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Kawasaki VERSYS - Service Manual

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

Summary of VERSYS -

  • Page 1

    Versys versys abs motorcycle service manual.

  • Page 3: Quick Reference Guide

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

  • Page 5: Versys

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

  • Page 6

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

  • Page 7

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

  • Page 8: 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

    Note ○ this note symbol indicates points of par- ticular interest for more efficient and con- venient operation. • indicates a procedural step or work to be done. ○ indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a note. Indicates...

  • Page 11: General Information

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

  • Page 12

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

  • Page 13

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

  • Page 14

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

  • Page 15

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

  • Page 16

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

  • Page 17

    General information 1-7 model identification kle650caf left side view kle650caf right side view.

  • Page 18

    1-8 general information model identification kle650daf left side view kle650daf right side view frame number engine number.

  • Page 19

    General information 1-9 general specifications items kle650caf ∼ cbf, kle650daf ∼ dbf dimensions overall length 2 125 mm (83.7 in.) overall width 840 mm (33.1 in.) overall height 1 330 mm (52.4 in.) wheelbase 1 415 mm (55.7 in.) road clearance 180 mm (7.1 in.) seat height 845 mm (33.3 in.) curb mass...

  • Page 20

    1-10 general information general specifications items kle650caf ∼ cbf, kle650daf ∼ dbf valve timing: intake: open 26° (btdc) close 54° (abdc) duration 260° exhaust: open 47° (bbdc) close 25° (atdc) duration 252° lubrication system forced lubrication (semi-dry sump) engine oil: type api sg, sh, sj, s...

  • Page 21

    General information 1-11 general specifications items kle650caf ∼ cbf, kle650daf ∼ dbf 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...

  • Page 22

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

  • Page 23: Periodic Maintenance

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

  • Page 24

    2-2 periodic maintenance electrical system ................................................................................................................. 2-39 lights and switches operation inspection........................................................................ 2-39 headlight aiming ins...

  • Page 25

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

  • Page 26

    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 (3.75) 12 (7.5) 18 (11.25) 24 (15) 30 (18.75) 36 (22.5) see page drive chain slack - inspect # every 1 000 km (600 mile) 2-30 drive chain wear -...

  • Page 27

    Periodic maintenance 2-5 periodic maintenance chart periodic replacement parts frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) item every 1 (0.6) 12 (7.5) 24 (15) 36 (22.5) 48 (30) see page air cleaner element # - replace 2 years 2-46 fuel hose - replace 4 years • 2-46 v...

  • Page 28

    2-6 periodic maintenance torque and locking agent the following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “remarks” column mean: al: tighten the two clamp bolts alternately two times to ensure...

  • Page 29

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks 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 30

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks crankcase bolt (m8, l = 110 mm) 27.5 2.8 20 s 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...

  • Page 31

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks front brake disc mounting bolts 27 2.8 20 l front brake light switch screw 1.2 0.12 11 in·lb front brake reservoir cap screws 1.5 0.15 13 in·lb front caliper mounting bolts 34 3.5 25 front master cylinder clamp...

  • Page 32

    2-10 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks alternator lead holding plate bolt 9.8 1.0 87 in·lb l alternator rotor bolt 155 15.8 114 mo engine ground cable terminal bolt 9.8 1.0 87 in·lb front brake light switch screw 1.2 0.12 11 in·lb left switch housi...

  • Page 33

    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 34

    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.) 319 mm (12.6 in.) standard chain: kle650caf/daf make enuma – – – type ek520mvxl – – – link 114 li...

  • Page 35

    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 36

    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. Warning if dirt or dust is allowed to pass through into the throttle assy, the throttle may bec...

  • Page 37

    Periodic maintenance 2-15 periodic maintenance procedures warning gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the element in a well-ventilated area, and take care that there is no spark or flame any- where near the working areas. Do not use g...

  • Page 38

    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 39

    Periodic maintenance 2-17 periodic maintenance procedures if the vacuum is not within the specification, turn the by- pass screw until the vacuum becomes within the specifi- cation. Special tool - pilot screw adjuster, e [a]: 57001-1603 • open and close the throttle after each measurement, and adjus...

  • Page 40

    2-18 periodic maintenance periodic maintenance procedures • back out the same number of turns counted when first turned in. This is to set the screw to its original position. Note ○ a throttle body has different “turns out” of the bypass screw for each individual unit. On setting the bypass screw, u...

  • Page 41

    Periodic maintenance 2-19 periodic maintenance procedures idle speed adjustment • start the engine and warm it up thoroughly. • turn the adjusting screw [a] until the idle speed is correct. ○ open and close the throttle a few times to make sure that the idle speed is within the specified range. Read...

  • Page 42

    2-20 periodic maintenance periodic maintenance procedures ○ remove the canister [a], and disconnect the hoses from the canister. ○ visually inspect the canister for cracks or other damage. If the canister has any cracks or bad damage, replace it with a new one. Note ○ the canister is designed to wor...

  • Page 43

    Periodic maintenance 2-21 periodic maintenance procedures cooling system coolant level inspection note ○ check the level when the engine is cold (room or ambi- ent temperature). • check the coolant level in the reserve tank [a] with the motorcycle held perpendicular (do not use the sidestand). If th...

  • Page 44

    2-22 periodic maintenance periodic maintenance procedures air suction system air suction system damage inspection • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) fuel hose (see fuel hose replacement) • connect the following parts temporarily. Fuel pump lead connector [a]...

  • Page 45

    Periodic maintenance 2-23 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 46

    2-24 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 47

    Periodic maintenance 2-25 periodic maintenance procedures valve clearance adjustment chart intake valve 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where t...

  • Page 48

    2-26 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 49

    Periodic maintenance 2-27 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 50

    2-28 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 51

    Periodic maintenance 2-29 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 52

    2-30 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 53

    Periodic maintenance 2-31 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 54

    2-32 periodic maintenance periodic maintenance procedures drive chain wear inspection • remove the chain cover (see swingarm removal in the suspension chapter). • rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace t...

  • Page 55

    Periodic maintenance 2-33 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 56

    2-34 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 test riding the vehicle, be aware of surr...

  • Page 57

    Periodic maintenance 2-35 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 58

    2-36 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 59

    Periodic maintenance 2-37 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 60

    2-38 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 the claw washer touches the stem nut [d]. • tighten the stem locknut c...

  • Page 61

    Periodic maintenance 2-39 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 light [a] goes on taillight [b] goes on license plate light [c] goes on me...

  • Page 62

    2-40 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 63

    Periodic maintenance 2-41 periodic maintenance procedures • set the dimmer switch to high beam position. • the low beam [a] and high beam [b] headlights should go on. • the high beam indicator light (led) [c] should go on. If the high beam headlight and/or high beam indicator light (led) does not go...

  • Page 64

    2-42 periodic maintenance periodic maintenance procedures note ○ for us model, the proper angle is 0.4 degrees below horizontal. This is 50 mm (2 in.) drop at 7.6 m (25 ft) measured from the center of the headlight with the motorcycle on its wheels and the rider seated. 50 mm (2 in.) [a] center of b...

  • Page 65

    Periodic maintenance 2-43 periodic maintenance procedures if the sidestand switch operation does not work, inspect or replace the following item. Battery (see charging condition inspection in the elec- trical system chapter) main fuse 30 a (see fuse inspection in the electrical system chapter) ignit...

  • Page 66

    2-44 periodic maintenance periodic maintenance procedures others chassis parts lubrication • before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • lubricate the points listed below with indicated lubricant. Note ○ whenever the vehic...

  • Page 67

    Periodic maintenance 2-45 periodic maintenance procedures bolts, nuts and fasteners tightness inspection • check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. Note ○ for the engine fasteners, check the tightness of them wh...

  • Page 68

    2-46 periodic maintenance periodic maintenance procedures replacement parts air cleaner element replacement • refer to the air cleaner element cleaning. Fuel hose replacement notice when removing and installing the fuel hose joint, do not apply strong force to the outlet pipe on the fuel pump and de...

  • Page 69

    Periodic maintenance 2-47 periodic maintenance procedures vehicle-down sensor mounting dampers replacement notice never drop the vehicle-down sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove: right frame cover (see frame cover removal in the frame chapter) con...

  • Page 70

    2-48 periodic maintenance periodic maintenance procedures • remove: bolts [a] reserve tank bracket [b] • put the projection [a] on the reserve tank into the hole [b] on the frame bracket, and place the reserve tank on the right side of frame. • place a container under the water pump drain bolt [a], ...

  • Page 71

    Periodic maintenance 2-49 periodic maintenance procedures • when filling the coolant, choose a suitable mixture ratio by referring to the coolant manufacturer’s directions. Notice soft or distilled water must be used with the an- tifreeze in the cooling system. If hard water is used in the system, i...

  • Page 72

    2-50 periodic maintenance periodic maintenance procedures radiator hose and o-ring replacement • drain the coolant (see coolant change). • remove: thermostat housing [a] (see water pump removal in the cooling system chapter) water pump cover [b] (see water pump removal in the cooling system chapter)...

