until the proper amount ...

  • Page 37

    Periodic maintenance 2-17 periodic maintenance procedures if any one vacuum is not within the specification, turn in the bypass screws until it seats fully but not tightly. Special tool - pilot screw adjuster, e [a]: 57001-1603 caution do not over tighten them. They could be damaged, requiring repla...

  • Page 38

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

  • Page 39

    Periodic maintenance 2-19 periodic maintenance procedures • check that the hose joints are securely connected. ○ push and pull [a] the hose joint [b] back and forth more than two times, and make sure it is locked. If it does not locked, reinstall the hose joint. Warning make sure the hose joint is i...

  • Page 40

    2-20 periodic maintenance periodic maintenance procedures air suction system air suction system damage inspection • remove: fuel tank (see fuel tank removal in the fuel system chapter) fuel hose (see fuel hose replacement) • connect the following parts temporary. Fuel pump lead connector [a] fuel le...

  • Page 41

    Periodic maintenance 2-21 periodic maintenance procedures ○ measure the valve clearance of the valves for which the cams [a] are turned away from each other. • using the thickness gauge [a], measure the valve clear- ance between cam and valve lifter. Valve clearance standard: exhaust 0.22 ∼ 0.31 mm ...

  • Page 42

    2-22 periodic maintenance periodic maintenance procedures note ○ mark and record the valve lifter and shim locations so they can be reinstalled in their original positions. ○ if there is no clearance, select a shim which is several sizes smaller and then measure the clearance. • to select a new shim...

  • Page 43

    Periodic maintenance 2-23 periodic maintenance procedures valve clearance adjustment chart inlet valve 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where th...

  • Page 44

    2-24 periodic maintenance periodic maintenance procedures valve clearance adjustment chart exhaust valve 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where ...

  • Page 45

    Periodic maintenance 2-25 periodic maintenance procedures clutch clutch operation inspection • pull the clutch lever just enough to take up the free play [a]. • measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow,...

  • Page 46

    2-26 periodic maintenance periodic maintenance procedures wheel/tire damage inspection • remove any imbedded stones [a] or other foreign parti- cles [b] from tread. • visually inspect the tire for cracks and cuts, and replace the tire if necessary. Swelling or high spots indicate inter- nal damage, ...

  • Page 47

    Periodic maintenance 2-27 periodic maintenance procedures wheel bearing damage inspection • raise the front wheel off the ground with jack (see front wheel removal in the wheels/tires chapter). • turn the handlebar all the way to the right or left. • inspect the roughness of the front wheel bearing ...

  • Page 48

    2-28 periodic maintenance periodic maintenance procedures • apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the o-rings so that the o-rings will be coated with oil. • wipe off any excess oil. Oil applied areas [a] o-rings [b] drive chain...

  • Page 49

    Periodic maintenance 2-29 periodic maintenance procedures • insert a new cotter pin [a]. Note ○ when inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [b] up to next alignment. ○ it should be within 30°. ○ loosen once and t...

  • Page 50

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

  • Page 51

    Periodic maintenance 2-31 periodic maintenance procedures brake system brake fluid leak (brake hose and pipe) inspection • for models equipped with an abs, remove the rear fender front (see rear fender front removal in the frame chap- ter). • apply the brake lever or pedal and inspect the brake flui...

  • Page 52

    2-32 periodic maintenance periodic maintenance procedures brake operation inspection • inspect the operation of the front and rear brake by run- ning the vehicle on the dry road. If the brake operation is insufficiency, inspect the brake system. Warning when inspecting by running the vehicle, note a...

  • Page 53

    Periodic maintenance 2-33 periodic maintenance procedures • follow the procedure below to install the rear brake fluid reservoir cap correctly. ○ first, tighten the rear brake fluid reservoir cap [b] clock- wise [c] by hand until slight resistance is felt indicating that the cap is seated on the res...

  • Page 54

    2-34 periodic maintenance periodic maintenance procedures suspensions front forks/rear shock absorber operation inspection • pump the forks down and up [a] 4 or 5 times, and inspect the smooth stroke. If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see fron...

  • Page 55

    Periodic maintenance 2-35 periodic maintenance procedures steering system steering play inspection • raise the front wheel off the ground with jack (see front wheel removal in the wheels/tires chapter). • with the front wheel pointing straight ahead, alternately tap each end of the handlebar. The fr...

  • Page 56

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

  • Page 57

    Periodic maintenance 2-37 periodic maintenance procedures electrical system lights and switches operation inspection first step • turn on the ignition switch. • the following lights should go on according to below table. City lights [a] goes on taillight [b] goes on license plate light [c] goes on m...

  • Page 58

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

  • Page 59

    Periodic maintenance 2-39 periodic maintenance procedures • set the dimmer switch to high beam position. • the low beam [a] and high beam [b] headlights should go on. • the high beam indicator light (led) [c] should go on. If the high beam headlight and/or high beam indicator light (led) does not go...

  • Page 60

    2-40 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. Low beam [a] height of headlight ...

  • Page 61

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

  • Page 62

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

  • Page 63

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

  • Page 64

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

  • Page 65

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

  • Page 66

    2-46 periodic maintenance periodic maintenance procedures • place a container under the water pump drain bolt [a], then remove the drain bolt. • remove the radiator cap [a] in two steps. First turn the cap counterclockwise to the first stop. Then push and turn it further in the same direction and re...

  • Page 67

    Periodic maintenance 2-47 periodic maintenance procedures • fill the radiator up to the filler neck [a] with coolant. Note ○ pour in the coolant slowly so that it can expel the air from the engine and radiator. • check the cooling system for leaks. • tap the radiator hoses to force any air bubbles c...

  • Page 68

    2-48 periodic maintenance periodic maintenance procedures engine oil change • situate the motorcycle so that it is vertical after warming up the engine. • unscrew the oil filler plug [a]. • place on oil pan beneath the engine. • remove the engine oil drain bolt [a] to drain the oil. ○ the oil in the...

  • Page 69

    Periodic maintenance 2-49 periodic maintenance procedures • replace the filter with a new one. • apply engine oil to the gasket [a] before installation. • tighten the filter with the oil filter wrench. Torque - oil filter: 17.5 n·m (1.8 kgf·m, 13 ft·lb) note ○ hand tightening of the oil filter can n...

  • Page 70

    2-50 periodic maintenance periodic maintenance procedures • for models equipped with an abs, note the following. ○ remove: rear fender front (see rear fender front removal in the frame chapter) air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter) right rear frame co...

  • Page 71

    Periodic maintenance 2-51 periodic maintenance procedures • level the brake fluid reservoir. • remove the reservoir cap and diaphragm. • remove the rubber cap from the bleed valve [a] on the caliper. • attach a clear plastic hose [b] to the bleed valve, and run the other end of the hose into a conta...

  • Page 72

    2-52 periodic maintenance periodic maintenance procedures master cylinder rubber parts replacement front master cylinder disassembly • remove the front master cylinder (see front master cylin- der removal in the brakes chapter). • remove the reservoir cap and diaphragm, and pour the brake fluid into...

  • Page 73

    Periodic maintenance 2-53 periodic maintenance procedures • apply brake fluid to the new parts and to the inner wall of the cylinder. • take care not to scratch the piston or the inner wall of the cylinder. • tighten the brake lever pivot bolt and locknut. • apply silicone grease. Brake lever pivot ...

  • Page 74

    2-54 periodic maintenance periodic maintenance procedures • replace the fluid seals [a] with new ones. ○ apply brake fluid to the fluid seals, and install them into the cylinders by hand. • replace the dust seals [b] with new ones if they are dam- aged. ○ apply brake fluid to the dust seals, and ins...

  • Page 75

    Periodic maintenance 2-55 periodic maintenance procedures rear caliper assembly • clean the caliper parts except for the pads. Caution for cleaning of the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • install the bleed valve and rubber cap. Torque - bleed valve: 7.8 n·m (0...

  • Page 76

    2-56 periodic maintenance periodic maintenance procedures • insert the spark plug [a] vertically into the plug hole with the spark plug installed in the plug wrench [b]. Owner’s tool - spark plug wrench, 16 mm: 92110-1132 caution the insulator of the spark plug may break if when the wrench is inclin...

  • Page 77: Fuel System (Dfi)

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

  • Page 78

    3-2 fuel system (dfi) speed sensor (service code 24, 25)..................................................................................... 3-56 speed sensor removal/installation.................................................................................. 3-56 speed sensor inspection............

  • Page 79

    Fuel system (dfi) 3-3 fuel injector power source voltage inspection ................................................................ 3-92 fuel injector output voltage inspection ............................................................................ 3-93 injector signal test.......................

  • Page 80

    3-4 fuel system (dfi) exploded view.

  • Page 81

    Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 fuel pump bolts 9.8 1.0 87 in·lb l, s 2 right switch housing screws 3.5 0.36 31 in·lb 3 sidestand switch bolt 3.9 0.40 35 in·lb l 4. Injectors 5. Throttle body assy 6. Throttle cable (accelerator) 7. Throttle cable (de...

  • Page 82

    3-6 fuel system (dfi) exploded view.

  • Page 83

    Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 crankshaft sensor bolts 6.0 0.61 53 in·lb 2 oxygen sensor (europe models) 44.1 4.5 33 3 spark plugs 15 1.5 11 4 speed sensor bolt 7.8 0.80 69 in·lb 5 timing rotor bolt 40 4.1 30 6 water temperature sensor 12 1.2 106 in...

  • Page 84

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

  • Page 85

    Fuel system (dfi) 3-9 dfi system 1. Inlet air pressure sensor 2. Crankshaft sensor 3. Injector 4. Main throttle sensor 5. Delivery pipe 6. Subthrottle sensor 7. Subthrottle valve 8. Main throttle valve 9. Subthrottle valve actuator 10. Fuel pump 11. Pressure regulator 12. Fuel tank 13. Air cleaner e...

  • Page 86

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

  • Page 87

    Fuel system (dfi) 3-11 dfi system part name 1. Oxygen sensor (europe models) 2. Crankshaft sensor 3. Inlet air temperature sensor 4. Water temperature sensor 5. Water-proof joint e 6. Injectors 7. Vehicle-down sensor 8. Water-proof joint d 9. Inlet air pressure sensor 10. Main throttle sensor 11. Su...

  • Page 88

    3-12 fuel system (dfi) dfi system terminal names 1. Subthrottle valve actuator drive signal 2 2. Subthrottle valve actuator drive signal 1 3. Water temperature warning light signal 4. Unused 5. Oxygen sensor signal (europe models) 6. Speed sensor signal 7. Main throttle sensor signal 8. Inlet air pr...

  • Page 89

    Fuel system (dfi) 3-13 dfi parts location 1. Fi indicator light (led) 2. Ignition switch 3. Throttle body assy 4. Inlet air temperature sensor 5. Injectors 6. Fuel pump 7. Relay box (ecu main relay, fuel pump relay, radiator fan relay) 8. Fuse box (ecu fuse 15 a, oxygen sen- sor heater fuse 10 a) 9....

  • Page 90

    3-14 fuel system (dfi) specifications item standard digital fuel injection system idle speed 1 300 ±50 r/min (rpm) throttle body assy: type two barrel type bore 38 mm (1.50 in.) ecu (electronic control unit): make denso type digital memory type, with built in ic igniter, sealed with resin usable eng...

  • Page 91

    Fuel system (dfi) 3-15 specifications item standard subthrottle sensor: non-adjustable and non-removal input voltage dc 4.75 ∼ 5.25 v between bl and br/bk leads output voltage at idle throttle opening dc 0.4 ∼ 0.6 v between bl/w and br/bk leads output voltage at full throttle opening dc 3.825 ∼ 3.97...

  • Page 92

    3-16 fuel system (dfi) special tools and sealant oil pressure gauge, 5 kgf/cm²: 57001-125 fork oil level gauge: 57001-1290 hand tester: 57001-1394 throttle sensor setting adapter #1: 57001-1400 peak voltage adapter: 57001-1415 needle adapter set: 57001-1457 throttle sensor setting adapter: 57001-153...

  • Page 93

    Fuel system (dfi) 3-17 special tools and sealant oxygen sensor measuring adapter: 57001-1682 kawasaki bond (silicone sealant): 56019-120

  • Page 94

    3-18 fuel system (dfi) dfi servicing precautions dfi servicing precautions there are a number of important precautions that should be followed servicing the dfi system. ○ 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 95

    Fuel system (dfi) 3-19 dfi servicing precautions ○ to maintain the correct fuel/air mixture (f/a), there must be no inlet air leaks in the dfi system. Be sure to install the oil filler plug [a] after filling the engine oil. Clutch cover [b] torque - oil filler plug: hand-tighten.

  • Page 96

    3-20 fuel system (dfi) troubleshooting the dfi system outline outline when an abnormality in the dfi system occurs, the fi indicator light (led) goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ecu (electronic control unit). With...

  • Page 97

    Fuel system (dfi) 3-21 troubleshooting the dfi system ○ the dfi part connectors [a] have seals [b], including the ecu. • join the connector and insert the needle adapters [c] inside the seals [b] from behind the connector until the adapter reaches the terminal. Special tool - needle adapter set: 570...

  • Page 98

    3-22 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 99

    Fuel system (dfi) 3-23 troubleshooting the dfi system ○ there are two ways to inspect the dfi system. One is voltage check method and the other is resistance check method. (voltage check method) ○ this method is conducted by measuring the input voltage [b] to a sensor [a] first, and then the output ...

  • Page 100

    3-24 fuel system (dfi) troubleshooting the dfi system dfi diagnosis flow chart inquiries to rider 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...

  • Page 101

    Fuel system (dfi) 3-25 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 102

    3-26 fuel system (dfi) troubleshooting the dfi system □ other □ spark plug loose (tighten it) □ spark plug dirty, broken, or gap maladjusted (remedy it) □ spark plug incorrect (replace it) □ knocking (fuel poor quality or incorrect, → use high-octane gasoline) □ brake dragging □ clutch slipping □ en...

  • Page 103

    Fuel system (dfi) 3-27 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. ○ the ecu may be involved in the dfi electri...

  • Page 104

    3-28 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) clutch lever not pulled in and gear not in neutral whether sidestand up or not pull the lever in and shift the gear in neutral. Though clutch lever pulled in, sidestand up and gear not in neutral si...

  • Page 105

    Fuel system (dfi) 3-29 dfi system troubleshooting guide symptoms or possible causes actions (chapter) no valve clearance adjust (see chapter 2). Valve guide worn inspect and replace (see chapter 5). Valve spring broken or weak inspect and replace (see chapter 5). Valve not seating properly (valve be...

  • Page 106

    3-30 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) engine stalls easily: fuel pump trouble inspect (see chapter 3). Fuel injector trouble inspect (see chapter 3). Main throttle sensor trouble inspect (see chapter 3). Fuel pressure too low or too hig...

