Kawasaki VN1700 Voyager ABS Service Manual

Page 3: Quick Reference Guide

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

Page 5

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 7: Foreword

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

Page 9: General Information 1-1

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

Page 11: General Information 1-3

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 13: General Information 1-5

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 15: General Information 1-7

General information 1-7 model identification vn1700a9f left side view vn1700a9f right side view frame number engine number.

Page 17: General Information 1-9

General information 1-9 model identification vn1700b9f (eur models) left side view vn1700b9f (eur models) right side view.

Page 19: General Information 1-11

General information 1-11 general specifications items vn1700a9f ∼ aaf, vn1700b9f ∼ baf exhaust: open 55° bbdc close 25° atdc duration 260° lubrication system forced lubrication (semi-dry sump) engine oil: grade api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity sae10w-40 capacity 5.0 l (5.3...

Page 21: General Information 1-13

General information 1-13 technical information-electronic throttle valve(etv) system overview vn1700 series is equipped with the electronically-controlled throttle valve system called the elec- tronic throttle valve(etv) system. The throttle pulley and the throttle valves of this system are not conn...

Page 23: General Information 1-15

General information 1-15 technical information-electronic throttle valve(etv) system d. Throttle valve opening control section e. Etv actuator drive section f. Cpu monitoring section 5. Partial opening holding device when the etv actuator (dc motor) becomes incapable of throttle valve control, this ...

Page 25: General Information 1-17

General information 1-17 technical information-kawasaki advanced coactive-braking technology anti -lock brake system (k-act abs) 8. K-act abs kawasaki diagnostic system connector brake fluid flow chart [when k-act operates] case1) when operating only the front brake lever. Case2) when operating only...

Page 27: General Information 1-19

General information 1-19 technical information-kawasaki advanced coactive-braking technology anti -lock brake system (k-act abs) (decreased mode) (increased mode).

Page 29: General Information 1-21

General information 1-21 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 32: 2-2 Periodic Maintenance

2-2 periodic maintenance headlight aiming inspection ............................................................................................. 2-44 sidestand switch operation inspection ............................................................................ 2-46 engine stop switch operation...

Page 34: 2-4 Periodic Maintenance

2-4 periodic maintenance periodic maintenance chart the scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic inspection frequency whichever comes first * odom...

Page 36: 2-6 Periodic Maintenance

2-6 periodic maintenance periodic maintenance chart periodic replacement parts frequency whichever come first * odometer reading × 1 000 km (× 1 000 mile) item every 1 (0.6) 12 (7.5) 24 (15) 36 (22.5) 48 (30) see page air cleaner element-replace # every 18 000 km (11 250 mile) 2-50 fuel hose-replace...

Page 38: 2-8 Periodic Maintenance

2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks cylinder head inner cover bolts 9.8 1.0 87 in·lb cylinder head nuts (m12) (first) 39 4.0 29 mo, s cylinder head nuts (m12 new nuts) (final) 70 7.1 52 mo, s cylinder head nuts (m12 used nuts) (final) 77 7.8 57 m...

Page 40: 2-10 Periodic Maintenance

2-10 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks upper balancer chain guide bolts 12 1.2 106 in·lb wheels/tires front axle 127 13.0 94 front axle clamp bolts 20 2.0 15 s rear air valve nuts 1.5 0.15 13 in·lb rear axle nut 108 11.0 80 final drive engine pulle...

Page 42: 2-12 Periodic Maintenance

2-12 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks alternator stator coil lead connector stay bolt 9.8 1.0 87 in·lb alternator stator coil mounting bolts 12 1.2 106 in·lb l crankshaft sensor bolts 5.9 0.60 52 in·lb crankshaft sensor lead holding plate bolt 5.9...

Page 44: 2-14 Periodic Maintenance

2-14 periodic maintenance specifications item standard service limit final drive drive belt deflection: (45 n, 4.6 kgf, 10 lb force) 3.0 ∼ 4.5 mm (0.12 ∼ 0.18 in.) – – – (when installing new belt or engine is remounted) 3.0 mm (0.12 in.) – – – brakes brake fluid: grade dot4 – – – brake pad lining th...

Page 46: 2-16 Periodic Maintenance

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

Page 48: 2-18 Periodic Maintenance

2-18 periodic maintenance periodic maintenance procedures • push the “s” button [a] of the right handlebar switch hous- ing for more than two seconds to display the clock setting mode [b] on the lcd (liquid crystal display)..

Page 50: 2-20 Periodic Maintenance

2-20 periodic maintenance periodic maintenance procedures ○ the idle speed goes up 50 r/min (rpm) at one time by pushing the “mode-a” switch. ○ when pushing the “mode-a” switch, the value on the display shows the “+50” [a] (this shows 1 000 r/min (rpm)). ○ the idle speed goes down 50 r/min (rpm) at ...

Page 52: 2-22 Periodic Maintenance

2-22 periodic maintenance periodic maintenance procedures • check the liquid/vapor separator as follows. ○ remove: canister (see evaporative emission control system in- spection (cal and sea models)) band [a] ○ disconnect the hoses from the separator [b], and remove the separator. ○ visually inspect...

Page 54: 2-24 Periodic Maintenance

2-24 periodic maintenance periodic maintenance procedures clutch clutch operation inspection • start the engine and check that the clutch does not slip and that it releases properly. If the clutch operation is insufficiency, inspect the clutch system. Warning when test riding the vehicle, be aware o...

Page 56: 2-26 Periodic Maintenance

2-26 periodic maintenance 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 tire removal/installat...

Page 58: 2-28 Periodic Maintenance

2-28 periodic maintenance periodic maintenance procedures • inspect the drive belt deflection at arbitrary position, and record the value [a]. • turn the rear wheel 90 degrees. • inspect the drive belt deflection, and record the value [b]. • decide the belt deflection at the position [c] of one wher...

Page 60: 2-30 Periodic Maintenance

2-30 periodic maintenance periodic maintenance procedures wheel alignment inspection/adjustment • check that the notch [a] on the belt adjuster [b] aligns with the same swingarm mark [c] or position that the other side notch aligns with. If they do not, adjust the belt deflection (see belt deflec- t...

Page 62: 2-32 Periodic Maintenance

2-32 periodic maintenance periodic maintenance procedures drive belt wear and damage analysis pattern condition required action 1 internal tooth cracks (slight) o.K. For continued use, but inspect the belt periodically. 2 scuffing to side of teeth o.K. For continued use, but inspect the belt periodi...

Page 64: 2-34 Periodic Maintenance

2-34 periodic maintenance periodic maintenance procedures brake hose and pipe damage and installation condition inspection • for k-act abs equipped models; note the following. • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) right side cover (see right side cover removal ...

Page 66: 2-36 Periodic Maintenance

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

Page 68: 2-38 Periodic Maintenance

2-38 periodic maintenance periodic maintenance procedures rear shock absorber oil leak inspection • visually inspect the shock absorber [a] for oil leakage. If the oil leakage is found on it, replace the shock absorber with a new one. Swingarm pivot lubrication • remove the swingarm (see swingarm re...

Page 70: 2-40 Periodic Maintenance

2-40 periodic maintenance periodic maintenance procedures • install the steering stem head. • tighten: torque - steering stem head nut: 108 n·m (11.0 kgf·m, 80 ft·lb) upper front fork clamp bolts: 20 n·m (2.0 kgf·m, 15 ft·lb) • install: handlebar (see handlebar installation in the steering chapter) ...

Page 72: 2-42 Periodic Maintenance

2-42 periodic maintenance periodic maintenance procedures tail/brake light (led) and high mount tail/brake light (led) (see taillight (led) replacement in the electrical system chapter) license plate light bulb (see license plate light bulb replacement in the electrical system chapter) ecu (see ecu ...

Page 74: 2-44 Periodic Maintenance

2-44 periodic maintenance periodic maintenance procedures fourth step • set the dimmer switch to low beam position [a]. • start the engine. • the low beam headlight should go on. If the low beam headlight does not go on, inspect or re- place the following parts. Headlight bulb (see headlight bulb re...

Page 76: 2-46 Periodic Maintenance

2-46 periodic maintenance periodic maintenance procedures • insert the projections [a] into the grommets [b] and install the headlight cover [c]. Sidestand switch operation inspection • raise the rear wheel off the ground with the jack (see rear wheel removal in the wheels/tires chapter). • inspect ...

Page 78: 2-48 Periodic Maintenance

2-48 periodic maintenance periodic maintenance procedures points: lubricate with grease. Throttle inner cable upper and lower ends [a] cables: lubricate with rust inhibitor throttle cables • lubricate the cables by seeping the oil between the cable and housing. ○ the cable may be lubricated by using...

Page 80: 2-50 Periodic Maintenance

2-50 periodic maintenance periodic maintenance procedures replacement parts air cleaner element replacement note ○ in dusty areas, the element should be replaced more frequently than the recommended interval. Warning if dirt or dust is allowed to pass through into the throttle body assy, the throttl...

Page 82: 2-52 Periodic Maintenance

2-52 periodic maintenance periodic maintenance procedures coolant change warning coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it cool completely. Immediately wipe any spi...

Page 84: 2-54 Periodic Maintenance

2-54 periodic maintenance periodic maintenance procedures radiator hose and o-ring replacement • drain the coolant (see coolant change). • remove: thermostat housing [a] with bracket [b] (see thermo- stat removal in the cooling system chapter) alternator cover (see alternator removal in the electri-...

Page 86: 2-56 Periodic Maintenance

2-56 periodic maintenance periodic maintenance procedures oil filter replacement • drain the engine oil (see engine oil change). • remove the oil filter [a] with the oil filter wrench [b] and discard the oil filter. Special tool - oil filter wrench: 57001-1249 note ○ the filter has an oil filter byp...

