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Kawasaki VN1600 MEAN STREAK - SERVICE Service Manual

Other manuals for VN1600 MEAN STREAK - SERVICE: Installation Instructions

Summary of VN1600 MEAN STREAK - SERVICE

  • Page 1

    Vulcan 1600 mean streak vn1600 mean streak motorcycle service manual 2004 vulcan 1600 mean streak, vn1600 mean streak motorcycle service manual part no. 99924-1321-01 kawasaki heavy industries, ltd. Consumer products & machinery company printed in japan year model beginning frame no. □ : this digit ...

  • Page 3: Quick Reference Guide

    Quick reference guide general information 1 j periodic maintenance 2 j fuel system (dfi) 3 j cooling system 4 j engine top end 5 j clutch 6 j engine lubrication system 7 j engine removal/installation 8 j crankshaft/transmission 9 j wheels/tires 10 j final drive 11 j brakes 12 j suspension 13 j steer...

  • Page 5: Vulcan 1600 Mean Streak

    Vulcan 1600 mean streak vn1600 mean streak 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 assura...

  • Page 6

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

  • Page 7

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

  • Page 8

    We recommend that all dealers observe these provisions of federal law, the violation of which is punishable by civil penalties not exceeding $10,000 per violation. Tampering with noise control system prohibited federal law prohibits the following acts or the causing thereof: (1) the removal or rende...

  • Page 9: Foreword

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

  • Page 11: General Information

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

  • Page 12

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

  • Page 13

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

  • Page 14

    1-4 general information before servicing tightening sequence bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating dia...

  • 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 direction of engine rotation when rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro- tate the crankshaft to positive direction (clockwise viewed from output side). Electrical wires a two-color wire is i...

  • Page 17

    General information 1-7 model identification vn1600-b1 (us, and canada) left side view: vn1600-b1 (us, and canada) right side view:.

  • Page 18

    1-8 general information model identification vn1600-b1 (europe) left side view: vn1600-b1 (europe) right side view:.

  • Page 19

    General information 1-9 general specifications items vn1600–b1 dimensions: overall length 2 410 mm (94.9 in.) overall width 850 mm (33.5 in.) overall height 1 100 mm (43.3 in.) wheelbase 1 705 mm (67.1 in.) road clearance 125 mm (4.92 in.) seat height 700 mm (27.6 in.) dry mass 290 kg (639 lb) curb ...

  • Page 20

    1-10 general information general specifications items vn1600–b1 capacity 3.5 l (3.7us qt, when engine is completely disassembled and dry) drive train: primary reduction system: type gear reduction ratio 1.517 (85/56) clutch type wet multi disc transmission: type 5-speed, constant mesh, return shift ...

  • Page 21

    General information 1-11 general specifications items vn1600–b1 electrical equipment: battery capacity 12 v 18 ah headlight: type semi-sealed beam bulb 12 v 60/55 w (quartz-halogen) tail/brake light 12 v 5/21 w alternator: type three-phase ac rated output 23 a × 14 v @6 000 r/min (rpm) specification...

  • 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 .............. 2-2 torque and locking agent................. 2-4 specifications .................................... 2-10 special tools ..................................... 2-12 periodic maintenance procedu...

  • Page 24

    2-2 periodic maintenance periodic maintenance chart the scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Frequency whichever comes first * odometer reading km × 10...

  • Page 25

    Periodic maintenance 2-3 periodic maintenance chart frequency whichever comes first * odometer reading km × 1000 (mile × 1000) 1 12 24 36 48 see change/replace item every (0.6) (7.5) (15) (24) (30) page spark plug (e) • • • 2–33 engine oil # year • • • • 2–22 oil filter year • • • • 2–24 coolant 3 y...

  • Page 26

    2-4 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 liquid gasket. Letters used in the “remarks” column mean: g: apply grease to the threads. Eo: apply engine oil to the threads a...

  • Page 27

    Periodic maintenance 2-5 torque and locking agent torque fastener n·m kgf·m ft·lb remarks radiator fan switch 18 1.8 13 radiator fan bolts 8.3 0.85 74 in·lb water temperature switch 7.8 0.80 69 in·lb ss water pump impeller bolt 8.8 0.90 78 in·lb lh water pump cover bolts 11 1.1 97 in·lb water pump a...

  • Page 28

    2-6 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks starter lockout switch screws 1.2 0.12 10 in·lb push rod guide bolts 11 1.1 95 in·lb l clutch cover bolts 11 1.1 95 in·lb clutch damper cover bolts 9.8 1.0 87 in·lb l clutch damper plate bolts 9.8 1.0 87 in·lb ...

  • Page 29

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks oil hose banjo bolts 9.8 1.0 87 in·lb primary gear bolt 147 15 108 mo water pump chain guide spring hook bolt 2.9 0.30 26 in·lb water pump chain guide bolt 8.3 0.85 73 in·lb idle shaft holder bolts 8.3 0.85 73 ...

  • Page 30

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks final gear case studs – – – l final gear case cover bolts: 8 mm 23 2.3 17 l 10 mm 34 3.5 25 l pinion gear nut (final gear) 127 13 93 mo, st bearing retainer bolt 6.9 0.70 61 in·lb l brakes: caliper bleed valves...

  • Page 31

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks sidestand nut 44 4.5 32 electrical system: spark plugs 18 1.8 13 crankshaft sensor screws 2.9 0.30 26 in·lb stator lead holder screw 9.8 1.0 87 in·lb l crankshaft sensor lead holder bolt 2.9 0.30 26 in·lb l alt...

  • Page 32

    2-10 periodic maintenance specifications item standard service limit fuel system (dfi): throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 950 ±50 r/min (rpm) – – – air cleaner element paper filter – – – cooling system: coolant: type (recommended) permanent type antifreeze – – – col...

  • Page 33

    Periodic maintenance 2-11 specifications item standard service limit final drive: final gear case oil: grade api service classification: gl-5 – – – hypoid gear oil viscosity when above 5°c (41°f) sae90 – – – when below 5°c (41°f) sae80 oil level filler opening bottom – – – amount 200 ml (6.76 us oz)...

  • Page 34

    2-12 periodic maintenance special tools steering stem nut wrench: 57001–1100 jack: 57001–1238 attachment jack: 57001–1398 driver-filler cap: 57001–1454.

  • Page 35

    Periodic maintenance 2-13 periodic maintenance procedures fuel system (dfi) fuel hose and connection inspection ○ the fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure in- side the fuel l...

  • Page 36

    2-14 periodic maintenance periodic maintenance procedures idle speed inspection • start the engine and warm it up thoroughly. ○ at first the engine will run fast to decrease warm up time (fast idle). ○ gradually the fast idle will lower to a certain rpm auto- matically. This is the idle speed. • che...

  • Page 37

    Periodic maintenance 2-15 periodic maintenance procedures • clean the element by tapping it lightly to loosen dust. • blow away the remaining dust by applying compressed air [a] from the inside to the outside (from the clean side to the dirty side). • visually check the element for no tears or no br...

  • Page 38

    2-16 periodic maintenance periodic maintenance procedures cooling system radiator hose and connection inspection ○ the high pressure inside the radiator hose can cause coolant to leak [a] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deteriorati...

  • Page 39

    Periodic maintenance 2-17 periodic maintenance procedures • remove : right side cover (see frame chapter) reserve tank bolts • turn over the reserve tank [a], remove the cap [b], and pour the coolant into a suitable container. • install the reserve tank. • when filling the coolant, choose a suitable...

  • Page 40

    2-18 periodic maintenance periodic maintenance procedures • fill the radiator up to the filler neck [a] with coolant. • install the radiator cap. • tighten the air bleeder bolt [b]. Torque - thermostat air bleeder bolt: 7.8 n·m (0.80 kgf·m, 69 in·lb) • fill the reserve tank up to the “f” (full) leve...

  • Page 41

    Periodic maintenance 2-19 periodic maintenance procedures clutch clutch hose and connection inspection • the high pressure inside the clutch line can cause fluid to leak [a] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while exam- ining it. Replace it i...

  • Page 42

    2-20 periodic maintenance periodic maintenance procedures clutch fluid change • level the clutch fluid reservoir and remove the reservoir cap. • remove the alternator outer cover (see electrical system chapter.) and the rubber cap from the bleed valve on the clutch slave cylinder. • attach a clear p...

  • Page 43

    Periodic maintenance 2-21 periodic maintenance procedures clutch master cylinder cup and dust seal replacement • remove the clutch master cylinder (see clutch chapter). • remove the reservoir cap [a] and diaphragm [b], and pour the clutch fluid into a container. • unscrew the locknut [c] and pivot b...

  • Page 44

    2-22 periodic maintenance periodic maintenance procedures clutch slave cylinder piston seal replacement • remove the alternator outer cover (see electrical system chapter) • loosen the banjo bolt [a] at the clutch pipe lower end, and tighten it loosely. • unscrew the slave cylinder bolts [b] and det...

  • Page 45

    Periodic maintenance 2-23 periodic maintenance procedures • remove: oil screen plug [a] • remove the oil screen [a], the spring [b], and the washer [c]. • clean the oil screen with a high-flash point solvent and remove any particles stuck to it. • clean the screen thoroughly whenever the engine oil ...

  • Page 46

    2-24 periodic maintenance periodic maintenance procedures engine oil type: api se, sf or sg class api sh or sj class with jaso ma viscosity: sae 10w-40 amount: 2.9 l (3.1 us qt, when filter is not removed) 3.1 l (3.3 us qt, when filter is removed) 3.5 l (3.7 us qt, when engine is completely disassem...

  • Page 47

    Periodic maintenance 2-25 periodic maintenance procedures • measure the tread depth at the center of the tread with a depth gauge [a]. Since the tire may wear unevenly, take measurement at several places. If any measurement is less than the service limit, replace the tire (see wheels/tires chapter)....

  • Page 48

    2-26 periodic maintenance periodic maintenance procedures • the oil level [a] should come to the bottom of the filler opening. If it is low, first check the final gear case for oil leakage, remedy it if necessary, and add oil through the filler open- ing. Use the same type and brand of oil that is a...

  • Page 49

    Periodic maintenance 2-27 periodic maintenance procedures brakes brake pad wear inspection • unscrew the bolts [a] and remove the pad spring [b] (front brake caliper) • unscrew the bolts [a] and remove the caliper [b] (rear brake caliper). • check the lining thickness [a] of the pads in each caliper...

  • Page 50

    2-28 periodic maintenance periodic maintenance procedures brake fluid level inspection • check that the brake fluid level in the front brake reservoir [a] is above the lower [b] level line. Note ○ hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid le...

  • Page 51

    Periodic maintenance 2-29 periodic maintenance procedures brake fluid change note ○ the procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is almost the same as for the front brake. • level the brake fluid reservoir. • remove the reservoir cap [a], plate [b] and...

  • Page 52

    2-30 periodic maintenance periodic maintenance procedures • remove the clear plastic hose. • install the reservoir cap. • 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 the resi...

  • Page 53

    Periodic maintenance 2-31 periodic maintenance procedures if it does not, adjust the brake light switch. • while holding the switch body, turn the adjusting nut to adjust the switch. Switch body [a] adjusting nut [b] light sooner as the body rises [c] light later as the body lowers [d] caution to av...

  • Page 54

    2-32 periodic maintenance periodic maintenance procedures steering stem bearing lubrication • remove the steering stem. (see steering chapter). • using a high-flash point solvent, wash the upper and lower tapered roller bearings [a] in the cages, and wipe the upper and lower outer races, which are p...

  • Page 55

    Periodic maintenance 2-33 periodic maintenance procedures • remove the claw washer. • tighten the stem nut [a] firmly with the stem nut wrench [b], and loosen it. • tighten the stem nut again with the specified torque. Special tool - steering stem nut wrench: 57001-1100 torque - steering stem nut: 4...

  • Page 56

    2-34 periodic maintenance periodic maintenance procedures points: lubricate with grease. Throttle inner cable upper ends [a] clutch lever pivot (apply silicone grease) brake lever pivot (apply silicone grease) brake pedal pivot sidestand cable: lubricate with cable lubricant. Choke cable throttle ca...

  • Page 57

    Periodic maintenance 2-35 periodic maintenance procedures nut, bolt and fastener to be checked wheels: front axle front axle clamp bolts rear axle nut rear axle nut cotter pin final drive: final gear case mounting nuts brakes: front master cylinder clamp bolts caliper mounting bolts rear master cyli...

  • Page 59: Fuel System (Dfi)

    Fuel system (dfi) 3-1 3 fuel system (dfi) table of contents exploded view................................... 3-4 dfi parts location............................. 3-8 dfi system........................................ 3-12 dfi wiring diagram ........................... 3-14 specifications ...............

  • Page 60

    3-2 fuel system (dfi) resistance inspection.................. 3-86 fuel line............................................ 3-88 fuel pressure inspection ............. 3-88 pressure regulator removal....... 3-90 fuel flow rate inspection ........... 3-90 throttle grip and cables ................... 3-9...

  • Page 62

    3-4 fuel system (dfi) exploded view.

  • Page 63

    Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 water temperature sensor 18 1.8 13 ss 2 left air cleaner cover allen bolt 16 1.6 12 3 left air cleaner base bolts 11 1.1 97 in·lb 4 left air cleaner base screws 2.2 0.22 19 in·lb l 5 right air cleaner base screws 2.2 0...

  • Page 64

    3-6 fuel system (dfi) exploded view.

  • Page 65

    Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 fuel pump bolts 6.9 0.70 61 in·lb s, l 2 inlet air temperature sensor nut 7.8 0.80 69 in·lb 3 isc pipe bolts 11 1.1 97 in·lb 4 throttle body assy holder bolts 11 1.1 97 in·lb 5 spark plug lead holder bolts 11 1.1 97 in...

  • Page 66

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

  • Page 67

    Fuel system (dfi) 3-9 dfi parts location dfi: dfi parts (this chapter) f: front 1. Atmospheric pressure sensor (dfi) 2. Water temperature sensor (dfi) 3. Ignition coils 4. Ignition switch 5. Starter motor 6. Water temperature switch 7. Regulator/rectifier 8. Crankshaft sensors 9. Alternator 10. Side...

  • Page 68

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

  • Page 69

    Fuel system (dfi) 3-11 dfi parts location dfi: dfi parts (this chapter) f: front 1. Atmospheric pressure sensor (dfi) 2. Water temperature sensor (dfi) 3. Ignition coils 4. Ignition switch 5. Starter motor 6. Water temperature switch 7. Regulator/rectifier 8. Crankshaft sensors 9. Alternator 10. Sid...

  • Page 70

    3-12 fuel system (dfi) dfi system.

  • Page 71

    Fuel system (dfi) 3-13 dfi system #1: for front cylinder #2: for rear cylinder 1. Ecu (electronic control unit) 2. Crankshaft sensor #1 3. Crankshaft sensor #2 4. Pressure regulator 5. Throttle sensor (front view) 6. Atmospheric pressure sensor 7. Inlet air pressure sensor 8. Water temperature senso...

  • Page 72

    3-14 fuel system (dfi) dfi wiring diagram.

  • Page 73

    Fuel system (dfi) 3-15 dfi wiring diagram dfi and electrical parts dfi: dfi parts a. Ecu: electronic control unit (dfi) b. Engine stop switch c. Starter button d. Ignition coils e. Crankshaft sensors f. Junction box g. Starter circuit relay h. Interlock diodes j. Diode: (for water temperature warnin...

  • Page 74

    3-16 fuel system (dfi) dfi wiring diagram terminal numbers of ecu connectors terminal names #1: front cylinder, #2: rear cylinder 1. Starter lockout switch signal 2. Interlock circuit signal 3. Self-diagnosis signal (generated by grounding this terminal and shown by fi indicator led light) 4. Tachom...

  • Page 75

    Fuel system (dfi) 3-17 specifications item standard throttle grip free play: 2 ∼ 3 mm (0.079 ∼ 0.118 in.) air cleaner element: paper filter dfi (digital fuel injection) system: make: mitsubishi electric idle speed: 950 ±50 r/min (rpm) throttle assy: type × bore two barrel type × 40 mm (1.57 in.) ecu...

  • Page 76

    3-18 fuel system (dfi) specifications item standard water temperature sensor: resistance 2.162 ∼ 3.112 kΩ at 20° c (68° f) 0.785 ∼ 1.049 kΩ at 50° c (122° f) 0.207 ∼ 0.253 kΩ at 100° c (212° f) vehicle-down sensor: detection method magnetic flux detection method detection angle more than 45° ±5° for...

  • Page 77

    Fuel system (dfi) 3-19 special tools and sealant oil pressure gauge, 5 kg/cm² : 57001–125 fork oil level gauge : 570101–1290 hand tester : 57001–1394 fuel pressure gauge adapter : 57001–1417 filler cap driver : 57001–1454 needle adapter set : 57001–1457 kawasaki bond (silicone sealant) : 56019–120

  • Page 78

    3-20 fuel system (dfi) dfi servicing precautions there are a number of important precautions that should be followed servicing the dfi system. ○ to maintain the correct fuel-air mixture (f/a), there must be no inlet air leaks in the dfi system. Be sure to install the oil filler cap [a] after filling...

  • Page 79

    Fuel system (dfi) 3-21 dfi servicing precautions ○ to prevent corrosion and deposits n the fuel system, do not add any fuel antifreeze chemicals to fuel. ○ when any fuel hose is disconnected, do not turn on the ignition sw. Otherwise, the fuel pump will operate and fuel will spout from the fuel hose...

  • Page 80

    3-22 fuel system (dfi) dfi servicing precautions ○ fit the outlet hose joint #1 or #2 [a] onto the pipe until the joint clicks [b]. Front [c] ○ push and pull [a] the hose joint #1 or #2 [b] back and forth more than two times and make sure it is locked and doesn’t come off. When the hose joint is cor...

  • Page 81

    Fuel system (dfi) 3-23 troubleshooting the dfi system outline when an abnormality in the system occurs, the fi indica- tor led light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the mem- ory of the ecu (electronic control unit). With the engin...

  • Page 82

    3-24 fuel system (dfi) troubleshooting the dfi system ○ there are two ways to inspect the dfi system. One is voltage check method and the other is resistance check method. Voltage check method ○ this method is conducted by measuring the input voltage [b] to a sensor [a] first, and then the output vo...

  • Page 83

    Fuel system (dfi) 3-25 troubleshooting the dfi system ○ after measurement, remove the needle adapters and ap- ply silicone sealant to the seals [a] of the connector [b] for waterproofing. Silicone sealant (kawasaki bond: 56019-120) - seals of connectors • always check battery condition before replac...

  • Page 84

    3-26 fuel system (dfi) troubleshooting the dfi system if any wiring is deteriorated, replace the wiring. • 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 sec...

  • Page 85

    Fuel system (dfi) 3-27 troubleshooting the dfi system dfi diagnosis flow chart inquiries to rider • refer to the next sample diagnosis chart. ○ 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 wh...

  • Page 86

    3-28 fuel system (dfi) troubleshooting the dfi system sample diagnosis sheet rider name: year of initial registration: registration no. (license plate no.): frame no.: model: engine no.: mileage: date problem occurred: environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ al...