  • Page 73

    Periodic maintenance 2-51 periodic maintenance procedures recommended engine oil type: api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity: sae 10w-40 capacity: 1.7 l (1.8 us qt) (when filter is not removed) 1.9 l (2.0 us qt) (when filter is removed) 2.4 l (2.5 us qt) (when engine is complet...

  • Page 74

    2-52 periodic maintenance periodic maintenance procedures brake hose replacement notice brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • remove the banjo bolts [a]. • when removing the brake hose, take care not to spill the brake f...

  • Page 75

    Periodic maintenance 2-53 periodic maintenance procedures note ○ when removing the brake pipes and hoses on the hy- draulic unit, remove them according to each assembly of the exploded view in the brakes chapter. • for models equipped with an abs, note the following. ○ remove: rear fender front (see...

  • Page 76

    2-54 periodic maintenance 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 77

    Periodic maintenance 2-55 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 78

    2-56 periodic maintenance 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 79

    Periodic maintenance 2-57 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 80

    2-58 periodic maintenance periodic maintenance procedures rear caliper assembly • clean the caliper parts except for the pads. Notice 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 81

    Periodic maintenance 2-59 periodic maintenance procedures • insert the spark plug [a] vertically into the plug hole with the spark plug installed in the plug wrench [b]. Notice the insulator of the spark plug may break if when the wrench is inclined during tightening. • tighten: torque - spark plugs...

  • Page 83: Fuel System (Dfi)

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

  • Page 84

    3-2 fuel system (dfi) subthrottle sensor removal/adjustment .......................................................................... 3-61 subthrottle sensor input voltage inspection..................................................................... 3-61 subthrottle sensor output voltage inspecti...

  • Page 85

    Fuel system (dfi) 3-3 throttle cable installation ................................................................................................. 3-97 throttle cable lubrication................................................................................................. 3-97 throttle body assy...

  • Page 86

    3-4 fuel system (dfi) exploded view.

  • Page 87

    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 8.8 0.90 78 in·lb l 4. Injectors 5. Throttle body assy 6. Throttle cable (accelerator) 7. Throttle cable (de...

  • Page 88

    3-6 fuel system (dfi) exploded view.

  • Page 89

    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 (equipped 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 ...

  • Page 90

    3-8 fuel system (dfi) exploded view cal, th and sea models.

  • Page 91

    Fuel system (dfi) 3-9 exploded view 1. Separator 2. Canister 3. Tube (green) 4. Tube (blue) 5. Tube (white) 6. Tube (blue) 7. Tube (red).

  • Page 92

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

  • Page 93

    Fuel system (dfi) 3-11 dfi system 1. Intake air pressure sensor 2. Crankshaft sensor 3. Fuel injectors 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 c...

  • Page 94

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

  • Page 95

    Fuel system (dfi) 3-13 dfi system part name 1. Oxygen sensor (equipped models) 2. Crankshaft sensor 3. Intake air temperature sensor 4. Water temperature sensor 5. Water-proof joint e 6. Fuel injectors 7. Vehicle-down sensor 8. Water-proof joint d 9. Intake air pressure sensor 10. Main throttle sens...

  • Page 96

    3-14 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. Oxygen sensor signal (equipped models) 5. Speed sensor signal 6. Main throttle sensor signal 7. Intake air pressure ...

  • Page 97

    Fuel system (dfi) 3-15 dfi parts location 1. Fi indicator light (led) 2. Ignition switch 3. Throttle body assy 4. Intake air temperature sensor 5. Fuel 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...

  • Page 98

    3-16 fuel system (dfi) specifications item standard digital fuel injection system idle speed 1 300 ±50 r/min (rpm) throttle body assy: throttle valve dual throttle valve bore 38 mm (1.50 in.) ecu (electronic control unit): make denso type digital memory type, with built in ic igniter, sealed with re...

  • Page 99

    Fuel system (dfi) 3-17 specifications item standard subthrottle sensor: non-adjustable and non-removal input voltage dc 4.75 ∼ 5.25 v output voltage at idle throttle opening dc 0.4 ∼ 0.6 v output voltage at full throttle opening dc 3.825 ∼ 3.975 v resistance 4 ∼ 6 k Ω subthrottle valve actuator: res...

  • Page 100

    3-18 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 101

    Fuel system (dfi) 3-19 special tools and sealant oxygen sensor measuring adapter: 57001-1682 liquid gasket, tb1211: 56019-120

  • Page 102

    3-20 fuel system (dfi) dfi servicing precautions dfi servicing precautions there are a number of important precautions that should be followed servicing the dfi system. ○ this dfi system is designed to be used with a 12 v sealed battery as its power source. Do not use any other battery except for a ...

  • Page 103

    Fuel system (dfi) 3-21 dfi servicing precautions ○ to maintain the correct fuel/air mixture (f/a), there must be no intake 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 104

    3-22 fuel system (dfi) troubleshooting the dfi system outline when an abnormality in the dfi system occurs, the fi indicator light (led) goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ecu (electronic control unit). With the eng...

  • Page 105

    Fuel system (dfi) 3-23 troubleshooting the dfi system ○ the dfi part connectors [a] have seals [b], including the ecu. • join the connector and insert the needle adapters [c] inside the seals [b] from behind the connector until the adapter reaches the terminal. Special tool - needle adapter set: 570...

  • Page 106

    3-24 fuel system (dfi) troubleshooting the dfi system • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. • check the wiring for continuity. ○ use the...

  • Page 107

    Fuel system (dfi) 3-25 troubleshooting the dfi system dfi diagnosis flow chart inquiries to rider ○ each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ try to find out exactly what problem occurred under exactly what condi...

  • Page 108

    3-26 fuel system (dfi) troubleshooting the dfi system sample diagnosis sheet rider name: registration no. (license plate no.): year of initial registration: model: engine no.: frame no.: date problem occurred: mileage: environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ al...

  • Page 109

    Fuel system (dfi) 3-27 troubleshooting the dfi system □ other □ spark plug loose (tighten it) □ spark plug dirty, broken, or gap maladjusted (remedy it) □ spark plug incorrect (replace it) □ knocking (fuel poor quality or incorrect, → use high-octane gasoline) □ brake dragging □ clutch slipping □ en...

  • Page 110

    3-28 fuel system (dfi) dfi system troubleshooting guide note ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in dfi system. ○ the ecu may be involved in t...

  • Page 111

    Fuel system (dfi) 3-29 dfi system troubleshooting guide symptoms or possible causes actions (chapter) fuel line clogged inspect and repair (see chapter 3). Intake air pressure sensor trouble inspect (see chapter 3). Intake air temperature sensor trouble inspect (see chapter 3). Water temperature sen...

  • Page 112

    3-30 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) main throttle sensor trouble inspect (see chapter 3). Intake air pressure sensor trouble inspect (see chapter 3). Spark plug dirty, broken or gap maladjusted inspect and replace (see chapter 2). Stu...

  • Page 113

    Fuel system (dfi) 3-31 dfi system troubleshooting guide symptoms or possible causes actions (chapter) stick coil trouble inspect (see chapter 16). Stick coil shorted or not in good contact inspect or reinstall (see chapter 16). Spark plug incorrect replace it with the correct plug (see chapter 2). E...

  • Page 114

    3-32 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) exhaust smokes excessively: (black smoke) air cleaner element clogged clean element (see chapter 2). Fuel pressure to high inspect (see chapter 3). Fuel injector trouble inspect (see chapter 3). Wat...

  • Page 115

    Fuel system (dfi) 3-33 self-diagnosis self-diagnosis outline the self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User mode the ecu notifies the rider of troubles in dfi system and ignition system by lighting the fi indicator when df...

  • Page 116

    3-34 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 117

    Fuel system (dfi) 3-35 self-diagnosis.

  • Page 118

    3-36 fuel system (dfi) self-diagnosis how to read service codes ○ service codes are shown by a series of long and short blinks of the fi indicator light (led) as shown below. ○ read 10th digit and unit digit as the fi indicator light (led) blinks. ○ when there are a number of problems, all the servi...

  • Page 119

    Fuel system (dfi) 3-37 self-diagnosis service code table service code fi indicator light (led) problems 11 main throttle sensor malfunction, wiring open or short 12 intake air pressure sensor malfunction, wiring open or short 13 intake air temperature sensor malfunction, wiring open or short 14 wate...

  • Page 120

    3-38 fuel system (dfi) self-diagnosis backups ○ the ecu takes the following measures to prevent engine damage when the dfi or the ignition system parts have troubles. Service codes parts output signal usable range or criteria backups by ecu 11 main throttle sensor main throttle sensor output voltage...

  • Page 121

    Fuel system (dfi) 3-39 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 122

    3-40 fuel system (dfi) main throttle sensor (service code 11) main throttle sensor removal/adjustment notice do not remove or adjust the main throttle sensor [a] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface. Such a ...

  • Page 123

    Fuel system (dfi) 3-41 main throttle sensor (service code 11) wiring connection ecu connector [a] ←→ main throttle sensor connector [b] bl lead (ecu terminal 8) br/bk lead (ecu terminal 22) if the wiring is good, check the ecu for its ground and power supply (see ecu power supply inspection). If the...

  • Page 124

    3-42 fuel system (dfi) main throttle sensor (service code 11) • turn the ignition switch off. If the output voltage is out of the standard, inspect the main throttle sensor resistance (see main throttle sensor resistance inspection). Wiring connection ecu connector [a] ←→ main throttle sensor connec...