Page 88: 2-58 Periodic Maintenance

2-58 periodic maintenance periodic maintenance procedures • for k-act abs equipped models, note the following. • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) right saddlebag (see saddlebag removal in the frame chapter) left muffler body (see muffler body removal in the ...

Page 90: 2-60 Periodic Maintenance

2-60 periodic maintenance periodic maintenance procedures • remove the rubber cap from the bleed valve [a] on the caliper [b]. • attach a clear plastic hose [c] to the bleed valve, and run the other end of the hose into a container. • fill the reservoir with fresh specified brake fluid. Note ○ for t...

Page 92: 2-62 Periodic Maintenance

2-62 periodic maintenance periodic maintenance procedures rear master cylinder disassembly • remove the rear master cylinder (see rear master cylin- der removal in the brakes chapter). • remove the reservoir cap [a], plate [b] and diaphragm [c]. • remove the circlip [d], connector [e] and o-ring [f]...

Page 94: 2-64 Periodic Maintenance

2-64 periodic maintenance periodic maintenance procedures front caliper assembly • clean the caliper parts except for the pads. Notice for cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • install the bleed valve and rubber cap. Torque - bleed valves: 7.8 n·m (0.8...

Page 96: 2-66 Periodic Maintenance

2-66 periodic maintenance periodic maintenance procedures • apply brake fluid to the outside of the pistons, and push them into each cylinder by hand . • replace the friction boot [a] and dust boot [b] with new ones. • apply silicone grease to the sliding surface of the caliper holder shafts [c]. • ...

Page 98: 2-68 Periodic Maintenance

2-68 periodic maintenance periodic maintenance procedures clutch fluid change • level the clutch fluid reservoir and remove the reservoir cap. • remove the engine pulley outer cover (see engine pulley outer cover removal in the final drive chapter). • remove the rubber cap from the bleed valve on th...

Page 100: 2-70 Periodic Maintenance

2-70 periodic maintenance periodic maintenance procedures clutch slave cylinder piston seal replacement • remove the engine pulley outer cover (see engine pulley outer cover removal in the final drive). • loosen the banjo bolt [a] at the clutch pipe lower end, and tighten it loosely. • unscrew the s...

Page 103: Fuel System (Dfi) 3-1

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

Page 105: Fuel System (Dfi) 3-3

Fuel system (dfi) 3-3 fuel pump operating voltage inspection ......................................................................... 3-95 pressure regulator removal............................................................................................ 3-96 fuel filter cleaning...................

Page 107: Fuel System (Dfi) 3-5

Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air cleaner housing cover bolts 4.9 0.50 43 in·lb 2 air cleaner element bolt 4.9 0.50 43 in·lb 3 air cleaner housing bolts 9.8 1.0 87 in·lb 4 crankshaft sensor bolts 5.9 0.60 52 in·lb 5 delivery joint bolts 9.8 1.0 87 ...

Page 109: Fuel System (Dfi) 3-7

Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oxygen sensor (equipped models) 25 2.5 18 2. Cal and sea models 3. Canister 4. Separator.

Page 111: Fuel System (Dfi) 3-9

Fuel system (dfi) 3-9 specifications item standard vehicle-down sensor: input voltage dc 4.75 ∼ 5.25 v output voltage with sensor tilted 40 ∼ 50° or more right or left: dc 0.65 ∼ 1.35 v with sensor arrow mark pointed up: dc 3.55 ∼ 4.45 v oxygen sensor (equipped models): output voltage (rich) dc 0.8 ...

Page 113: Fuel System (Dfi) 3-11

Fuel system (dfi) 3-11 special tools and sealant liquid gasket, tb1211: 56019-120

Page 115: Fuel System (Dfi) 3-13

Fuel system (dfi) 3-13 dfi system 1. Fuel tank 2. Fi indicator led light 3. Ecu 4. Battery 12 v 18 ah 5. Pressure regulator 6. Fuel pump 7. Water temperature sensor 8. Intake air pressure sensor 9. Delivery joint 10. Fuel injector #1 11. Fuel injector #2 12. Air switching valve 13. Intake air temper...

Page 117: Fuel System (Dfi) 3-15

Fuel system (dfi) 3-15 dfi system part names 1. Ecu 2. Oxygen sensor (equipped models) 3. Speed sensor 4. Gear position switch 5. Etv actuator relay 6. Throttle position sensor/etv actuator 7. Etv actuator 8. Throttle position sensor 2 9. Throttle position sensor 1 10. Accelerator position sensor 11...

Page 119: Fuel System (Dfi) 3-17

Fuel system (dfi) 3-17 dfi system 35. Battery monitor voltage: w/r 36. Intake air temperature sensor: r 37. Unused 38. Crankshaft sensor (+): y 39. Speed sensor: lg/r 40. Gear position switch: g 41. Unused 42. Unused 43. Power supply to accelerator position sensor 2: bl/bk 44. Power supply to ecu (f...

Page 121: Fuel System (Dfi) 3-19

Fuel system (dfi) 3-19 dfi parts location gear position switch [a] speed sensor [a] kawasaki diagnostic system connector (6-pin connec- tor) [b] etv actuator relay [a] (r/bl, y/bl, r/bl, g/o leads) vehicle-down sensor [b] fuse box 2 [c] (ecu fuse 10 a, etv actuator relay fuse 10 a, oxygen sensor hea...

Page 123: Fuel System (Dfi) 3-21

Fuel system (dfi) 3-21 dfi servicing precautions ○ if the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see fuel tank removal) and check the fuel hose [a]. Replace the fuel hose if any fraying, cracks o...

Page 125: Fuel System (Dfi) 3-23

Fuel system (dfi) 3-23 troubleshooting the dfi system when the service code [a] is displayed, for first ask the rider about the conditions [b] of trouble, and then start to determine the cause [c] of problem. As a pre-diagnosis inspection, check the ecu for ground and power supply, the fuel line for...

Page 127: Fuel System (Dfi) 3-25

Fuel system (dfi) 3-25 troubleshooting the dfi system • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. • check the wiring for continuity. ○ use the...

Page 129: Fuel System (Dfi) 3-27

Fuel system (dfi) 3-27 troubleshooting the dfi system sample diagnosis sheet rider name: registration no. (license plate no.): year of initial registration: model: engine no.: frame no.: date problem occurred: mileage: environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ al...

Page 131: Fuel System (Dfi) 3-29

Fuel system (dfi) 3-29 dfi system troubleshooting guide note ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in dfi system. ○ the ecu may be involved in t...

Page 133: Fuel System (Dfi) 3-31

Fuel system (dfi) 3-31 dfi system troubleshooting guide symptoms or possible causes actions (chapter) intake air temperature sensor trouble inspect (see chapter 3). Spark plug dirty, broken or gap maladjusted inspect and replace (see chapter 2). Ignition coil trouble inspect (see chapter 16). Stumbl...

Page 135: Fuel System (Dfi) 3-33

Fuel system (dfi) 3-33 dfi system troubleshooting guide symptoms or possible causes actions (chapter) air cleaner element clogged clean element (see chapter 2). Fuel pressure too high inspect (see chapter 3). Fuel injector trouble inspect (see chapter 3). Water temperature sensor trouble inspect (se...

Page 137: Fuel System (Dfi) 3-35

Fuel system (dfi) 3-35 self-diagnosis • turn the ignition switch on. • the service code [a] is displayed by the number of two digits. • when pushing the “s” button [b] of the right handlebar switch housing for more than two seconds while the “er- ror” segments [c], service code and fi warning symbol...

Page 139: Fuel System (Dfi) 3-37

Fuel system (dfi) 3-37 self-diagnosis service code reading ○ the service code(s) is displayed on the lcd by the number of two digits. ○ when there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical or...

Page 141: Fuel System (Dfi) 3-39

Fuel system (dfi) 3-39 self-diagnosis backups ○ the ecu takes the following measures to prevent engine damage when the dfi, ignition or etv system parts have troubles. Service codes parts output signal usable range or criteria backups by ecu 11 throttle position sensor output voltage (full throttle ...

Page 143: Fuel System (Dfi) 3-41

Fuel system (dfi) 3-41 throttle position sensor (service code 11) throttle position sensor removal notice do not remove throttle position sensor in the gear case [a] since it has been adjusted and set with pre- cision at the factory. Never drop the throttle body assy, especially on a hard surface. S...

Page 145: Fuel System (Dfi) 3-43

Fuel system (dfi) 3-43 throttle position sensor (service code 11) throttle position sensor circuit 1. Ecu 2. Throttle position sensor/etv actuator 3. Throttle position sensor 1 4. Throttle position sensor 2.

Page 147: Fuel System (Dfi) 3-45

Fuel system (dfi) 3-45 intake air pressure sensor (service code 12) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main harness connectors. Special tool - hand tester: 57001-1394 ○ disconnect the ecu and sensor connectors. Wiring continuity inspecti...

Page 149: Fuel System (Dfi) 3-47

Fuel system (dfi) 3-47 intake air pressure sensor (service code 12) then pv = pl – pg for example, suppose the following data is obtained: pg = 8 cmhg (vacuum gauge reading) pl = 70 cmhg (barometer reading) vv = 3.2 v (digital meter reading) then pv = 70 – 8 = 62 cmhg (absolute) plot this pv (62 cmh...

Page 151: Fuel System (Dfi) 3-49

Fuel system (dfi) 3-49 intake air pressure sensor (service code 12) intake air pressure sensor circuit 1. Ecu 2. Intake air pressure sensor.

Page 153: Fuel System (Dfi) 3-51

Fuel system (dfi) 3-51 intake air temperature sensor (service code 13) • turn the ignition switch off. If the reading is within the standard, check the ecu for its ground and power supply (see ecu power supply in- spection). If the ground and power supply are good, replace the ecu (see ecu removal/i...

