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Kawasaki VN900 CLASSIC Service Manual

Other manuals for VN900 CLASSIC: Brochure, Installation Instructions

Summary of VN900 CLASSIC

  • Page 1

    Vulcan900 classic vulcan900 classic lt vn900 classic motorcycle service manual.

  • Page 3: Quick Reference Guide

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

  • Page 5: Vulcan900 Classic

    Vulcan900 classic vulcan900 classic lt vn900 classic motorcycle service manual all rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior ...

  • Page 6

    List of abbreviations a ampere(s) lb pounds(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 inc...

  • Page 7

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

  • Page 8

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

  • Page 9: Foreword

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

  • Page 10

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

  • Page 11: General Information

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

  • Page 12

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

  • Page 13

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

  • Page 14

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

  • Page 15

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

  • Page 16

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

  • Page 17

    General information 1-7 model identification vn900b6f (us and canada) left side view: vn900b6f (us and canada) right side view: frame number [a] frame number [b] front fork (right side) engine number [a] engine number [b] right engine cover.

  • Page 18

    1-8 general information model identification vn900b6f (europe and australia) left side view: vn900b6f (europe and australia) right side view:.

  • Page 19

    General information 1-9 model identification vn900d6f (us and canada) left side view: vn900d6f (us and canada) right side view:.

  • Page 20

    1-10 general information general specifications items vn900b6f/d6f dimensions overall length 2 465 mm (97.05 in.) overall width 1 005 mm (39.57 in.), (au) 980 mm (38.6 in.) overall height (vn900b) 1 065 mm (41.93 in.) (vn900d) 1 480 mm (58.27 in.) wheelbase 1 645 mm (64.76 in.) road clearance 135 mm...

  • Page 21

    General information 1-11 general specifications items vn900b6f/d6f valve timing: inlet open 40° btdc close 40° abdc duration 260° exhaust open 55° bbdc close 25° atdc duration 260° lubrication system forced lubrication (wet sump) engine oil: type api se, sf or sg class api sh or sj class with jaso m...

  • Page 22

    1-12 general information general specifications items vn900b6f/d6f front suspension: type telescopic fork wheel travel 150 mm (5.90 in.) rear suspension: type swingarm (uni-trak) wheel travel 103 mm (4.06 in.) brake type: front single disc rear single disc electrical equipment battery: capacity 12 v...

  • Page 23

    General information 1-13 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 25: Periodic Maintenance

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

  • Page 26

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

  • Page 27

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

  • Page 28

    2-4 periodic maintenance periodic maintenance chart frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) 1 6 12 18 24 30 36 inspection every (0.6) (4) (7.5) (12) (15) (20) (24) see page brake hose damage - inspect year • • • • • • • 2-32 brake hose installation condition - in...

  • Page 29

    Periodic maintenance 2-5 periodic maintenance chart periodic replacement parts frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) 1 12 24 36 48 change/replace item every (0.6) (7.5) (15) (24) (30) see page air cleaner element # every 18 000 km (12 000 mile) 2-47 engine oil ...

  • Page 30

    2-6 periodic maintenance torque and locking agent the following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “remarks” column mean: 2t: apply 2-stroke oil. L: apply a non-permanent locking agent to the ...

  • Page 31

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks cylinder head cover bolts 12 1.2 106 in·lb cylinder head outer cover bolts 9.8 1.0 87 in·lb plug (pt1/4) 15 1.5 11 l plug (pt1/2) 20 2.0 15 l muffler mounting bolts 25 2.5 18 muffler mounting nut 25 2.5 18 muff...

  • Page 32

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks rear shift lever clamp bolt 12 1.2 106 in·lb shift pedal clamp bolt 12 1.2 106 in·lb shift rod locknut (front) 9.8 1.0 87 in·lb oil nozzle 3.9 0.40 34 in·lb shift rod locknut (rear) 9.8 1.0 87 in·lb lh rear shi...

  • Page 33

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks suspension swingarm pivot shaft nut 98 10 72 rear shock absorber nuts 59 6.0 44 lower tie-rod nut 59 6.0 44 upper tie-rod nut 108 11.0 80 rocker arm pivot shaft nut 59 6.0 44 upper front fork clamp bolts 20 2.0...

  • Page 34

    2-10 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks spark plugs 18 1.8 13 in·lb sidestand switch mounting bolts 8.8 0.90 78 in·lb l the table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for...

  • Page 35

    Periodic maintenance 2-11 specifications item standard service limit fuel system throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 1 000 ±50 r/min (rpm) – – – air cleaner element polyurethane foam – – – cooling system coolant: type (recommended) permanent type of antifreeze – – – c...

  • Page 36

    2-12 periodic maintenance specifications item standard service limit final drive drive belt deflection: – – – (45 n, 4.6 kgf, 10 lb fprce) 1.5 ∼ 4.0 mm (0.059 ∼ 0.16 in.) – – – when installing new belt or engine remounted 1.5 mm (0.059 in.) – – – brakes brake fluid: grade dot4 – – – brake pad lining...

  • Page 37

    Periodic maintenance 2-13 special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 jack: 57001-1238 oil filter wrench: 57001-1249 spark plug wrench, hex 16: 57001-1262 tension gauge: 57001-1585.

  • Page 38

    2-14 periodic maintenance periodic maintenance procedures fuel system (dfi) fuel hose inspection (fuel leak, damage, installation condition) ○ the fuel hose is designed to be used throughout the mo- torcycle’s life without any maintenance. However, if the motorcycle is not properly handled, the high...

  • Page 39

    Periodic maintenance 2-15 periodic maintenance procedures • if necessary, adjust the throttle cable as follows: ○ loosen the locknuts [a] and screw the adjusters [b] all the way in so as to give the throttle grip plenty of play. ○ turn out the adjuster of the decelerator cable [d] until there is no ...

  • Page 40

    2-16 periodic maintenance periodic maintenance procedures cooling system coolant level inspection note ○ check the level when the engine is cold (room or ambi- ent temperature). • check the coolant level in the reserve tank [a] with the motorcycle held upright. If the coolant level is lower than the...

  • Page 41

    Periodic maintenance 2-17 periodic maintenance procedures air suction system air suction system damage inspection • pull the air switching valve hose [a] out of the right air cleaner housing. • start the engine and run it at idle speed. • plug the air switching valve hose end with your finger and fe...

  • Page 42

    2-18 periodic maintenance periodic maintenance procedures • to select a new shim which brings the valve clearance within the specified range, refer to the valve clearance adjustment charts. • remeasure any valve clearance that was adjusted. Readjust if necessary. Caution do not put shim stock under ...

  • Page 43

    Periodic maintenance 2-19 periodic maintenance procedures valve clearance adjustment chart inlet valve 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where th...

  • Page 44

    2-20 periodic maintenance periodic maintenance procedures valve clearance adjustment chart exhaust valve 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where ...

  • Page 45

    Periodic maintenance 2-21 periodic maintenance procedures clutch clutch operation inspection clutch lever free play inspection • pull the clutch lever just enough to take up the free play [a]. • measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not releas...

  • Page 46

    2-22 periodic maintenance periodic maintenance procedures wheels and tires tire air pressure inspection • measure the tire air pressure with an air pressure gauge [a] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours). Adjust the tire ...

  • Page 47

    Periodic maintenance 2-23 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. Tread depth standard: fron...

  • Page 48

    2-24 periodic maintenance periodic maintenance procedures spoke tightness and rim runout inspection • check that all the spokes are tightened evenly. If spoke tightness is uneven or loose, tighten the spoke nipples evenly. Torque - spoke nipples: 5.2 n·m (0.53 kgf·m, 46 in·lb) • check the rim runout...

  • Page 49

    Periodic maintenance 2-25 periodic maintenance procedures drive train belt deflection inspection note ○ belt deflection must be checked and adjusted when the belt is cold (at room temperature). ○ belt deflection also should be checked at first 1000 km ride after belt replacement. • check to see if w...

  • Page 50

    2-26 periodic maintenance periodic maintenance procedures note ○ push the belt by the gauge until the top surface [a] of the stopper comes to the 45 n loaded scale [b], marked “45n”. ○ push up on the center of the belt. An inaccurate reading will occur if the edge of the belt is pushed up. ○ look pa...

  • Page 51

    Periodic maintenance 2-27 periodic maintenance procedures • decide the belt deflection at the position [c] of one where deflection is large. Drive belt deflection (with 45 n, 4.6 kgf, 10 lb force) standard: 1.5 ∼ 4.0 mm (0.059 ∼ 0.16 in.) drive belt deflection (with 45 n, 4.6 kgf, 10 lb force, when ...

  • Page 52

    2-28 periodic maintenance periodic maintenance procedures • insert a new cotter pin [a]. Note ○ when inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [b] up to next alignment. ○ it should be within 30 degree. ○ loosen once...

  • Page 53

    Periodic maintenance 2-29 periodic maintenance procedures • visually inspect the belt [a] for wear and damage. If the nylon fabric facing of any portion is worn off, and the polyurethane compound is exposed, or belt is damaged, replace the belt immediately with a new one. • otherwise, refer to the d...

  • Page 54

    2-30 periodic maintenance periodic maintenance procedures drive belt tooth wear and damage patterns a. Belt cross section b. Edge bevel wear c. Rub wear d. Stone.

  • Page 55

    Periodic maintenance 2-31 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 56

    2-32 periodic maintenance periodic maintenance procedures brake hose damage and installation condition inspection • inspect the brake hoses and fittings for deterioration, cracks and signs of leakage. ○ the high pressure inside the brake line can cause fluid to leak [a] or the hose to burst if the l...

  • Page 57

    Periodic maintenance 2-33 periodic maintenance procedures • check that the brake fluid level in the rear brake reservoir [a] is above the lower level line [b]. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [c]. Warning change the brake fluid in the...

  • Page 58

    2-34 periodic maintenance periodic maintenance procedures if it does not, adjust the brake light switch. • while holding the switch body, turn the adjusting nut [a] to adjust the switch. Caution to avoid damaging the electrical connections in- side the switch, be sure that the switch body does not t...

  • Page 59

    Periodic maintenance 2-35 periodic maintenance procedures front fork oil leak inspection • visually inspect the front forks [a] for oil leakage. Replace or repair any defective parts, if necessary. Rear shock absorber oil leak inspection • remove the left side cover (see left side cover removal in t...

  • Page 60

    2-36 periodic maintenance periodic maintenance procedures uni-trak linkage lubrication • remove: tie-rod (see tie-rod removal in the suspension chap- ter) • apply grease to the inner surfaces of the needle bearings [a] • for the rocker arm it has grease nipples [a] on the rocker arm for lubrication....

  • Page 61

    Periodic maintenance 2-37 periodic maintenance procedures • straighten the claws [a] of the claw washer. • remove the steering stem locknut [b] and claw washer [c]. • adjust the steering. Special tool - steering stem nut wrench [a]: 57001-1100 if the steering is too tight, loosen the stem nut [b] a ...

  • Page 62

    2-38 periodic maintenance periodic maintenance procedures steering stem bearing lubrication • remove the steering stem (see steering stem removal in the steering chapter). • using a high flash-point solvent, wash the upper and lower ball bearings in the cages, and wipe the upper and lower outer race...

  • Page 63

    Periodic maintenance 2-39 periodic maintenance procedures electrical system lights and switches operation inspection first step • turn on the ignition switch. • the following lights should go on according to below table. Position lights [a] ( us and canada models) goes on city light [b] (europe mode...

  • Page 64

    2-40 periodic maintenance periodic maintenance procedures third step • turn on the turn signal switch [a] (left or right position). • the left or right turn signal lights [b] (front and rear) ac- cording to the switch position should flash. • the turn signal indicator light (led) [c] in the meter un...

  • Page 65

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

  • Page 66

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

  • Page 67

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

  • Page 68

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

  • Page 69

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

  • Page 70

    2-46 periodic maintenance periodic maintenance procedures evaporative emission control system inspection (cal) evaporative emission control system inspection • inspect the canister as follows: ○ remove: muffler (see muffler removal in the engine top end chapter) ○ remove the bolts [a]. ○ remove the ...