  • Page 87

    Fuel system (dfi) 3-29 troubleshooting the dfi system poor running □ choke knob left pulled out fully (push it in fully). Or no power □ spark plug loose (tighten it). At high speed □ spark plug dirty, broken, or gap maladjusted (remedy it). □ spark plug incorrect (replace it). □ knocking (fuel poor ...

  • Page 88

    3-30 fuel system (dfi) dfi system troubleshooting guide note ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. ○ the ecu may be involved in the dfi electri...

  • Page 89

    Fuel system (dfi) 3-31 dfi system troubleshooting guide symptoms or possible causes actions (chapter) no spark or spark weak: ignition and engine stop switches not on turn both switches on. Clutch lever not pulled in and gear not in neutral whether sidestand up or not pull the lever in and shift the...

  • Page 90

    3-32 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) cylinder, piston worn inspect and replace (see chapter 5). Piston ring bad (worn, weak, broken or sticking) inspect and replace (see chapter 5). Piston ring/groove clearance excessive inspect and re...

  • Page 91

    Fuel system (dfi) 3-33 dfi system troubleshooting guide symptoms or possible causes actions (chapter) fuel injector trouble inspect (see chapter 3). Throttle sensor trouble inspect (see chapter 3). Inlet air temperature sensor trouble inspect (see chapter 3). Water temperature sensor trouble inspect...

  • Page 92

    3-34 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) inlet air temperature sensor trouble inspect (see chapter 3). Throttle sensor malfunction inspect (see chapter 3). Water temperature sensor trouble inspect (see chapter 3). Atmospheric pressure sens...

  • Page 93

    Fuel system (dfi) 3-35 dfi system troubleshooting guide symptoms or possible causes actions (chapter) throttle sensor malfunction inspect (see chapter 3). Inlet air temperature sensor trouble inspect (see chapter 3). Water temperature sensor trouble inspect (see chapter 3). Atmospheric pressure sens...

  • Page 94

    3-36 fuel system (dfi) dfi system troubleshooting guide poor running or no power at high speed: symptoms or possible causes actions (detailed reference) firing incorrect: spark plug dirty, broken or maladjusted clean spark plug and adjust plug gap (see chapter 2). Spark plug cap or high tension wiri...

  • Page 95

    Fuel system (dfi) 3-37 dfi system troubleshooting guide symptoms or possible causes actions (detailed reference) hla (hydraulic lash adjuster) damaged (worn, seizure or spring broken) inspect and replace (see chapter 5). Knocking: carbon buit up in combustion chamber repair (see chapter 5). Fuel poo...

  • Page 96

    3-38 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (detailed reference) air cleaner o-ring damaged replace (see chapter 3). Too low fuel pressure inspect (see chapter 3). Water temperature sensor trouble inspect and replace (see chapter 3). Inlet air temperat...

  • Page 97

    Fuel system (dfi) 3-39 self-diagnosis self-diagnosis conducting ○ when a problem occurs with the dfi system, the dfi in- dicator led light [a] goes on. • remove the seat (see frame chapter). • with the ecu connector joined, the self-diagnosis mode by grounding the self-diagnosis check female connect...

  • Page 98

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

  • Page 99

    Fuel system (dfi) 3-41 self-diagnosis service code reading ○ service codes are shown by a series of long and short blinks of the fi indicator led light as shown below. ○ read 10th digit and unit digit as the fi indicator led light blinks. ○ when there are a number of problems, all the service codes ...

  • Page 100

    3-42 fuel system (dfi) self-diagnosis service code table service code fi indicator led light problems (1) 11 throttle sensor malfunction, wiring open or short 12 inlet air pressure sensor malfunction, wiring open or short 13 inlet air temperature sensor malfunction, wiring open or short 14 water tem...

  • Page 101

    Fuel system (dfi) 3-43 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 throttle sensor throttle valve opening angle α = – 4° ∼ ...

  • Page 102

    3-44 fuel system (dfi) self-diagnosis service codes parts output signal usable range or criteria backups by ecu 51 ignition coil #1 the ignition coil primary winding must send signals (output voltage) continuously to the ecu. If the ignition primary winding #1 has failures (no signal, wiring short o...

  • Page 103

    Fuel system (dfi) 3-45 throttle sensor (service code 11) throttle sensor removal/adjustment caution do not remove or adjust the throttle sensor [a] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sensor can da...

  • Page 104

    3-46 fuel system (dfi) throttle sensor (service code 11) • remove the ecu (see this chapter). Do not disconnect the ecu connectors. • connect a digital meter [a] to the connector [b], using the needle adapters [c]. Special tool - needle adapter set: 57001–1457 caution insert the needle adapter strai...

  • Page 105

    Fuel system (dfi) 3-47 throttle sensor (service code 11) a. Ecu c. Throttle sensor.

  • Page 106

    3-48 fuel system (dfi) inlet air pressure sensor (service code 12) removal caution never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. • remove the fuel tank (see fuel tank section in this chap- ter). • disconnect the inlet air pressure sensor connector [a]. ...

  • Page 107

    Fuel system (dfi) 3-49 inlet air pressure sensor (service code 12) • turn the ignition sw on. Inlet air pressure sensor input voltage connections to ecu meter (+) → bl/w lead (terminal 35) meter (−) → br/bk lead (terminal 11) input voltage at ecu standard: 4.75 ∼ 5.25 v dc if the reading is less tha...

  • Page 108

    3-50 fuel system (dfi) inlet air pressure sensor (service code 12) if the output voltage is normal, check the inlet air pressure sensor output voltage for vacuum other than 76 cmhg (abs) as follows. If the output voltage changes within the usable range as vacuum changes, the sensor is normal and the...

  • Page 109

    Fuel system (dfi) 3-51 inlet air pressure sensor (service code 12) suppose: pg : vacuum (gauge) of throttle assy pl : local atmospheric pressure (absolute) measured by a barometer pv : vacuum (absolute) of throttle assy vv : sensor output voltage (v) then pv = pl – pg for example, suppose the follow...

  • Page 110

    3-52 fuel system (dfi) inlet air pressure sensor (service code 12) pv = 55 ∼ 86 cm hg vv: inlet air pressure sensor output voltage (v) (digital meter reading) pv: throttle vacuum (absolute) ps: standard atmospheric pressure (absolute) id: idling to: throttle full open st: standard of sensor output v...

  • Page 111

    Fuel system (dfi) 3-53 inlet air temperature sensor (service code 13) removal/installation caution never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove the right air cleaner base (see right air cleaner housing removal in this chapter). • disconnect ...

  • Page 112

    3-54 fuel system (dfi) inlet air temperature sensor (service code 13) sensor resistance inspection • remove the inlet air temperature sensor (see this sec- tion). • suspend the sensor [a] in a container of machine oil so that the heat-sensitive portion and threaded portion are submerged. • suspend a...

  • Page 113

    Fuel system (dfi) 3-55 water temperature sensor (service code 14) removal/installation caution never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove the thermostat housing [a] (see thermostat re- moval in the cooling system chapter). • disconnect the...

  • Page 114

    3-56 fuel system (dfi) water temperature sensor (service code 14) sensor resistance inspection • remove the water temperature sensor (see this section). • suspend the sensor [a] in a container of machine oil so that the heat-sensitive portion and threaded portion are submerged. • suspend a thermomet...

  • Page 115

    Fuel system (dfi) 3-57 atmospheric pressure sensor (service code 15) removal caution never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove the fuel tank (see fuel tank section in this chap- ter). • disconnect the atmospheric pressure sensor connector...

  • Page 116

    3-58 fuel system (dfi) atmospheric pressure sensor (service code 15) if the reading is within the standard range, check the wiring between the ecu and the atmospheric pressure sensor for continuity. If the wiring is good, check the output voltage. • remove the needle adapters. • apply silicone seala...

  • Page 117

    Fuel system (dfi) 3-59 atmospheric pressure sensor (service code 15) a. Ecu b. Atmospheric pressure sensor if you need to check the atmospheric pressure sensor for various altitudes other than sea level, check the output voltage as follows: ○ determine the local altitude (elevation). If you know the...

  • Page 118

    3-60 fuel system (dfi) atmospheric pressure sensor (service code 15) va: atmospheric pressure sensor output voltage (v) h: altitude (m or feet) sl: sea level (0 m) st: standard of sensor output voltage (v) ur: usable range of sensor output voltage (v).

  • Page 119

    Fuel system (dfi) 3-61 crankshaft sensors (#1, #2: service code 21, 22) crankshaft sensor #1: for front cylinder (service code 21) crankshaft sensor #2: for rear cylinder (service code 22) crankshaft sensor removal/installation • see ignition system section in the electrical system chapter. Cranksha...

  • Page 120

    3-62 fuel system (dfi) vehicle-down sensor (service code 31) removal caution never drop the down-sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove the seat (see frame chapter). • remove the bolt [a] and take out the vehicle-down sensor [b]. • raise the connecto...

  • Page 121

    Fuel system (dfi) 3-63 vehicle-down sensor (service code 31) if the power source is normal, check the output voltage of the sensor. • connect a digital volt meter [a] to the connector (natural, 3p), using two needle adapters [b]. • turn the ignition sw on, and measure the output voltage with the con...

  • Page 122

    3-64 fuel system (dfi) vehicle-down sensor (service code 31) a. Ecu n. Ignition switch q. Sealed battery d. Vehicle-down sensor o. Starter relay f. Ignition fuse 10 a f. Junction box p. Main fuse 30 a v. Dfi fuse 15a e. Dfi main relay.

  • Page 123

    Fuel system (dfi) 3-65 fuel injectors (#1, #2: service code 41, 42) fuel injector #1: front fuel injector for front cylinder (service code 41) fuel injector #2: rear fuel injector for rear cylinder (service code 42) caution never drop the injector, especially on a hard sur- face. Such a shock to the...

  • Page 124

    3-66 fuel system (dfi) fuel injectors (#1, #2: service code 41, 42) • if necessary, remove the screws [a] and the fuel hose [b], and then take off the pressure regulator [c]. ○ the screen [a] comes off from the pressure regulator [b]. Delivery joint [c] front [d] • clean the screen with a high-flash...

  • Page 125

    Fuel system (dfi) 3-67 fuel injectors (#1, #2: service code 41, 42) • apply engine oil to the o-ring [a], and install each injector [b] into the delivery joint [c]. • check that there is no dirt or dust on the injector seating surface [a] of the inlet manifold [b]. • check that the two dowel pins ar...

  • Page 126

    3-68 fuel system (dfi) fuel injectors (#1, #2: service code 41, 42) • check the injector fuel line for leakage as follows: ○ connect a commercially available vacuum/pressure pump [c] and a rubber hose [i] to the fuel hose [b] of the delivery joint [a] as shown. ○ plug the outlet of the pressure regu...

  • Page 127

    Fuel system (dfi) 3-69 fuel injectors (#1, #2: service code 41, 42) • push and pull [a] the fuel hose joint #2 [b] back and forth more than two times and make sure it is locked and doesn’t come off. When the fuel hose joint #2 is correctly installed, it should slide on the delivery pipe about 5 mm (...

  • Page 128

    3-70 fuel system (dfi) fuel injectors (#1, #2: service code 41, 42) if the power source voltage is incorrect, check the dfi power source (see dfi power source in this chapter). If the dfi power source is good, check the ecu for its ground and power supply. If the ground and power supply of the ecu a...

  • Page 129

    Fuel system (dfi) 3-71 fuel injectors (#1, #2: service code 41, 42) injector signal test • prepare two test light sets with male terminals as shown. Rating of bulb [a]: 12 v × 3 ∼ 3.4 w terminal width [b]: 1.8 mm (0.07 in.) terminal thickness [c]: 0.8 mm (0.013 in.) caution do not use larger termina...

  • Page 130

    3-72 fuel system (dfi) fuel injectors (#1, #2: service code 41, 42) injector unit test • use two wires [a] and the same test light set [b] as in “injector signal test”. Rating of bulb [c]: 12 v × (3 ∼ 3.4) w 12 v sealed battery [d] caution be sure to connect the bulb in series. The bulb works as a c...

  • Page 131

    Fuel system (dfi) 3-73 fuel pump (service code 45) fuel pump removal caution never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. Warning gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilate...

  • Page 132

    3-74 fuel system (dfi) fuel pump (service code 45) fuel pump installation • clean the pump screen (see pump filter cleaning). • remove dirt or dust from the fuel pump by lightly applying compressed air. • replace the fuel pump gasket with a new one. • install a new pump gasket [a] with its tab [b] f...

  • Page 133

    Fuel system (dfi) 3-75 fuel pump (service code 45) • secure the fuel pump leads [a] with the clamps [b]. • press the clamps flat by hands against the fuel tank bot- tom. • make sure that the end of each clamp is covered with a plastic cap [c] and touches the fuel tank bottom. • clamp the fuel pump l...

  • Page 134

    3-76 fuel system (dfi) fuel pump (service code 45) if the reading is good, the power source voltage is normal. Inspect operating source voltage (see in this section). If the reading is incorrect, check the following: battery main fuse 30 a in starter relay (see electrical system chapter) dfi fuse 15...

  • Page 135

    Fuel system (dfi) 3-77 fuel pump (service code 45) a. Ecu p. Main fuse 30 a v. Dfi fuse 15 a f. Junction box q. Sealed battery e. Dfi main relay n. Ignition switch u. Fuel pump f. Ignition fuse 10 a o. Starter relay.

  • Page 136

    3-78 fuel system (dfi) ignition coils (#1, #2: service code 51, 52) ignition coil #1: ignition coil for front cylinder (service code 51) ignition coil #2: ignition coil for rear cylinder (service code 52) removal/installation caution never drop the ignition coils, especially on a hard surface. Such ...

  • Page 137

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

  • Page 138

    3-80 fuel system (dfi) fi indicator led light the fi indicator led light [a] goes on when the ignition sw is turned on and the led light goes off 2 seconds later. This is to ensure that the fi indicator led light has not burned out and the dfi system and the ignition system function properly. Led li...

  • Page 139

    Fuel system (dfi) 3-81 ecu ecu identification ○ most countries have their own regulations, so each ecu has different characteristic of fuel injection according to each country. So, do not confuse ecu’s with each other and use only the ecu’s for your country. Otherwise, the motorcycle could not clear...

  • Page 140

    3-82 fuel system (dfi) ecu ecu power supply inspection • visually inspect the terminals of the ecu connector. If the connector is clogged with mud or dust, blow it off with compressed air. Replace the main harness if the terminals [a] of the main harness connectors are cracked, bent, or otherwise da...

  • Page 141

    Fuel system (dfi) 3-83 dfi power source dfi fuse removal • remove the seat (see frame chapter). • pull the lock [a] and open the lid [b]. • pull out the dfi fuse [c] from the case with needle nose pliers. Front [d] if a fuse fails during operation, inspect the dfi system to determine the cause, and ...

  • Page 142

    3-84 fuel system (dfi) dfi power source dfi power source circuit a. Ecu q. Sealed battery w. Isc valve #2 f. Junction box r. Fuel injector #1 x. Isc valve #1 n. Ignition sw s. Fuel injector #2 e. Dfi main relay o. Starter relay u. Fuel pump f. Ignition fuse 10 a p. Main fuse 30 a v. Dfi fuse 15 a p....

  • Page 143

    Fuel system (dfi) 3-85 isc valves removal/installation caution never drop the isc valves, especially on a hard sur- face. Such a shock to the valve can damage it. ○ the isc valves are removed during right air cleaner hous- ing removal (see this chapter). ○ the isc valve itself is the same for front ...

  • Page 144

    3-86 fuel system (dfi) isc valves output voltage inspection • check the output voltage at the connectors [a] of the isc valves. • remove the right air cleaner cover (see this chapter). Special tool - hand tester [b] : 57001–1394 • measure the output voltage with the engine stopped, and with the conn...

  • Page 145

    Fuel system (dfi) 3-87 isc valves a. Ecu v. Dfi fuse 15 a f. Junction box w. Isc valve #2 n. Ignition switch x. Isc valve #1 o. Starter relay e. Dfi main relay p. Main fuse 30 a f. Ignition fuse 10 a q. Sealed battery.

  • Page 146

    3-88 fuel system (dfi) fuel line fuel pressure inspection note ○ this inspection can detect the faults of the dfi fuel line other than the dfi electronic system. ○ it is preferable to measure the fuel pressure while run- ning the motorcycle when the trouble has occurred in order to know symptom well...

  • Page 147

    Fuel system (dfi) 3-89 fuel line • turn the ignition sw on. The fuel pump will turn for 3 seconds, and then stop. • measure the fuel pressure with the engine stopped. Fuel pressure right after ignition sw on, with pump running: standard: 310 kpa (3.2 kgf/cm², 46 psi) after 3 seconds from ignition sw...

  • Page 148

    3-90 fuel system (dfi) fuel line • fit the fuel hose joint #2 [a] onto the pipe (for delivery joint) until the joint clicks [b]. ○ insert the hose joint straight along the pipe. Front [c] • push and pull [a] the fuel hose joint #2 [b] back and forth more than two times and make sure it is locked and...

  • Page 149

    Fuel system (dfi) 3-91 fuel line • prepare a plastic hose of the inside diameter 7.5 mm × l about 400 mm and a measuring cylinder. • remove: seat (see frame chapter) indicator unit (see fuel tank removal in this chapter). Fuel tank bolts • raise the fuel tank. • stuff a clean shop towel around the f...

  • Page 150

    3-92 fuel system (dfi) throttle grip and cables throttle grip free play inspection ○ refer to throttle control system check in the periodic maintenance chapter. Throttle grip free play adjustment • loosen the locknuts [a] and screw the adjusters [b] all the way in so as to give the throttle grip ple...

  • Page 151

    Fuel system (dfi) 3-93 throttle body assy idle speed check ○ refer to idle speed check in the periodic maintenance chapter. Idle speed adjustment ○ refer to idle speed check in the periodic maintenance chapter. High altitude performance adjustment ○ any modification is not necessary in this model si...

  • Page 152

    3-94 fuel system (dfi) throttle body assy • remove the following from the choke cable holder [a] (left -behind view). Screw [b] choke cable plate [c] • while pushing the choke lever [a] forward, remove the cable housing from the choke cable holder [b] and the inner cable out of the holder slit [c]. ...

  • Page 153

    Fuel system (dfi) 3-95 throttle body assy • remove the decelerator cable end [a] from the throttle pulley [b]. • using needle nose pliers, move the accelerator inner ca- ble outside the engine, and remove the cable end [c] from the pulley. Front [d] • pinch the lock of the fuel hose joint #2 [a] wit...

  • Page 154

    3-96 fuel system (dfi) throttle body assy • stuff a piece of lint-free, clean cloth into the throttle body assy, and the inlet ports of the cylinder heads to keep dirt out of the engine. Warning if dirt or dust is allowed to pass through into the throttle bore, the throttle may become stuck, possi- ...

  • Page 155

    Fuel system (dfi) 3-97 throttle body assy • apply a thin coating of grease to the throttle cable upper ends. • install the upper ends of the throttle cables in the grip. • fit the projection [a] of the right switch housing into the hole [b] of the handlebar (front view). • turn the throttle grip and...