  • Page 107

    Fuel system (dfi) 3-31 dfi system troubleshooting guide symptoms or possible causes actions (chapter) loose terminal of battery (–) cable or engine ground lead inspect and repair (see chapter 16). Delay of ignition timing inspect crankshaft sensor and ic igniter in ecu (see chapter 16). Poor acceler...

  • Page 108

    3-32 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) inlet air temperature sensor trouble inspect (see chapter 3). Water temperature sensor trouble inspect (see chapter 3). Inlet air pressure sensor trouble inspect (see chapter 3). Fuel injector troub...

  • Page 109

    Fuel system (dfi) 3-33 dfi system troubleshooting guide symptoms or possible causes actions (chapter) throttle body assy o-ring damaged replace (see chapter 3). Fuel tank air vent obstructed inspect and repair (see chapter 3). Fuel line clogged inspect and repair (see chapter 3). Fuel pump operates ...

  • Page 110

    3-34 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) drive train trouble inspect drive chain (see chapter 2) and sprockets (see chapter 11). Camshaft cam worn inspect and replace (see chapter 5). Air switching valve trouble inspect and replace (see ch...

  • Page 111

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

  • Page 112

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

  • Page 113

    Fuel system (dfi) 3-37 self-diagnosis.

  • Page 114

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

  • Page 115

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

  • Page 116

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

  • Page 117

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

  • Page 118

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

  • Page 119

    Fuel system (dfi) 3-43 main throttle sensor (service code 11) • if the input voltage is less than the standard, remove the ecu and check the wiring between these connectors. ○ disconnect the ecu and sensor connectors. Wiring connection ecu connector [a] ←→ main throttle sensor connector [b] bl lead ...

  • Page 120

    3-44 fuel system (dfi) main throttle sensor (service code 11) if the output voltage is normal, check the wiring for conti- nuity. ○ disconnect the ecu and sensor connectors. Wiring connection ecu connector [a] ←→ main throttle sensor connector [b] y/w lead (ecu terminal 7) br/bk lead (ecu terminal 2...

  • Page 121

    Fuel system (dfi) 3-45 main throttle sensor (service code 11) main throttle sensor circuit 1. Ecu 2. Water-proof joint e 3. Water-proof joint d 4. Main throttle sensor.

  • Page 122

    3-46 fuel system (dfi) inlet air pressure sensor (service code 12) caution never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Inlet air pressure sensor removal • remove the left middle fairing (see middle fairing re- moval in the frame chapter). • disconnect...

  • Page 123

    Fuel system (dfi) 3-47 inlet air pressure sensor (service code 12) inlet air pressure sensor output voltage inspection note ○ the output voltage changes according to the local at- mospheric pressure. • measure the output voltage at the ecu in the same way as input voltage inspection. Note the follow...

  • Page 124

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

  • Page 125

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

  • Page 126

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

  • Page 127

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

  • Page 128

    3-52 fuel system (dfi) inlet air temperature sensor (service code 13) inlet air temperature sensor resistance inspection • remove the inlet air temperature sensor (see inlet air temperature sensor removal/installation). • suspend the sensor [a] in a container of machine oil so that the heat-sensitiv...

  • Page 129

    Fuel system (dfi) 3-53 water temperature sensor (service code 14) water temperature sensor removal/installation caution never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • drain the coolant (see coolant change in the periodic maintenance chapter). • disco...

  • Page 130

    3-54 fuel system (dfi) water temperature sensor (service code 14) water temperature sensor resistance inspection • refer to the water temperature sensor inspection in the electrical system chapter. Water temperature sensor circuit 1. Ecu 2. Water temperature sensor 3. Water-proof joint e 4. Meter un...

  • Page 131

    Fuel system (dfi) 3-55 crankshaft sensor (service code 21) start the engine and switch the diagnosis mode to dealer 1 mode to know all the problem that the dfi system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of ...

  • Page 132

    3-56 fuel system (dfi) speed sensor (service code 24, 25) speed sensor removal/installation • refer to the speed sensor removal/installation in the electrical system chapter. Speed sensor inspection • refer to the speed sensor inspection in the electrical system chapter. Speed sensor input voltage i...

  • Page 133

    Fuel system (dfi) 3-57 speed sensor (service code 24, 25) speed sensor output voltage inspection • before this inspection, inspect the input voltage (see speed sensor input voltage inspection). Note ○ be sure the battery is fully charged. • turn the ignition switch off. • disconnect the speed sensor...

  • Page 134

    3-58 fuel system (dfi) speed sensor (service code 24, 25) speed sensor circuit 1. Ecu 2. Speed sensor 3. Meter unit 4. Water-proof joint b 5. Frame ground 6. Joint connector.

  • Page 135

    Fuel system (dfi) 3-59 vehicle-down sensor (service code 31) vehicle-down sensor removal caution never drop the vehicle-down sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove: bolts [a] connector [b] vehicle-down sensor [c] vehicle-down sensor installation • th...

  • Page 136

    3-60 fuel system (dfi) vehicle-down sensor (service code 31) • remove the vehicle-down sensor (see vehicle-down sensor removal). ○ do not disconnect the sensor connector. • connect a digital meter [a] to the connector with needle adapter set [b]. Special tool - needle adapter set: 57001-1457 vehicle...

  • Page 137

    Fuel system (dfi) 3-61 vehicle-down sensor (service code 31) vehicle-down sensor circuit 1. Ecu 2. Water-proof joint e 3. Vehicle-down sensor 4. Water-proof joint d.

  • Page 138

    3-62 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 139

    Fuel system (dfi) 3-63 subthrottle sensor (service code 32) if the input voltage is normal, check the sensor output voltage. If the input voltage is less than the standard, remove the ecu and check the wiring between these connectors. ○ disconnect the ecu and sensor connectors. Wiring connection ecu...

  • Page 140

    3-64 fuel system (dfi) subthrottle sensor (service code 32) if the output voltage is normal, check the wiring for conti- nuity. ○ disconnect the ecu and sensor connectrs. Wiring connection ecu connector [a] ←→ subthrottle sensor connector [b] bl/w lead (terminal 24) br/bk lead (terminal 28) if the w...

  • Page 141

    Fuel system (dfi) 3-65 subthrottle sensor (service code 32) subthrottle sensor circuit 1. Ecu 2. Water-proof joint e 3. Water-proof joint d 4. Subthrottle sensor.

  • Page 142

    3-66 fuel system (dfi) oxygen sensor-not activated (service code 33) (europe models) oxygen sensor removal/installation • refer to the oxygen sensor removal/installation in the electrical system chapter. Oxygen sensor inspection • warm up the engine thoroughly until the radiator fan starts. • turn t...

  • Page 143

    Fuel system (dfi) 3-67 oxygen sensor-not activated (service code 33) (europe models) oxygen sensor circuit 1. Ecu 2. Oxygen sensor 3. Water-proof joint e 4. Water-proof joint c 5. Oxygen sensor heater fuse 10 a 6. Main fuse 30 a 7. Battery 8. Frame ground 9. Joint connector.

  • Page 144

    3-68 fuel system (dfi) stick coils #1, #2: (service code 51, 52) stick coil #1: service code 51 stick coil #2: service code 52 stick coil removal/installation caution never drop the stick coils, especially on a hard sur- face. Such a shock to the stick coil can damage it. • refer to the stick coil (...

  • Page 145

    Fuel system (dfi) 3-69 stick coils #1, #2: (service code 51, 52) stick coil circuit 1. Ecu 2. Water-proof joint c 3. Stick coils 4. Engine stop switch 5. Ignition switch 6. Ignition fuse 10 a 7. Main fuse 30 a 8. Battery 9. Frame ground 10. Joint connector.

  • Page 146

    3-70 fuel system (dfi) radiator fan relay (service code 56) radiator fan relay removal/installation • radiator fan relay is built in the relay box [a]. • remove the relay box (see relay box removal in the electrical system chapter). Radiator fan relay inspection • refer to the relay circuit inspecti...

  • Page 147

    Fuel system (dfi) 3-71 subthrottle valve actuator (service code 62) subthrottle valve actuator removal caution do not remove the subthrottle valve actuator [a] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface. Such a sh...

  • Page 148

    3-72 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. • connect the peak voltage adapter [a] and a digital meter [b] to the connector [c], using the needle a...

  • Page 149

    Fuel system (dfi) 3-73 air switching valve (service code 64) air switching valve removal/installation • refer to the air switching valve removal/installation in the engine top end chapter. Air switching valve inspection • refer to the air switching valve operation test/unit test in the electrical sy...

  • Page 150

    3-74 fuel system (dfi) oxygen sensor heater (service code 67) (europe models) oxygen sensor heater removal/installation the oxygen sensor heater is bult in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see oxygen sensor removal in the electrical system chap...

  • Page 151

    Fuel system (dfi) 3-75 oxygen sensor heater (service code 67) (europe models) if the tester reading is specified, check the power source voltage inspection. Note ○ be sure the battery is fully charged. • disconnect the oxygen sensor connector and connect the harness adapter [a] between these connect...

  • Page 152

    3-76 fuel system (dfi) oxygen sensor heater (service code 67) (europe models) oxygen sensor circuit 1. Ecu 2. Oxygen sensor 3. Water-proof joint e 4. Water-proof joint c 5. Oxygen sensor heater fuse 10 a 6. Main fuse 30 a 7. Battery 8. Frame ground 9. Joint connector.

  • Page 153

    Fuel system (dfi) 3-77 oxygen sensor-incorrect output voltage (service code 94) (europe models) oxygen sensor removal/installation • refer to the oxygen sensor removal/installation in the electrical system chapter. Oxygen sensor inspection • warm up the engine thoroughly until the radiator fan start...

  • Page 154

    3-78 fuel system (dfi) oxygen sensor-incorrect output voltage (service code 94) (europe models) oxygen sensor circuit 1. Ecu 2. Oxygen sensor 3. Water-proof joint e 4. Water-proof joint c 5. Oxygen sensor heater fuse 10 a 6. Main fuse 30 a 7. Battery 8. Frame ground 9. Joint connector.

  • Page 155

    Fuel system (dfi) 3-79 fi indicator light (led) inspection flow chart.

  • Page 156

    3-80 fuel system (dfi) fi indicator light (led) fi indicator light (led) inspection • remove the meter unit (see meter unit removal in the electrical system chapter). • using two auxiliary leads, supply battery power to the fi indicator light (led) [a]. 12 v battery [b] fi indicator light (led) chec...

  • Page 157

    Fuel system (dfi) 3-81 ecu caution never drop the ecu, especially on a hard surface. Such a shock to the ecu can damage it. Ecu removal • remove the seat covers (see seat cover removal in the frame chapter). • open the clamps [a]. • disconnect the connectors [b]. • remove the bolts [c]. • for equipp...

  • Page 158

    3-82 fuel system (dfi) ecu • disconnect the ecu connectors [a] and remove the ecu [b]. Ecu installation • install: ecu [a] (in rubber protector [b]) ecu connectors [c] • fit [a] the bracket on the ecu as shown. • install the removed parts (see appropriate chapters). Ecu power supply inspection • vis...

  • Page 159

    Fuel system (dfi) 3-83 ecu • check the ecu power source voltage with a digital meter [a]. ○ position the terminal in accordance with terminal numbers of ecu connector [b] in this chapter figure. Battery [c] ecu power source inspection meter connections: between terminal 16 (br/w) and battery (–) ter...

  • Page 160

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

  • Page 161

    Fuel system (dfi) 3-85 fuel line fuel pressure inspection note ○ this inspection can determine which trouble the dfi system has, mechanical or electrical trouble. ○ it is preferable to measure the fuel pressure while run- ning the motorcycle just when trouble occurred in order to know symptom well. ...

  • Page 162

    3-86 fuel system (dfi) fuel line • start the engine, and let it idle. • measure the fuel pressure with the engine idling. Fuel pressure (idling) standard: 294 kpa (3.0 kgf/cm², 43 psi) note ○ the gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. If...

  • Page 163

    Fuel system (dfi) 3-87 fuel line • open the fuel tank cap [a] to lower the pressure in the tank. • be sure to place a piece of cloth around the fuel pump outlet pipe. • remove the fuel hose from the fuel pump (see fuel tank removal). Warning be prepared for fuel spillage; any spilled fuel must be co...

  • Page 164

    3-88 fuel system (dfi) fuel pump fuel pump removal caution never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. Warning gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from an...

  • Page 165

    Fuel system (dfi) 3-89 fuel pump • replace the fuel pump gasket [a] with a new one. • apply a non-permanent locking agent to the threads of the fuel pump bolts. • tighten the fuel pump bolts to a snug fit, tighten them alternating diagonally. Torque - fuel pump bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) •...

  • Page 166

    3-90 fuel system (dfi) fuel pump • connect the hand tester (× dc 25 v) to the fuel pump connector [a] with needle adapter set. Special tools - hand tester: 57001-1394 needle adapter set: 57001-1457 pump operating voltage at pump connections to pump connectors tester (+) → w/r lead tester (–) → bk/y ...

  • Page 167

    Fuel system (dfi) 3-91 fuel pump fuel pump circuit 1. Ecu 2. Water-proof joint c 3. Engine stop switch 4. Ignition switch 5. Water-proof joint a 6. Ecu fuse 15 a 7. Ignition fuse 10 a 8. Ecu main relay 9. Fuel pump relay 10. Main fuse 30 a 11. Battery 12 v10 ah 12. Frame ground 13. Fuel pump 14. Joi...

  • Page 168

    3-92 fuel system (dfi) fuel injectors removal/installation • refer to the throttle body assy disassembly/assembly. Audible inspection • start the engine. • apply the tip of a screwdriver [a] to the injector [b]. Put the grip end onto your ear, and listen whether the injector is clicking or not. ○ a ...

  • Page 169

    Fuel system (dfi) 3-93 fuel injectors if the meter doesn’t read as specified, check the following. Main fuse 30 a (see fuse inspection in the electrical system chapter) fuel pump relay (see relay circuit inspection in the electrical system chapter) power source wiring (see wiring diagram below) ○ to...

  • Page 170

    3-94 fuel system (dfi) fuel injectors injector signal test • prepare two test light sets with terminals as shown. Rating of bulb [a]: 12 v × 3 ∼ 3.4 w terminal width [b]: 1.8 mm (0.071 in.) terminal thickness [c]: 0.8 mm (0.031 in.) caution do not use larger terminals than specified above. A larger ...

  • Page 171

    Fuel system (dfi) 3-95 fuel injectors injector resistance inspection • remove: fuel tank (see fuel tank removal) air cleaner housing (see air cleaner housing removal) • disconnect the connector from the injector [a]. • measure the injector resistance with the hand tester [b]. Special tool - hand tes...