Page 155: Fuel System (Dfi) 3-53

Fuel system (dfi) 3-53 water temperature sensor (service code 14) water temperature sensor removal/installation notice never drop the water temperature sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove: fuel tank (see fuel tank removal) • drain the coolant (s...

Page 157: Fuel System (Dfi) 3-55

Fuel system (dfi) 3-55 accelerator position sensor (service code 18) accelerator position sensor removal notice do not remove accelerator position sensor [a] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface. Such a shoc...

Page 159: Fuel System (Dfi) 3-57

Fuel system (dfi) 3-57 accelerator position sensor (service code 18) • connect the digital meter [a] to the terminals of the accel- erator position sensor connector [b]. Accelerator position sensor resistance connection: (1) bl/w lead terminal → bk/o lead terminal (2) bl/bk lead terminal → br lead t...

Page 161: Fuel System (Dfi) 3-59

Fuel system (dfi) 3-59 crankshaft sensor (service code 21) crankshaft sensor circuit 1. Ecu 2. Crankshaft sensor.

Page 163: Fuel System (Dfi) 3-61

Fuel system (dfi) 3-61 speed sensor (service code 24) speed sensor output voltage inspection • using the jack, raise the rear wheel off the ground (see rear wheel removal in the wheels/tires chapter). Special tool - jack: 57001-1238 • measure the output voltage at the speed sensor in the same way as...

Page 165: Fuel System (Dfi) 3-63

Fuel system (dfi) 3-63 gear position switch (service code 25) gear position switch removal/installation • refer to the gear position switch removal/installation in the electrical system chapter. Gear position switch resistance inspection • refer to the gear position switch inspection in the elec- tr...

Page 167: Fuel System (Dfi) 3-65

Fuel system (dfi) 3-65 vehicle-down sensor (service code 31) this sensor has a weight [a] with two magnets inside, and sends a signal to the ecu. But when the motorcycle banks 60 ∼ 70° or more to either side (in fact falls down), the weight turns and the signal changes. The ecu senses this change, a...

Page 169: Fuel System (Dfi) 3-67

Fuel system (dfi) 3-67 vehicle-down sensor (service code 31) vehicle-down sensor output voltage inspection • measure the output voltage at the vehicle-down sensor in the same way as input voltage inspection, note the follow- ing. ○ connect the measuring adapter [a] between the main har- ness connect...

Page 171: Fuel System (Dfi) 3-69

Fuel system (dfi) 3-69 oxygen sensor - not activated (service code 33, equipped models) oxygen sensor removal/installation • refer to the oxygen sensor removal/installation (equipped models) in the electrical system chapter. Oxygen sensor inspection • warm up the engine thoroughly until the radiator...

Page 173: Fuel System (Dfi) 3-71

Fuel system (dfi) 3-71 oxygen sensor - not activated (service code 33, equipped models) if the reading is out of the standard (with plugs: 0.8 v or more, without plugs: 0.24 v or less), remove the ecu and check the wiring for continuity between main harness connectors. Special tool - hand tester: 57...

Page 175: Fuel System (Dfi) 3-73

Fuel system (dfi) 3-73 return spring (service code 49) return spring removal notice do not remove return spring in the gear case [a] since it has been set with precision at the factory. Return spring inspection • turn the ignition switch off. • remove right air cleaner housing (see right air cleaner...

Page 177: Fuel System (Dfi) 3-75

Fuel system (dfi) 3-75 ignition coils #1, #2 (service code 51, 52) ignition coil circuit 1. Ecu 2. Ignition coil #2 (rear cylinder) 3. Ignition coil #1 (front cylinder) 4. Engine stop switch 5. Ignition switch 6. Main fuse 30 a 7. Ignition fuse 10 a 8. Battery 9. Engine ground 10. Frame ground 3.

Page 179: Fuel System (Dfi) 3-77

Fuel system (dfi) 3-77 etv acutuator (service code 58) etv actuator removal notice do not remove etv actuator in the gear case [a] since it has been set with precision at the factory. Etv actuator input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. •...

Page 181: Fuel System (Dfi) 3-79

Fuel system (dfi) 3-79 air switching valve (service code 64) air switching valve removal/installation • refer to the air switching valve removal/installation in the engine top end chapter. Air switching valve inspection • refer to the air switching valve unit test in the electrical system chapter. I...

Page 183: Fuel System (Dfi) 3-81

Fuel system (dfi) 3-81 oxygen sensor heater (service code 67, equipped models) oxygen sensor heater power source voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • disconnect the oxygen sensor lead connector and con- nect the measuring adapter [a] betwe...

Page 185: Fuel System (Dfi) 3-83

Fuel system (dfi) 3-83 battery voltage (service code 97) battery voltage inspection • refer to the charging condition inspection in the electri- cal system chapter for battery voltage inspection. If the battery voltage is good condition, replace the ecu (see ecu removal/installation). Battery monito...

Page 187: Fuel System (Dfi) 3-85

Fuel system (dfi) 3-85 warning indicator light (led) light (led) inspection ○ the warning indicator light (led) [a] is used for the fi in- dicator, etv (electronic throttle valve) indicator, oil pres- sure warning indicator and battery warning indicator. ○ in this model, the warning indicator light ...

Page 189: Fuel System (Dfi) 3-87

Fuel system (dfi) 3-87 ecu ecu installation • install: ecu (in rubber protector) ecu connectors • fit the hooks [a] of the bracket [b] into the recesses [c] of the battery case. • install the removed parts. Note ○ when the ecu was replaced with a new one, do not remove the battery, fuse or ecu for 6...

Page 191: Fuel System (Dfi) 3-89

Fuel system (dfi) 3-89 ecu ecu power source circuit 1. Ignition switch 2. Ignition fuse 10 a 3. Ecu fuse 10 a 4. Main fuse 30 a 5. Battery 6. Engine ground 7. Frame ground 3 8. Frame ground 7 9. Ecu.

Page 193: Fuel System (Dfi) 3-91

Fuel system (dfi) 3-91 fuel line fuel pressure inspection note ○ be sure the battery is fully charged. • remove: fuel hose (see fuel hose replacement in the periodic maintenance chapter) ○ be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of the thr...

Page 195: Fuel System (Dfi) 3-93

Fuel system (dfi) 3-93 fuel line • connect the prepared fuel hose [a] to the fuel outlet pipe. • secure the fuel hose with a clamp. • insert the fuel hose into the measuring cylinder [b]. Warning wipe off spilled out fuel immediately. Be sure to hold the measuring cylinder vertical. • close the fuel...

Page 197: Fuel System (Dfi) 3-95

Fuel system (dfi) 3-95 fuel pump fuel pump installation • remove dirt or dust from the fuel pump [a] by lightly ap- plying compressed air. • replace the fuel pump gasket with a new one. • check that the fuel pump terminal [a] and band [b] are in place. 200 ±10 mm (7.87 ±0.39 in.) [c] connector [d] f...

Page 199: Fuel System (Dfi) 3-97

Fuel system (dfi) 3-97 fuel pump fuel filter cleaning ○ the fuel filter [a] is built into the pump and cannot be cleaned or checked. If the fuel filter is suspected of clogging or being damaged, replace it with the fuel pump as a set. Fuel pump circuit 1. Ecu 2. Engine stop switch 3. Ignition switch...

Page 201: Fuel System (Dfi) 3-99

Fuel system (dfi) 3-99 fuel injectors fuel injector installation • before installing the fuel injector, blow away dirt or dust from the delivery joint by applying compressed air. • replace the o-rings [a] of each fuel injector with new ones. • apply engine oil to the new o-rings, insert them to the ...

Page 203: Fuel System (Dfi) 3-101

Fuel system (dfi) 3-101 fuel injectors • turn the ignition switch off. If the reading is in the specification, but the injector does not operate, replace the ecu (see ecu removal/instal- lation). If the reading is out of the specification, check the input voltage (see fuel injector input voltage ins...

Page 205: Fuel System (Dfi) 3-103

Fuel system (dfi) 3-103 fuel injectors fuel injector circuit 1. Ecu 2. Engine stop switch 3. Fuel injector #2 4. Fuel injector #1 5. Ignition switch 6. Ignition fuse 10 a 7. Ecu fuse 10 a 8. Main fuse 30 a 9. Battery 10. Engine ground 11. Relay box 12. Fuel pump relay 13. Frame ground 3.

Page 207: Fuel System (Dfi) 3-105

Fuel system (dfi) 3-105 throttle grip and cables if the stopper of the pulley does not touch, adjust the throttle grip free play with the accelerator cable adjuster [a] and then use the decelerator cable adjuster [b] (see throttle control system inspection in the periodic main- tenance chapter). • c...

Page 209: Fuel System (Dfi) 3-107

Fuel system (dfi) 3-107 throttle body assy • remove: vacuum hose [a] electronic cruise control cancel switch (throttle) lead connector [b] • remove: throttle position sensor connector [a] accelerator position sensor connector [b] throttle body assy bolts [c] throttle body assy [d] (from intake manif...

Page 211: Fuel System (Dfi) 3-109

Fuel system (dfi) 3-109 throttle body assy • install: throttle body assy [a] throttle body assy bolt [b], 75 mm (3.0 in.) throttle body assy bolts [c], 60 mm (2.4 in.) • tighten: torque - throttle body assy bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install: electronic cruise control cancel switch (thro...

Page 213: Fuel System (Dfi) 3-111

Fuel system (dfi) 3-111 intake manifold intake manifold removal • remove: throttle body assy (see throttle body assy removal) fuel injectors (fuel injector removal) intake manifold bolts [a] intake manifold [b] intake manifold installation • wipe any carbon off the bores [a] around the intake man- i...

Page 215: Fuel System (Dfi) 3-113

Fuel system (dfi) 3-113 air cleaner • remove: breather hose [a] left air cleaner housing installation • when installing the damper [a] and collar [b], install them as shown. Air cleaner housing [c] engine side [d] big side [e] • insert the breather hose [a] into the grommet [b] as shown. ○ reach the...