  • Page 156

    3-98 fuel system (dfi) throttle body assy • remove the three throttle body flange bolts [a]. • split the throttle body assy into the throttle body [a] and the inlet manifold [b]. The gasket [c] comes off. • discard the gasket. ○ do not remove or adjust the following parts. These parts are set at the...

  • Page 157

    Fuel system (dfi) 3-99 throttle body assy • remove the delivery joint and injectors (see injector sec- tion in this chapter). • open the butterfly valves [a], and wipe any carbon off the throttle bores [b] around the valves, using a piece of lint-free cloth penetrated with a high-flash point solvent...

  • Page 158

    3-100 fuel system (dfi) air cleaner air cleaner element removal • remove: allen bolt and washer [a] left air cleaner cover [b] front [c] • remove the element [a]. • push a clean, lint-free towel into the lower air cleaner duct to keep dirt or other foreign material from entering. Warning if dirt or ...

  • Page 159

    Fuel system (dfi) 3-101 air cleaner right air cleaner housing removal • remove: allen bolt and washer [a] right air cleaner cover [b] front [c] • remove: isc valve hoses [a] isc valve lead connectors [b] air cleaner allen bolts [c] and screws [d] air cleaner base bolt [e] • remove: air cleaner base ...

  • Page 160

    3-102 fuel system (dfi) air cleaner if the air cleaner drain hose [a] has been removed with it attached to the right air cleaner base, pull the drain hose off the right air cleaner base. Remove the left air cleaner base and insert the drain hose under the lower air cleaner duct. • install the inlet ...

  • Page 161

    Fuel system (dfi) 3-103 fuel tank fuel tank removal warning gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignit...

  • Page 162

    3-104 fuel system (dfi) fuel tank • disconnect: indicator unit connector [a] ignition switch connector [b] • remove: ignition switch [c] and screws [d] bracket [e] and bolt [f] front [g] • remove the seat (see frame chapter). • disconnect the battery (−) terminal [a]. • open the fuel pump lead clamp...

  • Page 163

    Fuel system (dfi) 3-105 fuel tank • prepare a 8 mm plug ( 7.8 ∼ 8.0 mm [a] × l 35 mm [b] with a rounded end [c]), and a 7.3 ∼ 7.5 mm inside diameter fuel hose [d] (e.G. Part no. 92191–1264). ○ the 8 mm plug can be made by cutting the threaded portion off a 8 mm bolt [f] (e.G. Part no. 92151–1444). ○...

  • Page 164

    3-106 fuel system (dfi) fuel tank ○ be careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump. Warning store the fuel tank in an area which is well -ventilated and free from any source of flame or sparks. Do not smoke in this area. Place the fuel tank on ...

  • Page 165

    Fuel system (dfi) 3-107 fuel tank • fit the fuel return hose [a] onto the pipe fully and install the plate clamp [b] beyond the raised rib [c]. • secure the fuel pump leads [a] with the clamps [b]. • press the clamps flat by hands against the fuel tank bot- tom. • make sure that the end of each clam...

  • Page 166

    3-108 fuel system (dfi) fuel tank fuel tank cleaning warning clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvent to clean the tank. ...

  • Page 167

    Fuel system (dfi) 3-109 evaporative emission control system the evaporative emission control system for california model routes fuel vapors from the fuel system into the run- ning engine or stores the vapors in a canister when the en- gine is stopped. Although no adjustments are required, a thorough...

  • Page 168

    3-110 fuel system (dfi) evaporative emission control system hose inspection (periodic inspection) ○ refer to evaporative emission control system check in the periodic maintenance chapter. Separator operation test warning gasoline is extremely flammable and can be explo- sive under certain conditions...

  • Page 169: Cooling System

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

  • Page 170

    4-2 cooling system exploded view.

  • Page 171

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 water temperature sensor (dfi) 18 1.8 13 ss 2 water pipe bolts 11 1.1 97 in·lb 3 radiator fan bolts 8.3 0.85 74 in·lb 4 radiator drain bolt 2.2 0.22 19 in·lb 5 water temperature switch 7.8 0.80 69 in·lb ss 6 radiator fan ...

  • Page 172

    4-4 cooling system 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 as coolant temperature change...

  • Page 173

    Cooling system 4-5 coolant flow chart 1. Water pump 2. Water jacket 3. Cylinder head 4. Water pipe 5. Water hose 6. Radiator cap 7. Thermostat 8. Reserve tank hose 9. Radiator 10. Radiator fan 11. Throttle body assy 12. Front 13. Cold coolant 14. Hot coolant 15. Reserve tank 16. Reserve tank overflo...

  • Page 174

    4-6 cooling system specifications coolant provided when shipping: type (recommended) permanent type 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 point − 35°c (− ...

  • Page 175

    Cooling system 4-7 special tools and sealant bearing driver set : 57001–1129 bearing remover shaft : 57001–1265 bearing remover head, φ 10 x φ 12 : 57001–1266 kawasaki bond (silicone sealant) : 56019–120

  • Page 176

    4-8 cooling system coolant coolant deterioration inspection • remove the right side cover (see frame chapter). • visually inspect the coolant [a] in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel ...

  • Page 177

    Cooling system 4-9 coolant pressure testing • remove the fuel tank (see fuel system chapter). • remove the radiator cap, and install a cooling system pressure tester [a] on the radiator filler neck [b]. Note ○ wet the cap sealing surfaces with water or coolant to prevent pressure leakage. • build up...

  • Page 178

    4-10 cooling system water pump water pump removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: water hose clamp [a] water hose [b] front [c] • remove: water pump cover bolts [a] water pump cover [b] • remove: impeller bolt [a] impeller [b] note ○ the impell...

  • Page 179

    Cooling system 4-11 water pump • install the clamp [a] so that the clamp end is about 16 mm (0.63 in.) [b] apart from the pump inlet step. This prevents coolant leakage from the hose end. • tighten the hose clamp screw securely. Water pump inspection • check the water pump drainage outlet hose [a] a...

  • Page 180

    4-12 cooling system water pump if the coolant still leaks through the drainage outlet hose, the seal and ball bearings is probably damaged. Replace the mechanical seal, ball bearings, and oil seal by splitting the crankcase. • split the crankcase (see crankshaft/transmission chap- ter). • remove the...

  • Page 181

    Cooling system 4-13 water pump • clean both sliding surfaces of a new mechanical seal with a high-flash point solvent (e.G. Ethyl alcohol), and apply a little coolant to the sliding surface to give the mechanical seal initial lubrication. • apply coolant to the surface of the rubber seal [a] and sea...

  • Page 182

    4-14 cooling system radiator warning the radiator fan is connected directly to the bat- tery. The radiator fan may start even if the ignition switch is off. Never touch the radiator fan until the radiator fan connector is dis- connected. Touching the fan before the connector is disconnected could ca...

  • Page 183

    Cooling system 4-15 radiator • remove: radiator fan bolts [a] radiator fan [b] radiator installation • be sure to install the radiator fan ground lead terminal [a]. Torque - radiator fan bolts and fan ground lead terminal bolt: 8.3 n·m (0.85 kgf·m, 74 in·lb) • fit the radiator stoppers [a] into the ...

  • Page 184

    4-16 cooling system radiator radiator cap inspection • check the condition of the top and bottom valve seals of the radiator cap. If any one of them shows visible damage, replace the cap. Bottom valve seal [a] top valve seal [b] valve spring [c] • install the cap [a] on a cooling system pressure tes...

  • Page 185

    Cooling system 4-17 thermostat thermostat removal • remove: coolant : drain about 200 ml fuel tank (see fuel system chapter) four water hoses [a] bracket bolts [b] water temperature sensor connector [c] • remove the thermostat housing [d] along with the bracket. Front [e] • remove the screws [a], ta...

  • Page 186

    4-18 cooling system hoses and pipes hose installation • install the hoses and pipes being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening, or twisting. • install the clamps [a] as near as possible to the hose end to clear the raised rib on the fitting. This will preve...

  • Page 187: Engine Top End

    Engine top end 5-1 5 engine top end table of contents exploded view................................... 5-2 specifications .................................... 5-8 special tools and sealant ................. 5-11 clean air system............................... 5-14 air suction valve removal.............

  • Page 188

    5-2 engine top end exploded view.

  • Page 189

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rocker case cover bolts 8.8 0.90 78 in·lb s 2 air suction valve cover bolts 7.4 0.75 65 in·lb 3 rocker case nuts φ 12 mm 78 8.0 58 s, mo 4 rocker case nuts φ 8 mm 25 2.5 18 s 5 rocker case bolts φ 6 mm 8.8 0.90 78 in·lb s...

  • Page 190

    5-4 engine top end exploded view.

  • Page 191

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rocker shafts 25 2.5 18 2 exhaust pipe cover clamp screws 6.9 0.70 61 in·lb 3 premuffler chamber bolts 29 3.0 21 4 upper muffler bracket nut 29 3.0 21 5 muffler stay mounting bolts, φ 8 25 2.5 18 6 upper muffler mounting ...

  • Page 192

    5-6 engine top end exploded view.

  • Page 193

    Engine top end 5-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 cylinder head nuts 25 2.5 18 s 2 cylinder nuts 25 2.5 18 s 3 chain tensioner cap 20 2.0 15 s 4 chain tensioner lockbolt 4.9 0.50 43 in·lb s 5 chain tensioner mounting bolts 11 1.1 97 in·lb s 6 chain guide mounting bolts 1...

  • Page 194

    5-8 engine top end specifications item standard service limit clean air system: air switching valve resistance: 18 ~ 22 Ω at 20° (68°f) – – – camshafts: cam height: exhaust 33.741 ~ 33.857 mm 33.64 mm (1.32839 ~ 1.33295 in.) (1.3244 in.) inlet 33.928 ~ 34.044 mm 33.83 mm (1.33575 ~ 1.34031 in.) (1.3...

  • Page 195

    Engine top end 5-9 specifications item standard service limit valve stem diameter: exhaust 6.955 ~ 6.970 mm 6.94 mm (0.2732 in.) (0.27382 ~ 0.27441 in.) inlet 6.965 ~ 6.980 mm 6.95 mm (0.2736 in.) (0.27421 ~ 0.27480 in.) valve guide inside diameter: exhaust 7.000 ~ 7.015 mm 7.08 mm (0.2787 in.) (0.2...

  • Page 196

    5-10 engine top end specifications item standard service limit valve seat surface: valve seat cutting angle 45°, 32°, 55° – – – outside diameter: exhaust 31.9 ~ 32.1 mm – – – (1.256 ~ 1.264 in.) inlet 36.4 ~ 36.6 mm – – – (1.433 ~ 1.441 in.) width: exhaust 0.8 ~ 1.2 mm – – – (0.031 ~ 0.047 in.) inle...

  • Page 197

    Engine top end 5-11 special tools and sealant valve guide reamer, φ 7 : 57001–162 valve guide arbor, φ 7 : 57001–163 compression gauge : 57001–221 valve spring compressor assembly : 57001–241 valve spring compressor adapter, φ 28.2 : 57001–243 piston pin puller assembly : 57001–910 compression gauge...

  • Page 198

    5-12 engine top end special tools and sealant valve seat cutter, 32° – φ 35 : 57001–1121 valve seat cutter, 32° – φ 38.5 : 57001–1122 valve seat cutter holder, φ 7 : 57001–1126 valve seat cutter holder bar : 57001–1128 hexagon wrench, hex 27 : 57001–1210 piston pin puller adapter : 57001–1211 valve ...

  • Page 199

    Engine top end 5-13 special tools and sealant valve seat cutter 45° – φ 40 : 57001–1496 valve seat cutter 55° – φ 38.5 : 57001–1497 kawasaki bond (silicone sealant) : 56019–120 ○ compression gauge adapter: 57001-1183 can also be used. ○ valve seat cutter, 32° – φ 33: 57001-1199 can also be used inst...

  • Page 200

    5-14 engine top end clean air system air suction valve removal • for rear air suction valve removal, remove the rear ex- haust pipe. • remove the hose [a]. • unscrew the mounting bolts [b] and remove the rear air suction valve cover [c]. • remove the rear air suction valve. • for front air suction v...

  • Page 201

    Engine top end 5-15 clean air system air switching valve removal • remove: fuel tank (see fuel system chapter) • pull off the hoses [a] and air switching valve connector [b], and take out the air switching valve [c]. Air switching valve installation • install the air switching valve [a] so that the ...

  • Page 202

    5-16 engine top end clean air system • connect the 12 v battery [a] to the air switching valve terminals as shown. • blow the air to the inlet air duct [a], and make sure does not flow the blown air from the outlet air ducts [b]. • disconnect the 12 v battery. • blow the air to the inlet air duct [a...

  • Page 203

    Engine top end 5-17 camshaft chain tensioner camshaft chain tensioner removal caution this is a non-return type cam 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 tensione...

  • Page 204

    5-18 engine top end camshaft chain tensioner • install the larger spring [a], and then the ball bearing assy [b]. ○ fit the ball bearing assy into the body until it bottoms out, using a thin-bladed screwdriver. • screw in the lockbolt [a] finger-tight to hold the ball bear- ing assy temporarily. • i...

  • Page 205

    Engine top end 5-19 rocker case cover rocker case cover removal • remove the engine (see engine removal/installation chapter). • remove the bolts [a] and take off the cover [b] from the rocker case. • take out the oil filter springs [a] and hla oil filters [b]. Rocker case cover installation • repla...

  • Page 206

    5-20 engine top end rocker case cover rocker case cover assembly • apply adhesive to the rubber dampers [a] and install them on the rocker case cover as shown. ○ insert the projections [b] of the dampers to the holes [c] of the cover. Front cover [d] rear cover [e].

  • Page 207

    Engine top end 5-21 rocker case rocker case removal • remove the engine (see engine removal/installation chapter). • remove the throttle body assy (see fuel system (dfi) chapter). • remove the rocker case covers (see rocker case cover removal). • remove the alternator outer cover (see electrical sys...

  • Page 208

    5-22 engine top end rocker case • using the pry points [a], take the rocker case out of the cylinder head. • unscrew the rocker shafts [a], and take the rocker arms [b] out of the rocker case. • take out the oil filters if necessary. • remove the lash adjuster if necessary (see hla re- moval). Cauti...

  • Page 209

    Engine top end 5-23 rocker case • apply molybdenum disulfide oil to the threads and seating surface of φ 12 mm nuts and both sides of washers. • tighten the rocker case nuts and bolts temporarily follow- ing the tightening sequence shown, and then tighten them to the specified torque. Torque - rocke...

  • Page 210

    5-24 engine top end rocker case rocker arm assembly • prepare a flat-end bar [a] and a block [b] with a recess [c]. • press the oil chamber [d] for the hla into the rocker arm end [e] until the chamber end is even with the step [f] of the hole. ○ install the oil chamber as shown so that the air blee...

  • Page 211

    Engine top end 5-25 rocker case hla installation • check that the hla plunger is not damaged. If the plunger does damage, replace the hla. Hla body [a] o-ring [b] plunger spring [c] pivot plunger [d] check valve [e] check valve spring [f] • air-bleed the hla (see hla air bleeding). • soak a rocker a...

  • Page 212

    5-26 engine top end camshafts camshaft removal • remove the timing inspection cap [a] and rotor bolt cap [b]. Special tool - driver-filler cap: 57001–1454 [c] • turn the crankshaft counterclockwise [a] and align the “f” mark [b] (tdc mark for the front piston) with the middle of the notch [c]. • rem...

  • Page 213

    Engine top end 5-27 camshafts • install the kacr on each camshaft. ○ the front kacr [a] and rear kacr [b] are different (inside view). Do not confuse these kacrs. • fit the pin [a] into the notch [b], and install the kacr [c] onto the camshaft [d]. • apply molybdenum disulfide oil to all cam parts, ...

  • Page 214

    5-28 engine top end camshafts • align the “r” mark [a] (tdc mark for the rear piston) with the middle of the notch [b] (310° turn from the front piston tdc). • engage the rear camshaft sprocket with the camshaft chain as shown. Timing marks [a] and r mark [b] cylinder head upper surface [c] front [d...

  • Page 215

    Engine top end 5-29 camshafts • apply molybdenum disulfide oil to the threads and seating surface of φ 12 mm nuts and both sides of washers. • tighten the rocker case nuts and bolts temporarily follow- ing the tightening sequence shown, and then tighten them to the specified torque. Torque - rocker ...

  • Page 216

    5-30 engine top end camshafts • remove: alternator rotor (see electrical system chapter) lower chain guide bolts [a] lower chain guide [b] • take out the front camshaft chain [c]. Rear camshaft chain removal • remove: rear camshaft (see camshaft removal) spark plug (left side, see cylinder compressi...

  • Page 217

    Engine top end 5-31 camshafts ○ the cylinder compression is released while the engine is running (abnormal): the pin [a] stays out the cam [b] and pushes up the exhaust rocker arm. • remove the spring [c] and move the weights [d] back and forth. If the weights do not move easily from the retracted p...

  • Page 218

    5-32 engine top end cylinder head cylinder compression measurement note ○ be sure the battery is fully charged. • warm up the engine thoroughly. • stop the engine. • remove one spark plug and attach the compression gauge and adapter firmly into the spark plug hole. Do not remove the other spark plug...

  • Page 219

    Engine top end 5-33 cylinder head the following table should be consulted if the obtainable compression reading is not within the us- able range. Problem diagnosis remedy (action) carbon buildup on piston and in combustion remove the carbon deposits chamber possibly due to damaged valve stem, and re...

  • Page 220

    5-34 engine top end cylinder head • do not remove the coolant drain plug [a] yet. • remove the cylinder head nuts [b]. • take the cylinder head off the cylinder. Cylinder head installation ○ the front cylinder head [a] has an f mark while the rear cylinder head [b] has an r mark. Be careful not to m...

  • Page 221

    Engine top end 5-35 cylinder head valve clearance adjustment note ○ since the hydraulic lash adjusters constantly maintain zero clearance, it is not necessary to inspect or adjust the valve clearance. Valve removal • remove the cylinder head (see cylinder head removal). • swing open the rocker arm. ...

  • Page 222

    5-36 engine top end cylinder head 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) in the engine oil. • drive the valve guide in from the top of the head using the valve gu...

  • Page 223

    Engine top end 5-37 cylinder head valve seat inspection • remove the valve (see valve removal). • check the valve seat surface [a] between the valve [b] and valve seat [c]. ○ measure the outside diameter [d] of the seating pattern on the valve seat with vernier calipers. If the outside diameter is t...

  • Page 224

    5-38 engine top end cylinder head 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. Do not drop or shock the valve seat cutter, or the diamond particles may fall off. Do not fai...

  • Page 225

    Engine top end 5-39 cylinder head ○ to make the 32° grind, fit a 32° cutter into the holder, and slide it into the valve guide. ○ turn the holder one turn at a time while pressing down very lightly. Check the seat after each turn. Caution the 32° cutter removes material very quickly. Check the seat ...

  • Page 226

    5-40 engine top end cylinder head.

  • Page 227

    Engine top end 5-41 cylinders, piston cylinder removal • remove the cylinder head (see cylinder head removal). • remove the coolant drain plug [a] and drain the coolant from the cylinder. • pull out the front camshaft chain guide [b]. • remove the cylinder nuts [c]. • tap lightly up the cylinder wit...