  • Page 172

    3-96 fuel system (dfi) fuel injectors • check the injector fuel line for leakage as follows. ○ connect a commercially available vacuum/pressure pump [a] to the nipple of the delivery pipe [b] with a high-pressure fuel hose [c] (both ends connected with the clamps [d]) as shown. Torque - fuel hose cl...

  • Page 173

    Fuel system (dfi) 3-97 fuel injectors fuel injector circuit 1. Ecu 2. Fuel injectors 3. Water-proof joint c 4. Engine stop switch 5. Ignition switch 6. Water-proof joint a 7. Ecu fuse 15 a 8. Ignition fuse 10 a 9. Ecu main relay 10. Fuel pump relay 11. Main fuse 30 a 12. Battery 12 v10 ah 13. Frame ...

  • Page 174

    3-98 fuel system (dfi) throttle grip and cables throttle grip free play inspection • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Throttle grip free play adjustment • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Thro...

  • Page 175

    Fuel system (dfi) 3-99 throttle body assy idle speed inspection • refer to the idle speed inspection in the periodic main- tenance chapter. Engine vacuum synchronization inspection/ad- justment • refer to the engine vacuum synchronization inspection in the periodic maintenance chapter. Throttle body...

  • Page 176

    3-100 fuel system (dfi) throttle body assy • remove the throttle case [a] to make a throttle cable slack. • remove the throttle cable lower ends [a] from the throttle pulley. • pull off the throttle body assy from the holder. • after removing the throttle body assy, stuff pieces of lint -free, clean...

  • Page 177

    Fuel system (dfi) 3-101 throttle body assy • fit the accelerator cable end [a] and the decelerator cable end [b] into the throttle pulley. • check fuel leakage from the throttle body assy. Warning fuel spilled from the carburetors is hazardous. • apply a thin coating of grease to the throttle cable ...

  • Page 178

    3-102 fuel system (dfi) throttle body assy • remove: throttle body assy (see throttle body assy removal) screws [a] delivery pipe [b] fuel injectors [c] throttle body assy assembly • replace the o-rings [a] and seals [b] with the new ones. • before assembling, blow away dirt or dust from the throttl...

  • Page 179

    Fuel system (dfi) 3-103 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 180

    3-104 fuel system (dfi) air cleaner • unscrew the bolts [a] and remove the air cleaner housing [b]. Air cleaner housing installation • install the clamp on the breather hose [a] so that its pinch heads [b] face the left..

  • Page 181

    Fuel system (dfi) 3-105 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 182

    3-106 fuel system (dfi) fuel tank • disconnect: fuel pump lead connector [a] fuel level sensor lead connector [b] • remove the fuel drain hose [c]. • be sure to place a piece of cloth [a] around the fuel hose joint. • insert a minus screwdriver [b] into the slit [c] on the joint lock. • turn the dri...

  • Page 183

    Fuel system (dfi) 3-107 fuel tank fuel tank installation • note the above warning (see fuel tank removal). • route the hoses correctly (see cable, wire, and hose routing in the appendix chapter). • check that the rubber dampers [a] are on the frame and the fuel tank. • check that the dampers [a] are...

  • Page 184

    3-108 fuel system (dfi) fuel tank fuel tank and cap inspection • visually inspect the gasket [a] on the tank cap for any damage. Replace the gasket if it is damaged. • check to see if the water drain pipe [b] and fuel breather pipe [c] in the tank is not clogged. Check the tank cap breather also. If...

  • Page 185: Cooling System

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

  • Page 186

    4-2 cooling system exploded view.

  • Page 187

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 baffle plate bolts 5.9 0.60 52 in·lb 2 radiator bolt 15 1.5 11 3 radiator hose clamp screws 2.0 0.20 18 in·lb 4 thermostat housing bolts 9.8 1.0 87 in·lb 5 water pump cover bolts 9.8 1.0 87 in·lb 6 water pump drain bolt 9...

  • Page 188

    4-4 cooling system coolant flow chart.

  • Page 189

    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 190

    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 191

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

  • Page 192

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

  • Page 193

    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 194

    4-10 cooling system water pump water pump removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: radiator hose [a] water pump cover bolts [b] right lower fairing bracket [c] water pump cover [d] • shift the transmission into 1st gear. • while applying the rea...

  • Page 195

    Cooling system 4-11 water pump • install the water pump cover, being careful of the two dowel pins [a]. • install the right lower fairing bracket and tighten the water pump cover bolts. Torque - water pump cover bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) mechanical seal inspection • remove the impeller (s...

  • Page 196

    4-12 cooling system water pump • press the mechanical seal [a] out of the housing with a bearing driver [b]. Special tool - bearing driver set: 57001-1129 water pump housing assembly • apply high-temperature grease [a] to the new oil seal [b]. • press the oil seal into the housing with a bearing dri...

  • Page 197

    Cooling system 4-13 radiator radiator and radiator fan removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove the left front frame cover (see front frame cover removal in the frame chapter). • open the clamp [a]. • disconnect the radiator fan lead connector [b...

  • Page 198

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

  • Page 199

    Cooling system 4-15 radiator radiator inspection • remove the radiator (see radiator and radiator fan re- moval). • check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [a] are deformed, carefully straighten them. If the air passages of the radiator cor...

  • Page 200

    4-16 cooling system radiator radiator filler neck inspection • remove the radiator cap (see coolant change in the pe- riodic maintenance chapter). • check the radiator filler neck for signs of damage. • check the condition of the top and bottom sealing seats [a] in the filler neck. They must be smoo...

  • Page 201

    Cooling system 4-17 thermostat thermostat removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove the left front frame cover (see front frame cover removal in the frame chapter). • disconnect the horn leads [a]. • remove: horn bolt [b] horn [c] • remove: radiat...

  • Page 202

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

  • Page 203

    Cooling system 4-19 hose and pipes hose installation • install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • run the hoses (see cable, wire, and hose routing sec- tion in the appendix chapter). • install the clamp [a] as nea...

  • Page 204

    4-20 cooling system water temperature sensor caution the water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it. Water temperature sensor removal/installation • refer to the water temperature sensor removal/instal- lat...

  • Page 205: Engine Top End

    Engine top end 5-1 5 engine top end table of contents exploded view........................................................................................................................ 5-3 exhaust system identification .................................................................................

  • Page 206

    5-2 engine top end piston ring thickness ...................................................................................................... 5-43 piston ring end gap ........................................................................................................ 5-44 throttle body assy ho...

  • Page 207

    Engine top end 5-3 exploded view dummy page.

  • Page 208

    5-4 engine top end exploded view.

  • Page 209

    Engine top end 5-5 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 2 baffle plate bolts 5.9 0.60 52 in·lb 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 9.8 1.0...

  • Page 210

    5-6 engine top end exploded view.

  • Page 211

    Engine top end 5-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 cylinder bolt (m8) 27.5 2.8 20 mo,s 2 cylinder nut (m10) 49 5.0 36 mo, s 3 cylinder bolts (m6) 12 1.2 106 in·lb 4 exhaust pipe manifold holder nuts 17 1.7 12 5 muffler body mounting bolt (front) 20 2.0 15 6 muffler body m...

  • Page 212

    5-8 engine top end exhaust system identification exhaust system kle650a7f, kle650b7f full: full power h: honeycomb type catalyst silencer [a] with hole [b] for oxygen sensor [c].

  • Page 213

    Engine top end 5-9 exhaust system identification muffler body mark position [a] manifold mark position [a].

  • Page 214

    5-10 engine top end specifications item standard service limit camshafts cam height: exhaust 35.343 ∼ 35.457 mm (1.3915 ∼ 1.3959 in.) 35.24 mm (1.387 in.) inlet 35.843 ∼ 35.957 mm (1.4111 ∼ 1.4156 in.) 35.74 mm (1.407 in.) camshaft journal, camshaft cap clearance 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in...

  • Page 215

    Engine top end 5-11 specifications item standard service limit valve spring free length: exhaust 41.9 mm (1.65 in.) 40.3 mm (1.587 in.) inlet 41.9 mm (1.65 in.) 40.3 mm (1.587 in.) cylinder, pistons cylinder inside diameter 82.994 ∼ 83.006 mm (3.2675 ∼ 3.2679 in.) 83.10 mm (3.272 in.) piston diamete...

  • Page 216

    5-12 engine top end special tools and sealant compression gauge, 20 kgf/cm²: 57001-221 valve spring compressor assembly: 57001-241 valve seat cutter, 45° - 35: 57001-1116 valve seat cutter, 32° - 30: 57001-1120 valve seat cutter, 32° - 35: 57001-1121 valve seat cutter, 60° - 30: 57001-1123 valve sea...

  • Page 217

    Engine top end 5-13 special tools and sealant compression gauge adapter, m10 × 1.0: 57001-1317 valve seat cutter holder, 4.5: 57001-1330 valve guide arbor, 4.5: 57001-1331 valve guide reamer, 4.5: 57001-1333 piston pin puller: 57001-1568 piston pin puller adapter c: 57001-1657 kawasaki bond (silicon...

  • Page 218

    5-14 engine top end clean air system air suction valve removal • remove: air switching valve (see air switching valve removal) air suction valve cover bolts [a] clamp [b] air suction valve cover [c] • remove the air suction valve [a]. Air suction valve installation • install the air suction valve [a...

  • Page 219

    Engine top end 5-15 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 220

    5-16 engine top end clean air system air switching valve unit test • refer to the air switching valve unit test in the electrical system chapter. Clean air system hose inspection • be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the air cl...

  • Page 221

    Engine top end 5-17 cylinder head cover cylinder head cover removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter) air suction valve (see air suction valve removal) stick coils (see s...

  • Page 222

    5-18 engine top end cylinder head cover cylinder head cover installation • replace the head cover gasket [a] with a new one. • apply silicone sealant [b] to the cylinder head as shown. Sealant - kawasaki bond (silicone sealant): 92104-0004 • replace the plug hole gaskets [a] with new ones. • be sure...

  • Page 223

    Engine top end 5-19 cylinder head cover • be sure that the dampers [a] of the baffle plate is in posi- tion. • tighten: torque - baffle plate bolts: 5.9 n·m (0.60 kgf·m, 52 in·lb).

  • Page 224

    5-20 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 225

    Engine top end 5-21 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 tensioner body [d]. • install the tensioner body so that the stopper [a] faces up...

  • Page 226

    5-22 engine top end camshaft, camshaft chain camshaft removal • remove: cylinder head cover (see cylinder head cover re- moval) timing inspection cap [a] timing rotor bolt cap [b] • using a wrench on the timing rotor bolt, turn the crank- shaft clockwise until the 2/t mark line [a] on the timing rot...

  • Page 227

    Engine top end 5-23 camshaft, camshaft chain • remove the camshaft chain tensioner (see camshaft chain tensioner removal). • loosen the camshaft cap bolts as shown sequence [1 ∼ 12 ] in the figure, and remove them. • remove: camshaft caps [a] camshafts [b] caution the crankshaft may be turned while ...

  • Page 228

    5-24 engine top end camshaft, camshaft chain camshaft installation • replace the plug hole gaskets [a] with new ones. • be sure to install the following parts. Plug hole gaskets dowel pins [b] • install the cam sprockets so that the marked (“in" and “ex”) side faces to the outward. ○ the inlet [a] a...

  • Page 229

    Engine top end 5-25 camshaft, camshaft chain • using a wrench on the timing rotor bolt, turn the crank- shaft clockwise until the 2/t mark line [a] on the timing rotor is aligned with the notch [b] in the edge of the timing inspection hole [c] in the clutch cover. Caution the crankshaft may be turne...

  • Page 230

    5-26 engine top end camshaft, camshaft chain • before installing the camshaft caps, install the camshaft chain tensioner body temporally (see camshaft chain tensioner installation). • install the camshaft caps as shown. Note ○ the exhaust cap has a “ex” mark [a] and the inlet cap has a “in” mark [b]...

  • Page 231

    Engine top end 5-27 camshaft, camshaft chain camshaft, camshaft cap wear • remove the camshaft caps (see camshaft removal). • cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position. • tighten the camshaft cap bolts to the s...

  • Page 232

    5-28 engine top end camshaft, camshaft chain camshaft chain removal • split the crankcase (see crankcase splitting in the crank- shaft/transmission chapter). • remove the camshaft chain [a] from the crankshaft sprocket..

  • Page 233

    Engine top end 5-29 cylinder head cylinder compression measurement note ○ use the battery which is fully charged. • warm up the engine thoroughly. • stop the engine. • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) air cleaner housing (see air cleaner housing removal in t...

  • Page 234

    5-30 engine top end cylinder head cylinder head removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: exhaust pipes (see exhaust pipe removal) cylinder head cover (see cylinder head cover re- moval) camshafts (see camshaft removal) throttle body assy (see th...

  • Page 235

    Engine top end 5-31 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 a new cylinder head gasket [a] and dowel pins [b]. • apply molybdenum disulfide o...

  • Page 236

    5-32 engine top end cylinder head • tighten the m6 cylinder head bolts and m6 cylinder bolts [a]. Torque - cylinder head bolts (m6): 12 n·m (1.2 kgf·m, 106 in·lb) cylinder bolts (m6): 12 n·m (1.2 kgf·m, 106 in·lb) • install the front camshaft chain guide [a]. ○ insert the end [b] of front camshaft c...

  • Page 237

    Engine top end 5-33 valves valve clearance inspection • refer to the valve clearance inspection in the periodic maintenance chapter. Valve clearance adjustment • refer to the valve clearance adjustment in the periodic maintenance chapter. Valve removal • remove cylinder head (see cylinder head remov...

  • Page 238

    5-34 engine top end valves valve guide installation • apply engine oil to the valve guide outer surface before installation. • heat the area around the valve guide hole to about 120 ∼ 150°c (248 ∼ 302°f). • drive the valve guide in from the top of the head using the valve guide arbor. The flange sto...

  • Page 239

    Engine top end 5-35 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 240

    5-36 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 241

    Engine top end 5-37 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 242

    5-38 engine top end valves if the seat width is too wide, make the 60° or 55° [a] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. • grind the seat at a 60° or 55° angle until the seat width is within the specified range. ○ to make...

  • Page 243

    Engine top end 5-39 valves.

  • Page 244

    5-40 engine top end cylinder, pistons cylinder removal • remove: cylinder head (see cylinder head removal) front engine mounting bolts (both sides) [a] (see en- gine removal in the engine removal/installation chap- ter) front engine brackets (both sides) [b] (see engine re- moval in the engine remov...