Page 217: Fuel System (Dfi) 3-115

Fuel system (dfi) 3-115 air cleaner • install: right air cleaner housing washers (vn1700a9f/b9f models) air cleaner housing bolts [a] • apply a non-permanent locking agent to the right air cleaner housing center bolts [b]. • tighten: torque - right air cleaner housing center bolts: 9.8 n·m (1.0 kgf·...

Page 219: Fuel System (Dfi) 3-117

Fuel system (dfi) 3-117 fuel tank • remove: fuel tank bolts [a] bracket [b] • disconnect: fuel pump lead connector [a] • be sure to place a piece of cloth [a] around the fuel hose joint. • insert a thin blade screwdriver [b] into the slit [c] on the joint lock [d]. • turn [a] the driver to disconnec...

Page 221: Fuel System (Dfi) 3-119

Fuel system (dfi) 3-119 fuel tank fuel tank installation • note the above warning (see fuel tank removal). • run the hoses correctly (see cable, wire, and hose rout- ing section in the appendix chapter). • check that the dampers [a] are in place on the fuel tank. If the dampers are damaged or deteri...

Page 223: Fuel System (Dfi) 3-121

Fuel system (dfi) 3-121 evaporative emission control system (cal and sea models) the evaporative emission control system routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough...

Page 225: Fuel System (Dfi) 3-123

Fuel system (dfi) 3-123 evaporative emission control system (cal and sea models) 1. Fuel tank 2. Red hose (return) 3. Blue hose (breather) 4. Band (for separator) 5. Separator 6. Throttle body assy 7. White hoses (vacuum) 8. Green hoses (purge) 9. Blue hose (breather) 10. Band (for canister) 11. Can...

Page 228: 4-2 Cooling System

4-2 cooling system exploded view.

Page 230: 4-4 Cooling System

4-4 cooling system coolant flow chart.

Page 232: 4-6 Cooling System

4-6 cooling system specifications item standard 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 poi...

Page 234: 4-8 Cooling System

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

Page 236: 4-10 Cooling System

4-10 cooling system water pump water pump removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: alternator cover (see alternator cover removal in the electrical system chapter) impeller bolt [a] and washer impeller [b] note ○ the impeller bolt has left-hand ...

Page 238: 4-12 Cooling System

4-12 cooling system water pump • replace the oil seal and ball bearing with new ones. • apply grease to the oil seal lips. • press the oil seal [a] into the hole from the outside of the left crankcase with the bearing driver set so that the spring side of the seal lips is toward the inside of the cr...

Page 240: 4-14 Cooling System

4-14 cooling system radiator • remove: radiator fan bolts [a] radiator fan [b] radiator installation • installation is the reverse of removal, note the following. ○ run the radiator fan lead [a] as shown. Radiator screen bracket [b] good route [c] • tighten: torque - radiator fan bolts: 8.3 n·m (0.8...

Page 242: 4-16 Cooling System

4-16 cooling system thermostat thermostat removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) water hoses [a] bracket bolts [b] water temperature sensor connector [c] • remove the water hos...

Page 244: 4-18 Cooling System

4-18 cooling system hoses and pipes water separator cover removal • drain the coolant (see coolant change in the periodic maintenance chapter) • remove: water separator outer cover bolts [a] water separator outer cover [b] • remove: water pipe bolts [a] upper water pipes [b] • remove: water pipe bol...

Page 246: 4-20 Cooling System

4-20 cooling system hoses and pipes hose inspection • whenever the radiator or radiator hoses are removed or in accordance with the periodic maintenance chart, check the radiator or radiator hoses and their connections. Re- fer to the radiator hose inspection (coolant leak, dam- age, installation co...

Page 249: Engine Top End 5-1

Engine top end 5-1 5 engine top end table of contents exploded view................................... 5-2 exhaust system identification ........... 5-6 specifications .................................... 5-8 special tools and sealant ................. 5-10 clean air system.............................

Page 251: Engine Top End 5-3

Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 breather check valve cover bolts 9.8 1.0 87 in·lb cylinder head nuts (m12) (first) 39 4.0 29 cylinder head nuts (m12 new nuts) (final) 70 7.1 52 2 cylinder head nuts (m12 used nuts) (final) 77 7.8 57 mo, s cylinder head n...

Page 253: Engine Top End 5-5

Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 camshaft chain tensioner bolts 12 1.2 106in·lb l 2 camshaft sprocket bolts 15 1.5 11 l 3 exhaust pipe holder nuts 17 1.7 12 4 muffler body mounting bolt 25 2.5 18 5 rear camshaft chain guide retainer bolts 9.8 1.0 87 in·l...

Page 255: Engine Top End 5-7

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

Page 257: Engine Top End 5-9

Engine top end 5-9 specifications item standard service limit valve seating surface: width: exhaust 0.8 ∼ 1.2 mm (0.031 ∼ 0.047 in.) – – – intake 0.8 ∼ 1.2 mm (0.031 ∼ 0.047 in.) – – – outside diameter: exhaust 34.9 ∼ 35.1 mm (1.374 ∼ 1.382 in.) – – – intake 38.9 ∼ 39.1 mm (1.531 ∼ 1.539 in.) – – – ...

Page 259: Engine Top End 5-11

Engine top end 5-11 special tools and sealant valve seat cutter, 45° - 40: 57001-1496 valve seat cutter, 55° - 38.5: 57001-1497 valve seat cutter, 32°- 44: 57001-1515 valve guide driver: 57001-1564 piston pin puller: 57001-1568 valve seat cutter holder, 6: 57001-1576 valve guide reamer, 6: 57001-159...

Page 261: Engine Top End 5-13

Engine top end 5-13 clean air system air switching valve removal notice never drop the air switching valve, especially on a hard surface. Such a shock to the air switching valve can damaged it. • remove the ignition coils (see ignition coil removal in the electrical system chapter). • disconnect the...

Page 263: Engine Top End 5-15

Engine top end 5-15 cylinder head covers cylinder head cover removal front cylinder head cover • remove: air switching valve (see air switching valve removal) cylinder head outer cover bolts [a] with collars cylinder head outer covers [b] • remove: cylinder head inner cover bolts [a] with gaskets cy...

Page 265: Engine Top End 5-17

Engine top end 5-17 cylinder head covers rear cylinder head cover • install the collars [a] on the seating surfaces (shaded por- tions) [b] of the cylinder head outer covers [c] as shown. • install the plate [d] so that the tabs [e] fit onto the seating surface of the cylinder head outer cover as sh...

Page 267: Engine Top End 5-19

Engine top end 5-19 rocker cases • remove the camshaft chain tensioner (see camshaft chain tensioner removal). • loosen the m6 and m8 rocker case bolts as shown se- quence [1 ∼ 6] in the figure, and remove them. • lift the rocker case [a], and remove the front camshaft chain guide [b] from the pin o...

Page 269: Engine Top End 5-21

Engine top end 5-21 rocker cases • apply molybdenum disulfide oil solution to all cam parts and journals. • install the plug hole gasket [a] so that the cutout portions [b] fit onto the ribs [c] of the cylinder head. • install the dowel pins [a]. • insert the pin [a] of the rocker case to the hole o...

Page 271: Engine Top End 5-23

Engine top end 5-23 rocker shafts, rocker arms rocker shaft and rocker arm removal • remove: rocker case (see rocker case removal) rocker shafts [a] rocker arms [b] rocker shaft and rocker arm installation • apply molybdenum disulfide oil solution to the rocker shafts. ○ the rocker shafts are identi...

Page 273: Engine Top End 5-25

Engine top end 5-25 hla (hydraulic lash adjuster) hla removal • remove the rocker arm (see rocker shaft and rocker arm removal). • pull the hla (hydraulic lash adjuster) [a] out of the rocker arm with fingers. Notice be careful not to damage or deform an hla by tap- ping it during removal or install...

Page 275: Engine Top End 5-27

Engine top end 5-27 camshaft chain tensioners camshaft chain tensioner installation if the pin was removed, install it as follows. ○ push the push rod [a] into the interior of tensioner body [b] while pushing the stopper [c]. Notice be careful the oil remaining in the tensioner body dashes out. ○ in...

Page 277: Engine Top End 5-29

Engine top end 5-29 camshafts, camshaft chains, camshaft sprockets if the rear camshaft chain guide [a] was removed, be sure to install it first. Torque - rear camshaft chain guide retainer bolt : 9.8 n·m (1.0 kgf·m, 87 in·lb) left side view [b] ○ pull the tension side (intake side) [c] of the chain...

Page 279: Engine Top End 5-31

Engine top end 5-31 camshafts, camshaft chains, camshaft sprockets cam wear • remove the camshaft (see camshaft removal). • measure the height [a] of each cam with a micrometer. If the cams are worn down past the service limit, replace the camshaft. Cam height standard: exhaust 34.422 ∼ 34.536 mm (1...

Page 281: Engine Top End 5-33

Engine top end 5-33 kacr (kawasaki automatic compression release) kacr inspection the kacr (kawasaki automatic compression release) momentarily opens the exhaust valves on the compression stroke at very low speeds. In this model, the kacr is oper- ated at 400 ∼ 500 r/min (rpm). This allows some of t...

Page 283: Engine Top End 5-35

Engine top end 5-35 kacr (kawasaki automatic compression release) • install the push rod [a], and then insert the shaft [b] to the camshaft. • pull out the wire [c] from the hole of the push rod. • for front kacr, set the shaft so that the “f” mark [a] is aligned with the “ ” mark [b] of the camshaf...