  • Page 125

    Fuel system (dfi) 3-43 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 126

    3-44 fuel system (dfi) intake air pressure sensor (service code 12) notice never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Intake air pressure sensor removal • remove the left middle fairing (see middle fairing re- moval in the frame chapter). • disconnec...

  • Page 127

    Fuel system (dfi) 3-45 intake air pressure sensor (service code 12) intake 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 foll...

  • Page 128

    3-46 fuel system (dfi) intake air pressure sensor (service code 12) ○ measure the output voltage from various vacuum readings, while pulling the handle of the fork oil level gauge. If the output voltage for various vacuum is normal, check the ecu for its ground, and power supply (see ecu power suppl...

  • Page 129

    Fuel system (dfi) 3-47 intake air pressure sensor (service code 12) pv = 24 ∼ 55 cmhg.

  • Page 130

    3-48 fuel system (dfi) intake 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: int...

  • Page 131

    Fuel system (dfi) 3-49 intake air pressure sensor (service code 12) intake air pressure sensor circuit 1. Ecu 2. Water-proof joint e 3. Water-proof joint d 4. Intake air pressure sensor.

  • Page 132

    3-50 fuel system (dfi) intake air temperature sensor (service code 13) intake air temperature sensor removal/instal- lation notice 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...

  • Page 133

    Fuel system (dfi) 3-51 intake air temperature sensor (service code 13) intake air temperature sensor resistance inspection • remove the intake air temperature sensor (see intake air temperature sensor removal/installation). • suspend the sensor [a] in a container of machine oil so that the heat-sens...

  • Page 134

    3-52 fuel system (dfi) water temperature sensor (service code 14) water temperature sensor removal/installation notice 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). • discon...

  • Page 135

    Fuel system (dfi) 3-53 water temperature sensor (service code 14) • measure the output voltage with the engine stopped and the connector joined. • turn the ignition switch on. Output voltage at ecu standard: about 2.80 ∼ 2.97 v at 20°c (68°f) • turn the ignition switch off. If the output voltage is ...

  • Page 136

    3-54 fuel system (dfi) crankshaft sensor (service code 21) start the engine and switch the diagnosis mode to dealer 1 mode to know all the problem that the dfi system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of ...

  • Page 137

    Fuel system (dfi) 3-55 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 138

    3-56 fuel system (dfi) 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 139

    Fuel system (dfi) 3-57 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 140

    3-58 fuel system (dfi) vehicle-down sensor (service code 31) vehicle-down sensor removal notice never drop the vehicle-down sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove: connector [a] vehicle-down sensor [b] and dampers [c] vehicle-down sensor installation...

  • Page 141

    Fuel system (dfi) 3-59 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 142

    3-60 fuel system (dfi) 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 143

    Fuel system (dfi) 3-61 subthrottle sensor (service code 32) subthrottle sensor removal/adjustment notice 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 144

    3-62 fuel system (dfi) subthrottle sensor (service code 32) wiring connection ecu connector [a] ←→ subthrottle sensor connector [b] bl lead (terminal 8) br/bk lead (terminal 22) if the wiring is good, check the ecu for its ground and power supply (see ecu power supply inspection). If the ground and ...

  • Page 145

    Fuel system (dfi) 3-63 subthrottle sensor (service code 32) wiring connection ecu connector [a] ←→ subthrottle sensor connector [b] br lead (terminal 19) br/bk lead (terminal 22) if the wiring is good, check the ecu for its ground and power supply (see ecu power supply inspection). If the ground and...

  • Page 146

    3-64 fuel system (dfi) subthrottle sensor (service code 32) subthrottle sensor circuit 1. Ecu 2. Water-proof joint e 3. Water-proof joint d 4. Subthrottle sensor.

  • Page 147

    Fuel system (dfi) 3-65 oxygen sensor-not activated (service code 33) (equipped models) oxygen sensor removal/installation • refer to the oxygen sensor removal/installation in the electrical system chapter. Oxygen sensor inspection • warm up the engine thoroughly until the radiator fan starts. • turn...

  • Page 148

    3-66 fuel system (dfi) oxygen sensor-not activated (service code 33) (equipped models) oxygen sensor circuit 1. Ecu 2. Oxygen sensor 3. Water-proof joint e 4. Ignition switch 5. Water-proof joint c 6. Oxygen sensor heater fuse 10 a 7. Main fuse 30 a (kle650caf/daf) 8. Main fuse 30 a (kle650cbf/dbf) ...

  • Page 149

    Fuel system (dfi) 3-67 stick coils #1, #2: (service code 51, 52) stick coil #1: service code 51 stick coil #2: service code 52 stick coil removal/installation notice 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 re...

  • Page 150

    3-68 fuel system (dfi) stick coils #1, #2: (service code 51, 52) stick coil circuit 1. Ecu 2. Stick coils 3. Engine stop switch 4. Ignition switch 5. Water-proof joint c 6. Ignition fuse 10 a 7. Main fuse 30 a (kle650caf/daf) 8. Main fuse 30 a (kle650cbf/dbf) 9. Battery 12 v 10 ah 10. Frame ground 1...

  • Page 151

    Fuel system (dfi) 3-69 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 152

    3-70 fuel system (dfi) radiator fan relay (service code 56) radiator fan relay circuit 1. Ecu 2. Water-proof joint c 3. Water-proof joint b 4. Radiator fan fuse 15 a 5. Relay box 6. Radiator fan relay 7. Main fuse 30 a (kle650caf/daf) 8. Main fuse 30 a (kle650cbf/dbf) 9. Battery 12 v 10 ah 10. Frame...

  • Page 153

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

  • Page 154

    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 155

    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 156

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

  • Page 157

    Fuel system (dfi) 3-75 oxygen sensor heater (service code 67) (equipped 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 conne...

  • Page 158

    3-76 fuel system (dfi) oxygen sensor heater (service code 67) (equipped models) oxygen sensor circuit 1. Ecu 2. Oxygen sensor 3. Water-proof joint e 4. Ignition switch 5. Water-proof joint c 6. Oxygen sensor heater fuse 10 a 7. Main fuse 30 a (kle650caf/daf) 8. Main fuse 30 a (kle650cbf/dbf) 9. Batt...

  • Page 159

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

  • Page 160

    3-78 fuel system (dfi) oxygen sensor-incorrect output voltage (service code 94) (equipped models) oxygen sensor circuit 1. Ecu 2. Oxygen sensor 3. Water-proof joint e 4. Ignition switch 5. Water-proof joint c 6. Oxygen sensor heater fuse 10 a 7. Main fuse 30 a (kle650caf/daf) 8. Main fuse 30 a (kle6...

  • Page 161

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

  • Page 162

    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 163

    Fuel system (dfi) 3-81 ecu ecu identification ○ most countries have their own regulations, so each ecu has different characteristic. So, do not confuse ecu with each other and use only the ecu for your model. Other- wise, the motorcycle can not clear the regulation. Ecu identification part number [a...

  • Page 164

    3-82 fuel system (dfi) ecu • fit [a] the bracket on the ecu as shown. • install the removed parts (see appropriate chapters). Ecu power supply inspection • visually inspect the terminals [a] of the ecu connectors. If the connector is clogged with mud or dust, blow it off with compressed air. Replace...

  • Page 165

    Fuel system (dfi) 3-83 ecu ecu power source inspection meter connections: between terminal 12 (br/w) and battery (–) terminal between terminal 27 (w/bk) and battery (–) terminal ignition switch off: terminal 12 (br/w): 0 v terminal 27 (w/bk): battery voltage ignition switch on: both: battery voltage...

  • Page 166

    3-84 fuel system (dfi) 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 167

    Fuel system (dfi) 3-85 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 168

    3-86 fuel system (dfi) 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 fuel is flammable and explosive under certain con- ditions...

  • Page 169

    Fuel system (dfi) 3-87 fuel pump fuel pump removal notice 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 ex- plosive under certain conditions, creating the potential for serious burns. Make sure the...

  • Page 170

    3-88 fuel system (dfi) fuel pump • replace the fuel pump gasket [a] with a new one. • apply a non-permanent locking agent to the threads of the fuel pump bolts. • tighten the fuel pump bolts in the opposite angle, tighten them alternating diagonally. Torque - fuel pump bolts: 9.8 n·m (1.0 kgf·m, 87 ...

  • Page 171

    Fuel system (dfi) 3-89 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 172

    3-90 fuel system (dfi) 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 (kle650caf/daf) 11. Main fuse 30 a (kle650cbf/dbf) 12. Batte...

  • Page 173

    Fuel system (dfi) 3-91 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 174

    3-92 fuel system (dfi) 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 175

    Fuel system (dfi) 3-93 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.) notice do not use larger terminals than specified above. A larger t...

  • Page 176

    3-94 fuel system (dfi) 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 177

    Fuel system (dfi) 3-95 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 178

    3-96 fuel system (dfi) 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 (kle650caf/daf) 12. Main fuse 30...

  • Page 179

    Fuel system (dfi) 3-97 throttle grip and cables throttle grip free play inspection • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Throttle grip free play adjustment • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Thro...