  • Page 228

    5-42 engine top end cylinders, piston • do not mix up the top ring and second ring. • install the top ring [a] so that the “r” mark [b] faces up. • install the second ring [c] so that the “rn” mark [d] faces up. • the piston ring openings must be positioned as shown in the figure. The openings of th...

  • Page 229

    Engine top end 5-43 cylinders, piston note ○ if a new piston or cylinder is used, check piston to cylin- der clearance (see piston/cylinder clearance), and use new piston ring. • replace the cylinder base gasket [a] with a new one, and install the gaskets aligning the holes with the crankcase water ...

  • Page 230

    5-44 engine top end cylinders, piston • install the front cylinder in the same way. ○ position the front piston at tdc. ○ tighten the cylinder nuts temporarily (these nuts are tightened to the specified torque after rocker case instal- lation). Cylinder wear • since there is a difference in cylinder...

  • Page 231

    Engine top end 5-45 cylinders, piston cylinder boring and honing ○ there is an oversize piston available. The oversize piston requires oversize rings. Oversize piston and rings: 0.5 mm (0.02 in.) oversize • before boring a cylinder [a], first measure the exact di- ameter of the oversize piston, and ...

  • Page 232

    5-46 engine top end cylinders, piston piston ring thickness • measure the thickness of the top [a] and second [b] rings. ○ use a micrometer to measure at several points around the ring. Piston ring thickness standard service limit top 1.17 ~ 1.19 mm 1.10 mm (0.04606 ~ 0.04685 in.) (0.0433 in.) secon...

  • Page 233

    Engine top end 5-47 mufflers exhaust pipe removal warning to avoid a serious burn, do not remove the exhaust pipe or muffler when the engine is still hot. Wait until the muffler cools down. • loosen the upper muffler bracket bolt [a] for easy removal or installation of exhaust pipes. • loosen the cl...

  • Page 234

    5-48 engine top end mufflers lower muffler removal • remove: front and rear exhaust pipe covers (see above) chamber flange nuts [a] muffler bracket bolts [b] • remove the lower muffler [c]. Note ○ if the chamber flange nuts are difficult to remove, spray a penetrating oil on the studs and nuts. Uppe...

  • Page 235

    Engine top end 5-49 mufflers • tighten the front exhaust pipe cover clamp screw [a] with its head inclined at 50° or less to horizontal as shown. This prevents the screw from touching ground when bank- ing. Front exhaust pipe [b] torque - exhaust pipe cover clamp screws: 6.9 n·m (0.70 kgf·m, 61 in·l...

  • Page 236

    5-50 engine top end mufflers chamber identification ○ the all models have a premuffler chamber (identification no. Khi m 092) with a honeycomb type catalytic con- verter and without any catalyst protection system. Do not mix up this chamber with the other type chamber (espe- cially with a non-cataly...

  • Page 237: Clutch

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

  • Page 238

    6-2 clutch exploded view.

  • Page 239

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 clutch reservoir cap screws 1.5 0.15 13 in·lb 2 clutch slave cylinder bleed valve 7.8 0.80 69 in·lb 3 clutch master cylinder clamp bolts 9.8 1.0 87 in·lb s 4 clutch hose banjo bolt 25 2.5 18 5 clutch slave cylinder bolts 6.9 0.70...

  • Page 240

    6-4 clutch specifications item standard service limit clutch fluid grade dot4 (provided when shipping) – – – clutch lever position no. 1 (to suit rider) 5-way adjustable clutch lever free play non-adjustable – – – clutch clutch spring free height 4.3 mm (0.235 in.) 4 mm (0.16 in.) spring plate gap (...

  • Page 241

    Clutch 6-5 special tools and sealant inside circlip pliers : 57001–143 clutch spring compressor : 57001–1162 gear holder: 57001–1557.

  • Page 242

    6-6 clutch clutch fluid clutch fluid level check ○ refer to clutch fluid level check in the periodic mainte- nance chapter. Clutch fluid change ○ refer to clutch fluid change in the periodic maintenance chapter. Clutch line bleeding • remove: alternator outer cover (see electrical system chapter) • ...

  • Page 243

    Clutch 6-7 clutch master cylinder clutch lever adjustment the adjuster has 5 positions so that the clutch lever posi- tion 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 holder (front view). ○ t...

  • Page 244

    6-8 clutch clutch master cylinder clutch master cylinder disassembly/assembly ○ refer to clutch master cylinder cup and dust seal re- placement in the periodic maintenance chapter. Clutch master cylinder inspection • disassemble the clutch master cylinder. • check that there are no scratches, rust o...

  • Page 245

    Clutch 6-9 clutch slave cylinder clutch slave cylinder removal • remove: alternator outer cover (see electrical system chapter) banjo bolt [a] clutch slave cylinder bolts [b] slave cylinder [c] caution immediately wash away any clutch fluid that spills. It may damage painted surfaces. • perform the ...

  • Page 246

    6-10 clutch clutch slave cylinder • tighten the bolts [a]. Torque - clutch slave cylinder bolts: 6.9 n·m (0.70 kgf·m, 61 in·lb) ○ put the clamp [b] together the clutch slave cylinder bolt and bend along the slave cylinder with the end of the clamp straight to the engine side as shown in the figure. ...

  • Page 247

    Clutch 6-11 clutch clutch cover removal • raise the rear wheel off the ground. Special tools - jack: 57001–1238 attachment jack: 57001–1398 • drain the engine oil (see periodic maintenance chapter). • support the engine with a suitable stand [a]. ○ put a plank [b] onto the stand. • remove: front exh...

  • Page 248

    6-12 clutch clutch • unscrew the clutch hub nut [a] by using an air impact wrench. • take the clutch spring [b], and the clutch spring holder [c] out of the clutch hub. • take the back torque limiter springs [a], and the clutch spring plate out of the clutch housing. • take the friction/steel plate ...

  • Page 249

    Clutch 6-13 clutch clutch installation when replacing any one of the following parts, check the spring plate gap (see spring plate gap measurement). Spring plate [a] friction plates [b] steel plates [c] • when installing the clutch housing, mesh the oil pump drive gear [a] with the oil pump gear [b]...

  • Page 250

    6-14 clutch clutch • the spring plate pusher [a] into the clutch hub. Squeeze the clutch lever slowly and hold it with a band. ○ install the needle bearing [b] and the washer onto the pusher. • pushing [a] the operating plate [b] into the clutch hub, and insert the retaining ring [c] by hand. Inner ...

  • Page 251

    Clutch 6-15 clutch • prepare sheet gum (chewing gum) or about 5 g clay [a]. • make an about 2.5 mm (0.098 in.) thick sheet [b] of gum or clay, using a press and two thickness gauges [c] which are overlapped to about 2.5 mm (0.098 in.). • cut the sheet with scissors into four strips [d] of gum or cla...

  • Page 252

    6-16 clutch clutch spring plate gap adjustment if the plate gap is out of the usable range, change one of the steel plates [a] to a thicker or thinner one to get the correct gap. ○ use the standard steel plates (2.0 mm (0.079 in.) thick) × (6 ∼ 7) plates, and the adjustment steel plate (1.6 or 2.3 m...

  • Page 253

    Clutch 6-17 clutch clutch spring height measurement • measure the height [b] of the clutch spring [a]. If the spring height is less than the service limit, it must be replaced. Clutch spring height standard: 4.3 mm (0.235 in.) service limit: 4 mm (0.16 in.) clutch housing finger inspection • visuall...

  • Page 255: Engine Lubrication System

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

  • Page 256

    7-2 engine lubrication system engine oil flow chart.

  • Page 257

    Engine lubrication system 7-3 engine oil flow chart →: oil flow (1 ∼ 30) --→: blowby gas 1. Oil screen 2. Oil pump 3. Relief valve 4. Oil filter 5. Bypass valve 6. Oil pressure switch 7. Inside oil pipe 8. Banjo bolts of right crankcase rear 9. Outside oil hoses 10. Hla oil filter 11. Rocker shafts ...

  • Page 258

    7-4 engine lubrication system exploded view.

  • Page 259

    Engine lubrication system 7-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oil pipe holder bolts 11 1.1 97 in·lb l 2 oil pipe clamp bolts 11 1.1 97 in·lb l 3 oil hose flange bolts 9.8 1.0 87 in·lb 4 oil hose banjo bolt 9.8 1.0 87 in·lb 5 relief valve 15 1.5 11 l 6 oil pump mounting bo...

  • Page 260

    7-6 engine lubrication system specifications item standard engine oil: type api service classification : se, sf or sg class api service classification : sh or sj class with jaso ma viscosity sae 10w-40 capacity 2.9 l (3.1 us qt, when filter is not removed) 3.1 l (3.3 us qt, when filter is removed) 3...

  • Page 261

    Engine lubrication system 7-7 special tools and sealant oil pressure gauge, 5 kg/cm² : 57001–125 oil pressure gauge adapter, pt 1/8 : 57001–1033 oil filter wrench : 57001–1249 filler cap driver : 57001–1454 kawasaki bond (silicone sealant) : 56019–120

  • Page 262

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

  • Page 263

    Engine lubrication system 7-9 oil pump and oil line oil pump removal • remove the engine (see engine removal/installation chapter). • split the crankcase (see crankshaft/transmission chap- ter). • remove the oil pump mounting bolts [a], and take off the pump [b] out of the right crankcase. • unscrew...

  • Page 264

    7-10 engine lubrication system oil pump and oil line oil hose installation • run the front oil hose over the rear oil hose as shown. ○ insert the rear oil hose [a] first. ○ next insert the front oil hose [b]. ○ run both oil hoses between the rocker case and the rocker case cover. Torque - oil hose f...

  • Page 265

    Engine lubrication system 7-11 oil pump and oil line • remove the oil pipe clamp bolt [a], and oil return pipe [b]. • remove the separator [a]. • remove: oil pipe clamp bolt [a] oil pipe holder bolt [b] • remove the inside oil pipe [c] and the oil return pipe [d] from the left crankcase [e]. ○ pull ...

  • Page 266

    7-12 engine lubrication system oil pump and oil line • install the inside oil pipe [a], separator [b] and the oil re- turn pipe [c] to left crankcase [d] as shown. ○ do not apply silicone sealant to the groove of the grommet and the mating surface of the grommet [e]. ○ apply silicone sealant to the ...

  • Page 267

    Engine lubrication system 7-13 oil pump and oil line • install the inside oil pipe [a], separator [b], and the oil return pipe [c] to the right crankcase [d]. ○ do not apply silicone sealant to the groove of the grommet and the mating surface of the grommet [e]. ○ install the separator so that it’s ...

  • Page 268

    7-14 engine lubrication system oil pump and oil line breather drain cleaning ○ the air cleaner drain hose is provided beneath the right air cleaner housing, and catches the water or oil from the crankcase breather hose. Usually water or oil does not collect at the bottom. In the event that rain wate...

  • Page 269

    Engine lubrication system 7-15 oil pressure oil pressure measurement • slide out the rubber boot [a]. • disconnect the oil pressure switch lead [b] from the ter- minal screw [c]. • unscrew the oil pressure switch [d]. Note ○ measure the oil pressure after the engine is warmed up. • attach the oil pr...

  • Page 270

    7-16 engine lubrication system oil pressure relief valve inspection • split the crankcase (see crankshaft/transmission chap- ter). • remove the relief valve [a] from the oil pump [b]. • check to see if the valve slides smoothly when pushing it in with a wooden or other soft rod, and see if it comes ...

  • Page 271: Engine Removal/installation

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

  • Page 272

    8-2 engine removal/installation exploded view.

  • Page 273

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 downtube bolts and nuts 44 4.5 32 2 engine mounting bolts and nuts 44 4.5 32 3 engine mounting bracket bolts 25 2.5 18 wl: apply a soap and water solution or rubber lubricant..

  • Page 274

    8-4 engine removal/installation specifications jack : 57001–1238 attachment jack : 57001–1398.

  • Page 275

    Engine removal/installation 8-5 engine removal/installation engine removal • support the rear part of the frame on the jack [a], and the attachment jack [b]. ○ fit the ribs of the frame into the groove of the attachments. Special tools - jack: 57001-1238 attachment jack: 57001-1398 • squeeze the bra...

  • Page 276

    8-6 engine removal/installation engine removal/installation • disconnect: snap-on clamps [a] (pry open) radiator fan motor connector [b] rear brake light switch connector [c] spark plug leads [d] front and rear exhaust pipes [e] (see engine top end chapter) • remove: shift pedal (see crankshaft/tran...

  • Page 277

    Engine removal/installation 8-7 engine removal/installation • support the engine with a commercially available stand [a]. • remove: right spark plug lead holder front and rear exhaust pipes (see engine top end chapter) engine mounting bracket bolts [b] downtube bolts [c] • remove the downtube [a] wi...

  • Page 278

    8-8 engine removal/installation engine removal/installation • apply a thin coat of high temperature grease to the driven gear joint and to the propeller shaft joint. • push on the lockpin [a] and move back the engine to en- gage the front bevel gear joint with the propeller shaft joint. • run the br...

  • Page 279

    Engine removal/installation 8-9 engine removal/installation • install the removed parts (see appropriate chapters). • adjust the throttle cables (see fuel system chapter). • fill the engine with engine oil (see periodic maintenance chapter). • fill the engine with coolant and bleed the air from the ...

  • Page 281: Crankshaft/transmission

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

  • Page 282

    9-2 crankshaft/transmission exploded view.

  • Page 283

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 connecting rod big end nuts 59 6.0 44 mo 2 starter clutch bolt 85 8.7 63 mo 3 left balancer gear bolt 85 8.7 63 mo 4 camshaft chain guide bolts 11 1.1 97 in·lb l 5 starter clutch coupling bolts 15 1.5 11 l 6 oil ...

  • Page 284

    9-4 crankshaft/transmission exploded view.

  • Page 285

    Crankshaft/transmission 9-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 shift shaft return spring pin 39 4.0 29 l 2 shift rod locknuts 9.8 1.0 87 in·lb 3 rear shift lever clamp bolt 12 1.2 106 in·lb 4 gear set lever bolt 11 1.1 97 in·lb l 5 shift drum cam bolt 15 1.5 11 in·lb l 6 shi...

  • Page 286

    9-6 crankshaft/transmission specifications item standard service limit crankshaft, connecting rods: connecting rod bend – – – tir 0.2/100 mm (0.08/3.94 in.) connecting rod twist – – – tir 0.2/100 mm (0.08/3.94 in.) connecting rod big end side clearance 0.16 ∼ 0.46 mm 0.7 mm connecting rod big end be...

  • Page 287

    Crankshaft/transmission 9-7 specifications item standard service limit crankshaft main bearing/journal clearance 0.025 ∼ 0.052 mm 0.10 mm (0.00098 ∼ 0.00205 in.) (0.00394 in.) crankshaft main journal diameter 54.986 ∼ 55.000 mm 54.96 mm (2.1648 ∼ 2.1654 in.) (2.1638 in.) crankcase main bearing bore ...

  • Page 288

    9-8 crankshaft/transmission special tools and sealants outside circlip pliers : 57001–144 damper cam holder : 57001–1025 bearing driver set : 57001–1129 flywheel holder : 57001–1313 flywheel holder : 57001–1410 gear holder : 57001–1557 kawasaki bond (silicone sealant) : 56019–120 kawasaki bond (liqu...

  • Page 289

    Crankshaft/transmission 9-9 crankcase disassembly • remove: engine (see engine removal/installation chapter) cylinder blocks (see engine top end chapter) pistons (see engine top end chapter) clutch (see clutch chapter) front gear case (see final drive chapter) alternator inner cover (see electrical ...

  • Page 290

    9-10 crankshaft/transmission crankcase • loosen the starter clutch bolt [a] while holding the primary gear bolt [b]. • take out the torque limiter [c]. • remove the following from the right end of the balancer shaft. Starter clutch bolt [a] washer [b] collar [c] needle bearing [d] copper washer [e] ...

  • Page 291

    Crankshaft/transmission 9-11 crankcase • remove the following from the left crankcase with the cylinder head removed. Front chain holder [a] lower chain guide [b] rear chain guide [c] front camshaft chain [d] front [e] • take the end of the spring [a] off the hook and unscrew the bolts [b]. • remove...

  • Page 292

    9-12 crankshaft/transmission crankcase • remove the starter motor bolts [b] and the motor [a] from the crankcase. • pull the water pump sprocket [a] with it’s chain [b] and shaft [c]. • remove the oil banjo bolt [a] with the hoses [b]. • remove the oil filter [a] with the oil filter wrench [b]. Spec...

  • Page 293

    Crankshaft/transmission 9-13 crankcase • remove all the left crankcase bolts in the order listed. 6 mm bolts (14) [a] 8 mm bolt (1) [b] 10 mm bolts (3) [c] ○ turn the left crankcase down. ○ lift up the right crankcase. ○ using the pry points, split the crankcase halves. Pry point (front) [a] pry poi...

  • Page 294

    9-14 crankshaft/transmission crankcase • install the bearing retainers. Special tool - bearing driver set: 57001-1129 bearings [a] bearing retainer [b] left crankcase [c] non-permanent locking agent - bearing retainer bolts torque - bearing retainer bolts: 11 n·m (1.1 kgf·m, 97 in·lb) • apply silico...

  • Page 295

    Crankshaft/transmission 9-15 crankcase • install the transmission assy as a set (see this chapter). • set the gear set lever to the neutral position. Shift drum cam [a] gear set lever [b] neutral position [c] • apply engine oil to the transmission gears, ball bearings, shift drum, and crankshaft mai...

  • Page 296

    9-16 crankshaft/transmission crankcase • install the water pump chain guide [a]. ○ be sure to install the collar [b] in the bolt hole. Torque - water pump chain guide bolt: 8.3 n·m (0.85 kgf·m, 73 in·lb) • check to see that the following parts are in place in the right crankcase. Oil pipe [a] oil pu...

  • Page 297

    Crankshaft/transmission 9-17 crankcase • after tightening all the crankcase bolts, check the follow- ing items. ○ wipe up the liquid gasket that seeps out around the crankcase mating surface. ○ turn the right crankcase down, and check that the drive shaft and output shaft turn freely. ○ check that t...

  • Page 298

    9-18 crankshaft/transmission crankcase • install the alternator rotor [a] while fitting the alignment notch [b] of the splines onto the alignment tooth [c]. ○ be sure to align the balancer gear mark with the alternator mark (shorter line mark) [a] while keeping the front piston on its top dead cente...

  • Page 299

    Crankshaft/transmission 9-19 crankcase • install: water pump sprocket [a] with shaft [b] chain [c] • install: washer [a] idle shaft sprocket [b] ○ fit the pin [c] into the slots [d] of the idle shaft sprocket. • install the primary gear [a] with the boss [b] facing toward the engine inside. • instal...

  • Page 300

    9-20 crankshaft/transmission crankcase • fit the alignment tooth [a] of the splines of the right bal- ancer [b] onto the alignment notch of the balancer shaft. • install the starter torque limiter [a] and washer [b]. • install the collar [c], copper washer [d], and needle bear- ing [e] in the order ...