Page 285: Engine Top End 5-37

Engine top end 5-37 cylinder heads cylinder compression measurement note ○ use the battery which is fully charged. • warm up the engine thoroughly. • stop the engine. • remove spark plugs (see spark plug replacement in the periodic maintenance chapter). • attach the compression gauge [a] and adapter...

Page 287: Engine Top End 5-39

Engine top end 5-39 cylinder heads note ○ the front cylinder head gasket has a “f” mark [a] and the rear cylinder head gasket has a “r” mark [b]. Be careful not to mix up these gaskets. • replace the cylinder head gasket with a new one, and install it. • install the dowel pins [a]. Note ○ the front ...

Page 289: Engine Top End 5-41

Engine top end 5-41 cylinder heads cylinder head warp • clean the cylinder head. • lay a straightedge across the lower surface of the cylinder head at several positions. • use a thickness gauge [a] to measure the space between the straightedge [b] and the head. Cylinder head warp standard: – – – ser...

Page 291: Engine Top End 5-43

Engine top end 5-43 valves valve guide installation • apply oil to the valve guide outer surface before installa- tion. • heat the area around the valve guide hole to about 120 ∼ 150°c (248 ∼ 302°f). Notice do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylind...

Page 293: Engine Top End 5-45

Engine top end 5-45 valves seat cutter operation care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. 3. Do not fai...

Page 295: Engine Top End 5-47

Engine top end 5-47 valves if the seat width is too wide, make the 60° or 55° [a] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. • grind the seat at a 60° or 55° angle until the seat width is within the specified range. ○ to make...

Page 297: Engine Top End 5-49

Engine top end 5-49 cylinders, pistons cylinder removal note ○ the front and rear cylinder removal are same proce- dures. • remove: cylinder head (see cylinder head removal) upper oil pipe [a] cylinder [b] cylinder installation note ○ if a new cylinder is used, use new piston ring. ○ the front cylin...

Page 299: Engine Top End 5-51

Engine top end 5-51 cylinders, pistons • carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [a] to remove it. • remove the 3-piece oil ring with your thumbs in the same manner. Piston installation note ○ if a new piston is used, use new piston ring. ...

Page 301: Engine Top End 5-53

Engine top end 5-53 cylinders, pistons piston ring, piston ring groove wear • check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. • with the piston rings in their grooves, make...

Page 303: Engine Top End 5-55

Engine top end 5-55 mufflers warning the muffler can become extremely hot during nor- mal operation and cause severe burns. Do not re- move the muffler while it is hot. Muffler body removal left muffler body • loosen the muffler body clamp bolt [a]. • remove: left saddlebag (see saddlebag removal in...

Page 305: Engine Top End 5-57

Engine top end 5-57 mufflers ○ for equipped with the oxygen sensor, run the oxygen sen- sor lead correctly (see cable, wire, and hose routing section in the appendix chapter). Notice do not pull strongly, twist, or bend the oxygen sen- sor lead. This may cause the wiring open. • thoroughly warm up t...

Page 307: Engine Top End 5-59

Engine top end 5-59 mufflers dummy page.

Page 309: Engine Top End 5-61

Engine top end 5-61 mufflers • install the left and right muffler bodies (see muffler body installation). • thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts and nuts..

Page 311: Clutch 6-1

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

Page 313: Clutch 6-3

Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 cam damper bolt 69 7.0 51 2 clutch cover bolts 12 1.2 106 in·lb 3 clutch hose banjo bolt 25 2.5 18 4 clutch hub nut 185 19.0 136 mo, r 5 clutch lever pivot bolt 1.0 0.10 8.8 in·lb si 6 clutch lever pivot bolt locknut 5.9 0.60 52 ...

Page 315: Clutch 6-5

Clutch 6-5 special tools bearing driver set: 57001-1129 clutch holder: 57001-1243 grip: 57001-1591 rotor holder: 57001-1726.

Page 317: Clutch 6-7

Clutch 6-7 clutch fluid clutch hose inspection • refer to the clutch hose and pipe damage and instal- lation condition inspection in the periodic maintenance chapter..

Page 319: Clutch 6-9

Clutch 6-9 clutch master cylinder clutch master cylinder inspection • disassemble the clutch master cylinder (see clutch mas- ter cylinder rubber parts replacement in the periodic maintenance chapter). Notice do not remove the secondary cup from the piston since removal will damage it. • check that ...

Page 321: Clutch 6-11

Clutch 6-11 clutch slave cylinder • apply a non-permanent locking agent to the threads of the slave cylinder bolts [a]. • hand-tighten all the clutch slave cylinder bolts evenly. • remove the band from the clutch lever and release the clutch lever. • tighten the slave cylinder bolts. Torque - clutch...

Page 323: Clutch 6-13

Clutch 6-13 clutch clutch outer covers installation • install the front and rear outer clutch covers. • when installing the rear outer clutch cover [a], set the round mark [b] downward. • apply a non-permanent locking agent to the threads of the front and rear outer clutch cover bolts, and tighten t...

Page 325: Clutch 6-15

Clutch 6-15 clutch • pull out the following parts as a set. Primary chain [a] clutch housing [b] starter clutch gear [c] damper cam sprocket [d] torque limiter [e] • remove the collar [a] and spacer [b] from the input shaft. • remove the thrust bearing [a] and spacer [b] from the crankshaft. • remov...

Page 327: Clutch 6-17

Clutch 6-17 clutch • insert the needle bearing [a] to the input shaft while turn- ing counterclockwise [b] the clutch housing. • install the cam damper [a] while fitting the alignment notch [b] of the splines onto the alignment tooth [c]. • install: spring [a] spring retainer [b] • tighten the cam d...

Page 329: Clutch 6-19

Clutch 6-19 clutch clutch plate, wear, damage inspection • visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. If any plates show signs of damage, replace the plates. • measure the thickness of the friction plates [a] at several points. I...

Page 331: Engine Lubrication System

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

Page 333

Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 breather check valve cover bolts 9.8 1.0 87 in·lb 2 engine oil drain bolts 20 2.0 14 3 inside oil pipe retainer bolt 9.8 1.0 87 in·lb l 4 oil filter 18 1.8 13 5 oil filter pipe 25 2.5 18 l 6 oil passage plug (p...

Page 335

Engine lubrication system 7-5 engine oil flow chart 1. Camshaft chain tensioner 2. Balancer chain tensioner 3. Alternator rotor bolt (for cooling stator coil) 4. Crankshaft 5. Piston oil jet 6. Drive shaft 7. Output shaft 8. Oil screen for scavenge pump 9. Oil screen for feed pump 10. Oil in transmi...

Page 337

Engine lubrication system 7-7 special tools and sealant outside circlip pliers: 57001-144 oil pressure gauge, 10 kgf/cm²: 57001-164 gear holder: 57001-1602 oil pressure gauge adapter, pt1/8: 57001-1731 liquid gasket, tb1211: 56019-120

Page 339

Engine lubrication system 7-9 engine oil and oil filter notice racing the engine before the oil reaches every part can cause engine seizure. If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not func- tion properly, the warning indicator light (led) [a] ...

Page 341

Engine lubrication system 7-11 oil screen oil screen installation note ○ clean the oil screen thoroughly whenever it is removed for any reason. ○ while cleaning the screen, check for any metal particles that might indicate internal engine damage. • clean the oil screen with a high-flash point solven...

Page 343

Engine lubrication system 7-13 oil pump oil pump gear removal • remove: clutch (see clutch removal in the clutch chapter) circlip [a] oil pump gear [b] special tool - outside circlip pliers: 57001-144 oil pump gear installation • check that the pin [a] is in place. • fit the pin into the slot [b] of...

Page 345

Engine lubrication system 7-15 oil pump • remove: pin [a] inner rotor [b] for feed pump outer rotor [c] for feed pump • remove: pin [a] inner rotor [b] for scavenge pump oil pump shaft [c] oil pump installation • apply molybdenum disulfide oil solution to the portion [a] of the oil pump shaft as sho...

Page 347

Engine lubrication system 7-17 oil pressure measurement oil pressure measurement • remove the oil passage plug (pt 1/8) [a] from the bottom of the right crankcase. • attach the adapter [a] and gauge [b] to the plug hole. Special tools - oil pressure gauge, 10 kgf/cm²: 57001-164 oil pressure gauge ad...

Page 349

Engine lubrication system 7-19 oil pipes oil pipe removal outside oil pipe • remove: clutch (see clutch removal in the clutch chapter) outside oil pipe bolt [a] torque limiter bearing retainer bolts [b] torque limiter bearing retainer [c] washer [d] • remove: outside oil pipe bolts [a] outside oil p...

Page 351

Engine lubrication system 7-21 blowby gas system blowby gas system inspection • remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • be certain that the breather hose [a] is routed without being flattened or kinked, and is connected correctly to left air cleaner housing. ...

Page 353: Engine Removal/installation

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

Page 355

Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 cross pipe bolts 34 3.5 25 2 downtube bolts 59 6.0 44 3 engine mounting adjusting bolt 9.8 1.0 87 in·lb s 4 engine mounting adjusting bolt locknut 49 5.0 36 s 5 engine mounting bolt (m10) 44 4.5 32 6 engine m...

Page 357

Engine removal/installation 8-5 engine removal/installation engine removal • raise the rear wheel off the ground, using the jack. Special tool - jack: 57001-1238 • squeeze the brake lever slowly and hold it with a band [a]. Warning motorcycle may fall over unexpectedly resulting in an accident or in...

Page 359

Engine removal/installation 8-7 engine removal/installation • remove the sidestand switch lead connector [a] from the clutch pipe bracket [b]. • remove the starter motor cable [a]. • open the clamp [b], and free the leads. • disconnect: speed sensor connector [c] gear position sensor lead connector ...

Page 361

Engine removal/installation 8-9 engine removal/installation • remove the downtube (see downtube removal in the frame chapter). • remove the drive belt [a] from the output shaft [b]. • remove the engine [a] from the motorcycle right side. Engine installation • support the engine with a suitable stand...