  • Page 245

    Engine top end 5-41 cylinder, pistons • remove the piston pins. Special tools - piston pin puller [a]: 57001-1568 piston pin puller adapter c [d]: 57001-1657 center bolt [b] shell of piston [c] • remove the pistons. • carefully spread the ring opening with your thumbs and then push up on the opposit...

  • Page 246

    5-42 engine top end cylinder, pistons note ○ if a new piston is used, use new piston ring. • install the piston with its marking hollow [a] facing forward. • fit a new piston pin snap ring into the side of the piston so that the ring opening [a] does not coincide with the slit [b] of the piston pin ...

  • Page 247

    Engine top end 5-43 cylinder, pistons piston ring, piston ring groove wear • check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. • with the piston rings in their grooves, make ...

  • Page 248

    5-44 engine top end cylinder, pistons piston ring end gap • place the piston ring [a] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. • measure the gap [b] between the ends of the ring with a thickn...

  • Page 249

    Engine top end 5-45 throttle body assy holder throttle body assy holder removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter) throttle body assy (see throttle body assy removal in th...

  • Page 250

    5-46 engine top end muffler muffler body removal warning to avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. • remove: right rear frame cover (see rear frame cover re- moval in the frame chapter) lower fairings (see lower fairing removal...

  • Page 251

    Engine top end 5-47 muffler • loosen the muffler body clamp bolt [a]. • remove the exhaust pipe to forward. Muffler body and exhaust pipe installation • replace the exhaust pipe gaskets [a] and muffler body gasket [b] with new ones and install them. ○ install the muffler body gasket until it is bott...

  • Page 253: Clutch

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

  • Page 254

    6-2 clutch exploded view.

  • Page 255

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 clutch cable clamp bolt 9.8 1.0 87 in·lb 2 clutch cable holder bolts 9.8 1.0 87 in·lb l 3 clutch cover mounting bolts 9.8 1.0 87 in·lb 4 clutch hub nut 130 13.3 96 5 clutch lever clamp bolts 7.8 0.80 69 in·lb s 6 clutch spring bo...

  • Page 256

    6-4 clutch specifications item standard service limit clutch lever free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – clutch friction plate thickness 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) 2.8 mm (0.110 in.) friction plate warp 0.15 mm (0.16 in.) or less 0.3 mm (0.012 in.) steel plate warp 0.2 mm (0.008 in.) or...

  • Page 257

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

  • Page 258

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

  • Page 259

    Clutch 6-7 clutch lever and cable clutch lever installation • install the clutch lever so that the mating surface [b] of the clutch lever clamp is aligned with the punch mark [a]. • tighten the upper clamp bolt first, and then the lower clamp bolt. ○ there will be a gap at the lower part of the clam...

  • Page 260

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

  • Page 261

    Clutch 6-9 clutch cover • fit the spring [a] as shown. Release shaft [b] clutch cover [c] clutch cover disassembly • remove: clutch cover (see clutch cover removal) release leer and shaft assembly (see release shaft removal) oil seal [a] needle bearings [b] • remove: oil level gauge [a] timing inspe...

  • Page 262

    6-10 clutch clutch clutch removal • remove: clutch cover (see clutch cover removal) clutch spring bolts [a] clutch springs clutch spring plate [b] (with bearing) pusher [c] • remove: friction plates steel plates • hold the clutch hub [a] steady with the clutch holder [b], and remove the clutch hub n...

  • Page 263

    Clutch 6-11 clutch clutch installation • engage the oil pump chain guide [a] to the groove of the shift rod [b], and apply a non-permanent locking agent to the upper chain guide bolt [c] and tighten the chain guide bolts. Torque - oil pump chain guide bolts: 12 n·m (1.2 kgf·m, 106 in·lb) • install t...

  • Page 264

    6-12 clutch clutch • install the washer so that the out side mark [a] faces outward. • replace the clutch hub nut [a] with a new one. • hold the clutch hub [b] steady with the clutch holder [c], and tighten the clutch hub nut. Special tool - clutch holder: 57001-1243 torque - clutch hub nut: 130 n·m...

  • Page 265

    Clutch 6-13 clutch • apply engine oil to the sliding surfaces of the bearing [a]. • install the spring plate [b] on the clutch hub [c]. • install the clutch springs, and tighten the clutch spring bolts. Torque - clutch spring bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install the clutch cover (see clutc...

  • Page 266

    6-14 clutch clutch clutch housing finger inspection • visually inspect the clutch housing fingers [a] where the friction plate tangs [b] hit them. If they are badly worn or if there are groove cuts where the tangs hit, replace the housing. Also, replace the friction plates if their tangs are damaged...

  • Page 267: Engine Lubrication System

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

  • Page 268

    7-2 engine lubrication system exploded view.

  • Page 269

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine oil drain bolt 30 3.1 22 2 filter plate bolts 9.8 1.0 87 in·lb l 3 holder mounting bolt 25 2.5 18 l 4 lower fairing bracket bolts 12 1.2 106 in·lb l 5 oil filter 17.5 1.8 13 eo, r 6 oil pan bolts 12 1.2 ...

  • Page 270

    7-4 engine lubrication system engine oil flow chart.

  • Page 271

    Engine lubrication system 7-5 engine oil flow chart.

  • Page 272

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

  • Page 273

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

  • Page 274

    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 275

    Engine lubrication system 7-9 oil pan oil pan removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: exhaust pipe (see exhaust pipe removal in the engine top end chapter) muffler body (see muffler body removal in the engine top end chapter) • remove t...

  • Page 276

    7-10 engine lubrication system oil pan oil pan installation • apply grease to the o-rings on the oil pipes [a]. • install the oil pipe plate [b] so that its guide portion fits the oil pipe as shown. • apply a non-permanent locking agent to the oil pipe plate bolt. Torque - oil pipe plate bolt [c]: 9...

  • Page 277

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

  • Page 278

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

  • Page 279

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

  • Page 280

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

  • Page 281

    Engine lubrication system 7-15 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 282

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

  • Page 283: Engine Removal/installation

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

  • Page 284

    8-2 engine removal/installation exploded view.

  • Page 285

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine mounting bracket bolts 25 2.5 18 s 2 front engine mounting bolts 44 4.5 32 s 3 rear engine mounting nuts 44 4.5 32 s 4. Collar 5. Engine mounting brackets s: follow the specified tightening sequence..

  • Page 286

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

  • Page 287

    Engine removal/installation 8-5 engine removal/installation • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) air switching valve (see air switching valve removal in the engine top end chapter) air cleaner housing (see air cleaner housing removal in the fuel system (dfi) c...

  • Page 288

    8-6 engine removal/installation engine removal/installation • open the clamp [a]. • disconnect the horn leads [b]. • support the engine with a suitable stand [a]. ○ put a plank [b] onto the suitable stand for engine balance. • remove: front engine mounting bolts [c] (both sides) engine mounting brac...

  • Page 289

    Engine removal/installation 8-7 engine removal/installation engine installation • firstly, insert the rear engine mounting bolts [a] from the left side of the engine. • secondly, temporally tighten the right engine mounting bracket bolts [b] and then the right front engine mounting bolt [c]. ○ posit...

  • Page 291: Crankshaft/transmission

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

  • Page 292

    9-2 crankshaft/transmission exploded view.

  • Page 293

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 breather plate bolts 9.8 1.0 87 in·lb l 2 race holder screw 4.9 0.50 43 in·lb l 3 connecting rod big end nuts see text ← ← 4 crankcase bolt (m8, l = 110 mm) 27.5 2.8 20 s 5 crankcase bolt (m6, l = 32 mm) 19.6 2.0...

  • Page 294

    9-4 crankshaft/transmission exploded view.

  • Page 295

    Crankshaft/transmission 9-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 drive shaft bearing holder screw 4.9 0.50 43 in·lb l 2 gear positioning lever bolt 12 1.2 106 in·lb l 3 neutral switch 15 1.5 11 4 neutral switch holder screw 4.9 0.50 43 in·lb l 5 oil jet nozzle 2.9 0.30 26 in·l...

  • Page 296

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

  • Page 297

    Crankshaft/transmission 9-7 specifications item standard service limit crankshaft runout tir 0.02 mm (0.0008 in.) or less tir 0.05 mm (0.0020 in.) crankshaft main bearing insert/journal clearance 0.012 ∼ 0.036 mm (0.0005 ∼ 0.0014 in.) 0.07 mm (0.0028 in.) crankshaft main journal diameter: 37.984 ∼ 3...

  • Page 298

    9-8 crankshaft/transmission specifications item standard service limit crankcase bearing bore diameter: 31.000 ∼ 31.016 mm (1.2205 ∼ 1.2228 in.) – – – marking: ○ 31.000 ∼ 31.008 mm (1.2205 ∼ 1.2208 in.) – – – none 31.009 ∼ 31.016 mm (1.2208 ∼ 1.2211 in.) – – – balancer shaft bearing insert thickness...

  • Page 299

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

  • Page 300

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

  • Page 301

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

  • Page 302

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

  • Page 303

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

  • Page 304

    9-14 crankshaft/transmission crankcase splitting • install the crankshaft and the balancer shaft on the upper crankcase half. ○ align [a] the timing mark on the balancer gear [b] with the timing mark on the balancer drive gear [c] of the crank- shaft. • be sure to hang the camshaft chain [a] on the ...

  • Page 305

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

  • Page 306

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

  • Page 307

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

  • Page 308

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

  • Page 309

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

  • Page 310

    9-20 crankshaft/transmission crankshaft and connecting rods • install the crankshaft (see crankshaft installation). • install each connecting rod on its original crankpin. Note ○ install each connecting rod so that its oil jet [a] faces the exhaust side (the front [b]) (see engine oil flow chart in ...

  • Page 311

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

  • Page 312

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

  • Page 313

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

  • Page 314

    9-24 crankshaft/transmission crankshaft and connecting rods if the clearance is within the standard, no bearing replace- ment is required. If the clearance is between 0.042 mm (0.00165 in.) and the service limit (0.08 mm, 0.0031 in.), replace the bear- ing inserts [a] with inserts painted blue [b]. ...

  • Page 315

    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 316

    9-26 crankshaft/transmission crankshaft and connecting rods crankshaft main bearing insert/journal clearance standard: 0.012 ∼ 0.036 mm (0.0005 ∼ 0.0014 in.) service limit: 0.07 mm (0.0028 in.) if the clearance is within the standard, no bearing replace- ment is required. If the clearance is between...

  • Page 317

    Crankshaft/transmission 9-27 crankshaft and connecting rods • select the proper bearing insert [a] in accordance with the combination of the crankcase and crankshaft coding. Size color [b] bearing insert* crankcase main bearing inside diameter marking crankshaft main journal diameter marking size co...

  • Page 318

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

  • Page 319

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

  • Page 320

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

  • Page 321

    Crankshaft/transmission 9-31 transmission shift pedal removal • remove: shift lever bolt [a] shift lever [b] bolts [c] left front footpeg stay [d] with shift pedal [e] • remove: footpeg holder bolt [a] footpeg [b] shift pedal [c] shift pedal installation • when the new oil seals [a] are installed in...

  • Page 322

    9-32 crankshaft/transmission transmission • align the mark [a] on the shift shaft with the mark [b] on the shift lever. • tighten the shift lever bolt [c] securely. • be sure the shift pedal [a] position is as shown. Shift pedal damper [b] about 136.1 mm (5.36 in.) [c] ○ align the lower surface of t...

  • Page 323

    Crankshaft/transmission 9-33 transmission • remove: clutch (see clutch removal in the clutch chapter) gear positioning lever bolt [a] spacer [b] gear positioning lever [c] washer and spring external shift mechanism installation • install the gear positioning lever [a] as shown. Spring [b] washer [c]...

  • Page 324

    9-34 crankshaft/transmission transmission • when the new needle bearing [a] is installed in the shift shaft cover [b], press and insert the new needle bearing until it is bottomed. Special tool - bearing driver set: 57001-1129 • when the new oil seal [c] is installed in the shift cover, press and in...

  • Page 325

    Crankshaft/transmission 9-35 transmission • check the gear positioning lever [a] and its spring for breaks or distortion. If the lever or spring are damaged in any way, replace them. • visually inspect the shift drum cam [b]. If they are badly worn or if they show any damage, replace it. Transmissio...

  • Page 326

    9-36 crankshaft/transmission transmission transmission assy installation • be sure that the dowel pins [a] are in position. • apply grease to the new o-ring [b] on the oil pipe [c]. • install the transmission assy on the crankcase. • tighten: torque - transmission case bolts: 20 n·m (2.0 kgf·m, 15 f...

  • Page 327

    Crankshaft/transmission 9-37 transmission transmission assy disassembly • remove the transmission assy (see transmission assy removal). • remove the following from the transmission case [a]. Shift rods [b] shift forks [c] drive shaft [d] output shaft [e] • remove: shift drum cam bolt [a] shift drum ...

  • Page 328

    9-38 crankshaft/transmission transmission • install the drive shaft bearing holder [a]. • apply a non-permanent locking agent to the threads of the drive shaft bearing holder screw [b] and tighten it. Torque - drive shaft bearing holder screw: 4.9 n·m (0.50 kgf·m, 43 in·lb) • install the following o...

  • Page 329

    Crankshaft/transmission 9-39 transmission transmission shaft removal • refer to the transmission assy disassembly. Transmission shaft installation • refer to the transmission assy assembly. Transmission shaft disassembly • remove the transmission shafts (see transmission assy disassembly). • remove ...

  • Page 330

    9-40 crankshaft/transmission transmission • the drive shaft gears can be recognized by size: the gear with the smallest diameter is 1st gear, and the largest one is 6th gear. Be sure that all parts are put back in the cor- rect sequence and all circlips and washers are properly in place. • install t...

  • Page 331

    Crankshaft/transmission 9-41 transmission 1. Drive shaft 2. 1st gear 3. 2nd gear 4. 3rd gear 5. 4th gear 6. 5th gear 7. 6th (top) gear 8. Bushing 9. Toothed washer, 34 mm (1.34 in.) 10. Circlip 11. Bushing 12. Thrust washer, 30 mm (1.18 in.) 13. Needle bearing 14. Circlip 15. Output shaft 16. Spacer...

  • Page 332

    9-42 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 • refer to the transmission assy disassembly. Shift drum assembly • refer to the tran...

  • Page 333

    Crankshaft/transmission 9-43 transmission gear dog and gear dog hole damage • visually inspect the gear dogs [a] and gear dog holes [b]. Replace any damaged gears or gears with excessively worn dogs or dog holes..

  • Page 334

    9-44 crankshaft/transmission ball bearing, needle bearing, and oil seal ball and needle bearing replacement caution do not remove the ball or needle bearings unless it is necessary. Removal may damage them. • using a press or puller, remove the ball bearing and/or needle bearings. Note ○ in the abse...