  • Page 71

    Periodic maintenance 2-47 periodic maintenance procedures replacement parts air cleaner element replacement warning if dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident. Caution if dirt gets through into the engine, excessiv...

  • Page 72

    2-48 periodic maintenance periodic maintenance procedures engine oil change • situate the motorcycle so that it is vertical after warning up the engine. • remove: oil filler cap [a] special tool - filler cap driver: 57001-1454 • remove the engine drain plug [a] to drain the oil. ○ the oil in the oil...

  • Page 73

    Periodic maintenance 2-49 periodic maintenance procedures oil filter replacement • drain the engine oil (see engine oil change). • remove: regulator/rectifier (see regulator/rectifier removal in the electrical system chapter) bolts [a] bracket [b] • remove the oil filter [a] with the oil filter wren...

  • Page 74

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

  • Page 75

    Periodic maintenance 2-51 periodic maintenance procedures coolant change warning to avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery, and can cause an accident and injury. Since c...

  • Page 76

    2-52 periodic maintenance periodic maintenance procedures water and coolant mixture ratio (when recommended) soft water : 50% coolant : 50% freezing point : − 35°c ( − 31°f) total amount : 2.2 l (2.3 us gt.) • tighten: torque - coolant drain bolt: 9.8 n·m (1.0 kgf·m, 87 in·lb) • fill the radiator up...

  • Page 77

    Periodic maintenance 2-53 periodic maintenance procedures radiator hose and o-ring replacement • drain the coolant (see coolant change). • remove: thermostat bracket [a] (see thermostat removal in the cooling system chapter) • loosen the radiator hose clamps and remove the hoses [b]. • unscrew the b...

  • Page 78

    2-54 periodic maintenance periodic maintenance procedures • when installing the hoses [a], avoid sharp bending, kink- ing, flattening or twisting, and route the hoses according to cable, wire and hose routing section in the appendix chapter. • fill the brake line after installing the brake hose (see...

  • Page 79

    Periodic maintenance 2-55 periodic maintenance procedures ○ repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. Open the bleed valve [a]. Pump the brake lever and hold it [b]. Close the bleed valve [c]. Release the brake lever [d]. Front b...

  • Page 80

    2-56 periodic maintenance periodic maintenance procedures master cylinder rubber parts replacement front master cylinder disassembly • remove the front master cylinder (see front master cylin- der removal in the brakes chapter). • remove the reservoir cap [a], plate [b], and diaphragm [c]. • unscrew...

  • Page 81

    Periodic maintenance 2-57 periodic maintenance procedures master cylinder assembly • before assembly, clean all parts including the master cylinder with brake fluid or alcohol. Caution except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brak...

  • Page 82

    2-58 periodic maintenance periodic maintenance procedures • using compressed air, remove the piston. Warning to avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply com- pressed air into the caliper, the piston may crush your hand or fingers. ○ insert a woo...

  • Page 83

    Periodic maintenance 2-59 periodic maintenance procedures • apply brake fluid to the inside of the cylinders and to the outside of the pistons and push the pistons [a] into the cylinders. • check the friction boot [b] and dust boot [c] and replace them with new ones if they are damaged. • apply a th...

  • Page 84

    2-60 periodic maintenance periodic maintenance procedures • remove: antirattle spring [a] dust seals [b] and fluid seals [c] rubber friction boots [d] bleed valves [e] and rubber caps [f] rear caliper assembly • tighten the bleed valve. Torque - rear caliper bleed valves: 7.8 n·m (0.80 kgf·m, 69 in·...

  • Page 85

    Periodic maintenance 2-61 periodic maintenance procedures caution the insulator [a] of the spark plug may break if when the wrench is inclined during loosening. Inclined spark plug wrench [b] contact (spark plug and plug wrench) [c] bad [d] vertically spark plug wrench [e] good [f] • replace the spa...

  • Page 87: Fuel System (Dfi)

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

  • Page 88

    3-2 fuel system (dfi) speed sensor removal .................................................................................................... 3-63 speed sensor installation ................................................................................................. 3-63 speed sensor inspectio...

  • Page 89

    Fuel system (dfi) 3-3 audible inspection............................................................................................................. 3-106 fuel injector power source voltage inspection ................................................................ 3-106 output voltage inspection.....

  • Page 90

    3-4 fuel system (dfi) exploded view.

  • Page 91

    Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 fuel pump bolts 9.8 1.0 87 in·lb l 2 air cleaner housing bolts 9.8 1.0 87 in·lb 3 air cleaner cover bolts 4.9 0.50 43 in·lb 4 throttle body assy holder bolts 9.8 1.0 87 in·lb 5 inlet manifold bolts 9.8 1.0 87 in·lb l 6...

  • Page 92

    3-6 fuel system (dfi) exploded view.

  • Page 93

    Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 fuel level sensor mounting bolts 6.9 0.70 61 in·lb l 2. California model 3. Breather hose (other than california models) l: apply a non-permanent locking agent. R: replacement parts.

  • Page 94

    3-8 fuel system (dfi) dfi parts location 1. Ignition coil #1 2. Fuel pump 3. Ignition coil #2 4. Main fuse 30 a 5. Relay box 6. Fuse box 7. Vehicle down sensor 8. Ecu 9. Battery 10. Crankshaft sensor 11. Injector #2 12. Injector #1 13. Water temperature sensor 14. Main throttle sensor 15. Subthrottl...

  • Page 95

    Fuel system (dfi) 3-9 dfi parts location.

  • Page 96

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

  • Page 97

    Fuel system (dfi) 3-11 specifications item standard throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) air cleaner element viscous paper element dfi system make denso idle speed 1 000 ±50 r/min (rpm) throttle body assy: type × bore two barrel type × 34 mm (1.34 in.) ecu (electronic control unit): ty...

  • Page 98

    3-12 fuel system (dfi) specifications item standard subthrottle sensor: non-adjustable and non-removable input voltage 4.75 ∼ 5.25 v dc between bl and br/bk leads output voltage 0.93 ∼ 4.59 v dc between bl/w and br/bk leads (at idle throttle opening to full throttle opening) resistance 4 ∼ 6 k Ω sub...

  • Page 99

    Fuel system (dfi) 3-13 special tools and sealant oil pressure gauge, 5 kgf/cm²: 57001-125 fork oil level gauge: 57001-1290 hand tester: 57001-1394 peak voltage adapter: 57001-1415 filler cap driver: 57001-1454 needle adapter set: 57001-1457 fuel pressure gauge adapter: 57001-1593 fuel hose: 57001-16...

  • Page 100

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

  • Page 101

    Fuel system (dfi) 3-15 dfi system 1. Battery 2. Ecu 3. Injector 4. Fuel pump 5. Fuel tank 6. Subthrottle valve actuator 7. Air cleaner 8. Subthrottle sensor 9. Main throttle sensor 10. Inlet air temperature sensor 11. Water temperature sensor 12. Inlet air pressure sensor 13. Vehicle-down sensor 14....

  • Page 102

    3-16 fuel system (dfi) dfi system dfi system wiring diagram (other than europe models).

  • Page 103

    Fuel system (dfi) 3-17 dfi system part name 1. Ecu 2. Diagnosis connector 3. Self-diagnosis terminal 4. Fuel pump 5. Vehicle-down sensor 6. Frame ground 7. Battery 8. Main fuse 30 a 9. Relay box 10. Fuel pump relay 11. Ecu main relay 12. Radiator fan relay 13. Radiator fan fuse 15 a 14. Ecu fuse 15 ...

  • Page 104

    3-18 fuel system (dfi) dfi system dfi system wiring diagram (europe models).

  • Page 105

    Fuel system (dfi) 3-19 dfi system part name 1. Ecu 2. Diagnosis connector 3. Self-diagnosis terminal 4. Fuel pump 5. Vehicle-down sensor 6. Frame ground 7. Battery 8. Main fuse 30 a 9. Relay box 10. Fuel pump relay 11. Ecu main relay 12. Radiator fan relay 13. Oxygen sensor heater fuse 10 a 14. Radi...

  • Page 106

    3-20 fuel system (dfi) dfi system other than europe models terminal names 1. Subthrottle valve actuator drive signal 2 2. Subthrottle valve actuator drive signal 1 3. Water temperature warning light signal 4. Unused 5. Speed sensor signal 6. Main throttle sensor signal 7. Inlet air pressure sensor s...

  • Page 107

    Fuel system (dfi) 3-21 dfi system europe model terminal names 1. Subthrottle valve actuator drive signal 2 2. Subthrottle valve actuator drive signal 1 3. Water temperature warning light signal 4. Oxygen sensor signal 2 5. Oxygen sensor signal 1 6. Speed sensor signal 7. Main throttle sensor signal ...

  • Page 108

    3-22 fuel system (dfi) dfi servicing precautions dfi servicing precautions there are a number of important precautions that should be followed servicing the dfi system. ○ this dfi system is designed to be used with a 12 v sealed battery as its power source. Do not use any other battery except for a ...

  • Page 109

    Fuel system (dfi) 3-23 dfi servicing precautions ○ to maintain the correct fuel/air mixture (f/a), there must be no inlet air leaks in the dfi system. Be sure to install the oil filler plug [a] after filling the engine oil. Alternator cover [b] special tool - filler cap driver: 57001-1454.

  • Page 110

    3-24 fuel system (dfi) troubleshooting the dfi system outline outline when an abnormality in the system occurs, the fi indica- tor led (light emitting diode) light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ecu (electronic ...

  • Page 111

    Fuel system (dfi) 3-25 troubleshooting the dfi system ○ the dfi part connectors [a] have seals [b], including the ecu. • join the connector and insert the needle adapters [c] inside the seals [b] from behind the connector until the adapter reaches the terminal. Special tool - needle adapter set: 570...

  • Page 112

    3-26 fuel system (dfi) troubleshooting the dfi system • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. • check the wiring for continuity. ○ use the...

  • Page 113

    Fuel system (dfi) 3-27 troubleshooting the dfi system ○ there are two ways to inspect the dfi system. One is voltage check method and the other is resistance check method. (voltage check method) ○ this method is conducted by measuring the input voltage [b] to a sensor [a] first, and then the output ...

  • Page 114

    3-28 fuel system (dfi) troubleshooting the dfi system dfi diagnosis flow chart inquiries to rider inquiries to rider ○ each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ try to find out exactly what problem occurred under...

  • Page 115

    Fuel system (dfi) 3-29 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, □ always, □ ...

  • Page 116

    3-30 fuel system (dfi) troubleshooting the dfi system □ engine overheating. □ clutch slipping. □ other: □ spark plug loose (tighten it). □ spark plug dirty, broken, or gap maladjusted (remedy it). □ spark plug incorrect (replace it). □ knocking (fuel poor quality or incorrect, → use high-octane gaso...

  • Page 117

    Fuel system (dfi) 3-31 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 118

    3-32 fuel system (dfi) 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 119

    Fuel system (dfi) 3-33 dfi system troubleshooting guide symptoms or possible causes actions (chapter) piston ring bad (worn, weak, broken or sticking) inspect and replace (see chapter 5). Piston ring/groove clearance excessive inspect and replace (see chapter 5). Cylinder head gasket damaged replace...

  • Page 120

    3-34 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) incorrect idle speed water temperature sensor trouble inspect (see chapter 3). Throttle sensor trouble inspect (see chapter 3). Throttle valves or actuator trouble inspect (see chapter 3). Engine st...

  • Page 121

    Fuel system (dfi) 3-35 dfi system troubleshooting guide symptoms or possible causes actions (chapter) delay of ignition timing inspect crankshaft sensor and ic igniter in ecu (see chapter 16). Poor acceleration too low fuel pressure inspect (see chapter 3). Water or foreign matter in fuel change fue...