Page 363

Engine removal/installation 8-11 engine removal/installation • when installing the upper engine mounting bracket [a], fit the lower end [b] of the bracket to the cylinder head [c]. • run the leads, cables and hoses correctly (see cable, wire and hose routing section in the appendix chapter). • insta...

Page 366: 9-2 Crankshaft/transmission

9-2 crankshaft/transmission exploded view.

Page 368: 9-4 Crankshaft/transmission

9-4 crankshaft/transmission exploded view.

Page 370: 9-6 Crankshaft/transmission

9-6 crankshaft/transmission specifications item standard service limit crankcase, crankshaft and connecting rods connecting rod bend – – – tir 0.2/100 mm (0.008/3.94 in.) connecting rod twist – – – tir 0.2/100 mm (0.008/3.94 in.) connecting rod big end side 0.08 ∼ 0.30 mm (0.003 ∼ 0.012 in.) 0.5 mm ...

Page 372: 9-8 Crankshaft/transmission

9-8 crankshaft/transmission special tools and sealants outside circlip pliers: 57001-144 bearing driver set: 57001-1129 grip: 57001-1591 rotor holder: 57001-1726 liquid gasket, tb1211f: 92104-0004 liquid gasket, tb1216b: 92104-1064.

Page 374

9-10 crankshaft/transmission crankcase • remove the left crankcase bolts (11) [a]. • remove the right crankcase bolts, following the specified sequence. ○ first, loosen the m6 bolts (9) [a]. ○ next, loosen the m10 bolts (3) [b]. • put the engine so that the right crankcase half [a] faces upside..

Page 376

9-12 crankshaft/transmission crankcase if the piston oil jet [a] was removed, install it as follows. ○ replace the o-ring [b] with a new one. ○ insert the piston oil jet [a] into the hole on the crankcase [b] as shown. ○ apply a non-permanent locking agent to the threads of the piston oil jet bolt [...

Page 378

9-14 crankshaft/transmission crankcase note ○ be sure to tighten the right crankcase bolts first. • tighten the right crankcase bolts using the following steps. ○ first, tighten the m10 bolts (3) [a]. Torque - crankcase bolts (m10) : 39 n·m (4.0 kgf·m, 29 ft·lb) ○ next, tighten the m6 bolts (9) [b]....

Page 380

9-16 crankshaft/transmission crankshaft and connecting rods crankshaft removal • split the crankcase (see crankcase splitting). • turn the balancer shafts [a] to clear the balancers [b] from the crankshaft web [c]. • remove the crankshaft. Crankshaft installation • apply molybdenum disulfide oil sol...

Page 382

9-18 crankshaft/transmission crankshaft and connecting rods • be sure the dowel pins [a] on the big end cap [b] are in position. • install each connecting rod on its original position as fol- lows. ○ left connecting rod [a] is for the rear cylinder and right connecting rod [b] is for the front cylin...

Page 384

9-20 crankshaft/transmission crankshaft and connecting rods if clearance is within the standard, no bearing replace- ment is required. If clearance is between 0.057 mm (0.0022 in.) and the service limit (0.09 mm, 0.035 in.), replace the bear- ing inserts [a] with inserts painted blue [b]. Check inse...

Page 386

9-22 crankshaft/transmission crankshaft and connecting rods crankshaft main bearing/main journal wear • measure the diameter [a] of the crankshaft main journal. If any journal has worn past the service limit, replace the crankshaft with a new one. Crankshaft main journal diameter standard: 52.986 ∼ ...

Page 388

9-24 crankshaft/transmission balancer balancer mechanism installation • align the line [a] on the following parts with the colored chain links [b] as shown. Balancer chain sprocket [c] front balancer sprocket [d] rear balancer sprocket [e] ○ the front and rear balancer sprockets are identical. • for...

Page 390

9-26 crankshaft/transmission balancer • for vn1700a9f/b9f models, install the upper balancer chain guide [a]. Torque - upper balancer chain guide bolts [b] : 12 n·m (1.2 kgf·m, 106 in·lb) • install the balancer chain tensioner [c] and lower balancer chain guide [d]. Torque - balancer chain tensioner...

Page 392

9-28 crankshaft/transmission starter clutch starter clutch removal • refer to the clutch removal in the clutch chapter. Starter clutch installation • refer to the clutch installation in the clutch chapter. Starter clutch disassembly • remove the clutch housing (see clutch removal in the clutch chapt...

Page 394

9-30 crankshaft/transmission torque limiter torque limiter removal • refer to the clutch removal in the clutch chapter. Notice do not disassemble the torque limiter [a]. The torque limiter will not function if this is done. Torque limiter installation • refer to the clutch installation in the clutch...

Page 396

9-32 crankshaft/transmission transmission transmission shaft assembly • when assembling the transmission shafts, refer to the transmission assembly illustration on ahead too. • apply engine oil to the bushings and shafts. • replace any circlips removed with new ones. • install the circlips [a] so th...

Page 398

9-34 crankshaft/transmission transmission shift drum removal • split the crankcase (see crankcase splitting). • remove: shift forks (see transmission shaft and shift fork re- moval) pin [a] and spring [b] shift drum bearing retainer bolts [c] • pull out the shift drum [d] while aligning the shift dr...

Page 400

9-36 crankshaft/transmission transmission shift fork bending • visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [a] shift fork/gear groove wear • measure the thickn...

Page 402

9-38 crankshaft/transmission external shift mechanism • after installation, confirm that the shift pedal [a] is posi- tioned as shown. 30 ∼ 40 mm (1.18 ∼ 1.57 in.) [b] about 1°[c] about 240.0 mm (9.45 in.) [d] about 7°[e] if the pedal position is different, adjust it as follows. ○ to adjust the peda...

Page 404

9-40 crankshaft/transmission external shift mechanism • remove the shift shaft assembly [a]. • remove: gear positioning lever nut [a] gear positioning lever [b] pin [c] and spring external shift mechanism installation if the shift shaft return spring pin [a] was removed, install it as follows. ○ app...

Page 406

9-42 crankshaft/transmission external shift mechanism • be sure to install the spacer [a] on the shift shaft [b]. • install the shift shaft assembly [a]. • be sure to install the spacer [b] on the shift shaft. • install the dowel pins [c]. • when the new needle bearing [a] is installed in the exter-...

Page 408

9-44 crankshaft/transmission ball bearing, needle bearing and oil seal bearing and oil seal installation left crankcase • refer to the mechanical seal replacement in the cooling system chapter for mechanical seal, ball bearing and oil seal of the water pump. • before installing the bearing or race, ...

Page 410

9-46 crankshaft/transmission ball bearing, needle bearing and oil seal • check the needle bearings. ○ the rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage. If there is any do...

Page 412: 10-2 Wheels/tires

10-2 wheels/tires exploded view.

Page 414: 10-4 Wheels/tires

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

Page 416: 10-6 Wheels/tires

10-6 wheels/tires wheels (rims) front wheel removal • remove: front wheel rotation sensor [a] (abs equipped mod- els) front caliper mounting bolts [b] (both sides) front caliper (with the hose installed) [c] (both sides) • for models equipped with an abs, remove the sensor bracket bolt [a]. • loosen...

Page 418: 10-8 Wheels/tires

10-8 wheels/tires wheels (rims) • for models equipped with an abs, tighten the sensor bracket bolt [a]. • install: front wheel rotation sensor [b] (abs equipped mod- els) front calipers [c] (see caliper installation in the brakes chapter) • check the front brake effectiveness. Warning after servicin...

Page 420: 10-10 Wheels/tires

10-10 wheels/tires wheels (rims) rear wheel installation • apply high-temperature grease to the grease seal lips on both sides of the hub. • fit the collars [a] on both sides of the hub. ○ fit the flange collar onto the right side. • turn the stepped side [a] of the belt adjusters outward. • install...

Page 422: 10-12 Wheels/tires

10-12 wheels/tires wheels (rims) axle inspection • remove the front and rear axles (see front/rear wheel removal). • visually inspect the front and rear axles for damages. If the axle is damaged or bent, replace it. • place the axle in v blocks that are 100 mm (3.94 in.) [a] apart, and set a dial ga...

Page 424: 10-14 Wheels/tires

10-14 wheels/tires tires air pressure inspection/adjustment • refer to the air pressure inspection in the periodic main- tenance chapter. Tire inspection • refer to the wheel/tire damage inspection in the peri- odic maintenance chapter. Tire removal • remove: wheel (see front/rear wheel removal) val...

Page 426: 10-16 Wheels/tires

10-16 wheels/tires tires • position the tire on the rim so that the valve [a] align with 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 suitable commercially available tire changer. • lubrica...

Page 428: 10-18 Wheels/tires

10-18 wheels/tires hub bearing ○ 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 grease to the grease...

Page 430: 11-2 Final Drive

11-2 final drive exploded view.

Page 432: 11-4 Final Drive

11-4 final drive specifications item standard drive belt make gates, 139t belt deflection (45 n, 4.6 kgf, 10 lb force) 3.0 ∼ 4.5 mm (0.12 ∼ 0.18 in.) (when installing new belt or engine is remounted) 3.0 mm (0.12 in.).

Page 434: 11-6 Final Drive

11-6 final drive drive belt the drive belt must be checked, and adjusted in accor- dance with the periodic maintenance chart for safety and to prevent excessive wear. If the belt becomes badly worn or maladjusted-either too loose or too tight-the belt could jump off the pulley or break. Belt handlin...

Page 436: 11-8 Final Drive

11-8 final drive drive belt drive belt installation • installation is the reverse of removal. Note the following. Note ○ be sure the printed information faces the same direction so the belt rotates in the same direction as originally in- stead. When installing a new belt, install it so the printed i...