  • Page 301

    Crankshaft/transmission 9-21 crankcase starter clutch disassembly • remove the starter clutch assy (see crankcase disas- sembly). • remove the allen bolts [a] with the balancer mass [b] held with the flywheel holder [c] (special tool). Special tool - flywheel holder: 57001-1313 • pull the coupling [...

  • Page 302

    9-22 crankshaft/transmission crankcase sliding surface [a] of coupling starter torque limiter check • remove the torque limiter (see crankcase disassembly) and visually inspect it. If the limiter has wear, discoloration, or other damage, replace it as a set. Gear [a] friction plates [b] spring [c] p...

  • Page 303

    Crankshaft/transmission 9-23 crankshaft/connecting rods connecting rod removal • remove the crankshaft. • remove the connecting rod big end nuts, and take off the rod and cap along with the bearing inserts from the crankshaft [a]. Note ○ mark and record the locations of the connecting rods [b] and t...

  • Page 304

    9-24 crankshaft/transmission crankshaft/connecting rods ○ when installing the inserts [a], be careful not to damage the insert surface with the edge of the connecting rod [b] or the cap [c]. One way to install inserts is as follows: installation [d] to cap installation [e] to connecting rod push [f]...

  • Page 305

    Crankshaft/transmission 9-25 crankshaft/connecting rods connecting rod big end side clearance • measure the side clearance [b] of the connecting rod big end [a]. ○ insert a thickness gauge between the big end and either crank web to determine clearance. Connecting rod big end side clearance standard...

  • Page 306

    9-26 crankshaft/transmission crankshaft/connecting rods if the clearance exceeds the service limit, measure the diameter of the crankpin [a]. Crankpin diameter standard: 54.981 ∼ 55.000 mm (2.1646 ∼ 2.1654 in.) service limit: 54.97 mm (2.1642 in.) if the crankpin has worn past the service limit, rep...

  • Page 307

    Crankshaft/transmission 9-27 crankshaft/connecting rods crankshaft runout • measure the crankshaft runout. If the measurement exceeds the service limit, replace the crankshaft. Crankshaft runout standard: tir 0.02 mm (0.0008 in.) or less service limit: tir 0.05 mm (0.0020 in.) crankshaft main bearin...

  • Page 308

    9-28 crankshaft/transmission primary gear primary gear removal • remove: clutch cover (see clutch chapter) starter clutch gear (see crankcase disassembly) • using the gear holder [a] to loosen the primary gear bolt [b]. Special tool - gear holder: 57001–1557 • remove: clutch (see clutch chapter) bol...

  • Page 309

    Crankshaft/transmission 9-29 primary gear • fit the pin [a] into the slot [b] of the water pump drive sprocket boss and install the sprockets. • install: dowel pins [a] washer [b] • pulling the chain guide [c] and install the idle shaft holder [d]. • install the clutch (see clutch chapter). Torque -...

  • Page 310

    9-30 crankshaft/transmission transmission shift pedal removal • unscrew the footpeg bracket bolts [a] and take off the left front footpeg [b]. Front [c] • unscrew the clamp bolt [b] and pull out the shift pedal [a]. Shift pedal installation • install the shift pedal [a] so that the punched mark on t...

  • Page 311

    Crankshaft/transmission 9-31 transmission external shift mechanism installation • install the gear set lever [a] and the spring [b] in the crankcase and tighten the bolt [c]. Torque - gear set lever bolt: 11 n·m (1.1 kgf·m, 97 in·lb) • install the shift mechanism arm assy. Be sure to install the was...

  • Page 312

    9-32 crankshaft/transmission transmission transmission removal • remove the engine (see engine removal/installation chapter). • split the crankcase (see this chapter). • remove the crankshaft. • first, remove the oil pipe [a] (see engine lubrication sys- tem chapter), and then remove the shift drum ...

  • Page 313

    Crankshaft/transmission 9-33 transmission ○ each output shaft shift fork has an identification number. Do not confuse them. • install the shift forks with each number faced left as shown. Shift fork (no. 270, 5th gear) [a] shift fork (no. 293, 4th gear) [b] front [c]. • apply a non-permanent locking...

  • Page 314

    9-34 crankshaft/transmission transmission transmission disassembly • remove the transmission shafts (see this chapter). Using the circlip pliers (special tool), remove the circlips, and disassemble the transmission shaft. Special tool - outside circlip pliers: 57001-144 the 4th gear [a] on the outpu...

  • Page 315

    Crankshaft/transmission 9-35 transmission shift fork bending • visually inspect the shift forks, and replace any fork that is bend. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear under load. 90° [a] shift fork/gear groove wear • measure the thickness of...

  • Page 316

    9-36 crankshaft/transmission transmission 1. Circlip ( 20 × 25.5 × t 1.2) 2. Needle bearing 3. Thrust washer ( 22.3 × 35 × t 1.6) 4. Three circlips ( 28) 5. 2nd gear 6. 5th (top) gear 7. Bushing (5th gear) 8. Two splined washers ( 28.5 × 34 × t 1.5) 9. 3rd gear 10. 4th gear 11. 1st gear (drive shaft...

  • Page 317

    Crankshaft/transmission 9-37 ball bearing, needle bearing, and oil seal ball bearing and outer race replacement caution do not remove the ball bearing or needle bearing outer race unless it is necessary. Removal may damage them. • using a press or puller, remove the ball bearing and/or needle bearin...

  • Page 318

    9-38 crankshaft/transmission ball bearing, needle bearing, and oil seal oil seal inspection • inspect the oil seal. Replace it if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened or otherwise damaged..

  • Page 319: Wheels/tires

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

  • Page 320

    10-2 wheels/tires exploded view.

  • Page 321

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 tire air valve stem nuts 1.5 0.15 13 in·lb 2 air valve cores 0.3 0.03 2.6 in·lb 3 tire air valve caps 0.15 0.015 1.3 in·lb 4 front axle clamp bolts 29 3.0 21 al 5 front axle 108 11 79.6 6 rear axle nut 108 11 79.6 g: apply...

  • Page 322

    10-4 wheels/tires specifications item standard service limit wheels (rims): rim runout: axial tir 0.5 mm (0.02 in.) radial tir 0.8 mm (0.03 in.) axle runout/100 mm tir 0.05 mm (0.002 in.) or less tir 0.2 mm (0.008 in.) wheel balance 10 g (0.35 oz.) or less – – – balance weights 10 g (0.35 oz.), 20 g...

  • Page 323

    Wheels/tires 10-5 special tools inside circlip pliers : 57001–143 bearing driver set : 57001–1129 jack : 57001–1238 bearing remover head, φ 20 x φ 22 : 57001–1293 bearing remover head, φ 25 x φ 28 : 57001–1346 bearing remover shaft, φ 13 : 57001–1377 attachment jack : 57001–1398.

  • Page 324

    10-6 wheels/tires wheels (rims) front wheel removal • unscrew the front brake caliper mounting bolts [a] and remove the brake calipers [b] with the hose installed. • for the european model, remove the cap. • loosen: front axle clamp bolts [a] front axle [b] ○ using the jack [a] and the attachment ja...

  • Page 325

    Wheels/tires 10-7 wheels (rims) front wheel installation • apply grease to the seal lips. • fit the collars [a] on the both side of the hub. ○ the collars are identical. • insert the axle from the right side of the wheel. • tighten the axle. Torque - front axle: 108 n·m (11 kgf·m, 79.6 ft·lb) • befo...

  • Page 326

    10-8 wheels/tires wheels (rims) rear wheel removal • using the jack [a] and attachment jack [b] under the frame pipe ribs [c], lift the rear wheel [d] off the ground until the front wheel [e] touches the ground. Caution be sure to put the front wheel on the ground when removing the rear wheel, or th...

  • Page 327

    Wheels/tires 10-9 wheels (rims) • pull out the axle, and slide the rear wheel [a] toward the right [b] to disengage the wheel from the final gear case. • move the rear wheel back [c] and remove it. Caution do not lay the wheel directly on the ground with the disc facing down. This can damage or warp...

  • Page 328

    10-10 wheels/tires wheels (rims) • bend the cotter pin [a] over the nut as shown. • visually inspect the tire for stuck any grease [a]. If any grease have stuck to the surface of the tire, wash the tire clean with soap and water solution. • check the rear brake effectiveness. Warning do not attempt ...

  • Page 329

    Wheels/tires 10-11 wheels (rims) wheel inspection • raise the front or rear wheel off the ground. Special tools - jack: 57001-1238 attachment jack: 57001-1398 • spin [a] the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings. • inspect the f...

  • Page 330

    10-12 wheels/tires wheels (rims) balance inspection • remove the wheel. • support the wheel so that it can be spun freely. • spin the wheel lightly, and mark [a] the wheel at the top when the wheel stops. ○ repeat this procedure several times. If the wheel stops of its own accord in various position...

  • Page 331

    Wheels/tires 10-13 wheels (rims) balance weight removal (a) when the tire is not on the rim. • push [a] the blade portion toward the outside with a reg- ular tip screw driver, and slip the weight off the rim flange. • discard the used balance weight. (b) when the tire is on the rim. • pry [a] the ba...

  • Page 332

    10-14 wheels/tires wheels (rims) • check that the blade [a] seat fully on the rim flange [b], and that the weight bottom [c] reaches rim flat portion. • when required total weight exceeds 20 g (0.71 oz.), install balance weight at both sides of rim flange as shown. Required weight selection total we...

  • Page 333

    Wheels/tires 10-15 tires air pressure inspection/adjustment • refer to tire inspection in the periodic maintenance chap- ter. Tire inspection • refer to tire inspection in the periodic maintenance chap- ter. Tire removal • remove the following. Wheel (see front/rear wheel removal) brake disc (see br...

  • Page 334

    10-16 wheels/tires tires • insert the new air valve in the front wheel rim. Valve cap [a] valve body [b] valve nuts [c] valve washer [d] rim [e] valve grommet [f] ○ remove the valve cap, valve nuts, valve washer and in- sert the valve body through the rim from the inside out. Torque - tire air valve...

  • Page 335

    Wheels/tires 10-17 tires • position the tire on the rim so that the valve [a] is at the tire balance mark [b] (the chalk mark made during removal, or the yellow paint mark on a new tire). • install the tire bead over the rim flange using a commer- cially available tire changer. • lubricate the tire ...

  • Page 336

    10-18 wheels/tires tires tire repair currently two types of repair for tubeless tires have come into wide use. One type is called a temporary (external) re- pair which can be carried out without removing the tire from the rim, and the other type is called permanent (internal) repair which requires t...

  • Page 337

    Wheels/tires 10-19 hub bearings (wheel bearings) hub bearings removal • remove the wheel, and take out the following. Collars grease seals [a] circlips [b] coupling [c] (out of rear hub) front hub [d] rear hub [e] special tool - inside circlip pliers: 57001-143 • use the bearing remover to remove th...

  • Page 338

    10-20 wheels/tires hub bearings (wheel bearings) ○ replace the circlips with new ones. Special tool - inside circlip pliers: 57001-143 • replace the grease seals with new ones. • press in the grease seals [a] so that the seal surface is flush [b] with the end of the hole. ○ apply high temperature gr...

  • Page 339: Final Drive

    Final drive 11-1 11 final drive table of contents exploded view................................... 11-2 specifications .................................... 11-6 special tools ..................................... 11-7 final gear case and oil .................... 11-9 oil level inspection...............

  • Page 340

    11-2 final drive exploded view.

  • Page 341

    Final drive 11-3 exploded view front gear case torque no. Fastener n·m kgf·m ft·lb remarks 1 oil pipe banjo bolts (front gear) 12 1.2 106 in·lb 2 front gear case bolts 6 mm 12 1.2 106 in·lb s 3 neutral switch 15 1.5 11 4 oil nozzle (front gear) 2.9 0.30 26 in·lb 5 oil nozzle (front gear) 18 1.8 13 6...

  • Page 342

    11-4 final drive exploded view.

  • Page 343

    Final drive 11-5 exploded view final gear case torque no. Fastener n·m kgf·m ft·lb remarks 1 final gear case mounting nuts 34 3.5 25 2 pinion gear nut (final gear) 127 13 94 mo, st 3 final gear case cover bolts 10 mm 34 3.5 25 l 4 final gear case cover bolts 8 mm 23 2.3 17 l 5 bearing retainer bolt ...

  • Page 344

    11-6 final drive specifications item standard final gear case oil: grade api service classification: gl-5 hypoid gear oil viscosity when above 5°c (41°f) sae90 when below 5°c (41°f) sae80 oil level filler opening bottom amount 200 ml (6.76 us oz.) final bevel gear backlash 0.06 ∼ 0.09 mm (0.0024 ∼ 0...

  • Page 345

    Final drive 11-7 special tools outside circlip pliers: 57001–144 bearing puller: 57001–158 bearing puller adapter: 57001–317 bearing driver: 57001–382 damper cam holder: 57001–1025 driven gear holder: 57001–1027 oil seal & bearing remover: 57001–1058 bearing driver set: 57001–1129 pinion gear holder...

  • Page 346

    11-8 final drive special tools drive shaft holder: 57001–1407.

  • Page 347

    Final drive 11-9 final gear case and oil oil level inspection • refer to oil level inspection in periodic maintenance chapter. Oil change • refer to oil change in periodic maintenance chapter. Final gear case removal if the final gear case is to be disassembled, drain the final gear case oil. • remo...

  • Page 348

    11-10 final drive final gear case and oil • remove the final gear case cover bolts [a]. • use three tapped holes [b] to lift the ring gear assy from the gear case. The shim(s) comes off with the assy. Note ○ do not disassemble the ring gear assy (ring gear, ring gear hub, and final gear case cover),...

  • Page 349

    Final drive 11-11 final gear case and oil final gear case 1. Pinion gear nut 2. Washer 3. Shim(s) for preload 4. Pinion gear joint 5. O-ring 6. Ring gear hub 7. Ring gear oil seal 8. Ball bearing 9. Final gear case cover 10. Cover mounting bolts 11. Ring gear shim(s) 12. Ring gear 13. Studs 14. Pini...

  • Page 350

    11-12 final drive final gear case and oil • replace the needle bearings [a] with new ones. • apply a hypoid gear oil to the roller parts of the needle bearings. Note ○ install the bearing so that the marked side faces out. ○ press in the bearings until they are bottomed. Special tool - bearing drive...

  • Page 351

    Final drive 11-13 final gear case and oil pinion gear removal • pry open the staking [a] on the pinion gear nut [b]. • unscrew the nut [a] while holding the pinion gear assem- bly [b] with the pinion gear holder [c]. Special tool - pinion gear holder: 57001–1165 • remove: washer [a] shim(s) [b] pini...

  • Page 352

    11-14 final drive final gear case and oil pinion gear installation • the pinion gear and ring gear are lapped as a set in the factory to get the best tooth contact. They must be re- placed as a set. • check the tapered roller bearing (see this chapter). • apply a hypoid gear oil to the roller bearin...

  • Page 353

    Final drive 11-15 final gear case and oil • replace the oil seal with a new one. • drive the oil seal [a] using the bearing driver set [b]. Special tool - bearing driver set: 57001–1129 [c] • reinstall the above removed parts. ○ stake [a] the pinion gear nut with a punch. Caution when staking the nu...

  • Page 354

    11-16 final drive final gear case and oil • apply a little hypoid gear oil to the bearings, and turn the gear shaft more than 5 turns to allow the bearings to seat. • measure the bearing preload. Bearing preload is defined as the force or torque which is needed to start the gear shaft turning. Prelo...

  • Page 355

    Final drive 11-17 final gear case and oil 1. Washer 2. Shim(s) 3. Pinion gear joint 4. Bearing housing 5. Tapered roller bearing 6. Tapered roller bearing a. Before tightening b. After tightening c. Initial clearance d. Under no preload e. No clearance f. Under preload bevel gear inspection • visual...

  • Page 356

    11-18 final drive final gear case and oil final bevel gear adjustment ○ the backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged. • after replacing any of the backlash-related parts, be sure to check and adjust the backlash an...

  • Page 357

    Final drive 11-19 final gear case and oil ring gear shims for backlash adjustment pinion gear shims for tooth contact adjustment thickness (mm) parts number thickness (mm) parts number 0.15 (0.0059 in.) 92025-1783 0.15 (0.0059 in.) 92180-0009 0.5 (0.02 in.) 92025-1784 0.5 (0.02 in.) 92180-0010 0.6 (...

  • Page 358

    11-20 final drive final gear case and oil • mount a dial gage [d] on a vise so that the tip of the gage is against the splines of the ring gear hub. • to measure the backlash, turn the ring gear hub [b] back and forth [c] while holding the pinion gear steady with the pinion gear holder [a]. The diff...

  • Page 359

    Final drive 11-21 final gear case and oil • hold the pinion gear assembly with the final gear case holder [a]. Special tool - final gear case holder: 57001–1250 torque - final gear case mounting nuts: 34 n·m (3.5 kgf·m, 25 ft·lb) • turn the pinion gear for one revolution [b] back and forth, while cr...

  • Page 360

    11-22 final drive final gear case and oil correct tooth contact pattern: no adjustment is required. A. Heel b. Bottom c. Top d. Toe incorrect tooth contact patterns (example 1) ○ decrease the thickness of the pinion gear shim(s) by 0.05 mm (0.002 in.) to correct the pattern shown above. A. Heel b. B...

  • Page 361

    Final drive 11-23 propeller shaft propeller shaft removal • remove: final gear case (see this chapter) swingarm (see suspension chapter) • remove the propeller shaft from the front driven gear joint. ○ turn the propeller shaft so that the lockpin access hole [a] in the propeller shaft comes outside....

  • Page 362

    11-24 final drive propeller shaft propeller shaft joint lubrication • remove the final gear case and propeller shaft joint (see final drive chapter). • wipe the old grease off the propeller shaft sliding joint and pinion joint. • pack the propeller shaft sliding joint with 20 ml (16 grams) of high t...

  • Page 363

    Final drive 11-25 front bevel gears front gear case removal • remove: engine (see engine removal/installation chapter) rear shift lever [a] ○ the speed sensor connector [b] is disconnected during engine removal. • unscrew the front gear case bolts [c] and remove the front gear case [d]. ○ the cam fo...

  • Page 364

    11-26 final drive front bevel gears ○ raise the driven gear, using the following pry points [a]. • remove the drive gear assy as follows. ○ pry off the gear case cap [a] with a tool. ○ pry open the drive gear nut [a] with a small chisel. ○ install: damper spring cam follower [b] ○ unscrew the drive ...

  • Page 365

    Final drive 11-27 front bevel gears front gear case assembly ○ the drive and driven gear are lapped as a set in the fac- tory to get the best tooth contact. They must be replaced as a set. • press the drive gear [b] slowly with the bearing driver [a] onto the shaft [c]. Special tool - bearing driver...

  • Page 366

    11-28 final drive front bevel gears driven gear disassembly • holding the driven gear joint with the driven gear holder [a] in a vise, unscrew the driven gear bolt [b]. Special tool - driven gear holder: 57001–1027 • remove the driven gear joint [a] with the o-ring [b]. • remove the driven gear from...

  • Page 367

    Final drive 11-29 front bevel gears damper cam removal • remove the front gear case (see this chapter). • remove the retainer and needle bearing of the output shaft. • remove the clutch push rod guide [a] and bolts, and crankcase bearing upper retainer and bolts. • insert a bolt ( 12 mm, l100 mm, 0....