  • Page 122

    3-36 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) fuel injector trouble inspect (see chapter 3). Run-on (dieseling) ignition switch trouble inspect and replace (see chapter 16). Engine switch trouble inspect and repair or replace (see chapter 16). ...

  • Page 123

    Fuel system (dfi) 3-37 dfi system troubleshooting guide symptoms or possible causes actions (detailed reference) inlet air temperature sensor trouble inspect (see chapter 3). Throttle sensor malfunction inspect (see chapter 3). Inlet air pressure sensor trouble inspect (see chapter 3). Cracked or ob...

  • Page 124

    3-38 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (detailed reference) cylinder worn inspect and replace (see chapter 5). Valve oil seal damaged replace (see chapter 5). Valve guide worn replace the guide (see chapter 5). Engine oil level too high repair (se...

  • Page 125

    Fuel system (dfi) 3-39 self-diagnosis self-diagnosis outline self-diagnosis outline the self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User mode the ecu notifies the rider of troubles in dfi system and ignition system by lighting t...

  • Page 126

    3-40 fuel system (dfi) self-diagnosis • to enter the self-diagnosis dealer mode 2, open [b] and ground [a] the lead more than five times [f] within 2 sec- onds [c] after the lead is first grounded, and then keep it grounded continuously [d] for more than 2 seconds. ○ count the blinks of the light (l...

  • Page 127

    Fuel system (dfi) 3-41 self-diagnosis.

  • Page 128

    3-42 fuel system (dfi) self-diagnosis how to read service codes how to read service codes ○ service codes are shown by a series of long and short blinks of the fi indicator light (led) as shown below. ○ read 10th digit and unit digit as the fi indicator light (led) blinks. ○ when there are a number ...

  • Page 129

    Fuel system (dfi) 3-43 self-diagnosis service code table service code table service code fi indicator light (led) problems 11 main throttle sensor malfunction, wiring open or short 12 inlet air pressure sensor malfunction, wiring open or short 13 inlet air temperature sensor malfunction, wiring open...

  • Page 130

    3-44 fuel system (dfi) self-diagnosis notes: ○ the ecu may be involved in these problems. If all the parts and circuits checked out good, be sure to check the ecu for ground and power supply. If the ground and power supply are checked good, replace the ecu. ○ when no service code is displayed, the e...

  • Page 131

    Fuel system (dfi) 3-45 self-diagnosis backups backups ○ the ecu takes the following measures to prevent engine damage when the dfi or the ignition system parts have troubles. Service codes parts output signal usable range or criteria backups by ecu 11 main throttle sensor main throttle sensor output...

  • Page 132

    3-46 fuel system (dfi) self-diagnosis service codes parts output signal usable range or criteria backups by ecu 51 ignition coil #1* the stick coil primary winding must send signals (output voltage) continuously to the ecu. If the ignition primary winding #1 has failures (no signal, wiring short or ...

  • Page 133

    Fuel system (dfi) 3-47 main throttle sensor (service code 11) the main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ecu senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm,...

  • Page 134

    3-48 fuel system (dfi) main throttle sensor (service code 11) output voltage inspection • measure the output voltage at the ecu in the same way as input voltage inspection. Special tool - needle adapter set: 57001-1457 main throttle sensor output voltage connections to ecu (other than europe models ...

  • Page 135

    Fuel system (dfi) 3-49 main throttle sensor (service code 11) note ○ the standard voltage marked with an asterisk refers to the value when the voltage reading at the input voltage inspection shows 5 v exactly. ○ when the input voltage reading shows other than 5 v, derive a voltage range as follows. ...

  • Page 136

    3-50 fuel system (dfi) main throttle sensor (service code 11) main throttle sensor circuit (other than europe models) main throttle sensor circuit (europe models) 1. Ecu 2. Main throttle sensor 3. Joint connector b.

  • Page 137

    Fuel system (dfi) 3-51 inlet air pressure sensor (service code 12) inlet air pressure sensor removal caution never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. • remove: fuel tank (see fuel tank removal) bolt [a] • disconnect the inlet air pressure sensor co...

  • Page 138

    3-52 fuel system (dfi) inlet air pressure sensor (service code 12) if the reading is within the standard range, remove the fuel tank, and check wiring from ecu to the inlet pressure sensor for continuity. If wiring is good, check the output voltage of the inlet air pressure sensor. Output voltage in...

  • Page 139

    Fuel system (dfi) 3-53 inlet air pressure sensor (service code 12) • remove the inlet air pressure sensor [a] and disconnect the vacuum hose from the sensor. ○ do not disconnect the sensor connector. • connect an auxiliary hose [b] to the inlet air pressure sen- sor. • temporarily install the inlet ...

  • Page 140

    3-54 fuel system (dfi) inlet air pressure sensor (service code 12) id: idling ps: standard atmospheric pressure (absolute) pv: throttle vacuum pressure (absolute) st: standard of sensor output voltage (v) to: throttle full open ur: usable range of sensor output voltage (v) vv: inlet air pressure sen...

  • Page 141

    Fuel system (dfi) 3-55 inlet air pressure sensor (service code 12) inlet air pressure sensor circuit (other than europe models) inlet air pressure sensor circuit (europe models) 1. Ecu 2. Inlet air pressure sensor 3. Joint connector b.

  • Page 142

    3-56 fuel system (dfi) inlet air temperature sensor (service code 13) inlet air temperature sensor removal/installation caution never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove the air cleaner housing (see air cleaner housing removal). • remove ...

  • Page 143

    Fuel system (dfi) 3-57 inlet air temperature sensor (service code 13) sensor resistance inspection • remove the inlet air temperature sensor (see inlet air temperature sensor removal). • suspend the sensor [a] in a container of machine oil so that the heat-sensitive portion is submerged. • suspend a...

  • Page 144

    3-58 fuel system (dfi) inlet air temperature sensor (service code 13) inlet air temperature sensor circuit (other than europe models) inlet air temperature sensor circuit (europe models) 1. Ecu 2. Inlet air temperature sensor 3. Joint connector b.

  • Page 145

    Fuel system (dfi) 3-59 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 fuel tank (see fuel tank removal). • drain the coolant (see coolant change in the periodic mainte...

  • Page 146

    3-60 fuel system (dfi) water temperature sensor (service code 14) water temperature sensor circuit (other than europe models) water temperature sensor circuit (europe models) 1. Ecu 2. Water temperature sensor 3. Joint connector b.

  • Page 147

    Fuel system (dfi) 3-61 crankshaft sensor (service code 21) start the engine and switch the diagnosis mode to dealer 1 mode to know all the problem that the dfi system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of ...

  • Page 148

    3-62 fuel system (dfi) crankshaft sensor (service code 21) crankshaft sensor circuit (other than europe models) crankshaft sensor circuit (europe models) 1. Ecu 2. Crankshaft sensor.

  • Page 149

    Fuel system (dfi) 3-63 speed sensor (service code 24, 25) speed sensor removal • refer to the speed sensor removal in the electrical sys- tem chapter. Speed sensor installation • refer to the speed sensor installation in the electrical system chapter. Speed sensor inspection • refer to the speed sen...

  • Page 150

    3-64 fuel system (dfi) speed sensor (service code 24, 25) output voltage inspection • before this inspection, inspect the input voltage (see input voltage inspection in the speed sensor section). Note ○ be sure the battery is fully charged. • turn the ignition switch off. • using the jack, raise the...

  • Page 151

    Fuel system (dfi) 3-65 speed sensor (service code 24, 25) speed sensor circuit (other than europe models) speed sensor circuit (europe models) 1. Ecu 2. Meter unit 3. Joint connector b 4. Speed sensor.

  • Page 152

    3-66 fuel system (dfi) vehicle-down sensor (service code 31) vehicle-down sensor removal • remove: tool box (see tool box removal in the frame chapter) bolts [a] vehicle-down sensor [b] connector [c] (disconnect) vehicle-down sensor installation • install the vehicle-down sensor [a] in the original ...

  • Page 153

    Fuel system (dfi) 3-67 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, using two needle adapters [b]. • turn the ignition switch on, and measure the output volt- age with the connector j...

  • Page 154

    3-68 fuel system (dfi) vehicle-down sensor (service code 31) vehicle-down sensor circuit (other than europe models) vehicle-down sensor circuit (europe models) 1. Ecu 2. Vehicle-down sensor 3. Joint connector b.

  • Page 155

    Fuel system (dfi) 3-69 subthrottle sensor (service code 32) the subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ecu senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and...

  • Page 156

    3-70 fuel system (dfi) subthrottle sensor (service code 32) • turn the ignition switch off. If the reading of input voltage is less than the standard, check the ecu for its ground, power supply and wiring shorted. If the input voltage is within the standard range, remove the fuel tank, and check wir...

  • Page 157

    Fuel system (dfi) 3-71 subthrottle sensor (service code 32) note ○ the standard voltage marked with an asterisk refers to the value when the voltage reading at the input voltage inspection shows 5 v exactly. ○ when the input voltage reading shows other than 5 v, derive a voltage range as follows. Ex...

  • Page 158

    3-72 fuel system (dfi) subthrottle sensor (service code 32) subthrottle sensor circuit (other than europe models) subthrottle sensor circuit (europe models) 1. Ecu 2. Subthrottle sensor 3. Joint connector b.

  • Page 159

    Fuel system (dfi) 3-73 oxygen sensor-not activated (#1, #2: service code 33, 83)-europe models oxygen sensor #1: service code 33 oxygen sensor #2: service code 83 oxygen sensor removal/installation • refer to oxygen sensor removal and installation in the electrical system chapter. Oxygen sensor insp...

  • Page 160

    3-74 fuel system (dfi) oxygen sensor-not activated (#1, #2: service code 33, 83)-europe models • next, remove the plugs [a] (both sides) from the fittings with idling. • measure the output voltage of the sensor with the con- nector joined. Oxygen sensor output voltage (without plugs) standard: 0.05 ...

  • Page 161

    Fuel system (dfi) 3-75 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) ignition coil removal/installation caution never drop the ignition coils, especially on a hard ...

  • Page 162

    3-76 fuel system (dfi) ignition coils (#1, #2: service code 51, 52) if the reading is out of the standard, check the ecu for its ground and power supply (see ecu power supply in- spection). If the reading is good remove the fuel tank and check the wiring between the ecu and the primary lead terminal...

  • Page 163

    Fuel system (dfi) 3-77 radiator fan relay (service code 56) radiator fan relay removal/installation • radiator fan relay is bult in the relay box. • remove the relay box (see relay box removal in the electrical system chapter). Radiator fan relay inspection • refer to the relay circuit inspection in...

  • Page 164

    3-78 fuel system (dfi) radiator fan relay (service code 56) radiator fan relay circuit 1. Ignition switch 2. Radiator fan 3. Joint connector b 4. Water temperature sensor 5. Ecu 6. Frame ground 7. Battery 8. Main fuse 30 a 9. Relay box 10. Ecu main relay 11. Radiator fan relay 12. Ecu fuse 15 a 13. ...

  • Page 165

    Fuel system (dfi) 3-79 subthrottle valve actuator (service code 62) subthrottle valve actuator removal caution do not remove the subthrottle valve actuator [a] since it has been adjusted and set with precision at the factory. Never drop the actuator , especially on a hard sur- face. Such a shock to ...

  • Page 166

    3-80 fuel system (dfi) subthrottle valve actuator (service code 62) input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the fuel tank (see fuel tank removal). • connect the peak voltage adapter [a] and a digital meter [b] to the connector (m...

  • Page 167

    Fuel system (dfi) 3-81 subthrottle valve actuator (service code 62) subthrottle valve actuator circuit (other than europe models) subthrottle valve actuator circuit (europe models) 1. Ecu 2. Subthrottle valve actuator.

  • Page 168

    3-82 fuel system (dfi) air switching valve (service code 64) air switching valve removal/installation • see clean air system section in the engine top end chapter. Air switching valve inspection • see air switching valve unit test in the electrical system chapter. • check the wiring continuity, usin...