  • Page 335: Wheels/tires

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

  • Page 336

    10-2 wheels/tires exploded view.

  • Page 337

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front axle 108 11.0 80 2 front axle clamp bolt 20 2.0 15 3 rear axle nut 108 11.0 80 4. Caliper bracket (kle650b models) g: apply grease. Hg: apply high-temperature grease. R: replacement parts wl: apply soap and water sol...

  • Page 338

    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 339

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

  • Page 340

    10-6 wheels/tires wheels (rims) front wheel removal • remove: brake caliper mounting bolts [a] (both side) front brake calipers [b] • loosen: axle clamp bolt [a] front axle [b] • remove the lower fairing (see lower fairing removal in the frame chapter). • raise the front wheel off the ground with ja...

  • Page 341

    Wheels/tires 10-7 wheels (rims) • apply high-temperature grease to the grease seal lips. • fit the collars [a] on the both sides of the hub. • insert the front axle, and tighten the axle. Torque - front axle: 108 n·m (11.0 kgf·m, 80 ft·lb) • before tightening the axle clamp bolt on the right front f...

  • Page 342

    10-8 wheels/tires wheels (rims) rear wheel removal • raise the rear wheel off the ground with stand [a]. • remove: brake caliper mounting bolts [a] rear brake caliper [b] • for models eqquipped with an abs, remove the rear wheel rotation sensor from the caliper bracket (see rear wheel rotation senso...

  • Page 343

    Wheels/tires 10-9 wheels (rims) rear wheel installation • apply high-temperature grease to the grease seal lips. • fit the collars [a] on the both sides of the hub. • engage the drive chain with the rear sprocket. • install the caliper bracket [a] onto the stopper [b] of the swingarm. • insert the a...

  • Page 344

    10-10 wheels/tires wheels (rims) wheel inspection • raise the front/rear wheel off the ground with jack. 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. • inspect th...

  • Page 345

    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 346

    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 ...

  • Page 347

    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: wheel (see front/rear wheel removal) val...

  • Page 348

    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 349

    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 350

    10-16 wheels/tires hub bearing hub bearing removal • remove the wheel (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 351

    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 353: Final Drive

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

  • Page 354

    11-2 final drive exploded view.

  • Page 355

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

  • Page 356

    11-4 final drive specifications item standard service limit drive chain drive chain slack 25 ∼ 35 mm (1.0 ∼ 1.4 in.) – – – drive chain wear (20-link length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) standard chain: make enuma – – – type ek520mvxl1 – – – link 114 links – – – sprockets re...

  • Page 357

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

  • Page 358

    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 359

    Final drive 11-7 drive chain • grind [a] the pin head to make it flat. • set the cutting and riveting pin [b] as shown. • screw the pin holder until it touches chain pin. • be sure that the cutting pin hits center of chain pin. • screw the handlebar [a] into body. • turn the pin holder with wrench [...

  • Page 360

    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 link plate. • turn the pin holder by hand until plate holder (b) touches the other link plate. • turn the pin holder by wrench clockwise until two pins of link come into gr...

  • Page 361

    Final drive 11-9 drive chain • turn the wrench clockwise until tip of riveting pin hits of 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]. Link p...

  • Page 362

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

  • Page 363

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

  • Page 364

    11-12 final drive sprocket, coupling coupling installation • apply high-temperature grease to the coupling grease seal lips [a]. • apply grease to the coupling internal surface [b]. • apply grease to the new o-ring [a]. • install the collar [b]. Coupling bearing removal • remove: coupling grease sea...

  • Page 365

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

  • Page 366

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

  • Page 367: Brakes

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

  • Page 368

    12-2 brakes abs troubleshooting outline............................................................................................ 12-36 inquiries to rider............................................................................................................... 12-39 self-diagnosis outline ......

  • Page 369

    Brakes 12-3 exploded view dummy page.

  • Page 370

    12-4 brakes exploded view.

  • Page 371

    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 lever pivot bolt 1.0 0.10 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 light s...

  • Page 372

    12-6 brakes exploded view.

  • Page 373

    Brakes 12-7 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 bolt 8.8 0.90 78 in·lb 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 25 ...

  • Page 374

    12-8 brakes exploded view kle650b models.

  • Page 375

    Brakes 12-9 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 lever pivot bolt 1.0 0.10 9 in·lb si 4 brake lever pivot bolt locknut 5.9 0.60 52 in·lb 5 brake pipe joint nuts 18 1.8 13 6 front brake disc mounting bolts...

  • Page 376

    12-10 brakes exploded view kle650b models.

  • Page 377

    Brakes 12-11 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 bolt 8.8 0.90 78 in·lb 4 brake pipe joint nuts 18 1.8 13 5 rear brake disc mounting bolts 27 2.8 20 l 6 rear caliper mounting bolts 25 2.5 18 7 rear...

  • Page 378

    12-12 brakes specifications item standard service limit brake lever, brake pedal brake lever position 5-way adjustable (to suit rider) – – – brake lever free play non-adjustable – – – pedal free play non-adjustable – – – pedal position about 50 mm (2.0 in.) below top of footpeg – – – brake pads lini...

  • Page 379

    Brakes 12-13 special tools inside circlip pliers: 57001-143 jack: 57001-1238 hand tester: 57001-1394 jack attachment: 57001-1608.

  • Page 380

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

  • Page 381

    Brakes 12-15 brake lever, brake pedal brake pedal removal • remove: right rear frame cover (see rear frame cover re- moval in the frame chapter) bolts [a] right front footpeg stay [b] • remove: cotter pin [a] joint pin [b] rear brake light switch spring [c] return spring [d] • remove the mounting bo...

  • Page 382

    12-16 brakes brake lever, brake pedal • install: right front footpeg stay [a] washer [b] • tighten: torque - front footpeg stay bolts [c]: 25 n·m (2.5 kgf·m, 18 ft·lb) • check the brake pedal position (see brake pedal position inspection)..

  • Page 383

    Brakes 12-17 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. • unscrew the banjo bolt and remove the brake hose(s) [d] from the caliper (see brake hose ...

  • Page 384

    12-18 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 385

    Brakes 12-19 calipers caliper fluid seal damage the fluid seal (piston seal) [a] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- perature of ...

  • Page 386

    12-20 brakes calipers rear caliper holder shaft wear the caliper body must slide smoothly on the caliper holder shafts [a]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and con- stant drag on the disc will raise brake and brake fluid tem- peratu...

  • Page 387

    Brakes 12-21 brake pads front brake pad removal • remove the front caliper with the hose installed (see front caliper removal). • draw out the holder shaft pin [a], and take off the holder shaft [b]. • remove the pad [c] of the jaw side from the holder shaft [d]. • remove the pad [e] on the piston s...

  • Page 388

    12-22 brakes master cylinder front master cylinder removal • remove the banjo bolt [a] to disconnect the brake hose from the master cylinder [b] (see brake hose and pipe replacement in the periodic maintenance chapter). • disconnect the front brake light switch connectors [a]. • unscrew the clamp bo...

  • Page 389

    Brakes 12-23 master cylinder • the master cylinder clamp must be installed with the ar- row mark [a] upward. • tighten the upper clamp bolt [b] first, and then the lower clamp bolt [c]. ○ there will be a gap at the lower part of the clamp after tightening. Torque - front master cylinder clamp bolts:...

  • Page 390

    12-24 brakes master cylinder rear master cylinder installation • replace the cotter pin [a] with a new one. • replace the washers on each side of hose fitting with new ones. • tighten the following bolts. Torque - rear master cylinder mounting bolts: 25 n·m (2.5 kgf·m, 18 ft·lb) brake hose banjo bol...

  • Page 391

    Brakes 12-25 master cylinder master cylinder inspection • remove the master cylinders (see front/rear master cylinder removal). • disassemble the front and rear master cylinders. • check that there are no scratches, rust or pitting on the inner wall [a] of each master cylinder and on the outside of ...

  • Page 392

    12-26 brakes brake disc brake disc removal • remove the wheel (see front/rear wheel removal in the wheels/tires chapter). • unscrew the mounting bolts, and take off the disc. • remove the gaskets. Brake disc installation • replace the gaskets with new ones. • install the brake disc on the wheel so t...

  • Page 393

    Brakes 12-27 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 394

    12-28 brakes brake fluid • bleed the brake line and the caliper. ○ repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [a]. 2. Quickly open and close [b] the bleed valve while hold- ing...

  • Page 395

    Brakes 12-29 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 396

    12-30 brakes brake hose brake hose removal/installation • refer to the brake hose and pipe replacement in the periodic maintenance chapter. Brake hose inspection • refer to the brake hose damage and installation condi- tion inspection in the periodic maintenance chapter..

  • Page 397

    Brakes 12-31 anti-lock brake system (equipped models) parts location 1. Front wheel rotation sensor 2. Front wheel rotation sensor rotor 3. Rear wheel rotation sensor 4. Rear wheel rotation sensor rotor 5. Abs indicator light (led) 6. Abs hydraulic unit 7. Abs self-diagnosis terminal 8. Abs kawasaki...

  • Page 398

    12-32 brakes anti-lock brake system (equipped models) abs system wiring diagram 1. Ignition switch 2. Abs hydraulic unit 3. Abs self-diagnosis terminal 4. Abs kawasaki self-diagnosis system connector 5. Front wheel rotation sensor 6. Rear wheel rotation sensor 7. Abs solenoid valve relay fuse 25 a 8...

  • Page 399

    Brakes 12-33 anti-lock brake system (equipped models) terminal names 1. Ground to motor 2. Power supply to abs motor relay 3. Power supply to abs solenoid valve relay 4. Ground 5. Front wheel rotation sensor signal 6. Unused 7. Power supply to rear wheel rotation sensor 8. Unused 9. Unused 10. Unuse...

  • Page 400

    12-34 brakes anti-lock brake system (equipped models) abs servicing precautions there are a number of important precautions that should be followed servicing the abs system. ○ this abs system is designed to be used with a 12 v sealed battery as its power source. Do not use any other battery except f...

  • Page 401

    Brakes 12-35 anti-lock brake system (equipped models) ○ the abs indicator light (led) [a] may light if the tire pres- sure is incorrect, a non-recommended tire is installed, or the wheel is deformed. If the indicator light lights, remedy the problem and clear the service code. Warning use of non-rec...

  • Page 402

    12-36 brakes anti-lock brake system (equipped models) abs troubleshooting outline when an abnormality in the system occurs, the abs in- dicator light (led) lights up to alert the rider. In addition, the nature of the fault is stored in the memory of the abs hydraulic unit and when in the self-diagno...

  • Page 403

    Brakes 12-37 anti-lock brake system (equipped models) • visually inspect the wiring for signs of burning or fraying. If any wiring is poor, replace the damaged wiring. • pull each connector [a] apart and inspect it for corrosion, dirt and damage. If the connector is corroded or dirty, clean it caref...

  • Page 404

    12-38 brakes anti-lock brake system (equipped models) abs diagnosis flow chart.

  • Page 405

    Brakes 12-39 anti-lock brake system (equipped models) inquiries to rider ○ each rider reacts to problems in different ways, so it is important to confirm what kind of condition the rider is dissatisfied with. ○ try to find out exactly what problem occurs under exactly what conditions by asking the r...

  • Page 406

    12-40 brakes anti-lock brake system (equipped models) pre-diagnosis inspection 1.

  • Page 407

    Brakes 12-41 anti-lock brake system (equipped models) pre-diagnosis inspection 2 self-diagnosis outline when the indicator light has blinked or come on, the abs hydraulic unit memorizes and stores the service code (15 codes including “normal code”) for the service person to troubleshoot easily. The ...

  • Page 408

    12-42 brakes anti-lock brake system (equipped models) • remove the seat (see seat removal in the frame chap- ter). • ground the self-diagnosis terminal [a] (gray) to the bat- tery (–) terminal or battery (–) lead connector, using a lead. • turn on the ignition switch. ○ count the blinks of the light...

  • Page 409

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

  • Page 410

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

  • Page 411

    Brakes 12-45 anti-lock brake system (equipped models) service code table service code abs indicator light (led) problems light state 12 start code (not fault) after starts, turn off 13 rear inlet solenoid valve trouble (open, temperature abnormal) on 14 rear outlet solenoid valve trouble (open, temp...

  • Page 412

    12-46 brakes anti-lock brake system (equipped models) abs indicator light (led) inspection • turn the ignition switch on. If the abs indicator light (led) [a] lights, it is normal. If the abs indicator light (led) does not light, go to step “abs indicator light (led) is unlit (when the ignition swit...

  • Page 413

    Brakes 12-47 anti-lock brake system (equipped models) abs indicator light (led) lights (when the motorcycle is running, - no service code) • do the 1st step test. ○ check the terminal voltage between the orange/black and black/yellow lead terminals of the meter connector [a]. Special tool - hand tes...

  • Page 414

    12-48 brakes anti-lock brake system (equipped models) • do the 2nd step test. ○ disconnect the abs hydraulic unit connector [a]. ○ check for continuity between the white/red and black/yel- low lead terminals of the abs hydraulic unit connector. If there is the continuity in the lead, replace the abs...

  • Page 415

    Brakes 12-49 anti-lock brake system (equipped models) front, rear wheel rotation difference abnormal (service code 25) • do the 1st step test. ○ check the following and correct the faulty part. Incorrect the tire pressure. Tires not recommended for the motorcycle were installed (incorrect tire size)...

  • Page 416

    12-50 brakes anti-lock brake system (equipped models) • do the 4th step test. ○ check the battery terminal voltage between the red/white lead terminal of the fuse box [a] and ground. Special tool - hand tester: 57001-1394 battery terminal voltage standard: battery voltage if the battery terminal vol...

  • Page 417

    Brakes 12-51 anti-lock brake system (equipped models) • do the 2nd step test. ○ check that there is iron or other magnetic deposits be- tween the sensor [a] and sensor rotor [b], and the sensor rotor slots for obstructions. ○ check the installation condition of the sensor for loose- ness. ○ check th...

  • Page 418

    12-52 brakes anti-lock brake system (equipped models) • do the 3rd step test. ○ recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the abs indicator light (led) [a] lit, faulty ecu in the abs hydraulic unit. Re...

  • Page 419

    Brakes 12-53 anti-lock brake system (equipped models) rear wheel rotation sensor wiring inspection (service code 45) • do the 1st step test. ○ disconnect the abs hydraulic unit connector and rear wheel rotation sensor connector. ○ short the red and green lead terminals of the main har- ness side con...

  • Page 420

    12-54 brakes anti-lock brake system (equipped models) • do the 2nd step test. ○ connect the abs kawasaki self-diagnosis system con- nector and abs hydraulic unit connector. ○ check the battery terminal voltage, connect the hand tester to the brown terminal of abs kawasaki self-diagnosis system conne...