  • Page 180

    3-98 fuel system (dfi) 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 181

    Fuel system (dfi) 3-99 throttle body assy • loosen the throttle body assy holder clamp bolts [a] on both sides. • remove the throttle case [a] to make a throttle cable slack. • remove the throttle cable lower ends [a] from the throttle pulley. • pull off the throttle body assy from the holder. • aft...

  • Page 182

    3-100 fuel system (dfi) throttle body assy • install the throttle body assy holder clamp bolts [a] in the direction as shown. Bolt heads [b] • run the leads and hoses as shown in the cable, wire, and hose routing section of the appendix chapter. • fit the accelerator cable end [a] and the decelerato...

  • Page 183

    Fuel system (dfi) 3-101 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 184

    3-102 fuel system (dfi) air cleaner air cleaner element removal/installation • refer to the air cleaner element replacement in the pe- riodic maintenance chapter. Air cleaner element inspection • remove the air cleaner element (see air cleaner element replacement in the periodic maintenance chapter)...

  • Page 185

    Fuel system (dfi) 3-103 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. ○ insert the breather hose [a] into the crankcase as shown in the figure. 0 ∼ 5...

  • Page 186

    3-104 fuel system (dfi) fuel tank fuel tank removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a...

  • Page 187

    Fuel system (dfi) 3-105 fuel tank • disconnect: fuel pump lead connector [a] fuel level sensor lead connector [b] • remove the fuel drain hoses [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 dr...

  • Page 188

    3-106 fuel system (dfi) 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 189

    Fuel system (dfi) 3-107 fuel tank fuel tank and cap inspection • visually inspect the gasket [a] on the tank cap for any damage. Replace the gasket if it is damaged. • check to see if the water drain pipe [b] and fuel breather pipe [c] in the tank is not clogged. Check the tank cap breather also. If...

  • Page 190

    3-108 fuel system (dfi) evaporative emission control system (cal, th and sea models) the evaporative emission control system routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thor...

  • Page 191

    Fuel system (dfi) 3-109 evaporative emission control system (cal, th and sea models) separator inspection • remove the canister cover. • refer to the evaporative emission control system in- spection in the periodic maintenance chapter. Separator [a] separator operation test warning gasoline is extre...

  • Page 193: Cooling System

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

  • Page 194

    4-2 cooling system exploded view.

  • Page 195

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 baffle plate bolts 5.9 0.60 52 in·lb 2 radiator bolt 15 1.5 11 3 radiator hose clamp screws 3.0 0.31 27 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 196

    4-4 cooling system coolant flow chart.

  • Page 197

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

  • Page 198

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

  • Page 199

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

  • Page 200

    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 201

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

  • Page 202

    4-10 cooling system water pump water pump removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: 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 203

    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) • align the line [a] of the water pump cover with t...

  • Page 204

    4-12 cooling system water pump water pump housing disassembly notice be careful not to damage the sealing surface of the mechanical seal. • remove the water pump housing (see water pump re- moval). • take the oil seal [a] out of the housing [b] with a hook [c]. • press the mechanical seal [a] out of...

  • Page 205

    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 206

    4-14 cooling system radiator radiator and radiator fan installation if the radiator guard [a] was removed, install it (kle650caf/daf early models). • 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...

  • Page 207

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

  • Page 208

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

  • Page 209

    Cooling system 4-17 thermostat thermostat removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove 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] ○ for cal, th an...

  • Page 210

    4-18 cooling system thermostat • install a new o-ring [a] into the housing and apply grease it. • tighten: torque - thermostat housing bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • align the line [a] of the thermostat housing with the red mark [b] of the radiator hose [c]. • install the radiator hose clamp...

  • Page 211

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

  • Page 212

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

  • Page 213: Engine Top End

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

  • Page 214

    5-2 engine top end piston ring thickness ...................................................................................................... 5-42 piston ring end gap ........................................................................................................ 5-43 throttle body assy ho...

  • Page 215

    Engine top end 5-3 exploded view this page intentionally left blank..

  • Page 216

    5-4 engine top end exploded view.

  • Page 217

    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 218

    5-6 engine top end exploded view.

  • Page 219

    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 s 4 exhaust pipe manifold holder nuts 17 1.7 12 5 muffler body mounting bolt (front) 20 2.0 15 6 muffler bod...

  • Page 220

    5-8 engine top end exhaust system identification exhaust system manifold mark position [a] muffler body mark position [b] honeycomb type catalyst position [c] muffler body with hole [d] for oxygen sensor [e]..

  • Page 221

    Engine top end 5-9 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.) inltake 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 i...

  • Page 222

    5-10 engine top end specifications item standard service limit valve spring free length: exhaust 41.9 mm (1.65 in.) 40.3 mm (1.587 in.) intake 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 diamet...

  • Page 223

    Engine top end 5-11 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 224

    5-12 engine top end special tools and sealant compression gauge adapter, m10 × 1.0: 57001-1317 valve seat cutter holder, 4.5: 57001-1330 valve guide arbor, 4.5: 57001-1331 valve guide reamer, 4.5: 57001-1333 piston pin puller: 57001-1568 piston pin puller adapter, 12: 57001-1657 liquid gasket, tb121...

  • Page 225

    Engine top end 5-13 clean air system air suction valve removal • remove: air switching valve (see air switching valve removal) air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter) air suction valve cover bolts [a] clamp [b] air suction valve cover [c] • remove the a...

  • Page 226

    5-14 engine top end clean air system air suction valve inspection • remove the air suction valve (see air suction valve re- moval). • visually inspect the reeds [a] for cracks, folds, warps, heat damage or other damage. If there is any doubt as to the condition of the reeds, re- place the air suctio...

  • Page 227

    Engine top end 5-15 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 228

    5-16 engine top end 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 229

    Engine top end 5-17 cylinder head cover cylinder head cover installation • replace the head cover gasket [a] with a new one. • apply liquid gasket [b] to the cylinder head as shown. Sealant - liquid gasket, tb1211f: 92104-0004 • replace the plug hole gaskets [a] with new ones. • be sure to install t...

  • Page 230

    5-18 engine top end 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 231

    Engine top end 5-19 camshaft chain tensioner camshaft chain tensioner removal notice this is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: when removing the tens...

  • Page 232

    5-20 engine top end 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 233

    Engine top end 5-21 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 234

    5-22 engine top end 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] notice the crankshaft may be turned while t...

  • Page 235

    Engine top end 5-23 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 intake [a] ...

  • Page 236

    5-24 engine top end 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. Notice the crankshaft may be turned...

  • Page 237

    Engine top end 5-25 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 intake cap has a “in” mark [b...

  • Page 238

    5-26 engine top end 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 (press gauge) to the camshaft installed in the correct position. • tighten the camshaft cap ...

  • Page 239

    Engine top end 5-27 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 240

    5-28 engine top end cylinder head cylinder compression measurement note ○ use the battery which is fully charged. • warm up the engine thoroughly. • stop the engine. • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) air cleaner housing (see air cleaner housing removal in t...

  • Page 241

    Engine top end 5-29 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 242

    5-30 engine top end 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 243

    Engine top end 5-31 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 244

    5-32 engine top end valves valve clearance inspection • refer to the valve clearance inspection in the periodic maintenance chapter. Valve clearance adjustment • refer to the valve clearance adjustment in the periodic maintenance chapter. Valve removal • remove cylinder head (see cylinder head remov...

  • Page 245

    Engine top end 5-33 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 246

    5-34 engine top end 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 247

    Engine top end 5-35 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 248

    5-36 engine top end 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 249

    Engine top end 5-37 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 250

    5-38 engine top end valves.

  • Page 251

    Engine top end 5-39 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 252

    5-40 engine top end 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 253

    Engine top end 5-41 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 254

    5-42 engine top end 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 255

    Engine top end 5-43 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 256

    5-44 engine top end 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 257

    Engine top end 5-45 muffler muffler body removal warning the muffler can become extremely hot during nor- mal operation and cause severe burns. Do not re- move the muffler while it is hot. • remove: right rear frame cover (see rear frame cover re- moval in the frame chapter) lower fairings (see lowe...

  • Page 258

    5-46 engine top end 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 259: Clutch

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

  • Page 260

    6-2 clutch exploded view.

  • Page 261

    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 262

    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 263

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

  • Page 264

    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 265

    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 266

    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 267

    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 lever and shaft assembly (see release shaft removal) oil seal [a] needle bearings [b] • remove: oil level gauge [a] timing insp...

  • Page 268

    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 269

    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 270

    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 271

    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 272

    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 273: Engine Lubrication System

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

  • Page 274

    7-2 engine lubrication system exploded view.

  • Page 275

    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 276

    7-4 engine lubrication system engine oil flow chart.

  • Page 277

    Engine lubrication system 7-5 engine oil flow chart.

  • Page 278

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

  • Page 279

    Engine lubrication system 7-7 special tools and sealant oil pressure gauge, 10 kgf/cm²: 57001-164 oil pressure gauge adapter, pt3/8: 57001-1233 liquid gasket, tb1211: 56019-120

  • Page 280

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

  • Page 281

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

  • Page 282

    7-10 engine lubrication system oil pan oil pan installation • replace the o-rings with new one. • 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....