  • Page 169

    Fuel system (dfi) 3-83 air switching valve (service code 64) air switching valve circuit (europe models) 1. Ecu 2. Engine stop switch 3. Ignition switch 4. Ignition fuse 10 a 5. Ecu fuse 15 a 6. Fuse box 7. Ecu main relay 8. Fuel pump relay 9. Relay box 10. Main fuse 30 a 11. Starter relay 12. Batte...

  • Page 170

    3-84 fuel system (dfi) oxygen sensor heaters (#1, #2: service code 67)-europe models oxygen sensor heater removal/installation the oxygen sensor heater is bult in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see switch and sensors section in the electri- c...

  • Page 171

    Fuel system (dfi) 3-85 oxygen sensor heaters (#1, #2: service code 67)-europe models if the reading is incorrect, check the following. Battery (see charging condition inspection in the elec- trical system chapter) main fuse 30 a (see fuse inspection in the electrical system chapter) oxygen sensor he...

  • Page 172

    3-86 fuel system (dfi) oxygen sensors-incorrect output voltage (#1, #2: service code 94, 95)-europe models oxygen sensor #1: service code 94 oxygen sensor #2: service code 95 oxygen sensor removal/installation • refer to oxygen sensor removal and installation in the electrical system chapter. Oxygen...

  • Page 173

    Fuel system (dfi) 3-87 oxygen sensors-incorrect output voltage (#1, #2: service code 94, 95)-europe models • next, remove the plugs [a] (both sides) from the fittings with idling. • measure the output voltage of the sensor with the con- nector joined. Oxygen sensor output voltage (without plugs) sta...

  • Page 174

    3-88 fuel system (dfi) fi indicator led light inspection flow chart.

  • Page 175

    Fuel system (dfi) 3-89 fi indicator led light led light inspection ○ the fi indicator led light [a] goes on when the ignition switch is turned on and the led light goes off when the engine oil pressure is high enough (the engine is running). This is to ensure that the fi indicator led light has not ...

  • Page 176

    3-90 fuel system (dfi) fi indicator led light fi indicator led light circuit (other than europe models) fi indicator led light circuit (europe models) 1. Ecu 2. Ignition switch 3. Meter unit 4. Fi indicator led light 5. Main fuse 30 a 6. Starter relay 7. Joint connector a 8. Joint connector c 9. Bat...

  • Page 177

    Fuel system (dfi) 3-91 ecu ecu removal caution never drop the ecu, especially on a hard surface. Such a shock to the ecu can damage it. • remove: seat (see seat removal in the frame chapter) tool box (see tool box removal in the frame chapter) • pull out the ecu [a] along with the harness. If necess...

  • Page 178

    3-92 fuel system (dfi) ecu • check the ecu power source voltage with a digital meter. ○ position the terminal in accordance with terminal numbers of ecu connectors in this chapter figure. Ecu power source inspection meter connections: (other than europe models [a]) between terminal 12 (br/w) and bat...

  • Page 179

    Fuel system (dfi) 3-93 fuel line fuel pressure inspection note ○ this inspection can determine which trouble the dfi system has, mechanical or electrical trouble. ○ it is preferable to measure the fuel pressure while run- ning the motorcycle when the trouble has occurred in order to know symptom wel...

  • Page 180

    3-94 fuel system (dfi) fuel line • turn the ignition switch 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 switch on, with pump running: standard: 304 kpa (3.1 kgf/cm², 44 psi) after 3 seconds from ign...

  • Page 181

    Fuel system (dfi) 3-95 fuel line • insert the fuel hose joint [a] straight onto the delivery pipe. • push [b] the joint lock [c] until the hose joint clicks. • push and pull [a] the fuel hose joint [b] back and forth more than two times and make sure it is locked and doesn’t come off. Warning make s...

  • Page 182

    3-96 fuel system (dfi) fuel line • prepare a plastic hose of the inside diameter 7.5 mm × l = about 400 mm and a measuring cylinder. • remove: seat (see seat removal in the frame chapter) fuel tank bolts • raise the fuel tank. • stuff a clean shop towel around the fuel outlet hose joint. ○ while pin...

  • Page 183

    Fuel system (dfi) 3-97 fuel pump fuel pump removal caution never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. Warning gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from an...

  • Page 184

    3-98 fuel system (dfi) fuel pump • check that the terminals [a] and band [b] are in place. • apply a non-permanent locking agent to the threads of the fuel pump bolts. • tighten the fuel pump bolts [c] to a snug fit. • tighten: torque - fuel pump bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) pump screen, fue...

  • Page 185

    Fuel system (dfi) 3-99 fuel pump operating voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the ignition coil cover (see ignition coil removal in the electrical system chapter). • connect the hand tester (25 v dc) to the fuel pump con- nector [...

  • Page 186

    3-100 fuel system (dfi) fuel pump power source voltage inspection note ○ be sure the battery is fully charged. • remove the ignition coil cover (see ignition coil removal in the electrical system chapter). • connect a digital voltmeter [a] to the fuel pump connector [b] (3p), using the needle adapte...

  • Page 187

    Fuel system (dfi) 3-101 fuel pump fuel pump circuit (other than europe models) 1. Ecu 2. Engine stop switch 3. Ignition switch 4. Ignition fuse 10 a 5. Ecu fuse 15 a 6. Fuse box 7. Ecu main relay 8. Fuel pump relay 9. Relay box 10. Main fuse 30 a 11. Starter relay 12. Battery 13. Joint connector a 1...

  • Page 188

    3-102 fuel system (dfi) fuel pump fuel pump circuit (europe models) 1. Ecu 2. Engine stop switch 3. Ignition switch 4. Ignition fuse 10 a 5. Ecu fuse 15 a 6. Fuse box 7. Ecu main relay 8. Fuel pump relay 9. Relay box 10. Main fuse 30 a 11. Starter relay 12. Battery 13. Joint connector a 14. Joint co...

  • Page 189

    Fuel system (dfi) 3-103 fuel injectors caution never drop the injector, especially on a hard sur- face. Such a shock to the injector can damage it. Injector removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch off. Disconnect the b...

  • Page 190

    3-104 fuel system (dfi) fuel injectors • unscrew the delivery joint bolts [a], and lift up the delivery joint [b] with the injectors [c]. • remove the injectors from the delivery joint. Injector installation ○ the front and rear injectors are the same. • replace the seal [a] and o-ring [b] with new ...

  • Page 191

    Fuel system (dfi) 3-105 fuel injectors injector fuel line inspection • remove: fuel tank (see fuel tank removal) fuel hose (see fuel hose replacement in the periodic maintenance chapter) • check the injector fuel line for leakage as follows: ○ connect a commercially available vacuum/pressure pump [a...

  • Page 192

    3-106 fuel system (dfi) fuel injectors audible inspection • start the engine. • insert a screwdriver from the engine right side between the fuel tank bottom end and the engine top end. • apply the tip of a screwdriver [a] to the injector [b]. Put the grip end onto your ear, and listen whether the in...

  • Page 193

    Fuel system (dfi) 3-107 fuel injectors output voltage inspection • turn the ignition switch off. • remove the ecu (see ecu removal). Do not disconnect the ecu connector. • connect a digital voltmeter to the connector, using the needle adapter set. Special tool - needle adapter set: 57001-1457 inject...

  • Page 194

    3-108 fuel system (dfi) fuel injectors 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 terminal thickness [c]: 0.8 mm caution do not use larger terminals than specified above. A larger terminal could dam...

  • Page 195

    Fuel system (dfi) 3-109 fuel injectors 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 battery [d] caution be sure to connect the bulb in series. The bulb works as a current limiter to protect the soleno...

  • Page 196

    3-110 fuel system (dfi) fuel injectors fuel injector circuit (other than europe models) 1. Ecu 2. Engine stop switch 3. Ignition switch 4. Ignition fuse 10 a 5. Ecu fuse 15 a 6. Fuse box 7. Ecu main relay 8. Fuel pump relay 9. Relay box 10. Main fuse 30 a 11. Starter relay 12. Battery 13. Joint conn...

  • Page 197

    Fuel system (dfi) 3-111 fuel injectors fuel injector circuit (other than europe models) 1. Ecu 2. Engine stop switch 3. Ignition switch 4. Ignition fuse 10 a 5. Ecu fuse 15 a 6. Fuse box 7. Ecu main relay 8. Fuel pump relay 9. Relay box 10. Main fuse 30 a 11. Starter relay 12. Battery 13. Joint conn...

  • Page 198

    3-112 fuel system (dfi) throttle grip and cables throttle grip free play inspection • refer to throttle control system inspection in the peri- odic 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 ...

  • Page 199

    Fuel system (dfi) 3-113 throttle body assy idle speed inspection • refer to idle speed inspection in the periodic mainte- nance chapter. Idle speed adjustment • refer to idle speed adjustment in the periodic mainte- nance chapter. Throttle bore cleaning • check the throttle bore for cleanliness as f...

  • Page 200

    3-114 fuel system (dfi) throttle body assy • remove the screws and take off the right switch housing. • remove the accelerator cable end [a] and decelerator cable end [b] at the throttle grip. • disconnect the injector connectors [a]. • unscrew the bolts [b] and remove the throttle body assy [c] wit...

  • Page 201

    Fuel system (dfi) 3-115 throttle body assy ○ be careful not to damage (dent, nick, flaw, and crack) the flange mating surface and the plastic parts. ○ do not drop the throttle body assy, especially on a hard surface. Warning the throttle body assy should never be allowed to fall. Throttle may become...

  • Page 202

    3-116 fuel system (dfi) throttle body assy • before installation, visually inspect the mating surfaces [a] for any damage, like dent, nick, rust, flaw, and crack. • nick or rust damage can sometimes be repaired by using emery paper (first no. 200, then 400) to remove sharp edges or raised areas. If ...

  • Page 203

    Fuel system (dfi) 3-117 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. • turn the throttle grip and make sure t...

  • Page 204

    3-118 fuel system (dfi) air cleaner air cleaner element removal/installation • refer to the air cleaner element replacement in the pe- riodic maintenance chapter. Air cleaner housing removal • remove the air cleaner housing bolts [a]. • clear the idle speed screw [a] from the recess on the air clean...

  • Page 205

    Fuel system (dfi) 3-119 air cleaner • fit the idle speed screw [a] in the recess on the air cleaner housing. • be sure the dampers [a] and collars [b] are in position. ○ install the damper [a] into the air cleaner housing [c] as shown. Smaller diameter [d] larger diameter [e] torque - air cleaner ho...

  • Page 206

    3-120 fuel system (dfi) 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 207

    Fuel system (dfi) 3-121 fuel tank • remove: seat (see seat removal in the frame chapter) fuel tank bolts [a] • disconnect (california model): fuel return hose (red) [a] • unscrew the screw [a], and pull out the ignition coil cover [b]. • disconnect: fuel pump connector [a].

  • Page 208

    3-122 fuel system (dfi) fuel tank • place a cloth around the fuel hose joint. • insert a minus screw driver [a] into the slit on the joint lock [b]. • turn the driver to disconnect the joint lock. • pull [c] the fuel hose joint [d] out of the outlet pipe. Caution when removing the fuel hose joint, d...

  • Page 209

    Fuel system (dfi) 3-123 fuel tank fuel tank installation • read the above warning. • route the hoses correctly (see cable, wire and hose routing section in the appendix chapter). • for california model, note the following: ○ to prevent the gasoline from flowing into or out of the canister, hold the ...

  • Page 210

    3-124 fuel system (dfi) fuel tank fuel tank and cap inspection • visually inspect the gasket [a] on the tank cap for any damage. Replace the gasket if it is damaged. • check to see if the breather pipe [b] in the tank is not clogged. If the breather pipe is clogged, blow the breather free with compr...

  • Page 211

    Fuel system (dfi) 3-125 fuel tank • check to see if the valve [a] slides smoothly when push- ing it in with a wooden or other soft rod, and see if it comes back to its seat by pressure of the spring [b]. Note ○ inspect the valve in its assembled state. Disassembly and assembly may change the valve p...