Page 438: 11-10 Final Drive

11-10 final drive pulley and coupling • check the installation condition of the pad [a]. ○ stick the pad securely. • install the dowel pins [b] as shown. • install the engine pulley inner cover [a]. • tighten: torque - engine pulley inner cover bolts [b] : 12 n·m (1.2 kgf·m, 106 in·lb) • install: cl...

Page 440: 11-12 Final Drive

11-12 final drive pulley and coupling rear pulley coupling installation • apply grease to the coupling grease seal lips [a]. • apply grease to the rear pulley coupling internal surface [b]. • install the sleeve [c]. • install the coupling dampers [a] so that the projections [b] face to the outside. ...

Page 442: 11-14 Final Drive

11-14 final drive pulley and coupling coupling bearing lubrication note ○ since the coupling bearing is packed with grease and sealed, lubrication is not required. Rubber damper inspection • remove the rear wheel (see rear wheel removal in the wheels/tires chapter). • take off the rear pulley with t...

Page 444: 12-2 Brakes

12-2 brakes k-act abs servicing precautions ................................................................................... 12-37 k-act abs troubleshooting outline ................................................................................ 12-39 inquiries to rider..............................

Page 446: 12-4 Brakes

12-4 brakes exploded view vn1700a model.

Page 448: 12-6 Brakes

12-6 brakes exploded view vn1700a model.

Page 450: 12-8 Brakes

12-8 brakes exploded view vn1700b9f model.

Page 452: 12-10 Brakes

12-10 brakes exploded view vn1700baf model.

Page 454: 12-12 Brakes

12-12 brakes exploded view vn1700b model.

Page 456: 12-14 Brakes

12-14 brakes specifications item standard service limit brake lever, brake pedal brake lever position 8-way adjustable (to suit rider) – – – brake lever free play non-adjustable – – – pedal free play non-adjustable – – – pedal position about 100 mm (3.94 in.) – – – (height from pedal top to footboar...

Page 458: 12-16 Brakes

12-16 brakes brake lever, brake pedal brake lever position adjustment • push the lever forward and turn the adjuster [a]. Brake pedal position inspection • check that the brake pedal [a] is in the correct position. Pedal position standard: about 100 mm (3.94 in.) [b] (height from pedal top to footbo...

Page 460: 12-18 Brakes

12-18 brakes calipers front caliper removal • loosen the banjo bolt [a] at the brake hose lower end, and tighten it loosely. • unscrew the caliper mounting bolts [b], and detach the caliper [c] from the disc. Notice do not loosen the caliper assembly bolts [d]. Take out only the caliper mounting bol...

Page 462: 12-20 Brakes

12-20 brakes calipers caliper fluid seal damage inspection the fluid seal (piston seal) [a] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- p...

Page 464: 12-22 Brakes

12-22 brakes brake pads front brake pad removal • loosen the pad pin [a]. • unscrew the bolts [b]. • remove the caliper with the hose installed. • remove: pad spring bolts [a] pad spring [b] • remove: pad pin [a] brake pads [b] front brake pad installation • push the caliper pistons in by hand as fa...

Page 466: 12-24 Brakes

12-24 brakes master cylinder front master cylinder removal • remove the banjo bolt [a] to disconnect the brake hose from the master cylinder (see brake hose replacement in the periodic maintenance chapter). • disconnect: front brake light switch connectors [a] electronic cruise control cancel switch...

Page 468: 12-26 Brakes

12-26 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 the cotter pin ends. • replace the washers that are on each side of the hose fitting with new ones. • tighten: torque - re...

Page 470: 12-28 Brakes

12-28 brakes brake discs brake disc removal • remove the wheels (see front/rear wheel removal in the wheels/tires chapter). • unscrew the mounting bolts [a], and take off the disc. Brake disc installation • install the brake disc [a] on the wheel so that the marked side [b] faces out. • apply a non-...

Page 472: 12-30 Brakes

12-30 brakes brake fluid • remove the rubber cap from the bleed valve [a] on the caliper [b]. • attach a clear plastic hose [c] to the bleed valve, and run the other end of the hose into a container. • bleed the brake line and the caliper. ○ repeat this operation until no more air can be seen com- i...

Page 474: 12-32 Brakes

12-32 brakes brake hose brake hose and pipe removal/installation • refer to the brake hose and pipe replacement in the periodic maintenance chapter. Brake hose and pipe inspection • refer to the brake hose and pipe damage and instal- lation condition inspection in the periodic maintenance chapter..

Page 476: 12-34 Brakes

12-34 brakes k-act abs (equipped models) k-act abs system wiring diagram (vn1700b9f model) 1. Ignition switch 2. Right handlebar switch housing 3. Front brake switch 4. Rear brake switch 5. K-act abs hydraulic unit 6. K-act abs self-diagnosis terminal 7. K-act abs kawasaki diagnostic system connecto...

Page 478: 12-36 Brakes

12-36 brakes k-act abs (equipped models) terminal names 1. Power supply to k-act abs motor relay 2. K-act abs self-diagnosis terminal 3. Unused 4. Unused 5. Unused 6. Unused 7. K-act abs indicator light (led) 8. Output fluid pressure sensor (rear brake) signal (vn1700b9f model) 9. Power supply to fl...

Page 480: 12-38 Brakes

12-38 brakes k-act abs (equipped models) warning air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If any of the brake line fittings, including the k-act abs hydraulic unit joint nuts, or the bleed valve is opened at any time, the air must be...

Page 482: 12-40 Brakes

12-40 brakes k-act abs (equipped models) even when the k-act abs is operating normally, the k-act abs indicator light (led) may light up under the conditions listed below. Turn the ignition switch off to stop the indicator light. If the motorcycle runs without erasing the service code, the light may...

Page 484: 12-42 Brakes

12-42 brakes k-act abs (equipped models) inquiries to rider ○ each rider reacts to problems in different ways, so it is important to confirm what kind of condition the rider is dissatisfied with. ○ try to find out exactly what problem occurs under exactly what conditions by asking the rider; know- i...

Page 486: 12-44 Brakes

12-44 brakes k-act abs (equipped models) pre-diagnosis inspection 2 self-diagnosis outline when the indicator light has blinked or come on, the k-act abs hydraulic unit memorizes and stores the service code (32 codes including “normal code”) for the service person to troubleshoot easily. The service...

Page 488: 12-46 Brakes

12-46 brakes k-act abs (equipped models) self-diagnosis flow chart.

Page 490: 12-48 Brakes

12-48 brakes k-act abs (equipped models) service code table service code k-act abs indicator light (led) problems light state 12 start code (not fault) after starts, turn off 13 rear intake solenoid valve trouble (open, temperature abnormal) on 14 rear outlet solenoid valve trouble (open, temperatur...

Page 492: 12-50 Brakes

12-50 brakes k-act abs (equipped models) • do the 2nd step test. ○ check for continuity between the orange/black lead ter- minal of the main harness side connector [a] and ground. Special tool - hand tester: 57001-1394 if there is the continuity in the lead, replace or repair the main harness. If th...

Page 494: 12-52 Brakes

12-52 brakes k-act abs (equipped models) • do the 6th step test. ○ recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the k-act abs indicator light (led) [a] lit, faulty k-act abs solenoid valve relay in the k-...

Page 496: 12-54 Brakes

12-54 brakes k-act abs (equipped models) • do the 5th step test. ○ check for continuity between the positive cable [a] of the battery and red/white lead terminal of the main harness side connector [b]. If there is the continuity in the lead, proceed the 4th step. If there is not the continuity in th...

Page 498: 12-56 Brakes

12-56 brakes k-act abs (equipped models) rear wheel rotation sensor signal abnormal (service code 44) • do the 1st step test. ○ measure the air gap between the rear wheel rotation sen- sor and sensor rotor. Thickness gauge [a] air gap standard: 1.0 mm (0.039 in.) if the measurement is over standard,...

Page 500: 12-58 Brakes

12-58 brakes k-act abs (equipped models) • do the 3rd step test. ○ inspect the following parts. Battery (see charging condition inspection in the elec- trical system chapter) ignition switch (see switch inspection in the electrical system chapter) main harness (see wiring inspection in the electrica...

Page 502: 12-60 Brakes

12-60 brakes k-act abs (equipped models) input fluid pressure sensor (front brake) wiring inspection (service code 81) vn1700b9f • do the 1st step test. ○ disconnect the fluid pressure sensor connector and con- nect the harness adapter [a] between these connectors as shown. Main harness [b] fluid pr...

Page 504: 12-62 Brakes

12-62 brakes k-act abs (equipped models) • do the 5th step test. ○ disconnect the k-act abs hydraulic unit connector and fluid pressure sensor connector. ○ check for continuity between the green lead terminal of the main harness side connector [a] and green lead ter- minal of the main harness side c...

Page 506: 12-64 Brakes

12-64 brakes k-act abs (equipped models) • do the 3rd step test. ○ disconnect the fluid pressure sensor connector. ○ connect the hand tester [a] to the fluid pressure sensor connector [b]. Special tool - hand tester: 57001-1394 ○ measure the fluid pressure sensor resistance. Fluid pressure sensor re...

Page 508: 12-66 Brakes

12-66 brakes k-act abs (equipped models) output fluid pressure sensor (front brake) (internal) offset abnormal (service code 84) vn1700b9f • do the 1st step test. ○ recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service cod...

Page 510: 12-68 Brakes

12-68 brakes k-act abs (equipped models) • do the 4th step test. ○ disconnect the fluid pressure sensor connector and con- nect the harness adapter [a] between these connectors as shown. Main harness [b] fluid pressure sensor [c] special tool - measuring adapter: 57001-1700 ○ connect the digital met...