  • Page 283

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

  • Page 284

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

  • Page 285

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

  • Page 286

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

  • Page 287

    Engine lubrication system 7-15 oil pressure measurement oil pressure measurement • remove: right lower fairing (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 288

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

  • Page 289: Engine Removal/installation

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

  • Page 290

    8-2 engine removal/installation exploded view.

  • Page 291

    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 r, s 4. Collar 5. Engine mounting brackets r: replacement parts s: follow the specifie...

  • Page 292

    8-4 engine removal/installation engine removal/installation engine removal • support the rear part of the swingarm with a stand. • squeeze the brake lever slowly and hold it with a band [a]. Warning motorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to hold the front b...

  • Page 293

    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 294

    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 295

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

  • Page 296

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

  • Page 297: Crankshaft/transmission

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

  • Page 298

    9-2 crankshaft/transmission exploded view.

  • Page 299

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

  • Page 300

    9-4 crankshaft/transmission exploded view.

  • Page 301

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

  • Page 302

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

  • Page 303

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

  • Page 304

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

  • Page 305

    Crankshaft/transmission 9-9 special tools and sealants outside circlip pliers: 57001-144 bearing driver set: 57001-1129 liquid gasket, tb1211f: 92104-0004 liquid gasket, tb1216b: 92104-1064 liquid gasket, tb1207b: 92104-2068.

  • Page 306

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

  • Page 307

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

  • Page 308

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

  • Page 309

    Crankshaft/transmission 9-13 crankcase splitting • when the new oil plug [a] and new race [b] for drive shaft is installed in the upper crankcase half [c], install them using the following steps. ○ apply grease to the new o-rings [d]. ○ apply liquid gasket to the portions [e] on the upper crankcase ...

  • Page 310

    9-14 crankshaft/transmission crankcase splitting • apply molybdenum disulfide oil solution to the edge of the oil pipe [e]. • install the oil pipe [a] so that its flange [b] touches to the surface [c] of the upper crankcase half. • apply grease to the new o-ring [d] on the oil pipe. • replace the o-...

  • Page 311

    Crankshaft/transmission 9-15 crankcase splitting • be sure that the dowel pins [a] are in position. • set the bearing groove [a] on the positioning ring [b] as shown. • apply liquid gasket [a] to the mating surface of the lower crankcase half. Sealant - liquid gasket, tb1216b: 92104-1064 note ○ espe...

  • Page 312

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

  • Page 313

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

  • Page 314

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

  • Page 315

    Crankshaft/transmission 9-19 crankshaft and connecting rods connecting rod installation notice 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 notice if the connecting rods, ...

  • Page 316

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

  • Page 317

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

  • Page 318

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

  • Page 319

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

  • Page 320

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

  • Page 321

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

  • Page 322

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

  • Page 323

    Crankshaft/transmission 9-27 crankshaft and connecting rods • measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. Crankcase main bearing inside diameter marks: “ ○ ” or no mark. • tighten the crankcase bolts to the specified torque (s...

  • Page 324

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

  • Page 325

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

  • Page 326

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

  • Page 327

    Crankshaft/transmission 9-31 external shift mechanism shift pedal removal • remove: right rear frame cover (see rear frame cover re- moval in the frame chapter) shift lever bolt [a] shift lever [b] bolts [c] left front footpeg stay [d] with shift pedal [e] • remove: footpeg holder bolt [a] footpeg [...

  • Page 328

    9-32 crankshaft/transmission external shift mechanism • 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 ...

  • Page 329

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

  • Page 330

    9-34 crankshaft/transmission external shift mechanism • replace the shift shaft cover gasket with a new one. • install the shift shaft cover. • apply a non-permanent locking agent to the shift shaft cover screw [a] and bolts [b, c]. ○ do not apply a non-permanent locking agent to the shift shaft cov...

  • Page 331

    Crankshaft/transmission 9-35 transmission transmission assy removal • remove: shift shaft assembly (see external shift mechanism re- moval) neutral switch holder screw [a] neutral switch holder [b] and pin shift drum holder [c] and pin • remove the collar [a] and the o-ring [b] from the output shaft...

  • Page 332

    9-36 crankshaft/transmission transmission if the gear positioning lever [a] was removed, install it (see external shift mechanism installation). If the shift rod plate [b] was removed, install it. ○ apply a non-permanent locking agent to the shift rod plate bolt, and tighten it. Torque - shift rod p...

  • Page 333

    Crankshaft/transmission 9-37 transmission • remove: shift drum cam bolt [a] shift drum [b] and pin shift drum [c] transmission assy assembly • when the new ball bearing [a] and new race [b] are in- stalled in the transmission case [c], press and insert them until they are bottomed. Special tool - be...

  • Page 334

    9-38 crankshaft/transmission transmission • install the following on the transmission case [a]. Shift drum [b] pin [c] shift drum cam [d] ○ align the pin with the hole on the shift drum cam. • apply a non-permanent locking agent to the shift drum cam bolt [e] and tighten it. Torque - shift drum cam ...

  • Page 335

    Crankshaft/transmission 9-39 transmission transmission shaft disassembly • remove the transmission shafts (see transmission assy disassembly). • remove the circlips, disassemble the transmission shafts. Special tool - outside circlip pliers: 57001-144 • the 5th gear [a] on the output shaft has three...

  • Page 336

    9-40 crankshaft/transmission transmission • fit the steel balls into the 5th gear holes in the output shaft, aligning oil hole as shown in the figure. 5th gear [a] output shaft [b] steel balls [c] oil hole [d] notice do not apply grease to the balls to hold them in place. This will cause the positiv...

  • Page 337

    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 338

    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 339

    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 340

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

  • Page 341: Wheels/tires

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

  • Page 342

    10-2 wheels/tires exploded view.

  • Page 343

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front axle 108 11.0 80 2 front axle clamp bolt 20 2.0 15 3 rear axle nut 108 11.0 80 4. Caliper bracket (kle650d models) g: apply grease. Hg: apply high-temperature grease. R: replacement parts wl: apply soap and water sol...

  • Page 344

    10-4 wheels/tires specifications item standard service limit wheels (rims) rim runout: axial tir 0.5 mm (0.02 in.) or less tir 1.0 mm (0.04 in.) radial tir 0.8 mm (0.03 in.) or less tir 1.0 mm (0.04 in.) axle runout/100 mm (3.94 in.) tir 0.03 mm (0.0012 in.) or less tir 0.2 mm (0.008 in.) wheel bala...

  • Page 345

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

  • Page 346

    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 347

    Wheels/tires 10-7 wheels (rims) • apply high-temperature grease to the grease seal lips. • fit the collars [a] on the both sides of the hub. • 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 348

    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 349

    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 350

    10-10 wheels/tires wheels (rims) • install the rear brake caliper (see caliper installation in the brakes chapter). • for models eqquipped with an abs, install the rear wheel rotation sensor (see rear wheel rotation sensor instal- lation in the brakes chapter). • check the rear brake effectiveness (...

  • Page 351

    Wheels/tires 10-11 wheels (rims) axle inspection • remove the front and rear axles (see front/rear wheel removal). • visually inspect the front and rear axle for damages. If the axle is damaged or bent, replace it. • place the axle in v blocks that are 100 mm (3.94 in.) [a] apart, and set a dial gau...

  • Page 352

    10-12 wheels/tires wheels (rims) balance weight installation • check if the weight portion has any play on the blade [a] and clip [b]. If it does, discard it. Warning unbalanced wheels can create an unsafe riding condition. If the balance weight has any play on the rib of the rim, the blade and/or c...

  • Page 353

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

  • Page 354

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

  • Page 355

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

  • Page 356

    10-16 wheels/tires hub bearing hub bearing removal • remove the 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]. Notice do not lay the wheel on the ground with the disc facing d...

  • Page 357

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

  • Page 359: Final Drive

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

  • Page 360

    11-2 final drive exploded view.

  • Page 361

    Final drive 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine sprocket nut 125 12.7 92 mo 2 rear axle nut 108 11.0 80 3 rear sprocket nuts 59 6.0 44 r 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-temperatu...

  • Page 362

    11-4 final drive specifications item standard service limit drive chain drive chain slack 25 ∼ 35 mm (1.0 ∼ 1.4 in.) – – – drive chain wear (20-link length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) standard chain: kle650caf/daf: make enuma – – – type ek520mvxl – – – link 114 links – – ...

  • Page 363

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

  • Page 364

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

  • Page 365

    Final drive 11-7 drive chain • grind [a] the 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 366

    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 367

    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 368

    11-10 final drive drive chain • remove: body [a] pin holder [b] positioning pin [c] “u” holder [d] plate holder [e] cutting and riveting pin [f] part for riveting [g] part for cutting [h] • grind [a] the heads of the link pin to make it flat. • set the cutting and riveting pin [c] in the pin holder ...

  • Page 369

    Final drive 11-11 drive chain • set the cutting and riveting pin [b] and plate holder [c] on the pin holder [a] as shown in the figure. • set the “u” holder and body, align the positioning pin [a] with the “a mark” [b]. • hold the body with a wrench [c]. • turn the pin holder clockwise [d] with anot...