  • Page 212

    3-126 fuel system (dfi) 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 213

    Fuel system (dfi) 3-127 evaporative emission control system separator operation test 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 li...

  • Page 214

    3-128 fuel system (dfi) evaporative emission control system 1. Fuel tank 2. Throttle body 3. Canister 4. Separator 5. Breather check valve 6. Breather hose 7. Breather hose (blue) 8. Vacuum hose (white) 9. Fuel return hose (red) 10. Purge hose (green) 11. To air switching valve 12. To air cleaner.

  • Page 215: Cooling System

    Cooling system 4-1 4 cooling system table of contents exploded view........................................................................................................................ 4-2 specifications ................................................................................................

  • Page 216

    4-2 cooling system exploded view.

  • Page 217

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 water pump impeller bolt 9.8 1.0 87 in·lb 2 water hose fitting bolts 9.8 1.0 87 in·lb 3 water (radiator) hose clamp screws 2.0 0.20 18 in·lb 4 thermostat housing cover bracket bolts 6.9 0.70 61 in·lb 5 thermostat housing ...

  • Page 218

    4-4 cooling system specifications item standard service limit coolant provided when shipping type permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) – – – color green – – – mixed ratio soft water 50%, coolant 5...

  • Page 219

    Cooling system 4-5 special tools and sealant bearing driver set: 57001-1129 bearing remover shaft, 9: 57001-1265 bearing remover head, 10 × 12: 57001-1266 kawasaki bond (silicone sealant): 56019-120

  • Page 220

    4-6 cooling system coolant flow chart.

  • Page 221

    Cooling system 4-7 coolant flow chart 1. Thermostat 2. Radiator cap 3. Cylinder head jacket 4. Radiator fan 5. Radiator 6. Cylinder jacket 7. Water pump 8. Reserve tank 9. Hot coolant 10. Cold coolant permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosio...

  • Page 222

    4-8 cooling system coolant coolant deterioration inspection • visually inspect the coolant 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 parts are rusting. In either case, flush the cooling sy...

  • Page 223

    Cooling system 4-9 coolant reserve tank removal • remove: left side cover (see left side cover removal in the frame chapter) bolt [a] reserve tank cover [b] • remove: bolts [a] cap [b] • drain the coolant to the suitable container. • remove: hose [c].

  • Page 224

    4-10 cooling system water pump water pump impeller removal • drain: engine oil (see engine oil change in the periodic main- tenance chapter) coolant (see coolant change in the periodic mainte- nance chapter) • remove: right engine cover (see right engine cover removal in the clutch chapter) bolt [a]...

  • Page 225

    Cooling system 4-11 water pump if the seal and ball bearing are damaged, replace the me- chanical seal, ball bearing, and oil seal by splitting the crankcase. • split the crankcase (see crankcase splitting in the crank- shaft/transmission chapter). • take the bearing [a] out of the right crankcase, ...

  • Page 226

    4-12 cooling system water pump water pump inspection • check the drainage outlet passage [a] at the bottom of the right crankcase for coolant leaks. If the mechanical seal is damaged, the coolant leaks through the seal and drains through the passage. Re- place the mechanical seal with a new one. • v...

  • Page 227

    Cooling system 4-13 radiator, radiator fan radiator and radiator fan removal 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 f...

  • Page 228

    4-14 cooling system radiator, radiator fan • remove: radiator fan connector [a] radiator • remove: radiator fan mounting bolts [a] radiator fan [b] caution do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling effi- ciency. Radiator fan installation • torq...

  • Page 229

    Cooling system 4-15 radiator, radiator fan radiator cap inspection • check the condition of the top [a] and bottom [b] valve seals and valve spring [c]. If any one of them shows visible damage, replace the cap with a new one. • install the cap [a] on a cooling system pressure tester [b]. Note ○ wet ...

  • Page 230

    4-16 cooling system thermostat thermostat removal • drain: coolant (about 200 ml) • remove: seat (see seat removal in the frame chapter) fuel tank (see fuel tank removal in the fuel system (dfi) chapter) reserve tank hose [a] radiator hose clamp [b] (loosen) water temperature connector [c] bolt [d] ...

  • Page 231

    Cooling system 4-17 thermostat • to check valve opening temperature, suspend the ther- mostat [a] in a container of water and raise the tempera- ture of the water. ○ the thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [b] in...

  • Page 232

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

  • Page 233

    Cooling system 4-19 water temperature sensor water temperature sensor removal/installation caution the water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to water temperature sensor can damage it. • refer to the water temperature sensor removal/instal- lation ...

  • Page 235: Engine Top End

    Engine top end 5-1 5 engine top end table of contents exploded view........................................................................................................................ 5-4 exploded veiw .................................................................................................

  • Page 236

    5-2 engine top end piston wear ...................................................................................................................... 5-35 piston/cylinder clearance ................................................................................................ 5-36 piston ring, pist...

  • Page 237

    Engine top end 5-3 dummy page.

  • Page 238

    5-4 engine top end exploded view.

  • Page 239

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks cylinder head nuts(m10)(first) 20 2.0 15 s, mo 1 cylinder head nuts(m10)(final) 49 5.0 36 s, mo 2 cylinder head nuts(m8) 25 2.5 18 s 3 camshaft cap bolts 25 2.5 18 4 cylinder head cover bolts 12 1.2 106 in·lb 5 cylinder hea...

  • Page 240

    5-6 engine top end exploded view.

  • Page 241

    Engine top end 5-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 muffler mounting bolts 25 2.5 18 2 muffler mounting nut 25 2.5 18 3 muffler joint clamp bolt 17 1.7 12 4 exhaust pipe cover clamp bolts 6.9 0.70 61 in·lb 5 exhaust pipe cover bolts 6.9 0.70 61 in·lb 6 exhaust pipe holder ...

  • Page 242

    5-8 engine top end exploded veiw exhaust system uk: u.K model full: full power h: honeycomb type catalyst silensor [a] without boss [a] for oxygen sensor silensor with boss [b] for oxygen sensor.

  • Page 243

    Engine top end 5-9 specifications item standard service limit camshafts cam height: exhaust 35.030 ∼ 35.144 mm (1.3791 ∼ 1.3836 in.) 34.93 mm (1.375 in.) inlet 35.302 ∼ 35.416 mm (1.3898 ∼ 1.3943 in.) 35.20 mm (1.386 in.) camshaft journal, camshaft cap clearance 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in....

  • Page 244

    5-10 engine top end specifications item standard service limit cylinder, piston cylinder inside diameter 88.000 ∼ 88.012 mm (3.4646 ∼ 3.4650 in.) 88.10 mm (3.468 in.) piston diameter 87.955 ∼ 87.970 mm (3.4628 ∼ 3.4634 in.) 87.80 mm (3.457 in.) piston/cylinder clearance 0.030 ∼ 0.057 mm (0.0012 ∼ 0....

  • Page 245

    Engine top end 5-11 special tools compression gauge, 20 kgf/cm²: 57001-221 valve spring compressor assembly: 57001-241 piston pin puller assembly: 57001-910 valve seat cutter, 45° - 32: 57001-1115 valve seat cutter, 32° - 28: 57001-1119 valve seat cutter, 60° - 30: 57001-1123 valve seat cutter holde...

  • Page 246

    5-12 engine top end special tools valve guide arbor, 5: 57001-1203 valve guide reamer, 5: 57001-1204 valve seat cutter holder, 5: 57001-1208 spark plug wrench, hex 16: 57001-1262 compression gauge adapter, m10 × 1.0: 57001-1317 valve seat cutter, 60° - 33: 57001-1334 note ○ the following valve seat ...

  • Page 247

    Engine top end 5-13 clean air system air suction valve removal • remove: cylinder head covers (see cylinder head cover re- moval) air suction valves [a] air suction valve installation • install each air suction valve so that stopper side [a] of the reed faces downward. Air suction valve inspection •...

  • Page 248

    5-14 engine top end clean air system clean air system hose inspection • be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the right air cleaner base, air switching valve, and fittings on the rocker case covers if they are not, correct them. ...

  • Page 249

    Engine top end 5-15 cylinder head cover cylinder head cover removal • remove: seat (see seat removal in the frame chapter) fuel tank (see fuel tank removal in the fuel system (dfi) chapter) • slide [a] the air switching valve [b] forward to clear the clamp. • remove: bolt [a] clamp [b] • remove: cyl...

  • Page 250

    5-16 engine top end cylinder head cover • remove: dampers [a] cylinder head cover bolts [b] and washers cylinder head cover [c] cylinder head cover gasket ○ just move everything that is between the cylinder head cover and the frame out of the may to make room. Then as a lift the cover up, make sure ...

  • Page 251

    Engine top end 5-17 camshaft chain tensioner camshaft chain tensioner removal • remove: engine (see engine removal/installation chapter) camshaft (see camshaft removal) cylinder head (see cylinder head removal) • remove the camshaft chain tensioner body from the cylinder. Camshaft chain tensioner in...

  • Page 252

    5-18 engine top end camshaft, camshaft chain camshaft removal • remove: cylinder head cover (see cylinder head cover re- moval) ignition coil cover (for front cylinder)(see ignition coil removal in the electrical system chapter) tensioner cap bolt [a], washer [b] and spring caution do not turn over ...

  • Page 253

    Engine top end 5-19 camshaft, camshaft chain camshaft installation • apply engine oil to all cam parts and journals. Note ○ the front and rear camshafts are different. The rear camshaft [a] has a groove [b]. • remove: alternator outer cover (see alternator outer cover re- moval in the electrical sys...

  • Page 254

    5-20 engine top end camshaft, camshaft chain note ○ installing the rear camshaft is the same as for the front camshaft. But noting the following. • set the rear piston at tdc. ○ align the rear piston tdc mark [a] and timing mark [b] by turning the crankshaft counterclockwise [c] 305° (left side view...

  • Page 255

    Engine top end 5-21 camshaft, camshaft chain camshaft runout • remove the camshaft (see camshaft removal). • set the camshaft in a camshaft alignment jig or on v blocks. • measure runout with a dial gauge at the specified place as shown. If the runout exceeds the service limit, replace the shaft. Ca...

  • Page 256

    5-22 engine top end camshaft, camshaft chain camshaft and sprocket assembly • clean the sprocket bolt [a] and threads of the camshaft. • be sure to install the pin [b]. • apply a non-permanent locking agent to the threads of the camshaft sprocket bolt, and tighten it. The sprockets are identical. To...

  • Page 257

    Engine top end 5-23 rocker shaft, rocker arm rocker shaft, rocker arm removal • remove: cylinder head cover (see cylinder head cover re- moval) camshaft cap (see camshaft removal) rocker shafts [a] rocker arms [b] and springs [c] rocker shaft, rocker arm installation • apply molybdenum disulfide gre...

  • Page 258

    5-24 engine top end cylinder head cylinder compression measurement note ○ use the battery which is fully charged. • warm up the engine thoroughly. • stop the engine. • remove: seat (see seat removal in the frame chapter) fuel tank (see fuel tank removal in the fuel system (dfi) chapter) spark plugs ...

  • Page 259

    Engine top end 5-25 cylinder head cylinder head removal • remove: engine (see engine removal in the engine removal/in- stallation chapter) camshaft (see camshaft removal) • remove the cylinder head nuts following sequence [1 ∼ 6]. • remove: cylinder head cylinder head installation note ○ the camshaf...

  • Page 260

    5-26 engine top end valves valve clearance inspection • refer to the valve clearance inspection in the periodic maintenance chapter. Valve clearance adjustment • refer to the valve clearance adjustment in the periodic maintenance chapter. Valve removal • remove the cylinder head (see cylinder head r...

  • Page 261

    Engine top end 5-27 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) (see valve guide removal). • drive the valve guide in from the top of the head using the valve guide ...