  • Page 421

    Brakes 12-55 anti-lock brake system (equipped models) • do the 3rd step test. ○ check the battery condition and regulator/rectifier (see charging condition inspection, regulator/rectifier in- spection in the electrical system chapter). • do the 4th step test. ○ recheck the service code indication; e...

  • Page 422

    12-56 brakes anti-lock brake system (equipped models) • clean the abs hydraulic unit [a]. Caution clean all fittings on the abs hydraulic unit and the rear master cylinder because dirt around the banjo bolts could contaminate the brake fluid in the line during removal/installation. Spread out a shop...

  • Page 423

    Brakes 12-57 anti-lock brake system (equipped models) abs hydraulic unit installation • install the abs hydraulic unit to the bracket. Caution brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • route the lead correctly, and join conn...

  • Page 424

    12-58 brakes anti-lock brake system (equipped models) • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) bolt [a] clamps [b] • disconnect the connector [a]. • remove: bolt [a] front wheel rotation sensor [b] front wheel rotation sensor installation • installation is the rev...

  • Page 425

    Brakes 12-59 anti-lock brake system (equipped models) • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter) • disconnect the connector [a]. • open the band [a]. • free the sensor lead from t...

  • Page 426

    12-60 brakes anti-lock brake system (equipped models) wheel rotation sensor inspection • remove the front wheel rotation sensor [a] from the front fork. • remove the rear wheel rotation sensor [b] from the caliper bracket. • visually inspect the wheel rotation sensors. Replace the wheel rotation sen...

  • Page 427

    Brakes 12-61 anti-lock brake system (equipped models) brake hose and pipe inspection • refer to the brake hose and pipe damage and instal- lation condition inspection in the periodic maintenance chapter. 25 a abs solenoid valve relay fuse removal • remove the seat (see seat removal in the frame chap...

  • Page 428

    12-62 brakes anti-lock brake system (equipped models) fuse inspection • remove the fuse (see 25 a abs solenoid valve relay/30 a abs motor relay fuse removal). • inspect the fuse element. If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected ci...

  • Page 429: Suspension

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

  • Page 430

    13-2 suspension exploded view.

  • Page 431

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front axle clamp bolt 20 2.0 15 2 front fork bottom allen bolts 20 2.0 15 3 front fork clamp bolts (lower) 29 3.0 21 al 4 front fork clamp bolts (upper) 20 2.0 15 5 front fork top plugs 35 3.6 26 6 piston rod nuts 20 2.0 15 ...

  • Page 432

    13-4 suspension exploded view.

  • Page 433

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear shock absorber bolt (upper) 59 6.0 44 2 rear shock absorber nut (lower) 59 6.0 44 3 swingarm pivot shaft nut 108 11.0 80 g: apply grease. R: replacement parts.

  • Page 434

    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 (only right fork leg) 1 3/4 turns out from the fully clockwise position (usable range: 0 ←→ 3 turns out) fork spri...

  • Page 435

    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 fork piston rod puller, m10 × 1.0: 57001-1298 fork spring stopper: 57001-1374 ja...

  • Page 436

    13-8 suspension special tools spacer, 28: 57001-1663 fork spring compressor: 57001-1685.

  • Page 437

    Suspension 13-9 front fork rebound damping force adjustment (only right fork leg) • to adjust the rebound damping force, turn the rebound damping adjuster [a] on top of the right front fork leg to the desired position. ○ the standard adjuster setting for the average-build rider of 68 kg (150 lb) wit...

  • Page 438

    13-10 suspension front fork front fork removal (each fork leg) • remove: middle fairings (see middle fairing removal in the frame chapter) inner cover (see inner cover removal in the frame chapter) front wheel (see front wheel removal in the wheels/tires chapter) front fender (see front fender remov...

  • Page 439

    Suspension 13-11 front fork fork oil change • remove the front fork (see front fork removal). • hold the inner tube lower end in a vice. • unscrew the top plug [a] out of the outer tube. • install the fork spring compressor as shown in the figure. Note ○ set the fork spring compressor so that the en...

  • Page 440

    13-12 suspension front fork • remove: slider [a] spacer [b] damper [c] fork spring [d] note ○ the right fork leg spacer [a] is shorter than the left fork leg spacer [b]. • drain the fork oil into a suitable container. ○ pump the piston rod [a] up and down at least ten times to expel the oil from the...

  • Page 441

    Suspension 13-13 front fork if necessary, measure the oil level as follows. ○ hold the inner tube vertically in a vise. ○ using the piston rod puller [a], move the piston rod [b] up and down more than ten times in order to expel all the air from the fork oil. Special tool - fork piston rod puller, m...

  • Page 442

    13-14 suspension front fork • screw the fork piston rod puller onto the end of the rod. Special tool - fork piston rod puller, m10 × 1.0: 57001 -1298 • install the fork spring [a] with the smaller end [b] facing upward. • install: spacer [a] damper [b] note ○ the right fork leg spacer [a] is shorter...

  • Page 443

    Suspension 13-15 front fork • while holding up the piston rod puller [a] by one person, push down [b] the fork spring compressor, and insert the fork spring stopper [c] between the piston rod nut [d] and the spacer [e]. Special tool - fork spring stopper: 57001-1685 • remove the piston rod puller. •...

  • Page 444

    13-16 suspension front fork • take the cylinder unit and center ring plate [a] out of the inner tube. ○ do not disassemble the cylinder unit. Cylinder unit [b] for right fork leg cylinder unit [c] for left fork leg • separate the inner tube from the outer tube as follows. ○ slide up the dust seal [a...

  • Page 445

    Suspension 13-17 front fork • insert the inner tube to the outer tube. • fit the new outer guide bush [a] into the outer tube. Note ○ when assembling the new outer tube guide bushing [a], hold the washer against the new outer tube guide bush- ing and tap the washer with the fork oil seal driver [b] ...

  • Page 446

    13-18 suspension front fork dust seal inspection • inspect the dust seals [a] for any signs of deterioration or damage. Replace it if necessary. Spring tension inspection • since a spring becomes shorter as it weakens, check its free length [a] to determine its condition. If the spring of either for...

  • Page 447

    Suspension 13-19 rear shock absorber 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 an average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 5th clic...

  • Page 448

    13-20 suspension rear shock absorber rear shock absorber removal • remove: right rear frame cover (see rear frame cover re- moval in the frame chapter) muffler body (see muffler body removal in the engine top end chapter) • raise the rear wheel off the ground with jack. Special tools - jack: 57001-1...

  • Page 449

    Suspension 13-21 rear shock absorber rear shock absorber inspection • remove the rear shock absorber (see rear shock ab- sorber removal). • visually inspect the following items. Smooth stroke oil leakage crack or dent if there is any damage to the rear shock absorber, replace it. • visually inspect ...

  • Page 450

    13-22 suspension swingarm swingarm removal • remove: muffler body (see muffler body removal in the engine top end chapter) engine sprocket (see engine sprocket removal in the final drive chapter) rear wheel (see rear wheel removal in the wheels/tiers chapter) • raise the rear wheel off the ground wi...

  • Page 451

    Suspension 13-23 swingarm swingarm bearing removal • remove: swingarm (see swingarm removal) collar [a] oil seals [b] sleeve [c] circlip [d] special tool - inside circlip pliers: 57001-143 • remove the ball bearing and needle bearings. Special tool - oil seal & bearing remover [a]: 57001-1058 swinga...

  • Page 452

    13-24 suspension swingarm • replace the circlip with a new one. • install the needle bearings [a], ball bearing [b] and oil seals [c] position as shown. Circlip [d] 25 mm (0.98 in.) [e] 17 mm (0.67 in.) [f] 1 mm (0.04 in.) [g] 0.5 mm (0.02 in.) [h] 1 mm (0.04 in.) [i] 23.5 mm (0.93 in.) [j] 6 mm (0....

  • Page 453

    Suspension 13-25 swingarm • turn the bearing in the swingarm back and forth [a] while checking for plays, roughness, or binding. If the bearing play, roughness, or binding is found, replace the bearing. • examine the bearing seal [b] for tears or leakage. If the seal is torn or is leaking, replace t...

  • Page 455: Steering

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

  • Page 456

    14-2 steering exploded view.

  • Page 457

    Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fork clamp bolts (lower) 29 3.0 21 al 2 front fork clamp bolts (upper) 20 2.0 15 3 upper handlebar holder bolts 25 2.5 18 s 4 lower handlebar holder bolts 25 2.5 18 5 left switch housing screws 3.5 0.36 31 in·lb 6 right ...

  • Page 458

    14-4 steering special tools 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.

  • Page 459

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

  • Page 460

    14-6 steering steering stem stem, stem bearing removal • remove: middle fairings (see middle fairing removal in the frame chapter) inner cover (see inner cover removal in the frame chapter) bolt [a] clamp [b] • remove: bolt [a] clamp [b] • remove: bolt [a] brake hose clamp bracket [b] • remove the h...

  • Page 461

    Steering 14-7 steering stem • pushing up the stem base, and remove the steering stem nut [a] with stem cap [b]. Special tool - steering stem nut wrench [c]: 57001-1100 • remove the steering stem [d] under side. • remove the upper stem bearing inner race [a] and bear- ing [b]. • to remove the bearing...

  • Page 462

    14-8 steering steering stem • replace the bearing inner races and oil seal with new ones. • apply grease to the oil seal. • drive the lower ball bearing inner race applied the grease onto the stem. Special tools - steering stem bearing driver, 42.5 [a]: 57001-1344 steering stem bearing driver adapte...

  • Page 463

    Steering 14-9 steering stem • install the claw washer [a] so that its bent side [b] faces upward, and engage the bent claws with the grooves of stem locknut [c]. • hand tighten the stem locknut until it touches the claw washer. • tighten the stem locknut clockwise until the claws are aligned with th...

  • Page 464

    14-10 steering steering stem stem cap deterioration, damage replace the stem cap if its oil seal [a] shows damage..

  • Page 465

    Steering 14-11 handlebar handlebar removal • remove: clutch lever assembly [a] left switch housing [b] left handlebar weight [c] left handlebar grip [d] clamp [e] • remove: front brake master cylinder [a] (see front master cylin- der removal in the brakes chapter) right switch housing [b] right hand...

  • Page 466

    14-12 steering handlebar • tighten the front holder bolts [a] first, and then the rear holder bolts [b]. ○ there will be a gap [c] at the rear part of the handlebar holder after tightening. Torque - upper handlebar holder bolts: 25 n·m (2.5 kgf·m, 18 ft·lb) • install the clutch lever (see clutch lev...

  • Page 467: Frame

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

  • Page 468

    15-2 frame exploded view.

  • Page 469

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 footpeg holder bolts 34 3.5 25 l 2 front footpeg stay bolts 25 2.5 18 3 rear footpeg stay bolts 25 2.5 18 4 sidestand bolt 44 4.5 32 5 sidestand switch bolt 3.9 0.40 35 in·lb l 6. Canada model g: apply grease. L: apply a non-perm...

  • Page 470

    15-4 frame exploded view.

  • Page 471

    Frame 15-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 lower fairing mounting bolts 8.8 0.90 78 in·lb 2 windshield mounting bolts 0.40 0.041 3.5 in·lb 3. Canada model s: follow the specified tightening sequence..

  • Page 472

    15-6 frame exploded view.

  • Page 473

    Frame 15-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 tandem grip mounting bolts 25 2.5 18 2. Kle650b models.

  • Page 474

    15-8 frame seat seat removal • insert the ignition switch key [a] into the seat lock, turning the key clockwise, pulling up on the rear of the seat [b], and pulling the seat backward. Seat installation • slip the seat hook [a] under the brace [b] on the fuel tank bracket. • insert the seat latch [a]...

  • Page 475

    Frame 15-9 fairings lower fairing removal • remove the mounting bolts [a] and lower fairing [b]. Lower fairing installation • tighten: torque - lower fairing mounting bolts: 8.8 n·m (0.90 kgf·m, 78 in·lb) middle fairing removal • remove: windshield (see windshield removal) bolts [a] • pull the middl...

  • Page 476

    15-10 frame fairings • tighten the middle fairing mounting bolts as shown se- quence [1 ∼ 6] in the figure middle fairing bracket removal • remove: middle fairings (see middle fairing removal) windshield brackets (see windshield bracket removal) inner cover (see inner cover removal) headlight assy (...

  • Page 477

    Frame 15-11 fairings inner cover removal • remove the middle fairings (see middle fairing re- moval). • push the central pin, and then remove the quick rivets [a]. • remove: bolts [b] inner cover [c] inner cover installation • installation is the reverse of removal. ○ insert the hook [a] of the inne...

  • Page 478

    15-12 frame side covers side cover removal • remove: seat (see seat removal) screw [a] • pull the side cover [b] evenly outward to clear the stop- pers [c]. Side cover installation • installation is the reverse of removal. ○ insert the projection [a] into the grommets [b] on the fuel tank and frame....

  • Page 479

    Frame 15-13 seat covers seat cover removal • remove: seat (see seat removal) screw [a] (both sides) • push the central pin, and then remove the quick rivet [b] on both sides. • remove the front seat cover [c] forward. • push the central pin, and then remove the quick rivet [a] on both sides. • remov...

  • Page 480

    15-14 frame fenders front fender removal • remove: brake hose clamps [a] bolts [b] (both sides) • remove the front fender [c] upward. Front fender installation • installation is the reverse of removal. ○ install the brake hose clamps to the front fender holes. Flap and rear fender rear removal • rem...

  • Page 481

    Frame 15-15 fenders • remove: tail/brake light [a] (see tail/brake light removal in the electrical system chapter) owner’s tool [b] for models equipped with an abs, remove the abs fuse boxes [c]. • push the center pin, and then remove the quick rivet [a]. • pull out the rear fender rear backward and...

  • Page 482

    15-16 frame fenders • remove: battery (see battery removal in the electrical system chapter) relay box (see relay box removal in the electrical sys- tem chapter) starter relay (see starter relay inspection in the elec- trical system chapter) fuse box [a] clamp [b] • unscrew the bolt [c] and pull out...

  • Page 483

    Frame 15-17 frame frame inspection • visually inspect the frame [a] for cracks, dents, bending or warp. ○ if there is any damage to the frame, replace it. Warning a repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it..

  • Page 484

    15-18 frame windshield windshield height adjustment ○ the windshield can be adjusted within 3 positions in height to suit the rider’s preference. • remove the windshield (see windshield removal). • move the position of the dampers [a] evenly and adjust the windshield height. • install the windshield...

  • Page 485

    Frame 15-19 sidestand sidestand removal • raise the rear wheel off the ground with stand [a]. • remove: sidestand switch bolt [a] clamp [b] sidestand switch [c] • remove: spring [a] sidestand nut [b] sidestand bolt [c] sidestand [d] sidestand installation • apply grease to the sliding area [a] of th...