  • Page 368

    11-30 final drive front bevel gears front bevel gear adjustment in order to prevent one gear from moving away from the other gear under load, the tapered roller bearings must be properly preloaded. Also the backlash (the distance one gear will move back and forth without moving the other gear) and t...

  • Page 369

    Final drive 11-31 front bevel gears front bevel gear adjustment ○ when any of the backlash-related parts are replaced, or the driven gear bolt is loosened; even if the purpose is not to replace the parts, be sure to check and adjust the bearing preload, the bevel gear backlash, and tooth con- tact b...

  • Page 370

    11-32 final drive front bevel gears preload measurement with spring scale • hold the bearing housing in a vise so that the gear shaft axis is vertical. • hook [c] the spring scale [b] on the driven gear holder [a] at a point 200 mm (7.87 in.) [d] apart from the center of the gear shaft. • apply forc...

  • Page 371

    Final drive 11-33 front bevel gears bearing preloading mechanism 1. Bearing housing 2. Tapered roller bearing a. Before tightening b. After tightening 3. Spacer 4. Collar c. Under no preload d. Initial clearance 5. Tapered roller bearing e. Under preload f. No clearance backlash adjustment • clean a...

  • Page 372

    11-34 final drive front bevel gears • install a holder [a] with 6 mm bolts and nuts on the front gear case to mount a dial gage. • set up a dial gage against a drive gear tooth to check gear backlash. The gage stem must be in line with the direction of tooth travel. • to measure the backlash, move t...

  • Page 373

    Final drive 11-35 front bevel gears • turn the driven gear for 3 or 4 revolutions in the drive and reverse (coast) directions, while creating a drag on the drive gear. • check the drive pattern and coast pattern of the bevel gear teeth. The tooth contact patterns of both drive and coast sides should...

  • Page 374

    11-36 final drive front bevel gears incorrect tooth contact patterns (example 2): • decrease the thickness of the drive gear shim(s) by 0.05 mm (0.002 in.), and/or decrease the thickness of the driven gear shim(s) by 0.05 mm (0.002 in.) to correct the pattern shown below. Repeat in 0.05 mm (0.002 in...

  • Page 375

    Final drive 11-37 bearing and oil seal ball or needle bearing replacement • using the bearing driver set or the oil seal & bearing re- mover, remove the bearings. Special tools - oil seal & bearing remover: 57001–1058 bearing driver set: 57001–1129 note ○ in the absence of the above mentioned tools,...

  • Page 376

    11-38 final drive bearing and oil seal tapered roller bearing inspection caution do not remove the tapered roller bearing for inspec- tion. Removal may damage them. • visually inspect the bearing in the front and final gear cases for abrasion, color change, or other damage. If there is any doubt as ...

  • Page 377: Brakes

    Brakes 12-1 12 brakes table of contents exploded view................................... 12-2 specifications .................................... 12-6 special tool ....................................... 12-7 brake lever, brake pedal.................. 12-8 brake lever position adjustment. 12-8 brake...

  • Page 378

    12-2 brakes exploded view.

  • Page 379

    Brakes 12-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake hose banjo bolts 25 2.5 18 2 front brake reservoir cap screws 1.5 0.15 13 in·lb 3 brake lever pivot bolt 1.0 0.10 8.9 in·lb si 4 brake lever pivot bolt locknut 5.9 0.60 52 in·lb 5 front master cylinder clamp bolts 8.8 0.90...

  • Page 380

    12-4 brakes exploded view.

  • Page 381

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear master cylinder mounting bolts 25 2.5 18 2 brake hose banjo bolts 25 2.5 18 3 rear master cylinder push rod locknut 18 1.8 13 4 brake pedal clamp bolt 25 2.5 18 5 caliper bleed valves 7.8 0.80 69 in·lb 6 rear caliper mounti...

  • Page 382

    12-6 brakes specifications item standard service limit brake lever, brake pedal: brake lever position no.1 5-way adjustable brake lever free play non-adjustable – – – pedal free play non-adjustable – – – pedal position about 110 mm (4.33 in.) – – – (height from pedal top to footpeg top) brake fluid:...

  • Page 383

    Brakes 12-7 special tool inside circlip pliers: 57001–143.

  • Page 384

    12-8 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 hold...

  • Page 385

    Brakes 12-9 brake lever, brake pedal • remove the right front footpeg bracket bolts [a] and turn over the footpeg [b]. • loosen the locknut [a] and turn the push rod with the hex head [b] to achieve the correct pedal position. If the length [c] is 80 ±1 mm (3.1 ±0.04 in.), the pedal position will be...

  • Page 386

    12-10 brakes brake lever, brake pedal • pull out the brake pedal [b] from the right footpeg bracket [a]. Brake pedal installation • apply grease to the brake pedal shaft. • install the pedal shaft [a] so that the punched mark on the shaft is aligned [b] with the punched mark on the brake lever [c]. ...

  • Page 387

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

  • Page 388

    12-12 brakes calipers front caliper disassembly • remove the pad spring and brake pads (see front brake pad removal). • for the u.S.A. And canadian models, remove the bolt [a] and reflector [b]. • unscrew the front upper caliper mounting bolt [c] and loosen the front lower caliper mounting bolt [d]....

  • Page 389

    Brakes 12-13 calipers • 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 install them into the cylinders by hand...

  • Page 390

    12-14 brakes calipers • remove the board and pull out the pistons [a] by hand. ○ these pistons can also be removed by disconnecting the hose and applying compressed air to the hose joint open- ing using the same wooden board. But be careful not to put your fingers or palm inside the caliper opening ...

  • Page 391

    Brakes 12-15 calipers • replace the caliper holder shaft rubber friction boot [a] and dust boot [b] if they are damaged. • apply a thin coat of silicone or pbc grease to the caliper holder shafts [c] and holder holes (silicone or pbc grease is a special high temperature, water-resistance grease). • ...

  • Page 392

    12-16 brakes brake pads front brake pad removal • unscrew the pad spring bolts [a], and remove the pad spring [b]. • draw out the snap pin [a], and take off the pad pin [b]. • remove the brake pads [c]. Front brake pad installation • push the caliper pistons in by hand as far as they will go. • inst...

  • Page 393

    Brakes 12-17 brake pads • remove the jaw side pad [a], and then remove the piston side pad [b]. Jaw [c] rear brake pad installation • before installation, clean the pads with a high-flash point solvent. • push [a] the caliper pistons in by hand as far as they will go. • be sure to install the snap p...

  • Page 394

    12-18 brakes master cylinder front master cylinder removal • disconnect the front brake light switch connectors [a]. • draw out the brake fluid from the reservoir with a means like the fork oil level gage. • pull the bolt caps [b] out. • remove the banjo bolt [a] to disconnect the brake hose from th...

  • Page 395

    Brakes 12-19 master cylinder rear master cylinder removal • remove the brake fluid reservoir cover (see brake pedal position adjustment). • draw out the brake fluid from the reservoir with a means like the fork oil level gage. • remove the brake fluid reservoir (see brake pedal posi- tion adjustment...

  • Page 396

    12-20 brakes master cylinder rear master cylinder installation • replace the cotter pin with a new one. • insert the cotter pin [a] to the hole of the joint pin [b] and separate [c] the cotter pin ends. • use a new flat washer on each side of the brake hose fitting. • tighten: torque - rear master c...

  • Page 397

    Brakes 12-21 master cylinder rear master cylinder disassembly note ○ do not remove the push rod clevis [a] for master cylin- der disassembly since removal requires brake pedal po- sition adjustment. • remove the rear master cylinder (see rear master cylin- der removal). • slide the dust cover on the...

  • Page 398

    12-22 brakes master cylinder master cylinder inspection • disassemble the front and rear master cylinders. • check that there are no scratches, rust or pitting on the inner wall [a] of each master cylinder and on the outside of each piston [b]. If a master cylinder or piston shows any damage, replac...

  • Page 399

    Brakes 12-23 brake discs brake disc removal • remove the wheel (see wheels/tires chapter). • unscrew the mounting bolts [a], and take off the disc. Brake disc installation • install the brake disc [a] on the wheel so that the marked side [b] faces out. • apply a non-permanent locking agent to the th...

  • Page 400

    12-24 brakes brake fluid brake fluid level inspection • refer to the brake fluid level inspection in periodic main- tenance chapter. Brake fluid change • refer to the brake fluid change in periodic maintenance chapter. Brake line bleeding the brake fluid has a very low compression coefficient so tha...

  • Page 401

    Brakes 12-25 brake fluid • remove the rubber cap from the bleed valve on the caliper. • attach a clear plastic hose to the bleed valve, and run the other end of the hose into a container. • bleed the brake line and the caliper as follows: ○ repeat this operation until no more air can be seen com- in...

  • Page 402

    12-26 brakes brake fluid • check the fluid level. • after bleeding is done, check the brake for good braking power, no brake drag, and no fluid leakage. 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 contai...

  • Page 403

    Brakes 12-27 brake hoses brake hose removal/installation caution brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately. • when removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts. • when removing the bra...

  • Page 405: Suspension

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

  • Page 406

    13-2 suspension exploded view.

  • Page 407

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper front fork clamp bolts 29 3.0 21 2 lower front fork clamp bolts 29 3.0 21 3 front fork top plugs 34 3.5 25 4 front fork bottom allen bolt 20 2.0 15 l 5 front axle clamp bolts 29 3.0 21 al 6 inner fork bolt 98 10 72 7 p...

  • Page 408

    13-4 suspension exploded view.

  • Page 409

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear shock absorber nuts 34 3.5 25 2 swingarm pivot shaft 108 11 79.6 g 3 shock absorber air valves 5.4 0.55 48 in·lb g: apply grease. L: apply a non-permanent locking agent. Wl: apply a soap and water solution or rubber lub...

  • Page 410

    13-6 suspension specifications item standard front fork (per one unit): fork inner tube diameter 43 mm ( 1.7 in.) fork spring setting non-adjustable air pressure atmospheric pressure (non-adjustable) rebound damper setting non-adjustable fork oil viscosity sae 10w-20 fork oil capacity: right fork le...

  • Page 411

    Suspension 13-7 special tools oil seal & bearing remover : 57001–1058 bearing driver set : 57001–1129 jack : 57001–1238 fork piston rod puller, m12 × 1.25 : 57001–1289 attachment jack : 57001–1398 fork cylinder holder : 57001–1502 fork oil seal driver, 43 : 57001–1530

  • Page 412

    13-8 suspension front fork fork oil change • remove the front fork (see front fork removal). • unscrew the top plug out of the outer tube. Right fork leg: • use the wrenches on the top plug [a] and piston rod nut [b] loosen the piston rod nut. • remove the top plug from the piston rod. • remove: pis...

  • Page 413

    Suspension 13-9 front fork • pull out the joint rod assy [a] together with the spring [b]. • compress and extend [b] the fork [a] upside down to draw out the fork oil into a suitable container [c], then drop out the collar [d], washer [e] and fork spring [f]. Both fork legs: • hold the fork tube upr...

  • Page 414

    13-10 suspension front fork ○ pump the outer tube several times to expel air bubbles. ○ wait until the oil level settles. ○ with the fork fully compressed and the piston rod fully pushed in (right fork leg), insert a tape measure or rod into the inner tube, and measure the distance from the top of t...

  • Page 415

    Suspension 13-11 front fork • install: spring seat [a] collar [b] washer [c] • screw the piston rod nut [d] stopped on to the piston rod. Left fork leg: • install the fork spring [a] with the smaller end facing up- ward [b]. • install: washer collar joint rod assy together with the spring • install ...

  • Page 416

    13-12 suspension front fork front fork removal (each fork leg) • loosen the front axle nut (see wheels/tires chapter). • using the jack [a] and attachment jack [b] under the frame pipe ribs [c], and a commercially available jack [d] under the engine [e], lift the front wheel [f] off the ground until...

  • Page 417

    Suspension 13-13 front fork front fork installation (each fork leg) • install the fork so that the top end [a] of the outer tube is flush with the upper surface [b] of the steering stem head bracket. • tighten the lower fork clamp bolts and fork top bolt. Torque - front fork clamp bolts (lower): 29 ...

  • Page 418

    13-14 suspension front fork • hold the fork leg with a vise [a]. • loosen the allen bolt [b] and tighten it loosely. • remove: piston rod nut [a] stopper [b] coller [c] spring joint [d] fork spring [e] • drain the fork oil into a suitable container. ○ using the piston rod puller [a], pump the piston...

  • Page 419

    Suspension 13-15 front fork left fork leg: ○ refer to the fork oil change for the left fork leg disas- sembly. • remove: joint rod nut [a] rubber stopper [b] inner fork bolt [c] joint rod assy [d] with spring special tool - fork cylinder holder: 57001–1502 • drain the fork oil into a suitable contai...

  • Page 420

    13-16 suspension front fork front fork assembly • replace the following parts with new ones after removal. Retaining ring [a] oil seal [b] slide bushing [c] guide bushing [d] bottom allen bolt gasket [e] (right fork leg) right fork leg: • install the centering plate [a] onto the bottom end of the cy...

  • Page 421

    Suspension 13-17 front fork right fork: • hold the front fork with a vise [a]. • tighten the allen bolt [b]. Torque - bottom allen bolt: 20 n·m (2.0 kgf·m, 15 ft·lb) inner tube, outer tube inspection • visually inspect the inner tube [a] and repair any damage. • nick or rust damage can sometimes be ...

  • Page 422

    13-18 suspension front fork spring inspection • since the fork spring becomes shorter as it weakens, check its free length [a] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of the replacement spring and that of the ...

  • Page 423

    Suspension 13-19 rear shock absorber (air type) rebound damping adjustment the rebound damping force adjuster on each rear shock absorber has 4 positions so that the rebound damping force can be adjusted for different road and loading conditions. The numbers on the adjuster show the setting position...

  • Page 424

    13-20 suspension rear shock absorber (air type) ○ raise the rear wheel [a] off the ground, using the jack [b], and the attachment jack [c]. Special tools - jack: 57001-1238 attachment jack: 57001-1398 ○ take off each air valve cap [a] on the right and left shock absorbers. Front [b] ○ check the air ...

  • Page 425

    Suspension 13-21 rear shock absorber (air type) rear shock absorber removal • lift the rear wheel off the ground, using the jack and the attachment jack. Special tools - jack: 57001-1238 attachment jack: 57001-1398 • squeeze the brake lever slowly and hold it with a band [a]. Caution be sure to hold...

  • Page 426

    13-22 suspension rear shock absorber (air type) • visually inspect the shock absorber sleeves [a] and nee- dle bearings [b]. • the roller in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing in the shock absorber for abrasion, col...

  • Page 427

    Suspension 13-23 swingarm swingarm removal • remove: bolts [a] and washers swingarm cover [b] • remove the rear exhaust pipe (see engine top end chap- ter). • loosen: right muffler chamber bolt [a] front exhaust pipe clamp bolt [b] • remove: swingarm pivot cap [c] • before removing the swingarm, uns...

  • Page 428

    13-24 suspension swingarm • remove: rear wheel (see wheels/tires chapter) final gear case (see final drive chapter) • remove the right rear shock absorber. • unscrew the pivot shaft [a], and pull it out while turning. • pull the swingarm [b] rearward, and take it off. Caution do not tap the swingarm...

  • Page 429

    Suspension 13-25 swingarm swingarm bearing removal • remove: swingarm (see swingarm removal) propeller shaft (see final drive chapter) right and left sleeves [a] right and left grease seals [b] • remove the needle bearings, using the oil seal & bearing remover [a]. Special tool - oil seal & bearing ...

  • Page 430

    13-26 suspension swingarm grease seal and needle bearing lubrication • refer to the swingarm pivot lubrication in the periodic maintenance chapter..

  • Page 431: Steering

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

  • Page 432

    14-2 steering exploded view.

  • Page 433

    Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 handlebar nuts 34 3.5 25 2 steering stem head nut 88 9.0 65 3 steering stem nut 4.9 0.50 43 in·lb s 4 upper front fork clamp bolts 29 3.0 21 5 lower front fork clamp bolts 29 3.0 21 al ad: apply adhesive. Al: tighten the two c...

  • Page 434

    14-4 steering special tools head pipe outer race press shaft: 57001–1075 head pipe outer race driver: 57001–1077 steering stem nut wrench: 57001–1100 head pipe outer race remover: 57001–1107 jack: 57001–1238 steering stem bearing driver: 57001–1344 steering stem bearing driver adapter: 57001–1345 at...

  • Page 435

    Steering 14-5 handlebar handlebar removal • remove: clutch master cylinder [a] left handlebar switch housing [b] front brake master cylinder [a] right handlebar switch housing [b] throttle grip [c] • unscrew the nuts [a] and remove the handlebar [b] from the stem head. Handlebar installation • tight...

  • Page 436

    14-6 steering handlebar • apply adhesive the inside the left grip [a]. • insert the left grip until punched mark [b] in the handlebar. • check and adjust the throttle cables and rear view mirrors..

  • Page 437

    Steering 14-7 steering steering check • refer to the steering check in the periodic maintenance chapter. Steering adjustment • refer to the steering adjustment in the periodic mainte- nance chapter..

  • Page 438

    14-8 steering steering stem steering stem removal • using the jack [a] and attachment jack [b] under the frame pipe ribs [c], and a commercially available jack [d] under the engine [e], lift the front wheel [f] off the ground until the rear wheel [g] touches the ground. Special tools - jack: 57001–1...

  • Page 439

    Steering 14-9 steering stem • remove: o-ring [a] • take off the steering stem head [a] with the handlebar [b]. Caution cover the fuel tank with a thick towel [c] or cloth to protect the painted surface of the fuel tank. • loosen: lower fork clamp bolts [a] • remove: front fork legs [b] with front fe...

  • Page 440

    14-10 steering steering stem steering stem installation • install: steering stem [a] bearing [b] new o-ring [c] (i.D. 34.5 × 2 mm) stem cap [d] • tighten the stem nut [e] firmly, and loosen it. Special tool - steering stem nut wrench: 57001–1100 • tighten the stem nut again with the specified torque...

  • Page 441

    Steering 14-11 steering stem • install the removed parts. Headlight body front brake hose joint front wheel (see wheels/tires chapter) • install the turn signal lights [a]. ○ run the signal light leads [b] to the clamp portion [c] of the signal light. ○ clamp the signal light leads onto the headligh...

  • Page 442

    14-12 steering steering stem bearing stem bearing removal • remove the steering stem (see steering stem removal). • drive out the bearing outer races from the head pipe. Special tool - head pipe outer race remover: 57001 -1107 [a] note ○ if either steering stem bearing is damaged, it is recom- mende...

  • Page 443

    Steering 14-13 steering stem bearing ○ check that there is no play and the steering stem turns smoothly without rattles. If not, the steering stem bearings may be damaged. • remove the stem nut. • install the o-rings and adjust the steering (see periodic maintenance chapter). Torque - steering stem ...

  • Page 445: Frame

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

  • Page 446

    15-2 frame exploded view.

  • Page 447

    Frame 15-3 exploded view 1. United states of america and canadian models.