  • Page 262

    5-28 engine top end valves valve seat inspection • remove the valve (see valve removal). • check the valve seating surface [a] between the valve [b] and valve seat [c]. ○ measure the outside diameter [d] of the seating pattern on the valve seat. If the outside diameter is too large or too small, rep...

  • Page 263

    Engine top end 5-29 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 264

    5-30 engine top end valves • measure the outside diameter (o.D.) of the seating sur- face with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind [a] until the diameter is within the specified range. Original seating surface [b] note ○ remove all pit...

  • Page 265

    Engine top end 5-31 valves • lap the valve to the seat, once the seat width and o.D. Are within the ranges specified above. ○ put a little coarse grinding compound on the face of the valve in a number of places around the valve head. ○ spin the valve against the seat until the grinding com- pound pr...

  • Page 266

    5-32 engine top end valves.

  • Page 267

    Engine top end 5-33 cylinders, pistons cylinder removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove the cylinder head (see cylinder head removal). • pull out the front camshaft chain guide [a] and oil pipe [b]. • tap lightly up the cylinder with a plastic m...

  • Page 268

    5-34 engine top end cylinders, pistons • 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 ...

  • Page 269

    Engine top end 5-35 cylinders, pistons 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 with a new one. • be sure to install the dowel pins [a]. • using the piston ring compre...

  • Page 270

    5-36 engine top end cylinders, pistons piston/cylinder clearance • subtract the piston diameter from the cylinder inside di- ameter to get the piston/cylinder clearance. Piston/cylinder clearance standard: 0.030 ∼ 0.057 mm (0.0012 ∼ 0.0022 in.) if the piston/cylinder clearance is less than the speci...

  • Page 271

    Engine top end 5-37 cylinders, pistons piston ring thickness • measure the piston ring thickness. ○ use a micrometer to measure at several points around the ring. Piston ring thickness standard: top and second 0.97 ∼ 0.99 mm (0.038 ∼ 0.039 in.) service limit: top and second 0.90 mm (0.035 in.) if an...

  • Page 272

    5-38 engine top end muffler muffler removal • remove: clamp screws (loosen) [a] bolt [b] rear muffler cover [c] • remove: clamp screws (loosen) [a] bolt [b] front muffler cover [c] • remove: muffler mounting nut [a], collar and damper muffler mounting bolt [b] • remove: muffler mounting bolts [a] • ...

  • Page 273

    Engine top end 5-39 muffler • remove: rear exhaust holder nuts [a] • remove the upper and lower muffler jointed. Muffler installation • joint the upper and lower muffler. • temporary tighten the muffler joint clamp bolt [a]. • install the muffler. • tighten: torque - muffler mounting nut: 25 n·m (2....

  • Page 275: Clutch

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

  • Page 276

    6-2 clutch exploded view.

  • Page 277

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 right engine cover bolts 98 1.0 87 in·lb l (1) 2 clutch hub nut 130 13.2 95.9 mo 3 clutch spring bolts 9.8 1.0 87 in·lb cl: apply cable lubricate. Eo: apply engine oil. G: apply grease. L: apply a non-permanent locking agent. Mo:...

  • Page 278

    6-4 clutch specifications item standard service limit clutch lever free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) clutch friction plate thickness 2.9 ∼ 3.1 mm (0.114 ∼ 0.122 in.) 2.8 mm (0.110 in.) friction and steel plate warp 0.2 mm (0.008 in.) or less 0.3 mm (0.01 in.) clutch spring free length 33.6 mm (1....

  • Page 279

    Clutch 6-5 special tool clutch holder: 57001-1243.

  • Page 280

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

  • Page 281

    Clutch 6-7 clutch lever and cable clutch lever installation • install the clutch lever so that the mating surface [a] of the lever holder is aligned with the punch mark [b] of the handlebar..

  • Page 282

    6-8 clutch right engine cover right engine cover removal • drain: engine oil (see engine oil change in the periodic main- tenance chapter) coolant (see coolant change in the periodic mainte- nance chapter) • remove: brake pedal (see brake pedal removal in the brakes chapter) right footboard (see foo...

  • Page 283

    Clutch 6-9 right engine cover release shaft removal caution do not remove the clutch release lever and shaft assembly unless it is absolutely necessary. If re- moved, the oil seal replacement may be required. • remove the right engine cover (see right engine cover removal). • remove the circlip [a] ...

  • Page 284

    6-10 clutch clutch clutch removal • remove: right engine cover (see right engine cover removal) clutch spring bolts [a] clutch springs clutch spring plate [b] (with thrust bearing and pusher [c]) • remove: friction plates, steel plates clutch hub nut [a] • holding the clutch hub [b], remove the nut....

  • Page 285

    Clutch 6-11 clutch • install the washer so that the outside mark [a] faces outward. • replace the clutch hub nut with a new one. • apply molybdenum disulfide oil to seating surface of the hub nut. • holding the clutch hub, tighten the clutch hub nut. Special tool - clutch holder: 57001-1243 torque -...

  • Page 286

    6-12 clutch clutch clutch plate warp inspection • place each friction plate or steel plate on a surface plate and measure the gap between the surface plate [a] and each friction plate or steel plate [b] with a thickness gauge [c]. The gap is the amount of friction or steel plate warp. If any plate i...

  • Page 287: Engine Lubrication System

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

  • Page 288

    7-2 engine lubrication system exploded view.

  • Page 289

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine oil drain plug 20 2.0 15 2 oil pump cover bolts 9.8 1.0 87 in·lb l 3 oil pump drive chain guide bolt 9.8 1.0 87 in·lb l 4 oil filter 18 1.8 13 5 oil filter plate bolts 7.8 0.80 69 in·lb 6 oil screen plug...

  • Page 290

    7-4 engine lubrication system engine oil flow chart 1. Rocker arm 2. Oil pipe 3. Output shaft 4. Drive shaft 5. Oil screen 6. Oil pump 7. Crankshaft 8. Oil pressure switch 9. Oil filter 10. Oil pressure relief valve.

  • Page 291

    Engine lubrication system 7-5 specifications item standard engine oil type api se, sfor sg api sh, sj or sl with jaso ma viscosity sae 10w-40 capacity 3.0 l (3.2 us qt) (when filter is not removed) 3.2 l (3.4 us qt) (when filter is removed) 3.7 l (3.9 us qt) (when engine is completely dry) level (af...

  • Page 292

    7-6 engine lubrication system special tools and sealant oil pressure gauge, 10 kgf/cm²: 57001-164 oil pressure gauge adapter, m10 × 1.25: 57001-1182 kawasaki bond (silicone sealant): 56019-120

  • Page 293

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

  • Page 294

    7-8 engine lubrication system engine oil and oil filter • pull out the oil screen [a]. • clean the screen with high flash-point solvent. Warning clean the screen in a well-ventilated area, and take care that there is no spark or frame anywhere near the working area. Because of the danger of highly f...

  • Page 295

    Engine lubrication system 7-9 oil pressure relief valve oil pressure relief valve removal/installation • split the crankcase (see crankcase splitting in the crank- shaft/transmission chapter). • remove the relief valve [a] from the right crankcase. • apply a non-permanent locking agent to the thread...

  • Page 296

    7-10 engine lubrication system oil pump, oil pump drive chain oil pump removal • split the crankcase (see crankcase splitting in the crank- shaft/transmission chapter). • remove: water pump impeller (see water pump impeller re- moval in the cooling system chapter) crankshaft (see crankshaft removal ...

  • Page 297

    Engine lubrication system 7-11 oil pump, oil pump drive chain oil pump drive chain guide installation • install the chain guide [a] to the left crankcase. • apply a non-permanent locking agent to the threads of the chain guide bolt [b], and tighten it. Torque - oil pump drive chain guide bolt: 9.8 n...

  • Page 298

    7-12 engine lubrication system oil pressure measurement oil pressure measurement • remove: • regulator/rectifier (see regulator/rectifier removal in the electrical system chapter) • remove the oil pressure switch together with the adapter (see oil pressure switch removal) without draining the engine...

  • Page 299

    Engine lubrication system 7-13 oil pressure switch oil pressure switch removal • drain: engine oil (see engine oil change in the periodic main- tenance chapter) • remove: switch cover [a] switch lead terminal [b] oil pressure switch [c] oil pressure switch installation • apply silicone sealant to th...

  • Page 300

    7-14 engine lubrication system oil pipe and oil hose oil pipe (crankcase outside) removal • remove: alternator cover (see alternator cover removal in the electrical system chapter) oil pipe mounting bolts [a] oil pipe [b] oil pipe (crankcase outside) installation • apply grease to the o-rings [a]. •...

  • Page 301

    Engine lubrication system 7-15 oil pipe and oil hose • install the oil return pipe [a]. • tighten: torque - oil return pipe bolts [b]: 9.8 n·m (1.0 kgf·m, 87 in·lb) blowby gas system inspection • remove: ignition coil with the bracket (see ignition coil removal in the electrical system chapter) • be...

  • Page 303: Engine Removal/installation

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

  • Page 304

    8-2 engine removal/installation exploded view.

  • Page 305

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine mounting nuts 44 4.5 32 2 engine mounting bracket bolts (m10) 44 4.5 32 3 engine mounting bracket bolts (m8) 25 2.5 18 4 downtube mounting bolts 44 4.5 32 wl: apply a soap and water solution..

  • Page 306

    8-4 engine removal/installation special tool jack: 57001-1238.

  • Page 307

    Engine removal/installation 8-5 engine removal/installation engine removal • drain: engine oil (see engine oil change in the periodic main- tenance chapter) coolant (see coolant change in the periodic mainte- nance chapter) • remove: seat (see seat removal in the frame chapter) fuel tank (see fuel t...

  • Page 308

    8-6 engine removal/installation engine removal/installation • remove: speed sensor connector [a] • remove: water temperature sensor connector [a] water hoses [b] thermostat housing cover bracket bolt [c] • remove: cap [a] and bolt ignition switch [b] • disconnect: alternator lead connector [a] • rem...

  • Page 309

    Engine removal/installation 8-7 engine removal/installation • support the frame with the jack. Special tool - jack: 57001-1238 • squeeze the brake lever slowly and hold it with a band [a]. Warning be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It could cau...

  • Page 310

    8-8 engine removal/installation engine removal/installation engine installation • when installing the rubber dampers into the bracket, lu- bricate the outer surface of the dampers with a soap and water solution. Caution do not lubricate the rubber damper with engine oil or petroleum distillates beca...

  • Page 311: Crankshaft/transmission

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

  • Page 312

    9-2 crankshaft/transmission exploded view.

  • Page 313

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 crankcase bolts (m6) 9.8 1.0 87 in·lb s 2 crankcase bolts (m10) 39 4.0 29 s 3 connecting rod big end bolts 46 4.7 34 mo 4 primary gear bolt 98 10 72 mo 5 balancer gear bolt 69 7.0 51 6 starter motor clutch gear b...

  • Page 314

    9-4 crankshaft/transmission exploded view.

  • Page 315

    Crankshaft/transmission 9-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 shift drum cam bolt 12 1.2 106 in·lb l 2 rear shift lever clamp bolt 12 1.2 106 in·lb 3 shift return spring pin 29 3.0 21 l 4 shift drum position lever bolt 9.8 1.0 87 in·lb 5 shift pedal clamp bolt 12 1.2 106 in...

  • Page 316

    9-6 crankshaft/transmission specifications item standard service limit crankshaft, connecting rods connecting rod big end side clearance 0.08 ∼ 0.3 mm 0.5 mm (0.003 ∼ 0.01 in.) (0.02 in.) 0.026 ∼ 0.054 mm 0.09 mm connecting rod big end bearing insert/crankpin clearance (0.0010 ∼ 0.0021 in.) (0.035 i...

  • Page 317

    Crankshaft/transmission 9-7 specifications item standard service limit crankshaft main journal diameter 44.984 ∼ 45.000 mm 44.96 mm (1.7710 ∼ 1.7716 in.) (1.770 in.) crankcase main bearing bore diameter 45.025 mm ∼ 45.041 mm 45.07 mm (1.7726 ∼ 1.7733 in.) (1.774 in.) transmission shift fork ear thic...