  • Page 486

    15-20 frame frame cover front frame cover removal • remove: middle fairings (see middle fairing removal) bolts [a] • pull the front frame cover [b] outward to clear the stopper [c]. • disconnect the turn signal light lead connector [a]. Front frame cover installation • installation is the reverse of...

  • Page 487

    Frame 15-21 rear view mirrors rear view mirrors removal • loosen the lower hexagonal area [a] for tightening to re- move the rear view mirror from the holder. Caution do not force to tighten and/or loosen the upper hexagonal area (adapter) [b] with a pair of span- ners. Disassembly of this area is n...

  • Page 489: Electrical System

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

  • Page 490

    16-2 electrical system starter motor removal...................................................................................................... 16-48 starter motor installation................................................................................................... 16-48 starter motor d...

  • Page 491

    Electrical system 16-3 exploded view dummy page.

  • Page 492

    16-4 electrical system exploded view.

  • Page 493

    Electrical system 16-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 tail/brake light mounting bolts 1.2 0.12 11 in·lb 2 license plate light cover screws 0.90 0.090 8 in·lb 3 license plate light mounting screws 1.2 0.12 11 in·lb 4 turn signal light lens screws 1.0 0.10 9 in·lb.

  • Page 494

    16-6 electrical system exploded view.

  • Page 495

    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 mo 4 engine ground cable terminal bolt 9.8 1.0 87 in·lb 5 front brake light switch s...

  • Page 496

    16-8 electrical system exploded view.

  • Page 497

    Electrical system 16-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 crankshaft sensor bolts 6.0 0.61 53 in·lb 2 neutral switch 15 1.5 11 3 oil pressure switch 15 1.5 11 ss 4 oxygen sensor (europe models) 44.1 4.50 32.5 5 spark plugs 15 1.5 11 6 speed sensor bolt 7.8 0.80 69 in·lb l 7 ...

  • Page 498

    16-10 electrical system specifications item standard battery type sealed battery model name ytx12-bs capacity 12 v 10 ah voltage 12.8 v or more charging system type three-phase ac alternator output voltage 42 v or more at 4 000 r/min (rpm) stator coil resistance 0.18 ∼ 0.27 Ω charging voltage 14.2 ∼...

  • Page 499

    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 rotor holder: 57001-1567 grip: 57001-1591 rotor holder: 57001-1658 kawasaki bond (silicone...

  • Page 500

    16-12 electrical system parts location.

  • Page 501

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

  • Page 502

    16-14 electrical system wiring diagram (other than canada, new zealand and malaysia).

  • Page 503

    Electrical system 16-15 wiring diagram (other than canada, new zealand and malaysia).

  • Page 504

    16-16 electrical system wiring diagram (canada, new zealand and malaysia).

  • Page 505

    Electrical system 16-17 wiring diagram (canada, new zealand and malaysia).

  • Page 506

    16-18 electrical system wiring diagram (kle650b models).

  • Page 507

    Electrical system 16-19 wiring diagram (kle650b models).

  • Page 508

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

  • Page 509

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

  • Page 510

    16-22 electrical system battery battery removal • remove the seat (see seat removal in the frame chap- ter). • slide the black [a] and red [b] caps out. • disconnect the negative (–) cable [a] and then positive (+) cable [b]. Caution be sure to disconnect the negative (–) cable first. • pull the bat...

  • Page 511

    Electrical system 16-23 battery caution do not remove the aluminum sealing sheet [a] from the filler ports [b] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. • place the battery on a level surface. • check to see that the sealing sheet has...

  • Page 512

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

  • Page 513

    Electrical system 16-25 battery note ○ to ensure maximum battery life and customer satisfac- tion, it is recommended the battery be load tested at three times its amp-hour rating for 15 seconds. Re-check voltage and if less than 12.8 v repeat the charging cycle and load test. If still below 12.8 v t...

  • Page 514

    16-26 electrical system battery charging condition inspection ○ battery charging condition can be checked by measuring battery terminal voltage with a digital meter [a]. • remove: seat (see seat removal in the frame chapter) battery cable caps (see battery removal) • disconnect the battery terminals...

  • Page 515

    Electrical system 16-27 battery terminal voltage: 11.5 ∼ less than 12.8 v standard charge 1.2 a × 5 ∼ 10 h (see following chart) quick charge 5 a × 1 h caution if possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on. Terminal voltage: less than 11.5 v charg...

  • Page 516

    16-28 electrical system charging system alternator cover removal • remove the lower fairing (see lower fairing removal in the frame chapter). • disconnect the alternator lead connector [a]. • place a suitable container under the alternator cover [a]. • remove: alternator cover bolts [b] clamp [c] br...

  • Page 517

    Electrical system 16-29 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) • secure the alternator lead with a holding plate, and tighten the bolt. ○ apply ...

  • Page 518

    16-30 electrical system charging system alternator rotor installation • using a cleaning fluid, clean off any oil or dirt on the fol- lowing portions and dry them with a clean cloth. Crankshaft tapered portion [a] alternator rotor tapered portion [b] • apply a thin coat of molybdenum disulfide greas...

  • Page 519

    Electrical system 16-31 charging system • install the rotor bolt and washer. • tighten the alternator rotor bolt [a] while holding the alter- nator rotor steady with the rotor holder [b]. Special tools - grip: 57001-1591 rotor holder: 57001-1658 torque - alternator rotor bolt: 155 n·m (15.8 kgf·m, 1...

  • Page 520

    16-32 electrical system charging system • to check the alternator output voltage, do the following procedures. ○ turn off the ignition switch. ○ disconnect the alternator lead connector [a]. ○ connect the hand tester as shown in the table 1. ○ start the engine. ○ run it at the rpm given in the table...

  • Page 521

    Electrical system 16-33 charging system regulator/rectifier inspection kle650a models • remove: left rear frame cover (see rear frame cover removal in the frame chapter) bolts [a] • disconnect the connector [a]. • remove: bolts [a] regulator/rectifier [b] kle650b models • remove: muffler body (see m...

  • Page 522

    16-34 electrical system charging system rectifier circuit check • check conductivity of the following pair of terminals. Rectifier circuit inspection w/bl-bk1, w/bl-bk2, w/bl-bk3 tester connection bk/y-bk1, bk/y-bk2, bk/y-bk3 the resistance should be low in one direction and more than ten times as m...

  • Page 523

    Electrical system 16-35 charging system • do the 3rd step regulator circuit test. ○ connect the test light and the 12 v battery in the same manner as specified in the “regulator circuit test-1st step”. ○ momentarily apply 24 v to the voltage br terminal by adding a 12 v battery. ○ check the bk1, bk2...

  • Page 524

    16-36 electrical system charging system charging voltage inspection • check the battery condition (see charging condition in- spection). • warm up the engine to obtain actual alternator operating conditions. • remove the seat (see seat removal in the frame chap- ter). • check that the ignition switc...

  • Page 525

    Electrical system 16-37 charging system charging system circuit 1. Ignition switch 2. Alternator 3. Regulator/rectifier 4. Water-proof joint c 5. Main fuse 30 a 6. Battery 12 v 10 ah 7. Load.

  • Page 526

    16-38 electrical system starter motor clutch starter motor clutch removal/installation • refer to the alternator rotor removal/installation. Starter motor clutch inspection • remove: alternator cover (see alternator cover removal) starter idle gear and torque limiter (see alternator re- moval) • tur...

  • Page 527

    Electrical system 16-39 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 528

    16-40 electrical system ignition system • remove: bolts [a] crankshaft sensor [b] • pull out the grommet [c]. Crankshaft sensor installation • route the crankshaft sensor lead correctly (see cable, wire, and hose routing section in the appendix chapter). • tighten: torque - crankshaft sensor bolts: ...

  • Page 529

    Electrical system 16-41 ignition system crankshaft sensor peak voltage inspection note ○ be sure the battery is fully charged. ○ using the peak voltage adapter [a] is a more reliable way to determine the condition of the crankshaft sen- sor than crankshaft sensor internal resistance measure- ments. ...

  • Page 530

    16-42 electrical system ignition system stick coil (ignition coil together with spark plug cap) removal • remove the air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter). • open the clamp [a]. • disconnect the stick coil connectors [b]. • pull the stick coils [c] of...

  • Page 531

    Electrical system 16-43 ignition system • remove the stick coils (see stick coil (ignition coil to- gether with spark plug cap) removal). ○ do not remove the spark plugs. • measure the primary peak voltage as follows. ○ install the new spark plug [a] into each stick coil [b], and ground them onto th...

  • Page 532

    16-44 electrical system ignition system spark plug condition inspection • remove the spark plugs (see spark plug replacement). • 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 insulator [c] is cracked, replace t...

  • Page 533

    Electrical system 16-45 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 → pulled in sidestand → up • set the sidestand on the ground,...

  • Page 534

    16-46 electrical system ignition system.

  • Page 535

    Electrical system 16-47 ignition system ignition system circuit 1. Ignition switch 2. Engine stop switch 3. Spark plugs 4. Stick coils 5. Water-proof joint c 6. Speed sensor 7. Subthrottle sensor 8. Main throttle sensor 9. Water-proof joint d 10. Vehicle-down sensor 11. Water-proof joint e 12. Water...

  • Page 536

    16-48 electrical system electric starter system starter motor removal caution do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • remove the throttle body assy (see throttle body assy removal in the fuel system (dfi) chapter). • slide back the rubber cap [...

  • Page 537

    Electrical system 16-49 electric starter system starter motor disassembly • remove the starter motor (see starter motor removal). • take off the starter motor through bolts [a] and remove the both end covers [b]. • pull out the armature [a] out of the yoke [b]. Note ○ do not remove the circlip [c] f...

  • Page 538

    16-50 electrical system electric starter system • align the stoppers [a] of the negative brush assy [b] to the grooves [c] of the brush holder [d]. • tighten the screw securely. • align the stoppers [a] of the positive brush assy [b] to the grooves [c] of the brush holder [d]. • install the starter ...

  • Page 539

    Electrical system 16-51 electric starter system • replace the o-rings [a] with new ones. • insert the armature [b] so that commutator side [c] faces hollow side [d] of the yoke [e]. • align the marks [a] to assembly the yoke and the end covers [b]. • replace the o-rings [a] with new ones. • tighten ...

  • Page 540

    16-52 electrical system electric starter system armature inspection • using the × 1 Ω hand tester range, measure the resis- tance between any two commutator segments [a]. Special tool - hand tester: 57001-1394 if there is a high resistance or no reading ( ∞ ) between any two segments, a winding is o...

  • Page 541

    Electrical system 16-53 electric starter system • disconnect the connector [a]. • disconnect the starter motor cable [b] and battery positive (+) cable [c] from the starter relay [d]. • connect the hand tester [a] and 12 v battery [b] to the starter relay [c] as shown. Special tool - hand tester: 57...

  • Page 542

    16-54 electrical system electric starter system electric starter circuit 1. Ignition switch 2. Water-proof joint b 3. Starter lockout switch 4. Ignition fuse 10 a 5. Fuse box 6. Starter circuit relay 7. Relay box 8. Starter motor 9. Starter relay 10. Main fuse 30 a 11. Battery 12 v 10 ah 12. Sidesta...

  • Page 543

    Electrical system 16-55 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 544

    16-56 electrical system lighting system • fit the dust cover [a] with the “top” mark upward onto the bulb [b] firmly as shown. Good [c] bad [d] top mark [e] • after installation, adjust the headlight aim (see headlight aiming inspection in the periodic maintenance chapter). ○ other bulb: repeat the ...

  • Page 545

    Electrical system 16-57 lighting system • disconnect the headlight connectors [a] and city light con- nectors [b]. • remove the headlight assy. • installation is the reverse of removal. ○ insert the hook [a] of the inner cover into the slot [b] of the headlight assy. Tail/brake light removal • remov...

  • Page 546

    16-58 electrical system lighting system license plate light bulb replacement • remove: screws [a] license plate light cover [b] • push and turn the bulb [a] counterclockwise and remove it. • insert the new bulb [a] by aligning its upper and lower pins [b] with the upper and lower grooves [c] in the ...

  • Page 547

    Electrical system 16-59 lighting system headlight/tail light circuit 1. Ignition switch 2. Water-proof joint a 3. Water-proof joint b 4. Right city right 5. Left city right 6. Headlight (high beam) 7. Headlight (low beam) 8. Dimmer switch 9. Passing switch 10. Headlight relay 11. Relay box 12. Start...

  • Page 548

    16-60 electrical system lighting system turn signal light bulb replacement • remove: screw [a] turn signal light lens [b] • push and turn the bulb [a] counterclockwise and remove it. • insert the new bulb [a] by aligning its upper and lower pins [b] with the upper and lower grooves [c] in the socket...

  • Page 549

    Electrical system 16-61 lighting system • connect one 12 v battery and turn signal lights as indi- cated in the figure, and count how may times the lights flash for one minute. Turn signal relay [a] turn signal lights [b] 12 v battery [c] if the lights do not flash as specified, replace the turn sig...

  • Page 550

    16-62 electrical system lighting system turn signal light circuit 1. Meter unit 2. Water-proof joint a 3. Water-proof joint b 4. Front right turn signal light 5. Front left turn signal light 6. Turn signal relay 7. Hazard button 8. Turn signal switch 9. Fuse box 10. Turn signal relay fuse 10 a 11. M...

  • Page 551

    Electrical system 16-63 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 552

    16-64 electrical system radiator fan system fan motor inspection • disconnect the connector [a]. • using an auxiliary leads, supply battery power to the fan motor. If the fan does not rotate, the fan motor is defective and must be replaced. Radiator fan circuit 1. Relay box 2. Radiator fan relay 3. ...

  • Page 553

    Electrical system 16-65 oil pressure warning system motorcycle operation with low engine oil level, even if it is higher than the lower level line, will cause oil level change when sudden acceleration, or deceleration, and may lead flicker of the oil pressure warning indicator light (led) because of...

  • Page 554

    16-66 electrical system oil pressure warning system oil pressure warning indicator light (led) delay unit removal • remove the right middle fairing (see middle fairing re- moval in the frame chapter). • disconnect the connector [a] and remove the delay unit [b]. Oil pressure warning system inspectio...

  • Page 555

    Electrical system 16-67 oil pressure warning system • do the 4th step test. ○ disconnect the oil pressure switch lead [a] (see oil pres- sure switch removal in the engine lubrication system chapter). ○ ground the oil pressure switch lead to the engine, using an auxiliary wire [b]. ○ turn the ignitio...