  • Page 448

    15-4 frame exploded view.

  • Page 449

    Frame 15-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear footpeg bracket bolts 25 2.5 18 l 2 sidestand nut 44 4.5 32 3 downtube bolts 44 4.5 32 g: apply grease. L: apply a non-permanent locking agent..

  • Page 450

    15-6 frame special tools jack: 57001–1238 attachment jack: 57001–1398.

  • Page 451

    Frame 15-7 seat seat removal • remove the seat bolts [a]. • pull the seat backward [b], then remove it. Seat installation • slip the seat hook [a] under the brace [b] on the frame. • tighten the seat bolts..

  • Page 452

    15-8 frame side covers left side cover removal • insert the ignition switch key [a] into the left side cover, and turn the key clockwise until the key slot is vertical. • pull [b] the rear part of the left side cover towards you, push [c] the left side cover slightly forward, and remove it. Left sid...

  • Page 453

    Frame 15-9 fenders front fender removal caution be careful not to scratch the painted surface during removal or installation. • remove the mounting bolts [a] on both sides to separate the front fender [b] from the front fork [c]. • remove the brake hose clamps [d]. • remove the front fender. Rear fe...

  • Page 454

    15-10 frame battery case battery case removal • remove: seat (see this chapter) bolts [a] and battery holder [b] battery [c] (see electrical system chapter) ecu [d] (see fuel system chapter) vehicle-down sensor [e] (see fuel system chapter) rear fender (see this chapter) • remove: oil pressure light...

  • Page 455

    Frame 15-11 tool box tool box removal • remove the left side cover (see this chapter). • for california model; remove the band [a] and canister [b]. • unscrew the bolts [c]. • pull the tool box [d] out..

  • Page 456

    15-12 frame downtube removal • using the jack and the attachment jack, raise the rear wheel off the ground (see wheels/tires chapter). Special tools - jack: 57001–1238 attachment jack: 57001–1398 remove: brake reservoir cover [a] brake reservoir (see brakes chapter) • open the lead clamps [b] • remo...

  • Page 457

    Frame 15-13 sidestand sidestand installation • tighten: torque - sidestand nut: 44 n·m (4.5 kgf·m, 32 ft·lb) • install the sidestand spring [a], noting the direction of the hooks [b]..

  • Page 458

    15-14 frame rear view mirrors rear view mirror removal (other than european model) • loosen the locknut [a]. • turn the rear view mirror stay [b] counterclockwise to re- move the rear view mirror from the holder [c]. Rear view mirror removal (european model) • loosen the lower hexagonal area [a]. • ...

  • Page 459

    Frame 15-15 rear view mirrors rear view mirror installation (european model) • screw the mounting area of the rear view mirror [a] into the holder [b] all the way, and tighten the lower hexagonal area [c] securely. Caution do not force to tighten and/or loosen the upper hexagonal area (adapter) [a] ...

  • Page 460

    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. If the frame is bent, dented, cracked, or warped, replace it..

  • Page 461: Electrical System

    Electrical system 16-1 16 electrical system table of contents electrical parts location .................... 16-3 exploded view................................... 16-6 wiring diagram (united states of america and canada)..................... 16-12 wiring diagram (other than united states of america,...

  • Page 462

    16-2 electrical system oil pressure light delay unit inspection.................................. 16-71 meter, gauge..................................... 16-72 meter unit removal ..................... 16-72 meter unit installation .................. 16-72 meter unit disassemble............... 16-73 ...

  • Page 463

    Electrical system 16-3 electrical parts location dfi: dfi parts (see fuel system chapter) 1. Speedometer 2. Tachometer 3. Ignition switch 4. Front brake light switch 5. Starter lockout switch 6. Fuel pump (dfi) with fuel reserve switch 7. Indicator light cover 8. Atmospheric pressure sensor (dfi) 9....

  • Page 464

    16-4 electrical system electrical parts location 33. Vehicle-down sensor (dfi) 34. Ecu (dfi, electronic control unit) 35. Sealed battery 36. Starter relay and main fuse 30a 37. Dfi fuse 20a 38. Junction box 39. Turn signal control relay 40. Dfi main relay 41. Oil pressure light delay unit.

  • Page 466

    16-6 electrical system exploded view.

  • Page 467

    Electrical system 16-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 starter lockout switch screw 1.2 0.12 11 in·lb 2 front brake light switch screw 1.2 0.12 11 in·lb 3 headlight mounting screws 2.9 0.30 26 in·lb 4 headlight rim screws 1.4 0.14 12 in·lb 5 headlight body bracket screws ...

  • Page 468

    16-8 electrical system exploded view.

  • Page 469

    Electrical system 16-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 spark plugs 18 1.8 13 2 water temperature switch 7.8 0.80 69 in·lb 3 radiator fan switch 18 1.8 13 4 sidestand switch bolt 8.8 0.90 78 in·lb l 5 rear turn signal light mounting nuts 6.9 0.70 61 in·lb 6 license plate l...

  • Page 470

    16-10 electrical system exploded view.

  • Page 471

    Electrical system 16-11 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 alternator stator bolts 13 1.3 115 in·lb l 2 alternator rotor bolt 78 8.0 58 mo 3 stator lead holder screw 9.8 1.0 87 in·lb l 4 rotor bolt cap 1.5 0.15 13 in·lb 5 timing inspection cap 1.5 0.15 13 in·lb 6 alternator ...

  • Page 472

    16-12 electrical system wiring diagram (united states of america and canada).

  • Page 473

    Electrical system 16-13 wiring diagram (united states of america and canada).

  • Page 474

    16-14 electrical system wiring diagram (other than united states of america, canada and australia).

  • Page 475

    Electrical system 16-15 wiring diagram (other than united states of america, canada and australia).

  • Page 476

    16-16 electrical system wiring diagram (australia).

  • Page 477

    Electrical system 16-17 wiring diagram (australia).

  • Page 478

    16-18 electrical system specifications item standard battery: type sealed battery model name ftz16-bs capacity 12 v 18 ah voltage 12.6 v or more charging system: alternator type three-phase ac with delta connection, and rare-earth single magnet rotor dc battery charging voltage 14.2 ∼ 15.2 v @3 000 ...

  • Page 479

    Electrical system 16-19 specifications item standard water temperature switch resistance from off to on: 113 ∼ 117°c (235 ∼ 243°f) (rising temperature) from on to off: 108°c (226°f) ∼ temperature less than on temperature fuel level switch resistance full position: 4 ∼ 10 Ω empty position: 90 ∼ 100 Ω...

  • Page 480

    16-20 electrical system special tools and sealant spark plug wrench, hex 18 : 57001–1024 jack : 57001–1238 hand tester : 57001–1394 attachment jack : 57001–1398 flywheel holder : 57001–1410 kawasaki bond (silicone sealant) : 56019–120

  • Page 481

    Electrical system 16-21 servicing precautions there are a number of important precautions that should be followed servicing electrical systems. ○ do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○ always check battery condition before condemning ot...

  • Page 482

    16-22 electrical system servicing precautions male connectors [b].

  • Page 483

    Electrical system 16-23 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 484

    16-24 electrical system battery battery removal caution do not disconnect the battery cables or any other electrical connections when the ignition switch in on, as this could damage the ecu (electronic con- trol unit). Never reverse the connections of the battery, this could damage the ecu. • turn o...

  • Page 485

    Electrical system 16-25 battery • put the battery holder [a] on the battery. • tighten the bolts securely. • connect the sub harness [b], fuel pump [c] and battery (−) lead [d] connectors. • install the seat (see frame chapter). Electrolyte filling • make sure that the model name [a] of the electrol...

  • Page 486

    16-26 electrical system battery • place the electrolyte container upside down aligning the six seals with the six battery filler ports. • push the container down strongly enough to break the seals. Now the electrolyte should start to flow into the battery. Note ○ do not tilt the container as the ele...

  • Page 487

    Electrical system 16-27 battery initial charge while a sealed battery can be used after only filling with electrolyte, a battery may not be able to sufficiently move a starter motor to start an engine in the cases shown in the table below, where an initial charge is required before use. However, if ...

  • Page 488

    16-28 electrical system battery warning keep the battery away from sparks and open flames during charging, since the battery gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure preve...

  • Page 489

    Electrical system 16-29 battery terminal voltage: 11.5 ∼ less than 12.6 v standard charge 1.8 a × 5 ∼ 10 h (see following chart) quick charge 9.0 a × 1.0 h caution if possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on. Terminal voltage: less than 11.5 v c...

  • Page 490

    16-30 electrical system charging system alternator outer cover removal • remove (left side view): left front footpeg [a] (see crankshaft/transmission chapter) shift pedal [b] (see crankshaft/transmission chapter) • unscrew the bolts [a] and take off the alternator outer cover [b]. Alternator outer c...

  • Page 491

    Electrical system 16-31 charging system • unscrew the bolts [a] and take off the alternator cover [b]. • discard and replace the gasket with a new one. • apply silicone sealant to the area [a] to the crankshaft sensor wire grommet [b]. Stator lead grommet [c] sealant - kawasaki bond (silicone sealan...

  • Page 492

    16-32 electrical system charging system • remove the front engine mounting bolt [a]. • loosen the rear engine mounting bolt [b]. • lift up [a] the front part of the engine, using the jack until the lower part of the alternator inner cover clears the lower frame [b]. Note ○ turn the propeller shaft s...

  • Page 493

    Electrical system 16-33 charging system • install the alternator rotor [a] while fitting the alignment notch [b] of the splines onto the alignment tooth [c]. ○ be sure to align the balancer gear mark (shorter) with the alternator mark (line marks) [a] while keeping the front position on its top dead...

  • Page 494

    16-34 electrical system charging system • set up the dampers [a] and crankshaft sensor holders [b] to the pickup coils [c]. • install the crankshaft sensors as shown. Crankshaft sensor [a] with shorter leads (bk and bk/y) for #1 (front) crankshaft sensor [b] with longer leads (bk/w and bk/r) for #2 ...

  • Page 495

    Electrical system 16-35 charging system charging voltage inspection • check the battery condition. • warm up the engine to obtain actual alternator operating conditions. • remove the seat (see frame chapter). • check that the ignition switch is turned off, and connect the hand tester to the battery ...

  • Page 496

    16-36 electrical system charging system alternator output voltage tester connections reading range tester (+) to tester (−) to @3 000 rpm 250 v ac one yellow wire another yellow wire 64 ∼ 96 v if the output voltage shows the value in the table, the alter- nator operates properly and the regulator/re...

  • Page 497

    Electrical system 16-37 charging system ○ open the clamp [a] with (−) screw driver [b]. • remove the regulator/rectifier bolts [a] and take off the regulator/rectifier [b]. Regulator/rectifier inspection • remove the alternator outer cover (see this chapter). • disconnect the regulator/rectifier [a]...

  • Page 498

    16-38 electrical system charging system regulator/rectifier internal resistance tester (+) lead connection terminal br w/r1 w/r2 y1 y2 y3 y4 bk1 bk2 br — ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ w/r1 ∞ — 0 ∞ ∞ ∞ ∞ ∞ ∞ w/r2 ∞ 0 — ∞ ∞ ∞ ∞ ∞ ∞ y1 ∞ 2 ∼ 20 2 ∼ 20 — ∞ ∞ 0 ∞ ∞ y2 ∞ 2 ∼ 20 2 ∼ 20 ∞ — ∞ ∞ ∞ ∞ y3 ∞ 2 ∼ 20 2 ∼ 20 ∞ ∞...

  • Page 499

    Electrical system 16-39 charging system charging system 1. Alternator 2. Regulator/rectifier 3. Ignition switch 4. Load 5. Main fuse 30 a 6. Starter relay 7. Sealed battery 12 v 18 ah 8. Headlight relay in junction box.

  • Page 500

    16-40 electrical system ignition system ignition system circuit #1: for front cylinder #2: for rear cylinder 1. Ignition switch 2. Engine stop switch 3. Starter button 4. Spark plugs 5. Ignition coil #1 6. Ignition coil #2 7. Vehicle-down sensor (dfi) 8. Junction box 9. Ignition fuse 10 a 10. Thrott...

  • Page 501

    Electrical system 16-41 ignition system.

  • Page 502

    16-42 electrical system ignition system warning the ignition system produces extremely high volt- age. Do not touch the spark plugs, ignition coils, or spark plug high-tension cables while the engine is running, or you could receive a severe electrical shock. Caution do not disconnect the battery ca...

  • Page 503

    Electrical system 16-43 ignition system • remove the mounting nuts [a] and connector bracket [b]. • take out the #1 ignition coil. • disconnect the right handlebar switch, fan motor and rear brake switch connectors [a]. • remove the mounting nuts [b] and connector bracket [c]. • take on the #2 ignit...

  • Page 504

    16-44 electrical system ignition system warning to avoid extremely high voltage shocks, do not touch the coil body or leads. If the distance reading is less than the specified value, the ignition coil or spark plug caps are defective. • to determine which part is defective, measure the arcing distan...

  • Page 505

    Electrical system 16-45 ignition system ignition coil primary peak voltage note ○ be sure the battery is fully charged. • remove the fuel tank (see fuel system chapter). • remove all the spark plug caps but do not remove the spark plugs. • install new spark plugs into all the spark plug caps, and gr...

  • Page 506

    16-46 electrical system ignition system crankshaft sensor removal • remove the alternator cover [a] (see this chapter). • unscrew the holder bolt [b] and take off the crankshaft sensor lead holder [c]. • unscrew the screws [d] and take off the crankshaft sen- sors with the grommet [e]. Crankshaft se...

  • Page 507

    Electrical system 16-47 ignition system note ○ be sure the battery is fully charged. Hand tester range: × dc 10 v • turn the ignition switch and the engine stop switch on. • pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measure the crankshaft sensor pe...

  • Page 508

    16-48 electrical system ignition system interlock operation inspection • remove: side cover (see frame chapter) ○ do not disconnect the connectors. 1st check • measure the terminal voltage of the r/w wire in the junc- tion box connector [a] in accordance with the following procedure. ○ set the teste...

  • Page 509

    Electrical system 16-49 ignition system ic igniter inspection ○ the ic igniter is built in the ecu [a]. Damper [b] battery case [c] groove [d] front [e] ○ refer to fuel system chapter for ecu inspection..

  • Page 510

    16-50 electrical system ignition system.

  • Page 511

    Electrical system 16-51 starter motor starter motor removal • slide out the cap [a] • remove: starter motor terminal nut [b] cable [c] starter motor bolts [d] • pull the starter motor [a] toward the left and remove it. Caution never drop the starter motor, especial on a hard sur- face. Such a shock ...

  • Page 512

    16-52 electrical system starter motor disassembly • remove the starter motor (see starter motor removal). • take off the starter motor assy bolts [a] and remove both end covers [b] and pull the armature out of the yoke. • take the positive carbon brushes [b] out of the brush hold- ers [a]. • take of...

  • Page 513

    Electrical system 16-53 starter motor • put the armature [a] among the brushes, and remove the plastic washers [b]. • fit the tang [a] of the brush plate into the left end cover groove [b]. • apply a thin coat of grease to the oil seal [b] in the right end cover [a]. • apply a thin coat of grease to...

  • Page 514

    16-54 electrical system starter motor brush inspection • measure the length [a] of each brush. If any is worn down to the service limit, replace the carbon brush holder assy [b] and the terminal bolt assy [c]. Starter motor brush length standard: 12 mm (0.47 in.) service limit: 8.5 mm (0.33 in.) com...

  • Page 515

    Electrical system 16-55 starter motor brush assy inspection • using the × 1 Ω hand tester range, measure the resis- tance as follows. Terminal bolt and positive brushes [a] brush plate and negative brushes [b] plastic [c] ○ the reading should be zero. If there is not close to zero ohms, the brush le...

  • Page 516

    16-56 electrical system starter motor electric starter circuit 1. Ignition switch 2. Engine stop switch 3. Starter button 4. Junction box 5. Starter circuit relay 6. Ignition fuse 10 a 7. Starter lockout switch 8. Side stand switch 9. Diode 10. Neutral switch 11. Starter motor 12. Starter relay 13. ...

  • Page 517

    Electrical system 16-57 lighting system this model adopts the daylight system and has a head light relay in the junction box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on when the engine starts running and stays on even ...

  • Page 518

    16-58 electrical system lighting system • pull the headlight unit and drop it out. • pull the headlight connector [a]. • remove the headlight dust cover [b]. • push the hook [a] to unlock. • take out the bulb [a]. Caution when handling the quartz-halogen bulb, never touch the glass portion with bare...

  • Page 519

    Electrical system 16-59 lighting system headlight body removal • remove the headlight rim screws [a]. • pull the headlight unit and drop it out. • disconnect the wiring connectors [a]. • remove the headlight body nuts [b], then take off the body [c]. City light bulb replacement (other than us, ca an...

  • Page 520

    16-60 electrical system lighting system • push the bulb in [a], turn it counterclockwise [b], and pull it out. • replace the bulb with a new one. • with the front pin [a] up and the rear pin [b] down, insert the new bulb by aligning the front pin with the left groove [c] in the walls of the socket [...

  • Page 521

    Electrical system 16-61 lighting system headlight/tail light circuit 1. Ignition switch 2. Alternator 3. Junction box 4. Headlight relay 5. Headlight fuse 10 a 6. Taillight fuse 10 a 7. License plate light 8. Tail/brake light 9. Sealed battery 12 v 18 ah 10. Main fuse 30 a 11. Starter relay 12. Dimm...

  • Page 522

    16-62 electrical system automatic turn signal canceling system automobiles use a turn signal canceling system actuated by steering wheel turn. But, motorcycles turn with a bank additionally, and so have a smaller steer angle. This makes difficult to adopt an automobile type turn signal canceling sys...

  • Page 523

    Electrical system 16-63 automatic turn signal canceling system turn signal cancelling system [ ]: other than canada and united states of america 1. Right turn signal indicator light 2. Left turn signal indicator light 3. Distance sensor 4. Meter unit 5. Front right turn signal light 6. Front left tu...

  • Page 524

    16-64 electrical system automatic turn signal canceling system wiring inspection • connect all the connectors. • remove the right side cover (see frame chapter). • remove the coolant reserve tank bolts and hanging the reserve tank. • remove the turn signal control relay [a]. • pull off the 6-pin con...

  • Page 525

    Electrical system 16-65 automatic turn signal canceling system • set the hand tester to the dc25 v range and connect it to the lb wire terminal [a] and battery (−) terminal [b] as shown. Connections hand tester (+) → lb wire terminal hand tester (−) → battery (−) terminal • remove all the spark plug...

  • Page 526

    16-66 electrical system automatic turn signal canceling system turn signal control relay inspection caution never drop the turn signal control relay, especially on a hard surface. Such a shock to the unit can damage it. • remove the right side cover (see frame chapter). • connect one 12 v battery an...

  • Page 527

    Electrical system 16-67 automatic turn signal canceling system • push the bulb [a] in the socket and turn the bulb counter- clockwise [b]. • replace the bulb. • insert the new bulb [a] by aligning the pins [b] with the groove in the walls of the socket [c]..