  • Page 318

    9-8 crankshaft/transmission special tools and sealants outside circlip pliers: 57001-144 bearing driver set: 57001-1129 grip: 57001-1591 rotor holder: 57001-1674 kawasaki bond (silicone sealant): 92104-0004 kawasaki bond (liquid gasket - black): 92104-1064.

  • Page 319

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

  • Page 320

    9-10 crankshaft/transmission crankcase splitting • put the engine so that the left crankcase is down. • pry the points [a] to split the crankcase halves apart, and remove the right crankcase half. ○ tap lightly around the crankcase joint with a plastic mallet, and split the crankcase. Take care not ...

  • Page 321

    Crankshaft/transmission 9-11 crankcase splitting • apply liquid gasket [a] to the mating surface of the right crankcase half. Sealant - kawasaki bond (liquid gasket - black): 92104 -1064 caution do not apply liquid gasket to the oil passage [b] and hole [c]. Note ○ make the application finish within...

  • Page 322

    9-12 crankshaft/transmission crankcase splitting • apply silicone sealant to the crankcace mating surface [a] as shown. Sealant - kawasaki bond (silicon sealant): 92104-0004.

  • Page 323

    Crankshaft/transmission 9-13 crankshaft/connecting rods crankshaft removal • split the crankcase (see crankcase splitting). • remove the crankshaft. Crankshaft installation • insert the crankshaft tapered end in to the left crankcase [a]. • install the left connecting rod [b] into the rear cylinder ...

  • Page 324

    9-14 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 325

    Crankshaft/transmission 9-15 crankshaft/connecting rods connecting rod bend • remove the connecting rod big end bearing insets, and reinstall the connecting rod big end cap. • select an arbor [a] of the same diameter as the connect- ing rod big end, and insert the arbor through the connect- ing rod ...

  • Page 326

    9-16 crankshaft/transmission crankshaft/connecting rods if clearance is within the standard, no bearing replace- ment is required. If clearance is between 0.054 mm (0.0021 in.) and the service limit (0.09 mm, 0.035 in.), replace the bear- ing inserts [a] with inserts painted blue [b]. Check insert/c...

  • Page 327

    Crankshaft/transmission 9-17 crankshaft/connecting rods • select the proper bearing insert [a] in accordance with the combination of the connecting rod and crankshaft coding. Size color [b] connecting rod big end bearing insert selection bearing insert con-rod big end bore diameter marking crankpin ...

  • Page 328

    9-18 crankshaft/transmission crankshaft/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: 44.984 ∼ 45.0...

  • Page 329

    Crankshaft/transmission 9-19 balancer, starter motor clutch left balancer removal • remove the alternator cover (see alternator cover re- moval in the electrical system chapter). • wipe oil off the outer circumference of the alternator rotor. • hold the alternator rotor steady with the rotor holder ...

  • Page 330

    9-20 crankshaft/transmission balancer, starter motor clutch • remove: starter motor clutch gear bolt [a] washers [b] • remove: starter motor clutch gear [a] torque limiter [b] needle bearing [c] collar [d] starter motor clutch assembly [e] washer if the assembly is hard to remove, use a suitable pul...

  • Page 331

    Crankshaft/transmission 9-21 balancer, starter motor clutch • install: torque limiter washer collar [a] and needle bearing [b] • install the starter motor clutch gear [c] while turning [d] the gear. • install the alternator rotor (see alternator rotor installa- tion in the electrical system chapter)...

  • Page 332

    9-22 crankshaft/transmission torque limiter torque limiter removal • remove: right engine cover (see right engine cover removal in the clutch chapter) washer [a] starter motor clutch gear [b] (see right balancer and starter motor clutch removal) torque limiter [c] caution do not disassemble the torq...

  • Page 333

    Crankshaft/transmission 9-23 primary gear primary gear removal • remove the alternator cover (see alternator cover re- moval in the electrical system chapter). • wipe oil off the outer circumference of the alternator rotor. • hold the alternator rotor steady with the rotor holder [a]. Special tools ...

  • Page 334

    9-24 crankshaft/transmission transmission shift pedal removal • remove: shift pedal clamp bolt [a] • remove: footboard bracket bolts [a] footboard [b] together with the shift pedal [c] • separate the shift pedal from the footboard. Shift pedal installation • apply grease to the shift pedal shaft. • ...

  • Page 335

    Crankshaft/transmission 9-25 transmission • remove: front and rear shift levers [a] • remove: bolts [a] external shift mechanism cover [b] together with the shift shaft [c] ○ remove the these bolts [d] with the cover. • remove: bolt [a] spring [b] gear set lever [c] external shift mechanism installa...

  • Page 336

    9-26 crankshaft/transmission transmission • install the front shift lever [a] to the shift pedal shaft so that the punched mark [b] on the shaft is aligned with the punched marked [c] on the front shift lever. • install the rear shift lever [a] on the shift shaft so that the punched mark [b] on the ...

  • Page 337

    Crankshaft/transmission 9-27 transmission • check the return spring pin [a] is not loose. If it is loose, unscrew it, apply a non-permanent locking agent to the threads, and tighten it. Torque - shift shaft return spring pin: 29 n·m (3.0 kgf·m, 21 ft·lb) • check the shift drum position lever [b] and...

  • Page 338

    9-28 crankshaft/transmission transmission transmission shaft assembly • install the 5th gear [a] on the output shaft with its oil hole [b] aligned with the shaft oil hole [c]. • fit the steel balls into the 4th gear holes as shown. (this illustration shows "section a-a" in the transmission assembly ...

  • Page 339

    Crankshaft/transmission 9-29 transmission shift drum installation • while aligning the shift drum cam [a] with the left crankcase hole, install the shift drum. • tighten: torque - shift drum bearing stopper bolts 9.8 n·m (1.0 kgf·m, 87 in·lb) shift drum disassembly • remove the shift drum (see shift...

  • Page 340

    9-30 crankshaft/transmission transmission 1. Drive shaft 2. Output shaft 3. 1st gear 4. 2nd gear 5. 3rd gear 6. 4th gear 7. 5th (top) gear 8. Circlip 9. Thrust washer (20 × 41 × 1) 10. Circlip 11. Thrust washer (25.3 × 30 × 1) 12. Circlip 13. Toothed washer 14. Thrust washer (30 × 38 × 1) 15. Thrust...

  • Page 341

    Crankshaft/transmission 9-31 transmission shift drum assembly • assemble: dowel pin (shorter) [a] shift drum holder [b] spring [c] circlip [d] special tool - outside circlip pliers: 57001-144 • assemble: dowel pin (longer) [e] bearing [f] shift drum cam [g] shift drum [i] • apply a non-permanent loc...

  • Page 342

    9-32 crankshaft/transmission transmission gear dog and gear dog hole damage • visually inspect the gear dogs [a] and gear dog holes [b]. Replace any damaged gears or gears with excessively worn dogs or dog holes..

  • Page 343

    Crankshaft/transmission 9-33 ball bearing and oil seal bearing and oil seal installation • when installing a bearing other than the following parts, press it in with the marked side facing out. Special tool - bearing driver set: 57001-1129 right crankcase • press the water pump shaft bearing and oil...

  • Page 345: Wheels/tires

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

  • Page 346

    10-2 wheels/tires exploded view.

  • Page 347

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front axle nut 108 11.0 79.7 2 front axle clamp bolt 20 2.0 15 3 rear axle nut 108 11.0 79.7 4 spoke nipples 5.2 0.53 46 in·lb 5. Axle cap (europe models) g: apply grease. R: replacement parts wl: apply sorp and water solu...

  • Page 348

    10-4 wheels/tires specifications item standard service limit wheels (rims) rim runout: radial tir 0.8 mm (0.03 in.) 2.0 mm (0.079 in.) axial 0.8 mm (0.03 in.) 2.0 mm (0.079 in.) axle runout/100 mm (3.94 in.) front less than 0.05 mm (0.002 in.) 0.2 mm (0.008 in.) rear less than 0.03 mm (0.001 in.) 0....

  • Page 349

    Wheels/tires 10-5 special tools rim protector: 57001-1063 bead breaker assembly: 57001-1072 bearing driver set: 57001-1129 jack: 57001-1238 bearing remover shaft, 9: 57001-1265 bearing remover head, 15 × 17: 57001-1267 bearing remover head, 20 × 22: 57001-1293.

  • Page 350

    10-6 wheels/tires wheels (rims) front wheel removal • unscrew the front brake caliper mounting bolts [a] and remove the brake caliper [b] with the brake hose installed. • for the europe models, remove the axle caps. • loosen: front axle clamp bolt [a] front axle [b] • remove: front fender (see front...

  • Page 351

    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: torque - front axle nuts: 108 n·m (11.0 kgf·m, 79.7 ft·lb) • install:...

  • Page 352

    10-8 wheels/tires wheels (rims) • squeeze the brake lever slowly and hold it with a band [a]. Caution be sure to hold the front brake when removing the rear wheel, or the motorcycle may fall over. The motorcycle could be damaged. Warning be sure to hold the front brake when removing the rear wheel, ...

  • Page 353

    Wheels/tires 10-9 wheels (rims) • place the suitable stand (about 30 mm (1.2 in.) thickness) [a] under the rear tire. • reduce the jack until the rear axle shaft pull out easily, and remove the axle shaft. • incline the rear wheel to the right diagonally. • remove the drive belt [a] from the rear pu...

  • Page 354

    10-10 wheels/tires wheels (rims) • install the rear wheel so that the grove [a] of the caliper bracket fit onto the swingarm stop [b]. • reduce the jack until the rear axle install easily. • engage the drive belt [a] with the pully [b]. • insert the axle from the left side of the rear wheel. • tight...

  • Page 355

    Wheels/tires 10-11 wheels (rims) rim and spokes removal • remove the tire and tube. • remove the rubber band. • tape or wire all the spokes intersections so that the spokes don’t get mixed up, and unscrew the nipples from all the spokes with a screwdriver, separate the rim from the spokes and hub. R...

  • Page 356

    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 357

    Wheels/tires 10-13 tires air pressure inspection/adjustment • refer to the tire air pressure inspection in the periodic maintenance chapter. Tire tread inspection • refer to the tire tread wear inspection in the periodic maintenance chapter. Tire removal caution do not lay the wheel on the ground wi...

  • Page 358

    10-14 wheels/tires tires tire installation warning use the same manufacture’s tires on both front and rear wheels. • check the tire rotation mark [a] on the front/rear tire and install it on the rim accordingly. Note ○ the direction of the tire rotation is shown by an arrow on the tire sidewall. • p...

  • Page 359

    Wheels/tires 10-15 hub bearing hub bearing removal • remove the wheel, and take out the following. Caution do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. Front grease seals [a] r...

  • Page 360

    10-16 wheels/tires hub bearing • replace the grease seals with new ones. • press in the grease seal [a] so that the seal surface is flush [b] with the end of the hole. ○ apply high temperature grease to the grease seal lips. Special tool - bearing driver set: 57001-1129 [c] hub bearing inspection ○ ...

  • Page 361: Final Drive

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

  • Page 362

    11-2 final drive exploded view.

  • Page 363

    Final drive 11-3 exploded view front gear case torque no. Fastener n·m kgf·m ft·lb remarks 1 rear pulley mounting nuts 59 6.0 44 2 rear pulley plate bolts 6.9 0.70 61 in·lb l 3 engine pulley mounting nut 127 13.0 93.7 m 4 engine pulley plate bolts 9.8 1.0 87 in·lb 5 engine pulley cover bolts 9.8 1.0...

  • Page 364

    11-4 final drive specifications item standard service limit drive belt make gates, 153t – – – belt deflection (45 n, 4.6 kgf, 10 lb force) 1.5 ∼ 4.0 mm (0.059 ∼ 0.16 in.) – – – (when installing new belt or engine is remounted) 1.5 mm (0.059 in.) – – –.