  • Page 556

    16-68 electrical system meter, gauge, indicator unit meter unit removal • remove the headlight assy (see headlight removal/in- stallation). • disconnect the connector [a]. • remove the meter unit by taking off the mounting screws [b] with the washers. Caution place the meter unit so that the face is...

  • Page 557

    Electrical system 16-69 meter, gauge, indicator unit electronic combination meter unit inspection • remove the meter unit [a] (see meter unit removal). [1] battery (+) [2] ignition [3] ground (–) [4] fuel lever sensor [5] speed sensor signal [6] tachometer signal [7] water temperature sensor (–) [8]...

  • Page 558

    16-70 electrical system meter, gauge, indicator unit ○ when the terminals are connected, all the lcd segment [a] appear for three seconds. If the lcd segments will not appear, replace the meter assembly. • disconnect the terminal [2]. ○ all the lcd segments disappear. If the segment do not disappear...

  • Page 559

    Electrical system 16-71 meter, gauge, indicator unit • in the hour/minute setting mode, press the reset button again to effect the hour setting mode. ○ the hour display flashes on the display. • press the mode button to set the hour. • in the hour setting mode, press the reset button to effect the m...

  • Page 560

    16-72 electrical system meter, gauge, indicator unit speed sensor electric source check • connect the 12 v battery and terminals in the same man- ner as specified in the “liquid crystal display (lcd) seg- ments check”. • set the hand tester to the dc 25 v range and connect it to the terminals [10] a...

  • Page 561

    Electrical system 16-73 meter, gauge, indicator unit fuel level gauge check • connect the 12 v battery and terminals in the same man- ner way as specified in the “liquid crystal display (lcd) segments check”. • connect the variable resistor [a] to the terminal [4] as shown. • check that the number o...

  • Page 562

    16-74 electrical system meter, gauge, indicator unit lights (led) inspection neutral indicator light (led) [a] fi indicator light (led) [b] oil pressure wiring indicator light (led) [c] water temperature warning indicator light (led) [d] right turn signal indicator light (led) [e] left turn signal i...

  • Page 563

    Electrical system 16-75 meter, gauge, indicator unit high beam indicator light (led) battery positive (+) terminal to terminal [11] neutral indicator light (led) battery negative (–) terminal to terminal [12] right and left turn signal indicator light (led) for right turn signal indicator light (led...

  • Page 564

    16-76 electrical system meter, gauge, indicator unit • connect the battery negative (–) terminal to the terminal [13]. ○ when the terminal are connected, the abs warning indi- cator light (led) should goes off. If the abs warning indicator light (led) does not go off, replace the meter assembly..

  • Page 565

    Electrical system 16-77 meter, gauge, indicator unit meter circuit 1. Abs hydraulic unit (le650b models) 2. Oil pressure warning indicator light (led) delay unit 3. Frame ground 4. Meter unit 5. Water-proof joint a 6. Water-proof joint b 7. Ecu fuse 15 a 8. Ignition fuse 10 a 9. Fuse box 10. Main fu...

  • Page 566

    16-78 electrical system switches and sensors brake light timing inspection • refer to the brake light switch operation inspection in the periodic maintenance chapter. Brake light timing adjustment • refer to the brake light switch operation inspection in the periodic maintenance chapter. Switch insp...

  • Page 567

    Electrical system 16-79 switches and sensors water temperature sensor inspection • remove the water temperature sensor (see removal/in- stallation in the fuel system (dfi) chapter). • suspend the sensor [a] in a container of coolant so that the threaded portion is submerged. • suspend an accurate th...

  • Page 568

    16-80 electrical system switches and sensors speed sensor inspection • remove the speed sensor (see speed sensor removal). • connect the speed sensor connector [a] with the battery [b], 10 k Ω resistor [c] and hand tester [d] as shown. • set the tester to the dc 25 v range. Special tool - hand teste...

  • Page 569

    Electrical system 16-81 switches and sensors • install a new gasket [a] on the fuel level sensor as shown. Hollows [b] front [c] • apply a non-permanent locking agent to the threads of the level sensor bolts and tighten it. Torque - fuel level sensor bolts: 6.9 n·m (0.70 kgf·m, 61 in·lb) oxygen sens...

  • Page 570

    16-82 electrical system switches and sensors fuel reserve switch inspection • fill the fuel tank with fuel. • close the fuel tank cap surely. • remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • connect the test light [a] (12 v 3.4 w bulb a socket with leads) and the 12...

  • Page 571

    Electrical system 16-83 relay box the relay box [a] has relays and diodes. The relays and diodes can not be removed. Relay box removal • remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter. • open the clamps [a]. • clear the hook portions [a] and take out the relay box [b]. ...

  • Page 572

    16-84 electrical system relay box relay circuit inspection (with the battery disconnected) tester connection tester reading ( Ω ) headlight relay 1-3 ∞ 7-6 ∞ ecu main relay 4-5 not ∞ * 7-8 ∞ fuel pump relay 9-10 not ∞ * 11-16 ∞ starter circuit relay 11-12 ∞ 17-20 ∞ fan relay 18-19 not ∞ * *: the act...

  • Page 573

    Electrical system 16-85 relay box relay box internal circuit a: headlight relay b: ecu main relay c: fuel pump relay d: starter circuit relay e: fan relay.

  • Page 574

    16-86 electrical system fuse 30 a main fuse removal • remove: right rear frame cover (see rear frame cover re- moval in the frame chapter) bolt [a] cover [b] • disconnect the connector [a]. • pull out the main fuse [a] from the starter relay with needle nose pliers. Fuse box fuse removal • remove th...

  • Page 575

    Electrical system 16-87 fuse 15 a ecu fuse removal • remove: seat (see seat removal in the frame chapter) • unlock the hook [a] to pull the lid [b]. • pull out the ecu fuse [a] from the fuse box. Fuse installation • if a fuse fails during operation, inspect the electrical sys- tem to determine the c...

  • Page 577: Appendix

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

  • Page 578

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

  • Page 579

    Appendix 17-3 cable, wire, and hose routing 1. Radiator 2. Reserver tank 3. Reserver tank hose 4. Reserver tank overflow hose 5. Outlet hose 6. Water pump cover 7. Thermostat housing 8. Inlet hose 9. Through the overflow hose as shown. 10. Wrap the clamp in the overflow hose. 11. Viewed upside 12. F...

  • Page 580

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

  • Page 581

    Appendix 17-5 cable, wire, and hose routing 1. Clamps 2. Clamp (insert the clamp in the bracket.) 3. Clamps (insert the clamps in the frame.) 4. Clamps (insert the clamps from air cleaner housing side.) 5. Clamp (insert the clamp from opening part turn to the body side.) 6. Clamp (through the igniti...

  • Page 582

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

  • Page 583

    Appendix 17-7 cable, wire, and hose routing 1. Seat lock cable 2. Insert the joint connector between the frame pipe and rear fender. 3. Run the harness through the cutout of the rear fender and between the frame pipes. 4. Frame ground 5. Kawasaki self-diagnosis system connector (insert the connector...

  • Page 584

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

  • Page 585

    Appendix 17-9 cable, wire, and hose routing 1. Install the clamp together with the rear fender rear (clamp the turn signal leads and license plate light lead.). 2. Run the turn signal leads and license plate light lead into the frame hook. 3. Ecu connectors 4. Install the clamp together with the rea...

  • Page 586

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

  • Page 587

    Appendix 17-11 cable, wire, and hose routing 1. To vehicle-down sensor, rear brake light switch and crankshaft sensor 2. Battery negative lead connector 3. Fuel pump lead 4. Fuel level sensor lead 5. Clamp the main harness, and insert it in the rear fender front. 6. Through the main harness to the r...

  • Page 588

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

  • Page 589

    Appendix 17-13 cable, wire, and hose routing 1. Through the main harness to the rear fender front opening. 2. Clamp (insert the clamp to the frame.) 3. Vehicle-down sensor 4. Rear brake hose (to rear master cylinder) 5. Through the leads of the rear brake light switch and vehicle-down sensor from fo...

  • Page 590

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

  • Page 591

    Appendix 17-15 cable, wire, and hose routing 1. Subthrottle valve actuator lead 2. Clamp (push the subthrottle valve actuator lead under the clamp, and clamp the subthrottle sensor lead and subthrottle valve actuator lead to the delivery pipe.) 3. Clamp (clamp the harness.) 4. Subthrottle sensor lea...

  • Page 592

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

  • Page 593

    Appendix 17-17 cable, wire, and hose routing 1. Clamp (insert the clamp in the frame.) 2. Clamp (insert the clamp in the horn bracket.) 3. Insert the horn lead terminal from the under. 4. Battery negative cable 5. Battery positive cable 6. Main harness 7. Starter motor cable.

  • Page 594

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

  • Page 595

    Appendix 17-19 cable, wire, and hose routing 1. Fuel tank drain hose (through the drain hose between main harness and air cleaner housing.) 2. Air cleaner drain hose 3. Fuel tank drain hose 4. Clamp (through the sidestand switch lead, oxygen sensor lead (europe models), and fuel tank drain hose in t...

  • Page 596

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

  • Page 597

    Appendix 17-21 cable, wire, and hose routing 1. Headlight (low) connector with green tape on the headlight lead. 2. Clamp (insert the clamp to the handle.) 3. Turn signal relay lead 4. Left city light connector 5. Run the main harness between the clamp and pipe. 6. Headlight (high) connector 7. Band...

  • Page 598

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

  • Page 599

    Appendix 17-23 cable, wire, and hose routing 1. Clamp (insert the clamp to the handlebar.) 2. Through the brake hose, right switch housing lead, and throttle cables in the upper and lower clamps. 3. Right switch housing lead 4. Throttle cable (accelerator) 5. Throttle cable (decelerator) 6. Clamp (f...

  • Page 600

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

  • Page 601

    Appendix 17-25 cable, wire, and hose routing 1. Seat lock cable 2. Seat lock 3. Through the seat lock cable to the space of the frame bracket. 4. Install the hook faces downward..

  • Page 602

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

  • Page 603

    Appendix 17-27 cable, wire, and hose routing 1. Clamp 2. Clamp 3. Brake hose 4. Bracket 5. Brake hose.

  • Page 604

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

  • Page 605

    Appendix 17-29 cable, wire, and hose routing 1. Clamp 2. Clamp 3. Brake hose 4. Face the paint mark outside. 5. Viewed a.

  • Page 606

    17-30 appendix cable, wire, and hose routing kle650b models.

  • Page 607

    Appendix 17-31 cable, wire, and hose routing 1. Abs hydraulic unit 2. Brake hose 3. Brake hose 4. Damper 5. Clamp 6. Clamp 7. Bracket 8. Brake hose 9. Front wheel rotation sensor lead 10. Front wheel rotation sensor 11. Front wheel rotation sensor rotor 12. Viewed bottom side 13. Viewed upside.

  • Page 608

    17-32 appendix cable, wire, and hose routing kle650b models.

  • Page 609

    Appendix 17-33 cable, wire, and hose routing 1. Through the front wheel rotation sensor lead to the outside of the main harness. 2. Through the front wheel rotation sensor lead inside the right switch housing lead and ignition switch lead, and outside of the head pipe. 3. Front wheel rotation sensor...

  • Page 610

    17-34 appendix cable, wire, and hose routing kle650b models.

  • Page 611

    Appendix 17-35 cable, wire, and hose routing 1. Run the brake hose between the throttle cables and left switch housing lead. 2. Front wheel rotation sensor lead 3. Clamp 4. Clamps (insert the clamps in the baffle plate.) 5. Front wheel rotation sensor lead (front side).

  • Page 612

    17-36 appendix cable, wire, and hose routing kle650b models.

  • Page 613

    Appendix 17-37 cable, wire, and hose routing 1. Brake hose 2. Clamp (clamp the right switch housing lead, throttle cables, and brake hose.) 3. Throttle cable (decelerator) 4. Throttle cable (accelerator) 5. Right switch housing lead 6. Install the clamp to the frame, and clamp the right switch housi...

  • Page 614

    17-38 appendix cable, wire, and hose routing kle650b models.

  • Page 615

    Appendix 17-39 cable, wire, and hose routing 1. Abs hydraulic unit 2. Brake hose 3. Rear wheel rotation sensor lead 4. Clamps 5. Band 6. Brake hose 7. Brake hose 8. Rear wheel rotation sensor 9. Face the paint mark outside. 10. Viewed a.

  • Page 616

    17-40 appendix cable, wire, and hose routing kle650b models.

  • Page 617

    Appendix 17-41 cable, wire, and hose routing 1. Clamp (clamp the brake hose and front wheel rotation sensor lead, and insert the clamp from the outside.) 2. Clamp the brake hose and rear wheel rotation sensor lead with the band to the frame bracket (position the band so that the edge of the band fac...

  • Page 618

    17-42 appendix cable, wire, and hose routing kle650b models.

  • Page 619

    Appendix 17-43 cable, wire, and hose routing 1. Abs solenoid valve relay fuse 25a (insert the connector from the bottom in the rear fender side bracket.) 2. Abs pump motor relay fuse 30a (insert the connector from the bottom in the rear fender side bracket.) 3. Battery positive cable 4. Abs kawasaki...

  • Page 620

    17-44 appendix cable, wire, and hose routing.

  • Page 621

    Appendix 17-45 cable, wire, and hose routing 1. Through the ecu lead to the forward of the frame cross pipe. 2. Abs hydraulic unit.

  • Page 622

    17-46 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 623

    Appendix 17-47 troubleshooting guide compression low: spark plug loose cylinder head not sufficiently tightened down no valve clearance cylinder, piston worn piston ring bad (worn, weak, broken, or sticking) piston ring/groove clearance excessive cylinder head warped cylinder head gasket damaged val...

  • Page 624

    17-48 appendix troubleshooting guide engine oil viscosity too high drive train trouble brake dragging lubrication inadequate: engine oil level too low engine oil poor quality or incorrect gauge incorrect: water temperature gauge broken water temperature sensor broken coolant incorrect: coolant level...

  • Page 625

    Appendix 17-49 troubleshooting guide engine mount loose crankshaft bearing worn primary gear worn or chipped camshaft chain tensioner trouble camshaft chain, sprocket, guide worn air suction valve damaged air switching valve damaged alternator rotor loose catalytic converter melt down due to muffler...

  • Page 626

    17-50 appendix troubleshooting guide rear shock adjustment too soft front fork, rear shock absorber spring weak rear shock absorber oil leaking brake doesn’t hold: air in the brake line pad or disc worn brake fluid leakage disc warped contaminated pad brake fluid deteriorated primary or secondary cu...

  • Page 627

    Model application year model beginning frame no. 2007 kle650a7f jkaleea1 □ 7a000001 jkale650aaa000001 le650a-000001 2007 kle650b7f jkale650aba000001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1369-01 printed in japan.