Page 512: 12-70 Brakes

12-70 brakes k-act abs (equipped models) • do the 2nd step test. ○ disconnect the k-act abs hydraulic unit connector and fluid pressure sensor connector. ○ check for continuity between the white/red lead terminal of the main harness side connector [a] and white/red lead terminal of the main harness ...

Page 514: 12-72 Brakes

12-72 brakes k-act abs (equipped models) • do the 6th step test. ○ recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the k-act abs indicator light (led) [a] lit, faulty input fluid pressure sensor (rear brake)...

Page 516: 12-74 Brakes

12-74 brakes k-act abs (equipped models) • do the 4th step test. ○ disconnect the fluid pressure sensor connector and con- nect the harness adapter [a] between these connectors as shown. Main harness [b] fluid pressure sensor [c] special tool - measuring adapter: 57001-1700 ○ connect the digital met...

Page 518: 12-76 Brakes

12-76 brakes k-act abs (equipped models) • do the 2nd step test. ○ disconnect the k-act abs hydraulic unit connector and fluid pressure sensor connector. ○ check for continuity between the white/red lead terminal of the main harness side connector [a] and white/red lead terminal of the main harness ...

Page 520: 12-78 Brakes

12-78 brakes k-act abs (equipped models) • do the 6th step test. ○ recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the k-act abs indicator light (led) [a] lit, faulty output fluid pressure sensor (rear brake...

Page 522: 12-80 Brakes

12-80 brakes k-act abs (equipped models) • do the 2nd step test. ○ disconnect the k-act abs hydraulic unit connector and fluid pressure sensor connector. ○ check for continuity between the white/red lead terminal of the main harness side connector [a] and white/red lead terminal of the main harness ...

Page 524: 12-82 Brakes

12-82 brakes k-act abs (equipped models) • do the 2nd step test. ○ disconnect the k-act abs hydraulic unit connector and fluid pressure sensor connector. ○ check for continuity between the white/red lead terminal of the main harness side connector [a] and white/red lead terminal of the main harness ...

Page 526: 12-84 Brakes

12-84 brakes k-act abs (equipped models) • do the 6th step test. ○ recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the k-act abs indicator light (led) [a] lit, faulty fluid pressure sensor in the k-act abs h...

Page 528: 12-86 Brakes

12-86 brakes k-act abs (equipped models) • do the 4th step test. ○ disconnect the fluid pressure sensor connector and con- nect the harness adapter [a] between these connectors as shown. Main harness [b] fluid pressure sensor [c] special tool - measuring adapter: 57001-1700 ○ connect the digital met...

Page 530: 12-88 Brakes

12-88 brakes k-act abs (equipped models) k-act abs hydraulic unit removal notice the k-act abs hydraulic unit [a] has been ad- justed and set with precision at the factory. There- fore, it should be handled carefully, never struck sharply with a hammer, or allowed to fall on a hard surface. Be caref...

Page 532: 12-90 Brakes

12-90 brakes k-act abs (equipped models) notice brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • when installing the hoses and pipes, avoid sharp bend- ing, kinking, flatting or twisting, and run the hoses accord- ing to cable, wir...

Page 534: 12-92 Brakes

12-92 brakes k-act abs (equipped models) rear wheel rotation sensor removal notice the wheel rotation sensor should be handled care- fully, never struck sharply with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made. Be careful not to get water or m...

Page 536: 12-94 Brakes

12-94 brakes k-act abs (equipped models) wheel rotation sensor rotor inspection • remove the front/rear wheel rotation sensor rotor (see front/rear wheel rotation sensor rotor removal). • visually inspect the wheel rotation sensor rotor. If the rotor is deformed or damaged (chipped teeth [a]), repla...

Page 539: Suspension 13-1

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

Page 541: Suspension 13-3

Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper front fork clamp bolts 20 2.0 15 2 lower front fork clamp bolts 30 3.0 22 al 3 front fork cover clamp bolts 4.2 0.43 37 in·lb 4 front fork bottom allen bolts 20 2.0 15 l 5 front axle clamp bolts 20 2.0 15 s al: tighten...

Page 543: Suspension 13-5

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 rear shock absorber air valve 5.5 0.56 49 in·lb 3 swingarm pivot shaft nut 108 11.0 80 g: apply grease. R: replacement parts wl: apply a soap and water solution or rubber lubricant..

Page 545: Suspension 13-7

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

Page 547: Suspension 13-9

Suspension 13-9 front fork fork oil change • remove: front wheel (see front wheel removal in the wheels/tires chapter) front fender (see front fender removal in the frame chapter) handlebar (see handlebar removal in the steering chapter) • loosen the upper front fork clamp bolt [a]. • remove the cap...

Page 549: Suspension 13-11

Suspension 13-11 front fork • install washer [a] rubber damper [b] front fork cover [c] • install the fork spring with the smaller end [a] facing down- ward [b]. Upward [c] • install the front fork, and tighten the lower fork clamp bolts only. Torque - lower front fork clamp bolts: 30 n·m (3.0 kgf·m...

Page 551: Suspension 13-13

Suspension 13-13 front fork • hold the front fork horizontally in a vise [a]. • stop the cylinder unit [b] from turning by using the special tools. Special tools - fork cylinder holder handle [c]: 57001-183 fork cylinder holder adapter [d]: 57001 -1057 • unscrew the bottom allen bolt [e], and take t...

Page 553: Suspension 13-15

Suspension 13-15 front fork • hold the front fork horizontally in a vise [a]. • hold the cylinder unit [b] with the special tools. Special tools - fork cylinder holder handle [c]: 57001-183 fork cylinder holder adapter [d]: 57001 -1057 • apply a non-permanent locking agent to the threads of the alle...

Page 555: Suspension 13-17

Suspension 13-17 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 557: Suspension 13-19

Suspension 13-19 rear shock absorber (air type) • remove: saddlebag (see saddlebag removal in the frame chap- ter) rear fender cover front (see trunk stay and saddle- bag stay removal in the frame chapter) • remove the nuts [a], spring washers, and flat washers from both ends of the rear shock absor...

Page 559: Suspension 13-21

Suspension 13-21 swingarm swingarm removal • remove: saddlebags (see saddlebag removal in the frame chapter) saddlebag stays (see trunk stay and saddlebag stay removal in the frame chapter) rear fender (see rear fender removal in the frame chapter) rear caliper (see caliper removal in the brakes cha...

Page 561: Suspension 13-23

Suspension 13-23 swingarm • remove: ball bearing [a] needle bearings [b] special tools - bearing remover head, 20 × 22: 57001 -1293 bearing remover shaft, 13: 57001-1377 oil seal & bearing remover: 57001-1058 swingarm bearing installation • replace the needle bearings, ball bearing, grease seals and...

Page 563: Steering 14-1

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

Page 565: Steering 14-3

Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 handlebar clamp bolts 34 3.5 25 o, s 2 handlebar holder nuts 34 3.5 25 r 3 lower front fork clamp bolts 30 3.0 22 al 4 steering stem head nut 108 11.0 80 5 steering stem nut 29 3.0 22 6 upper front fork clamp bolts 20 2.0 15 a...

Page 567: Steering 14-5

Steering 14-5 handlebar handlebar removal • remove: clamps [a] clutch master cylinder [b] (see clutch master cylinder removal in the clutch chapter) left handlebar switch housing [c] • remove the left grip end cap [a] from the handlebar [b]. ○ the left grip end cap has left-hand threads. • remove th...

Page 569: Steering 14-7

Steering 14-7 handlebar handlebar holder installation • when the rubber bushings [a] are installed in the steering stem head [b], apply soap and water solution or rubber lubricant to the outer surface first, and then press and insert them until rubber bush end is about 1.0 mm (0.039 in.) [c] from th...

Page 571: Steering 14-9

Steering 14-9 steering stem steering stem removal • remove: windshield (see windshield removal in the frame chapter) fairing (see fairing removal in the frame chapter) front wheel (see front wheel removal in the wheels/tires chapter) front fender (see front fender removal in the frame chapter) • rem...

Page 573: Steering 14-11

Steering 14-11 steering stem • install the front fork temporary. • install the washer [a] and the steering stem head nut [b]. Torque - steering stem head nut: 108 n·m (11.0 kgf·m, 80 ft·lb) • install the removed parts (see appropriate chapters). • check and adjust the following after installation. S...

Page 575: Steering 14-13

Steering 14-13 steering stem bearing • replace the bearing inner races and oil seal with new ones. • apply grease to the oil seal. • drive the lower ball bearing inner race [a] applied the grease onto the stem. Special tools - steering stem bearing driver, 42.5 [b]: 57001-1344 steering stem bearing ...

Page 578: 15-2 Frame

15-2 frame exploded view.

Page 580: 15-4 Frame

15-4 frame exploded view.

Page 582: 15-6 Frame

15-6 frame exploded view.

Page 584: 15-8 Frame

15-8 frame exploded view.

Page 586: 15-10 Frame

15-10 frame special tools jack: 57001-1238.

Page 588: 15-12 Frame

15-12 frame fairing and legshields fairing removal • remove: legshields (see legshield removal) windshield (see windshield removal) bolts [a] (both sides) speaker covers [b] (both sides) • remove the fairing mounting bolt (upper) [a] on both sides. • remove the fairing mounting bolts (lower) [a] on ...

Page 590: 15-14 Frame

15-14 frame fairing and legshields • remove the bolts [a] on both sides. • remove: bolts [a] clamp [b] • pull out the fairing inner cover [a] together with the fairing bracket [b], and remove it upward to prevent the bracket from contacting the front fork. • remove: bolts [a] and washers windshield ...

Page 592: 15-16 Frame

15-16 frame fairing and legshields • installation is the reverse of removal, note the following. ○ insert the rib [a] of the side cover into the hook potion [b]. ○ insert the projections [a] of the inner cover into the grom- mets [b]. Leg louver removal/installation • remove: nut [a] clip and pin [b...

Page 594: 15-18 Frame