  • Page 370

    11-12 final drive drive chain • after riveting, check the ends of the riveted pins for cracks. • measure the outside diameter [a] of the link pin and width [b] of the link plates. Link pin outside diameter standard: 5.7 ∼ 6.0 mm (0.22 ∼ 0.24 in.) link plate outside width standard: 17.25 ∼ 17.55 mm (...

  • Page 371

    Final drive 11-13 sprocket, coupling engine sprocket removal • remove: left rear frame cover (see rear frame cover removal in the frame chapter) engine sprocket cover bolts [a] engine sprocket cover [b] • remove: speed sensor bracket bolts [a] speed sensor bracket [b] • flatten out the bended washer...

  • Page 372

    11-14 final drive 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 373

    Final drive 11-15 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 374

    11-16 final drive 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 375

    Final drive 11-17 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 377: Brakes

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

  • Page 378

    12-2 brakes abs troubleshooting outline............................................................................................ 12-35 inquiries to rider............................................................................................................... 12-38 self-diagnosis outline ......

  • Page 379

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

  • Page 380

    12-4 brakes exploded view kle650c models.

  • Page 381

    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 382

    12-6 brakes exploded view kle650c models.

  • Page 383

    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 384

    12-8 brakes exploded view kle650d models.

  • Page 385

    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 386

    12-10 brakes exploded view kle650d models.

  • Page 387

    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 388

    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 389

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

  • Page 390

    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 391

    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 392

    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 393

    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 394

    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 395

    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 396

    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 397

    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 398

    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 replace- ment in the periodic maintenance chapter). • disconnect the front brake light switch connectors [a]. • unscrew the clamp bolts [b]...

  • Page 399

    Brakes 12-23 master cylinder rear master cylinder removal • remove: cotter pin [a] joint pin [b] note ○ pull off the joint pin while pressing down the brake pedal. • unscrew the brake hose banjo bolt [a] on the master cylin- der (see brake hose replacement in the periodic main- tenance chapter). • r...

  • Page 400

    12-24 brakes master cylinder front master cylinder disassembly • refer to the master cylinder rubber parts replacement in the periodic maintenance chapter. Rear master cylinder disassembly • refer to the master cylinder rubber parts replacement in the periodic maintenance chapter. Master cylinder as...

  • Page 401

    Brakes 12-25 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 402

    12-26 brakes brake fluid brake fluid level inspection • refer to the brake fluid level inspection in the periodic maintenance chapter. Brake fluid change • refer to the brake fluid change in the periodic mainte- nance chapter. Brake line bleeding the brake fluid has a very low compression coefficien...

  • Page 403

    Brakes 12-27 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 404

    12-28 brakes 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 405

    Brakes 12-29 brake hose brake hose removal/installation • refer to the brake hose 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 406

    12-30 brakes 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 407

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

  • Page 408

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

  • Page 409

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

  • Page 410

    12-34 brakes anti-lock brake system (equipped models) notice do not ride the motorcycle with air in the brake line, or the abs could malfunction. ○ 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 i...

  • Page 411

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

  • Page 412

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

  • Page 413

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

  • Page 414

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

  • Page 415

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

  • Page 416

    12-40 brakes anti-lock brake system (equipped models) pre-diagnosis inspection 2 self-diagnosis outline when the indicator light has blinked or come on, the abs hydraulic unit memorizes and stores the service code (15 codes including “normal code”) for the service person to troubleshoot easily. The ...

  • Page 417

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

  • Page 418

    12-42 brakes anti-lock brake system (equipped models) self-diagnosis flow chart.

  • Page 419

    Brakes 12-43 anti-lock brake system (equipped models) how to read service codes ○ service codes are shown by a series of long and short blinks of the abs indicator light (led) as shown below. ○ read 10th digit and unit digit as the abs indicator light (led) blinks. ○ when there are a number of fault...

  • Page 420

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

  • Page 421

    Brakes 12-45 anti-lock brake system (equipped models) abs indicator light (led) inspection • turn the ignition switch on. If the abs indicator light (led) [a] lights, it is normal. If the abs indicator light (led) does not light, go to step “abs indicator light (led) is unlit (when the ignition swit...

  • Page 422

    12-46 brakes 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 423

    Brakes 12-47 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 424

    12-48 brakes 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 425

    Brakes 12-49 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 426

    12-50 brakes 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 427

    Brakes 12-51 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 428

    12-52 brakes 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 429

    Brakes 12-53 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 430

    12-54 brakes 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 431

    Brakes 12-55 anti-lock brake system (equipped models) • clean the abs hydraulic unit [a]. Notice 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 432

    12-56 brakes anti-lock brake system (equipped models) abs hydraulic unit installation • install the abs hydraulic unit to the bracket. • before installing the brake pipe, check to see that there is no damage on the threads of the brake pipe joint nut. If there is any damage, replace the damaged part...

  • Page 433

    Brakes 12-57 anti-lock brake system (equipped models) front wheel rotation sensor removal notice the wheel rotation sensor should be handled care- fully, never struck sharply, as with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made. Be careful not...

  • Page 434

    12-58 brakes 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 435

    Brakes 12-59 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 436

    12-60 brakes anti-lock brake system (equipped models) brake hose inspection • refer to the brake hose damage and installation condi- tion inspection in the periodic maintenance chapter. 25 a abs solenoid valve relay fuse removal • remove the seat (see seat removal in the frame chap- ter). • unlock t...

  • Page 437

    Brakes 12-61 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 439: Suspension

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

  • Page 440

    13-2 suspension exploded view.

  • Page 441

    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 442

    13-4 suspension exploded view.

  • Page 443

    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 r 3 swingarm pivot shaft nut 108 11.0 80 g: apply grease. R: replacement parts.

  • Page 444

    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 445

    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 446

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

  • Page 447

    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 is 1 3/4 turns out from the fully clockwise posit...

  • Page 448

    13-10 suspension front fork front fork removal (each fork leg) • remove: upper fairings (see upper fairing removal in the frame chapter) front wheel (see front wheel removal in the wheels/tires chapter) front fender (see front fender removal in the frame chapter) • for models equipped with an abs, r...

  • Page 449

    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 450

    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 451

    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 452

    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 453

    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 454

    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 455

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

  • Page 456

    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 457

    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 is the 5th click (white mark position) from the 1st click of the fully clockwise position. Reboun...

  • Page 458

    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 459

    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 460

    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 461

    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 462

    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 463

    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 465: Steering

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

  • Page 466

    14-2 steering exploded view.

  • Page 467

    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 468

    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 469

    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 470

    14-6 steering steering stem stem, stem bearing removal • remove: middle fairings (see middle fairing removal in the frame chapter) meter unit (see meter unit removal in the electrical sys- tem chapter) bolt [a] clamp [b] • remove: bolt [a] clamp [b] • remove: bolt [a] brake hose clamp bracket [b] • ...

  • Page 471

    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 472

    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 473

    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 474

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

  • Page 475

    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 476

    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 477: Frame

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

  • Page 478

    15-2 frame exploded view.

  • Page 479

    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 8.8 0.90 78 in·lb l 6. Us and ca models g: apply grease. L: apply a non-...

  • Page 480

    15-4 frame exploded view.

  • Page 481

    Frame 15-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 lower fairing mounting bolts 8.8 0.90 78 in·lb 2 lower fairing bracket bolts 12 1.2 106 in·lb l 3. Us, ca and au models 4. Dampers (kle650cbf/dbf) l: apply a non-permanent locking agent. S: follow the specified tightening sequenc...

  • Page 482

    15-6 frame exploded view.

  • Page 483

    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. Au model 3. Kle650cbf/dbf.

  • Page 484

    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 pull the seat backward. Seat installation • slip the seat hook [a] under the brace [b] on the fuel tank bracket. • insert the seat hook [c] int...

  • Page 485

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

  • Page 486

    15-10 frame fairings middle fairing installation • insert the projection [a] into the grommet [b]. ○ hang the hook portion [c] inside the rib [d]. • insert the projections [a] into the grommets [b] on the fuel tank. Upper fairing removal • remove the windshield (see windshield removal). • push the c...

  • Page 487

    Frame 15-11 fairings upper fairing bracket removal • remove: middle fairings (see middle fairing removal) headlight assembly (see headlight removal in the elec- trical system chapter) meter unit (see meter unit removal in the electrical sys- tem chapter) coolant reserve tank (see coolant change in t...

  • Page 488

    15-12 frame side covers side cover removal • remove: seat (see seat removal) screw [a] (both sides) • pull the side cover [b] evenly outward to clear the stop- pers [c]. Side cover installation • installation is the reverse of removal. ○ insert the projections [a] to the inside of the grommets [b]. ...

  • Page 489

    Frame 15-13 seat covers seat cover removal • remove: bolts [a] tandem grips [b] • remove the screws [a] (both sides). • push the center pin, and then remove the quick rivets [b] on both sides. • remove the seat covers [c] on both sides. • remove the center seat cover [d] outward. Seat cover installa...

  • Page 490

    15-14 frame fenders front fender removal • remove: brake hose clamps [a] bolts [b] (both sides) reflectors [c] (both sides, us, ca and au models) • remove the front fender [d] upward. Front fender installation • installation is the reverse of removal. ○ install the brake hose clamps to the front fen...