  • Page 528

    16-68 electrical system radiator fan system warning the radiator fan is connected directly to the bat- tery. The fan may start even if the ignition switch is off. Never touch the radiator fan until the radiator fan connector is disconnected. Touching the fan before the connector is disconnected coul...

  • Page 529

    Electrical system 16-69 radiator fan system radiator fan circuit 1. Radiator fan 2. Radiator fan switch 3. Junction box 4. Fan fuse 15 a 5. Main fuse 30 a 6. Sealed battery 12 v 18 ah.

  • Page 530

    16-70 electrical system oil pressure warning system motorcycle operation with low engine oil level, even if it is higher than the lower level line, will cause oil level change when sudden acceleration, or deceleration, and may lead flicker of the oil pressure warning light because of too rapid respo...

  • Page 531

    Electrical system 16-71 oil pressure warning system oil pressure light delay unit removal • remove the right side cover (see frame chapter). • remove the coolant reserve tank bolts and hanging the reserve tank [a]. • pull the connectors out of the oil pressure light delay unit [b]. Oil pressure ligh...

  • Page 532

    16-72 electrical system meter, gauge meter unit removal • remove the headlight unit (see headlight body re- moval). • open the clamp [a] and disconnect the meter connectors [b]. • unscrew the bolts [a] and take the meter unit [b]. • unscrew the screws [a] and remove the meter cover [b] from the mete...

  • Page 533

    Electrical system 16-73 meter, gauge meter unit disassemble • remove the meter unit (see this chapter). • remove: screws [a] • separate the upper meter cover [b]. • remove the screw [a], meter light sockets [b] and rubber lid [c]. • remove the screws [d] on the lower cover [e] to free the digital me...

  • Page 534

    16-74 electrical system meter, gauge meter unit assembly • connect the connectors of the meter harness. • put on the rubber lid [a] on the lower cover [b]. ○ tighten the screw together with the harness clamp [c] as shown. Meter unit inspection mode select and reset button checks: • when the ignition...

  • Page 535

    Electrical system 16-75 meter, gauge clock setting: • in the hour/minute setting mode, push the reset but- ton [a] again to effect the hour setting mode. ○ the hour display flashes [b] on the display. • push the mode select button to set the hour. • in the hour setting mode, push the reset button [a...

  • Page 536

    16-76 electrical system meter, gauge • using the auxiliary wires, connect a 12 v battery to the meter unit connector terminals. First connections: battery positive terminal (+) → terminal [7] battery negative terminal (−) → terminal [3] next connections: battery positive terminal (+) → terminal [1] ...

  • Page 537

    Electrical system 16-77 meter, gauge • if an oscillator is available, check the speedometer as fol- lows. ○ connect the terminals in the same way as in the lcd segment inspection. ○ connect the oscillator [a] to the terminal [11]. The vehi- cle speed that corresponds to the input frequency will be d...

  • Page 538

    16-78 electrical system meter, gauge odo meter inspection: • turn the display [a] into odo. During the speedometer inspection with an oscillator, verify that the digital meter reading increases. If it does not increase, replace the digital meter assembly. Trip meter inspection: • turn the display [a...

  • Page 539

    Electrical system 16-79 meter, gauge • if an oscillation is unavailable, check that the distance sensor as follows. ○ remove the right side cover (see frame chapter). ○ remove the turn signal control relay [a], but do not dis- connect the connectors [b]. ○ use the jack and the attachment jack to lif...

  • Page 540

    16-80 electrical system meter, gauge water temperature warning led light connections: battery negative wire (−) to terminal [6] • connect the terminal [6]. ○ the water temperature warning led light. • disconnect the terminal [6]. ○ the water temperature warning led light disappears. If there is any ...

  • Page 541

    Electrical system 16-81 meter, gauge • pull out the indicator light socket [b] backward and then pull out the lens [a] from the socket . • turn over the socket rubber. • remove the wedge-base type bulb [a], pull the bulb straight out of the socket [b]. Caution do not turn the bulb. Pull the bulb out...

  • Page 542

    16-82 electrical system meter, gauge 1. Oil pressure warning light delay unit 2. Speed sensor 3. Speedometer 4. Tachometer 5. Odo/trip/clock indicator 6. Fi indicator led light 7. Water temperature warning led light 8. Oil pressure warning led light 9. Fuel level indicator light 10. Speedometer ligh...

  • Page 543

    Electrical system 16-83 water temperature warning system water temperature warning system check the water temperature warning led light goes on when the ignition switch is turned on and goes off soon to ensure that its circuit functions properly and the warning led light has not burned out. The warn...

  • Page 544

    16-84 electrical system switch and sensors fuel reserve switch inspection • fill the fuel tank with fuel. • close the fuel tank cap surely. • remove: seat (see frame chapter) fuel pump connector (see fuel system chapter) • connect the test light (12 v 3.4 w bulb a socket with wires) [b] and 12 v bat...

  • Page 545

    Electrical system 16-85 switch and sensors speed sensor inspection • remove: speed sensor (see speed sensor removal) • connect the speed sensor connector [a] with a battery [b], 10 kΩ resistor [c] and hand tester [d] as shown. • set the tester to the dc 25 v range. Special tool - hand tester : 57001...

  • Page 546

    16-86 electrical system switch and sensors radiator fan switch removal caution never drop the fan switch, especially on a hard sur- face. Such a shock to the part can damage it. • drain the coolant (see cooling system chapter). • disconnect the fan switch connector. • unscrew the radiator fan switch...

  • Page 547

    Electrical system 16-87 switch and sensors water temperature switch installation • apply silicone sealant to the threads of the water temper- ature switch. Sealant - kawasaki bond: 59019–120 torque - water temperature switch: 7.8 n·m (0.8 kgf·m, 69 in·lb) • fill the engine with coolant and bleed the...

  • Page 548

    16-88 electrical system switch and sensors • set the hand tester to the × 100 Ω range. Special tool - hand tester: 57001–1394 check the continuity between the diode terminals in both directions. If there is continuity in one direction (forward direction) but no continuity (infinity) in the reverse d...

  • Page 549

    Electrical system 16-89 junction box the junction box [a] has fuses [b], relays, and diodes. The relays and diodes can not be removed. Junction box fuse circuit inspection • remove the right side cover (see frame chapter). • remove the junction box. • pull off the connectors from the junction box. •...

  • Page 550

    16-90 electrical system junction box starter circuit/headlight relay inspection • remove the junction box. • check conductivity of the following numbered terminals by connecting the hand tester and one 12 v battery to the junction box as shown (see junction box internal circuit). If the tester does ...

  • Page 551

    Electrical system 16-91 junction box junction box internal circuit accessory fuse 10 a [a] ignition fuse 10 a [e] starter diode [i] fan fuse 15 a [b] headlight fuse 10 a [f] starter circuit relay [j] turn signal fuse 10 a [c] headlight relay [g] interlock diodes [k] horn fuse 10 a [d] headlight diod...

  • Page 552

    16-92 electrical system fuse main fuse removal • remove the right side cover (see frame chapter). • remove the coolant reserve tank bolts and hanging the reserve tank. • remove the starter relay [a]. • pull out the main fuse [b] from the starter relay with needle nose pliers. Junction box fuse remov...

  • Page 553: Appendix

    Appendix 17-1 17 appendix table of contents cable, wire, and hose routing .............................................................................................. 17-2 troubleshooting guide (except dfi) ...................................................................................... 17-5...

  • Page 554

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

  • Page 555

    Appendix 17-3 cable, wire, and hose routing f: front 1. Indicator lights 2. Fuel tank 3. Fuel pump base 4. Two clamps (fuel pump leads) 5. Plastic caps 6. Snap-on plastic clamps 7. Fuel tank breather hose 8. Fuel pump harness 9. Run the harness [8] under the hose [7]. 10. Indicator light connector: ...

  • Page 556

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

  • Page 557

    Appendix 17-5 cable, wire, and hose routing f: front 1. Front right spark plug cap 2. Rear right spark plug cap 3. 2nd lead from the left ignition coil lower side 4. 2nd lead from the right ignition coil lower side 5. Ignition coil for rear spark plugs 6. Ignition coil for front spark plugs 7. 2nd l...

  • Page 558

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

  • Page 559

    Appendix 17-7 cable, wire, and hose routing →: inlet air flow 1. Rear view 2. Air inlet 3. Left rubber gasket 4. Left air cleaner cover 5. Air cleaner element 6. Left air cleaner base 7. Lower air cleaner duct 8. Air switching valve hose 9. To air switching valve 10. Right rubber gasket 11. Right ru...

  • Page 560

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

  • Page 561

    Appendix 17-9 cable, wire, and hose routing →: bypass air flow f: front 1. Rear view 2. Throttle body assy 3. Air cleaner base seal 4. Spark plug lead holder 5. Right side view 6. Harness of inlet air temperature sensor & isc valves 7. T-joint 8. Vacuum hose from throttle body 9. Inlet air pressure ...

  • Page 562

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

  • Page 563

    Appendix 17-11 cable, wire, and hose routing - - →: vacuum pulsation →: fuel flow f: front #1. For front cylinder #2. For rear cylinder. 1. Fuel tank (left view) 2. Return fuel check valve 3. High pressure fuel hoses 4. Delivery joint 5. Fuel injector #1 6. Fuel injector #2 7. Pressure regulator 8. ...

  • Page 564

    17-12 appendix cable, wire, and hose routing f: front 1. Face the white marks top. 2. Air switching valve 3. Choke cable 4. Face the clamp knob as shown. 5. Front cylinder coolant hose 6. Breather hose: run the upper the air switching valve. 7. To the right air cleaner base 8. To the rear air suctio...

  • Page 565

    Appendix 17-13 cable, wire, and hose routing f: front 1. Air switching valve 2. Front air suction valve hose 3. Breather hose 4. Rear air suction valve hose 5. Idle adjusting screw 6. Rear cylinder coolant hose 7. Run the rear air suction valve hose under the pressure regulator on the throttle body ...

  • Page 566

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

  • Page 567

    Appendix 17-15 cable, wire, and hose routing f: front ←→: vacuum pulsation →: bypass air flow #1: for front cylinder #2: for rear cylinder 1. Top view 2. Rear view 3. Bottom view 4. Pressure regulator 5. Delivery joint 6. Fuel injector #2 7. Fuel injector #1 8. Vacuum hoses from throttle body 9. Isc...

  • Page 568

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

  • Page 569

    Appendix 17-17 cable, wire, and hose routing f: front 1. Clips 2. Air switching valve 3. Air switching valve hose (for front air suction valve) 4. White mark (face it upwards.) 5. Air switching valve hose (for right air cleaner base) 6. Air switching valve hose (for rear air suction valve): run the ...

  • Page 570

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

  • Page 571

    Appendix 17-19 cable, wire, and hose routing f: front 1. White marks on the hose [2] and [7] : the marks faces forwards. 2. Front coolant hose 3. Reserve tank hose 4. Clip 5. Rear cylinder coolant hose 6. White marks on the hose face backwards. 7. Radiator hose 8. Water pump 9. Clamp 10. Water pump ...

  • Page 572

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

  • Page 573

    Appendix 17-21 cable, wire, and hose routing f: front →: fuel flow ←→: vacuum pulsation 1. Atmospheric pressure sensor 2. Inlet air pressure sensor 3. Inlet air pressure sensor hose 4. Rear cylinder coolant hose 5. Injector harness 6. Low pressure fuel hose (return) 7. Fuel hose joint #2 8. Yellow m...

  • Page 574

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

  • Page 575

    Appendix 17-23 cable, wire, and hose routing →: fuel flow f: front 1. Fuel pump connector (outside the fuel tank) 2. Bottom of fuel tank 3. Outlet fuel pipe 4. Fuel pump body (dfi) 5. Fuel reserve switch (thermistor) 6. Pump motor (−) bk/w lead 7. Pump motor (+) w/r lead 8. Fuel reserve switch r/bk ...

  • Page 576

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

  • Page 577

    Appendix 17-25 cable, wire, and hose routing f: front 1. Rubber boot 2. Starter motor lead 3. Clutch hose 4. Upper washer ( 14 × 8.2 mm) 5. Lower washer ( 25 × 8.2 mm) 6. Engine oil pipe 7. Clamp (for harness protection since edge of the clutch slave cylinder) 8. Clutch slave cylinder bleed valve 9....

  • Page 578

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

  • Page 579

    Appendix 17-27 cable, wire, and hose routing f: front 1. Fuel tank fill opening (top view) 2. Fuel tank 3. Fuel tank breather pipe 4. Filler drainpipe 5. Fuel tank filler drain hose 6. Clip (face the tab rightwards.) 7. Fuel tank breather hose (except for california model) 8. Clip 9. Hole of bracket...

  • Page 580

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

  • Page 581

    Appendix 17-29 cable, wire, and hose routing f: front 1. Rear view 2. Rear fender 3. Grommets 4. Six clamps 5. Rear fender harness 6. Plastic cover 7. Run the harness [5] into the cut of the plastic cover [6] 8. Connector of [9] (fit the connector of [5] into the welded clamp.) 9. License plate ligh...

  • Page 582

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

  • Page 583

    Appendix 17-31 cable, wire, and hose routing f: front t: top ○ install the plastic snap-on clamps [11] [16], nothing the position of the opening as shown. 1. Meter connectors 2. Headlight connector 3. Plate clamp in [6] (lead [1] [4] [5]) 4. Front turn signal light lead connector (right) 5. Front tu...

  • Page 584

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

  • Page 585

    Appendix 17-33 cable, wire, and hose routing f: front t: top ○ : install the plastic snap-on clamps [3][17][18], noting the position of the opening as shown. 1. Clutch hose 2. Starter motor lead 3. Plastic snap-on clamp ( 17 mm, rear view) 4. Left fame pipe 5. Holder (run the clutch hose [8]). 6. Ec...

  • Page 586

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

  • Page 587

    Appendix 17-35 cable, wire, and hose routing f: front 1. Ignition coil #2 (for rear cylinder) 2. Ignition switch connector (onto the fuel tank) 3. Throttle cables (decelerator up and accelerator down, under the main harness [19]) 4. Right handlebar switch harness 5. Holders 6. Plastic snap-on clamps...

  • Page 588

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

  • Page 589

    Appendix 17-37 cable, wire, and hose routing f: front 1. Fit the clamp pin attached the main harness into the frame. 2. Plastic snap-on clamp (fuel pump harness) 3. Battery (−) lead or engine ground lead (to the engine ground terminal) 4. Oil pressure light delay unit 5. Dfi main relay 6. Battery (+...

  • Page 590

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

  • Page 591

    Appendix 17-39 cable, wire, and hose routing f: front 1. Fuel tank filler drain hose 2. Starter motor lead 3. Holder 4. Engine ground lead (run it downward) 5. Main harness 6. Coolant reserve tank hose (from the radiator cap to the coolant reserve tank) 7. To the inside of the alternator outer cover...

  • Page 592

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

  • Page 593

    Appendix 17-41 cable, wire, and hose routing f: front t: top 1. Main harness 2. Rear coolant hose 3. Right handlebar switch connector 4. Holder 5. Frame ground lead 6. Ignition coil #2 (for rear cylinder) 7. Throttle cables 8. Radiator fan connector 9. Rear brake light switch connector 10. Throttle ...

  • Page 594

    17-42 appendix cable, wire, and hose routing f: front 1. Rear brake caliper 2. Hose holders 3. Rear brake hose 4. Hose white marks (position here.) 5. Hose clamps 6. Run the brake hose between the engine mounting bracket bosses and the oil filter, and then along the downtube towards the front. 7. Oi...

  • Page 595

    Appendix 17-43 cable, wire, and hose routing 8. Rear brake reservoir 9. Rear master cylinder 10. Brake pedal 11. Bend both ends of the cotter pin [16] as shown. 12. Clevis 13. Rear brake reservoir cover 14. Downtube 15. Swingarm 16. Cotter pin 17. Rear brake disc.

  • Page 596

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

  • Page 597

    Appendix 17-45 cable, wire, and hose routing f: front 1. Throttle cable (accelerator) 2. Throttle cable (decelerator) 3. Front brake hose assembly 4. Meter bracket 5. Right handlebar switch harness 6. Tachometer 7. Speedometer 8. Front turn signal leads (connect them in the headlight body.) 9. Clutc...

  • Page 598

    17-46 appendix cable, wire, and hose routing evaporative emission control system (california model) with fuel line - - →: vapor flow →: fuel flow ←→: vacuum pulsation 1. Fuel return hose 2. Fuel tank breather hose 3. Separator breather hose 4. Canister purge hose 5. Vacuum hose 6. High pressure fuel...

  • Page 599

    Appendix 17-47 cable, wire, and hose routing evaporative emission control system (california model) f: front 1. Fuel tank 2. Left air cleaner base 3. Canister purge hose (green) 4. Canister (rear view) 5. Fuel tank breather hose (right, blue) 6. Throttle body assy (top view) 7. Fuel tank return hose...

  • Page 600

    17-48 appendix cable, wire, and hose routing evaporative emission control system (california model).

  • Page 601

    Appendix 17-49 cable, wire, and hose routing f: front 1. Fuel tank 2. Filler drainpipe 3. Fuel filler 4. Fuel tank breather pipe 5. Coolant reserve tank hose 6. Separator vacuum hose (white): run it over the throttle cables and choke cable. 7. Rear cylinder coolant hose: run it leftward the hose [6]...

  • Page 602

    17-50 appendix cable, wire, and hose routing evaporative emission control system.

  • Page 603

    Appendix 17-51 cable, wire, and hose routing r: rear view 1. Fuel tank 2. Filler drainpipe 3. Fuel tank breather pipe 4. Separator vacuum hose (white): run it over the throttle cables and choke cable. 5. Clips 6. Canister purge hose (green) 7. Starter motor lead: run the lead on the left of the sepa...

  • Page 604

    17-52 appendix troubleshooting guide (except dfi) note ○ refer to fuel system chapter for most of dfi troubleshooting 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 c...

  • Page 605

    Appendix 17-53 troubleshooting guide (except dfi) choke knob left pulled out (dfi) throttle body assy o-ring damage air cleaner duct loose air cleaner o-ring damaged fuel pump (dfi) trouble compression low: spark plug loose cylinder head not sufficiently tightened down cylinder, piston worn piston r...

  • Page 606

    17-54 appendix troubleshooting guide (except dfi) battery with jumper cables, and start the engine, using the electric starter) for kleen, do not start the engine under misfire due to spark plug fouling or poor connection of the spark plug for kleen, do not coast the motorcycle with the ignition swi...

  • Page 607

    Appendix 17-55 troubleshooting guide (except dfi) piston slap: cylinder/piston clearance excessive cylinder, piston worn connecting rod bent piston pin, piston pin hole worn valve noise: engine not sufficiently warmed up after hla installation hla damaged (worn, seizure, or spring bro- ken) hla aera...

  • Page 608

    17-56 appendix troubleshooting guide (except dfi) handling and/or stability unsatisfactory: handlebar hard to turn: cable routing incorrect hose routing incorrect wiring routing incorrect steering stem nut too tight steering stem bearing damaged steering stem bearing lubrication inade- quate steerin...

  • Page 609

    Model application year model beginning frame no. 2004 vn1600-b1 jkbvnkb1□4a000001 or jkbvnt60bba000001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1321-01 printed in japan.