  • Page 491

    Frame 15-15 fenders rear fender front removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) clamp [a] (open) bolts [b] bracket [c] • open the clamp [a]. • remove: battery (see battery removal in the electrical system chapter) relay box (see relay box removal in the ele...

  • Page 492

    15-16 frame 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 resulting in injury or death. If the frame is bent, dented, cracked, or wa...

  • Page 493

    Frame 15-17 windshield windshield height adjustment ○ the windshield can be adjusted within 3 positions in height to suit the rider’s preference. Windshield [a] bolts [b] nuts [c] quick rivets [d] windshield position 1 [e] windshield position 2 [f] windshield position 3 [g] note ○ keep the uninstall...

  • Page 494

    15-18 frame windshield windshield removal • remove: bolts [a] windshield [b] windshield installation • be sure that the nuts [a] are in position. • install: mounting bolts [b] washers [c] windshield [d].

  • Page 495

    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 496

    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]. Front frame cover installation • installation is the reverse of removal. ○ insert the projection [a] into the grommet ...

  • Page 497

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

  • Page 499: Electrical System

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

  • Page 500

    16-2 electrical system starter motor removal...................................................................................................... 16-46 starter motor installation................................................................................................... 16-46 starter motor d...

  • Page 501

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

  • Page 502

    16-4 electrical system exploded view.

  • Page 503

    Electrical system 16-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 tail/brake light mounting bolts 5.9 0.60 52 in·lb 2 license plate light mounting screws 1.2 0.12 11 in·lb.

  • Page 504

    16-6 electrical system exploded view.

  • Page 505

    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 506

    16-8 electrical system exploded view.

  • Page 507

    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 (equipped 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 ...

  • Page 508

    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 509

    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 needle adapter set: 57001-1457 rotor holder: 57001-1567 grip: 57001-1591 rotor holder: 570...

  • Page 510

    16-12 electrical system parts location.

  • Page 511

    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 9. Ignition switch 10. Meter unit 11. Neutral switch 12. Oil pressure switch 13. Rear brake light switch 14. Regulator/re...

  • Page 512

    16-14 electrical system wiring diagram (kle650c models other than us, ca and cal).

  • Page 513

    Electrical system 16-15 wiring diagram (kle650c models other than us, ca and cal).

  • Page 514

    16-16 electrical system wiring diagram (kle650c models us, ca and cal).

  • Page 515

    Electrical system 16-17 wiring diagram (kle650c models us, ca and cal).

  • Page 516

    16-18 electrical system wiring diagram (kle650d models).

  • Page 517

    Electrical system 16-19 wiring diagram (kle650d models).

  • Page 518

    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 519

    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 520

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

  • Page 521

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

  • Page 522

    16-24 electrical system battery • place the strip of caps [a] loosely over the filler ports, press down firmly with both hands to seat the strip of caps into the battery (don’t pound or hammer). When properly installed, the strip of caps will be level with the top of the battery. Notice once the str...

  • Page 523

    Electrical system 16-25 battery 2) refreshing charge. If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification (see refreshing change). When a fast charge is i...

  • Page 524

    16-26 electrical system battery if the reading is 12.8 v or more, no refresh charge is re- quired, however, if the read is below the specified, refresh charge is required. Battery terminal voltage standard: 12.8 v or more terminal voltage (v) [a] battery charge rate (%) [b] good [c] refresh charge i...

  • Page 525

    Electrical system 16-27 charging system alternator cover removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove the lower fairing (see lower fairing removal in the frame chapter). • disconnect the alternator lead connector [a]. • place a suitable conta...

  • Page 526

    16-28 electrical system 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 527

    Electrical system 16-29 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 528

    16-30 electrical system charging system • apply a thin coat of molybdenum disulfide grease to the shafts [a], and install them. • install the torque limiter [b] and starter idle gear [c]. • install the alternator cover (see alternator cover installa- tion). Alternator inspection there are three type...

  • Page 529

    Electrical system 16-31 charging system if there is more resistance than shown in the table, or no hand tester reading (infinity) for any two leads, the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced. • using the highest...

  • Page 530

    16-32 electrical system charging system kle650d models • remove: muffler body (see muffler body removal in the engine top end chapter) bolts [a] • disconnect the connector [a]. • remove the regulator/rectifier [b]. Rectifier circuit check • check conductivity of the following pair of terminals. Rect...

  • Page 531

    Electrical system 16-33 charging system • do the 1st step regulator circuit test. ○ connect the test light and the 12 v battery to the regula- tor/rectifier as shown. ○ check the bk1, bk2 and bk3 terminal respectively. If the test light turns on, the regulator/rectifier is defective. Replace it. If ...

  • Page 532

    16-34 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 533

    Electrical system 16-35 charging system charging system circuit 1. Ignition switch 2. Alternator 3. Regulator/rectifier 4. Water-proof joint c 5. Main fuse 30 a (kle650caf/daf) 6. Main fuse 30 a (kle650cbf/dbf) 7. Battery 12 v 10 ah 8. Load.

  • Page 534

    16-36 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 535

    Electrical system 16-37 ignition system warning the ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. Notice do not disconnect the battery cables or any ot...

  • Page 536

    16-38 electrical system ignition system • remove: bolts [a] crankshaft sensor [b] • pull out the grommet [c]. Crankshaft sensor installation • run the crankshaft sensor lead correctly (see cable, wire, and hose routing section in the appendix chapter). • tighten: torque - crankshaft sensor bolts: 6....

  • Page 537

    Electrical system 16-39 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 538

    16-40 electrical system ignition system stick coil 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] off the spark plugs. Notice do not pry the conn...

  • Page 539

    Electrical system 16-41 ignition system • remove the stick coils. ○ 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 the engine. ○ connect the peak voltage adapter [c] into the hand tester [d...

  • Page 540

    16-42 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 541

    Electrical system 16-43 ignition system ic igniter inspection ○ the ic igniter is built in the ecu [a]. • refer to the interlock operation inspection, ignition sys- tem troubleshooting chart and fuel system (dfi) chapter for ecu power supply inspection..

  • Page 542

    16-44 electrical system ignition system.

  • Page 543

    Electrical system 16-45 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 544

    16-46 electrical system electric starter system starter motor removal notice do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • remove the throttle body assy (see throttle body assy removal in the fuel system (dfi) chapter). • slide back the rubber cap [a...

  • Page 545

    Electrical system 16-47 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 546

    16-48 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 547

    Electrical system 16-49 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]. • install the end cover [a] so that the stopper [b] is aligned with the hollow [c] of the yoke. • align the marks [a] ...

  • Page 548

    16-50 electrical system electric starter system commutator cleaning and inspection • clean the metallic debris off the between commutator segments [a]. Note ○ do not use emery or sand paper on the commutator. • check the commutator for damage or abnormal wear. Replace the starter motor with a new on...

  • Page 549

    Electrical system 16-51 electric starter system right-hand end cover inspection • using the highest hand tester range, measure the resis- tance as shown. Terminal bolt and right-hand end cover [a] terminal bolt and negative brushes [b] special tool - hand tester: 57001-1394 if there is any reading, ...

  • Page 550

    16-52 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 (kle650caf/daf) 11. Main fuse 30 a...

  • Page 551

    Electrical system 16-53 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 552

    16-54 electrical system lighting system • fit the dust cover [a] onto the bulb [b] firmly as shown. Good [c] bad [d] • after installation, adjust the headlight aim (see headlight aiming inspection in the periodic maintenance chapter). ○ other bulb: repeat the above steps. City light bulb replacement...

  • Page 553

    Electrical system 16-55 lighting system headlight removal/installation • remove: upper fairing (see upper fairing removal in the frame chapter) mounting bolts [a] mounting nuts [b] • disconnect the headlight connectors [a] and city light con- nector [b]. • remove the headlight assy. • installation i...

  • Page 554

    16-56 electrical system lighting system license plate light bulb replacement • remove: screws [a] license plate light cover [b] • pull the bulb [a] out of the socket [b]. Notice do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage then the ...

  • Page 555

    Electrical system 16-57 lighting system headlight/tail light circuit 1. Ignition switch 2. Water-proof joint a 3. Water-proof joint b 4. City light 5. Headlight (high beam) 6. Headlight (low beam) 7. Dimmer switch 8. Passing switch 9. Headlight relay 10. Relay box 11. Main fuse 30 a (kle650cbf/dbf) ...

  • Page 556

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

  • Page 557

    Electrical system 16-59 lighting system • connect one 12 v battery and turn signal lights as indi- cated in the figure, and count how may times the lights flash for one minute. Turn signal relay [a] turn signal lights [b] 12 v battery [c] if the lights do not flash as specified, replace the turn sig...

  • Page 558

    16-60 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 559

    Electrical system 16-61 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 560

    16-62 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 561

    Electrical system 16-63 meter, gauge, indicator unit meter unit removal • remove: upper fairing (see upper fairing removal in the frame chapter) headlight cover (see headlight cover removal) • slide out the dust cover [a] and disconnect the connector [b]. • remove the bolts [c]. • remove the screws ...

  • Page 562

    16-64 electrical system meter, gauge, indicator unit electronic combination meter unit inspection • remove the meter unit [a] (see meter unit removal). [1] (kle650c models) unused (kle650d models) abs indicator light (led) (–) [2] left turn signal indicator light (led) (+) [3] neutral indicator ligh...

  • Page 563

    Electrical system 16-65 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 [6]. ○ all the lcd segments disappear. If the segments do not disappea...

  • Page 564

    16-66 electrical system 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 565

    Electrical system 16-67 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 [9] an...

  • Page 566

    16-68 electrical system 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 [15] as shown. • check that the number ...

  • Page 567

    Electrical system 16-69 meter, gauge, indicator unit lights (led) inspection neutral indicator light (led) [a] fi indicator light (led) [b] oil pressure warning indicator light (led) [c] water temperature warning indicator light (led) [d] right turn signal indicator light (led) [e] left turn signal ...

  • Page 568

    16-70 electrical system meter, gauge, indicator unit high beam indicator light (led) battery positive (+) terminal to terminal [5] neutral indicator light (led) battery negative (–) terminal to terminal [3] right and left turn signal indicator light (led) for right turn signal indicator light (led) ...

  • Page 569

    Electrical system 16-71 meter, gauge, indicator unit • connect the battery negative (–) terminal to the terminal [1]. ○ 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 570

    16-72 electrical system meter, gauge, indicator unit meter circuit 1. Abs hydraulic unit (kle650d models) 2. Water-proof joint c 3. Frame ground 4. Meter unit 5. Water-proof joint b 6. Ecu fuse 15 a 7. Ignition fuse 10 a 8. Fuse box 9. Main fuse 30 a (kle650caf/daf) 10. Main fuse 30 a (kle650cbf/dbf...

  • Page 571

    Electrical system 16-73 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 572

    16-74 electrical system 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 573

    Electrical system 16-75 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 574

    16-76 electrical system switches and sensors • using the hand tester [a], measure the resistance across the terminals in the fuel level sensor lead connector [b]. Special tools - hand tester: 57001-1394 if the tester readings are not as specified, or do not change smoothly according as the float mov...

  • Page 575

    Electrical system 16-77 switches and sensors oxygen sensor installation (equipped models) notice never drop the oxygen sensor [a], especially on a hard surface. Such a shock to the unit can damage it. Do not touch the sensing part [b] and filter holes [c] of the sensor to prevent oil contact. Oil co...

  • Page 576

    16-78 electrical system 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 577

    Electrical system 16-79 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 578

    16-80 electrical system relay box relay box internal circuit a: headlight relay b: ecu main relay c: fuel pump relay d: starter circuit relay e: fan relay.

  • Page 579

    Electrical system 16-81 fuse 30 a main fuse removal • remove: left rear frame cover (see rear frame cover removal 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 the s...

  • Page 580

    16-82 electrical system 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 581: Appendix

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

  • Page 582

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

  • Page 583

    Appendix 17-3 cable, wire, and hose routing 1. Clamps 2. Clamp (insert the clamp in the bracket.) 3. Clamps (insert the clamp in the frame.) 4. Insert the clamp in the frame. (position the band so that the edge of the band faces downward of the motorcycle.) 5. Clamp (insert the clamp so that the cla...

  • Page 584

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

  • Page 585

    Appendix 17-5 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 (apply to the turn stop of the frame and install the terminal as ...

  • Page 586

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

  • Page 587

    Appendix 17-7 cable, wire, and hose routing 1. Install the clamp together with the rear fender rear. (clamp the turn signal leads) 2. Clamp the turn signal leads, license plate light lead and tail/brake light lead, and install the clamp into the hole of frame bracket. (install the clamp so that the ...

  • Page 588

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

  • Page 589

    Appendix 17-9 cable, wire, and hose routing 1. To vehicle-down sensor, rear brake light switch and crankshaft sensor 2. Fuel pump lead 3. Fuel level sensor lead 4. Section a-a 5. Clamp the main harness, and insert it in the rear fender front. 6. Main harness 7. Battery negative cable 8. Battery posi...

  • Page 590

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

  • Page 591

    Appendix 17-11 cable, wire, and hose routing 1. Run 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. After regulator/rectifier connecting, put the connectors in the water-proof cover. 6...

  • Page 592

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

  • Page 593

    Appendix 17-13 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 594

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

  • Page 595

    Appendix 17-15 cable, wire, and hose routing 1. Clamp (insert the clamp in the frame.) 2. Clamp (insert the clamp in the horn bracket.) 3. Connect the horn lead terminals so that the leads face downward. 4. Battery negative cable 5. Battery positive cable 6. Main harness 7. Starter motor cable.

  • Page 596

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

  • Page 597

    Appendix 17-17 cable, wire, and hose routing 1. Fuel tank drain hose (run the drain hose between main harness and air cleaner housing.) 2. Fuel tank breather hose (run the breather hose between main harness and air cleaner hous- ing) 3. Air cleaner drain hose 4. Run the fuel tank breather hose, fuel...

  • Page 598

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

  • Page 599

    Appendix 17-19 cable, wire, and hose routing 1. Headlight (low) connector (install the connector in the direction as shown in the figure.) 2. Headlight (hi) connector (install the connector in the direction as shown in the figure.) 3. Left switch housing lead 4. Clamps (insert the clamp to the handl...

  • Page 600

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

  • Page 601

    Appendix 17-21 cable, wire, and hose routing 1. Clamp the brake hose, right switch housing lead, and throttle cables. 2. Clamp (from the on sequentially, run the clutch cable and throttle cables.) 3. Insert the clamp to the bracket and hold the rubber part of the brake hose. (install the clamp so th...

  • Page 602

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

  • Page 603

    Appendix 17-23 cable, wire, and hose routing 1. Run the radiator hose to the inside of the frame bracket. 2. Overflow hose 3. Run the reserve tank hose to the outside of the overflow hose. 4. Clutch cable 5. Clamp (run the clutch cable in the clamp.) 6. Clamp the overflow hose by the clamp together ...

  • Page 604

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

  • Page 605

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

  • Page 606

    17-26 appendix cable, wire, and hose routing kle650c models.

  • Page 607

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

  • Page 608

    17-28 appendix cable, wire, and hose routing kle650c models.

  • Page 609

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

  • Page 610

    17-30 appendix cable, wire, and hose routing kle650d models.

  • Page 611

    Appendix 17-31 cable, wire, and hose routing 1. Abs hydraulic unit 2. Brake hose 3. Brake hose 4. Yellow paint mark 5. White paint mark 6. Damper 7. Clamp 8. Clamp 9. Bracket 10. Brake hose 11. Front wheel rotation sensor lead 12. Front wheel rotation sensor 13. Front wheel rotation sensor rotor 14....

  • Page 612

    17-32 appendix cable, wire, and hose routing kle650d models.

  • Page 613

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

  • Page 614

    17-34 appendix cable, wire, and hose routing kle650d models.

  • Page 615

    Appendix 17-35 cable, wire, and hose routing 1. Right switch housing lead 2. Brake hose 3. Clamp the brake hose, right switch housing lead, and throttle cables. 4. Throttle cable (decelerator) 5. Throttle cable (accelerator) 6. Clamp the right switch housing connector, and insert it in the frame. 7....

  • Page 616

    17-36 appendix cable, wire, and hose routing kle650d models.

  • Page 617

    Appendix 17-37 cable, wire, and hose routing 1. Run the brake hose between the throttle cables and right switch housing lead. 2. Front wheel rotation sensor lead 3. Clamp (install the clamp so that the clamp opening faces right side.) 4. Run the front wheel rotation sensor lead to the front side of ...

  • Page 618

    17-38 appendix cable, wire, and hose routing kle650d models.

  • Page 619

    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. Viewed from a.

  • Page 620

    17-40 appendix cable, wire, and hose routing kle650d models.

  • Page 621

    Appendix 17-41 cable, wire, and hose routing 1. Clamp the brake hose and front wheel rotation sensor lead, and insert the clamp from the out- side. 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 faces ou...

  • Page 622

    17-42 appendix cable, wire, and hose routing kle650d models.

  • Page 623

    Appendix 17-43 cable, wire, and hose routing 1. Abs hydraulic unit 2. Run the ecu lead to the front side of the frame pipe. 3. Battery positive lead 4. Run the battery positive lead under the frame pipe and run it at the groove of the rear fender. 5. Put the abs kawasaki self-diagnosis system connec...

  • Page 624

    17-44 appendix cable, wire, and hose routing cal, th and sea models.

  • Page 625

    Appendix 17-45 cable, wire, and hose routing 1. Separator 2. Hose (blue tape) 3. Hose (blue) 4. To fuel tank 5. Clamps 6. Clamps 7. Band 8. Clamps 9. Hose (white stripe) 10. Hose (red) 11. Band 12. Canister 13. Clamp 14. Hose (green tape).

  • Page 626

    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 627

    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 628

    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 629

    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 630

    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 631

    Model application year model beginning frame no. 2010 kle650caf jkaleec1 □ aa000001 jkale650cca000001 2010 kle650daf jkaleed1 □ aa000001 jkale650cda000001 2011 kle650cbf jkaleec1 □ bda00001 jkale650ccda00001 2011 kle650dbf jkaleed1 □ bda00001 jkale650cdda00001 □ :this digit in the frame number chang...