  • Page 365

    Final drive 11-5 special tools inside circlip pliers: 57001-143 oil seal & bearing remover: 57001-1058 bearing driver set: 57001-1129 pulley holder: 57001-1572 grip: 57001-1591.

  • Page 366

    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 367

    Final drive 11-7 drive belt • do not twist [a] the drive belt [b] as shown. ○ this includes coiling the belt to make it smaller for pack- aging. • do not use tools [a] to pry [b] the drive belt [c] onto the application. ○ the rear pulley [d] should be in the front position in the swingarm so that th...

  • Page 368

    11-8 final drive drive belt drive belt installation • installation is 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 infor...

  • Page 369

    Final drive 11-9 pulley and coupling engine pulley cover removal • remove: alternator outer cover (see alternator outer cover re- moval in the electrical system chapter) bolt [a] clamp [b] bolts [c] engine pully cover [d] engine pulley cover installation • install: drive belt guide [a] • tighten: to...

  • Page 370

    11-10 final drive pulley and coupling • hold the engine pulley [a] steady with the pulley holder [b], and remove the pulley mounting nut [c]. Special tools - pulley holder: 57001-1572 grip: 57001-1591 • pull out the engine pulley from the output shaft. Engine pulley installation • installation is re...

  • Page 371

    Final drive 11-11 pulley and coupling rear pulley coupling removal • remove: rear wheel (see rear wheel removal in the wheels/tires chapter) • loosen (lightly): rear pulley mounting nuts [a] • remove the rear pulley [b] with the rear pulley coupling from the wheel. • remove: rear pulley mounting nut...

  • Page 372

    11-12 final drive pulley and coupling coupling bearing removal • remove: rear pulley coupling (see rear pulley coupling re- moval) sleeve [a] • remove: collar [a] grease seal [b] • remove: circlip [a] special tool - inside circlip pliers [b]: 57001-143 • remove: ball bearing [c] special tool - oil s...

  • Page 373

    Final drive 11-13 pulley and coupling coupling bearing inspection since the coupling bearing [a] is made to extremely close tolerances, the clearance cannot normally be measured. • wash the bearing with a high-flash point solvent, dry it (do not spin it while it is dry), and oil it. • spin it by han...

  • Page 374

    11-14 final drive belt adjuster belt adjuster removal • remove the left and right belt adjuster locknuts [a] and belt adjuster nuts [b]. • remove the belt adjuster [c] from the swingarm. Belt adjuster installation • apply 2-stroke oil to the inside of the belt adjuster sliding surface. • insert the ...

  • Page 375: Brakes

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

  • Page 376

    12-2 brakes exploded view.

  • Page 377

    Brakes 12-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake lever pivot bolt 1.0 0.10 8.8 in·lb si 2 brake lever pivot bolt locknut 5.9 0.60 52 in·lb 3 front brake disc bolts 27 2.8 20 l 4 front brake hose banjo bolts 25 2.5 18 5 front brake light switch screw 1.2 0.12 11 in·lb 6 f...

  • Page 378

    12-4 brakes exploded view.

  • Page 379

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

  • Page 380

    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 130 mm (5.12 in.) – – – (height from pedal top to footpeg top) brake fluid g...

  • Page 381

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

  • Page 382

    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 383

    Brakes 12-9 brake lever, brake pedal • 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 70 ±1 mm (2.8 ±0.04 in.) , the pedal position will be within the standard range. • tighten: torque - rear master cylinder push rod loc...

  • Page 384

    12-10 brakes brake lever, brake pedal brake pedal installation • apply grease to the brake pedal shaft. • install the brake pedal [a] so that the punched mark on the pedal is aligned [b] with the punched mark on the brake lever [c]. • install: brake pedal return spring brake switch return spring • t...

  • Page 385

    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]. • take off the caliper [c] from the disc. • unscrew the banjo bolt, and remove the brake hose from the caliper. Caution immediately w...

  • Page 386

    12-12 brakes calipers rear caliper disassembly • refer to the caliper rubber parts replacement in the pe- riodic maintenance chapter. Rear caliper assembly • refer to the caliper rubber parts replacement in the pe- riodic maintenance chapter. Caliper fluid seal damage the fluid seal (piston seal) [a...

  • Page 387

    Brakes 12-13 brake pads front brake pad removal • remove the front caliper with the hose installed (see front caliper removal). • remove: snap pin [a] pad pin [b] • remove the jaw side pad [a], and then remove the piston side pad [b]. Jaw [c] front brake pad installation • before installation, clean...

  • Page 388

    12-14 brakes 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 the caliper pistons [a] in by hand as far as they will go. • be sure to install the snap p...

  • Page 389

    Brakes 12-15 master cylinder front master cylinder removal • disconnect the front brake light switch connectors [a]. • remove the banjo bolt [b] to disconnect the brake hose from the master cylinder (see brake hose replacement in the periodic maintenance chapter). • remove the clamp bolt caps [c]. •...

  • Page 390

    12-16 brakes master cylinder rear master cylinder removal • remove the brake fluid reservoir (see brake pedal posi- tion adjustment). • unscrew the brake hose banjo bolt [a] on the master cylin- der. • loosen the rear master cylinder mounting bolts [b]. • unscrew the footboard bracket bolts [c]. • r...

  • Page 391

    Brakes 12-17 master cylinder master cylinder inspection • disassemble the front and rear master cylinders (see master cylinder rubber parts replacement in the peri- odic maintenance chapter). Caution do not remove the secondary cup from the piston since removal will damage it. • check that there are...

  • Page 392

    12-18 brakes brake discs brake disc removal • remove the wheel (see wheels (rims) section 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-perm...

  • Page 393

    Brakes 12-19 brake fluid brake fluid level inspection • refer to the brake fluid level inspection in the periodic maintenance chapter. Brake fluid change • refer to the brake fluid change in the periodic mainte- nance chapter. Brake line bleeding the brake fluid has a very low compression coefficien...

  • Page 394

    12-20 brakes brake fluid • bleed the brake line and the caliper. ○ repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake lever and hold it [a]. 2. Quickly open and close [b] the bleed valve while hol...

  • Page 395

    Brakes 12-21 brake fluid warning when working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types and brands of fluid for use in th...

  • Page 396

    12-22 brakes brake hoses brake hose removal/installation • refer to the brake hose replacement in the periodic maintenance chapter..

  • Page 397: Suspension

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

  • Page 398

    13-2 suspension exploded view.

  • Page 399

    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 34 3.5 25 3 front fork bottom allen bolts 20 2.0 15 l 4 front fork upper cover stopper bolts 4.2 0.43 37 in·lb g: apply grease. L: apply a non-permanent l...

  • Page 400

    13-4 suspension exploded view.

  • Page 401

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear shock absorber nuts 59 6.0 44 2 swing arm pivot shaft nut 98 10 72 3 rocker arm pivot shaft nut 98 10 72 4 lower tie-rod nuts 59 6.0 44 5 upper tie-rod nuts 108 11.0 79.7 g: apply grease. R: replacement parts.

  • Page 402

    13-6 suspension specifications item standard service limit front fork (per one unit) fork inner tube diameter 41 mm ( 1.6 in.) – – – fork oil: type showa ss-8 or equivalent – – – capacity: when changing oil approx. 355 ml (12.0 us oz.) – – – after disassembly and completely dry 417 ±2.5 ml (14.1 ±0....

  • Page 403

    Suspension 13-7 special tools inside circlip pliers: 57001-143 fork cylinder holder handle: 57001-183 fork cylinder holder adapter: 57001-1057 bearing driver set: 57001-1129 fork outer tube weight: 57001-1218 front fork oil seal driver: 57001-1219 jack: 57001-1238 fork oil level gauge: 57001-1290

  • Page 404

    13-8 suspension front fork front fork removal (each fork leg) • loosen the front axle nut (see front wheel removal in the wheels/tires chapter). • using the jack [a] under the frame pipes, and a com- mercially available jack [b] under the engine, lift the front wheel off the ground until the rear wh...

  • Page 405

    Suspension 13-9 front fork front fork installation • install the stopper [a] so that the distance between the fork top end [b] and the upper surface [c] of the stopper is 250.6 mm (9.866 in.) [d]. Torque - front fork upper cover stopper bolt: 4.2 n·m (0.43 kgf·m, 37 in·lb) • insert the washer, rubbe...

  • Page 406

    13-10 suspension front fork • wait for about five minutes so that any suspended air bub- bles can surface. • measure the oil level, using the fork oil level gauge [a]. Special tool - fork oil level gauge: 57001-1290 ○ set the gauge stopper [b] so that its lower side shows the oil level distance spec...

  • Page 407

    Suspension 13-11 front fork • remove the cylinder unit [a] and short spring [b] from the inner tube. • separate the inner tube from the outer tube as follows: ○ slide up the dust seal [a]. ○ remove the retaining ring [b] from the outer tube. ○ grasp the inner tube and stroke the outer tube up and do...

  • Page 408

    13-12 suspension front fork • insert the cylinder unit [a] into the inner tube [b]. • install the cylinder base [c] on the cylinder unit so that the tapered end face the upward. • insert the inner tube, cylinder unit, cylinder base as a set into the outer tube [d]. • fit the new outer guide bushing ...

  • Page 409

    Suspension 13-13 front fork inner tube inspection • visually inspect the inner tube, and repair any damage. • nicks or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage. If the damage is not repairable, replace the inner tube. Si...

  • Page 410

    13-14 suspension rear shock absorber spring preload adjustment • remove: reserve tank (see reserve tank removal in the cool- ing system chapter) • hang the under part of the reserve tank to the holder [a] of the frame as shown. • to adjust the spring force, turn the adjusting sleeve [a] on the shock...

  • Page 411

    Suspension 13-15 rear shock absorber • remove: lower shock absorber bolt [a] lower tie-rod bolt [b] upper shock absorber bolt [c] rear shock absorber rear shock absorber installation • pack the rocker arm needle bearings with grease. • install the rear shock absorber so that the caution label [a] fa...

  • Page 412

    13-16 suspension swingarm swingarm removal • remove: rear wheel (see rear wheel removal in the wheels/tires chapter) rear brake caliper (see rear caliper removal in the brakes chapter) rear shock absorber (see rear shock absorber re- moval) bolts [a] rear wheel mad guard [b] • remove: drive belt cov...

  • Page 413

    Suspension 13-17 swingarm swingarm installation • apply plenty of grease to the needle bearings and grease seals. • install: collar [a] • install the tie-rod to the swingarm. • install the swingarm and insert the swingarm pivot shaft from the right side. • tighten: torque - swingarm pivot shaft nut:...

  • Page 414

    13-18 suspension swingarm • remove the ball bearing [a] and needle bearing with the available bearing remover [b]. • remove: sleeve right side • remove: grease seal • remove the needle bearing [a] with the available bearing remover. Swingarm bearing installation • apply plenty of grease to the needl...

  • Page 415

    Suspension 13-19 swingarm swingarm bearing, sleeve inspection caution do not remove the bearings for inspection. Remove may damage them. • inspect the swingarm sleeve [a], needle bearings [b] and ball bearing [c] installed in the swingarm. • the rollers and balls in the bearing normally wear very li...

  • Page 416

    13-20 suspension tie-rod, rocker arm tie-rod removal • tie-rod is removed together with the swingarm. Refer to the swingarm removal. Tie-rod installation • refer to the swingarm installation. Rocker arm removal • remove: muffler (see muffler removal in the engine top end chapter) • squeeze the brake...

  • Page 417

    Suspension 13-21 tie-rod, rocker arm tie-rod and rocker arm bearing removal • remove: tie-rod (see swingarm removal) rocker arm [a] (see rocker arm removal) sleeves [b] grease seal [c] • remove the needle bearings [d], using the available bearing remover. Tie-rod and rocker arm bearing installation ...

  • Page 418

    13-22 suspension tie-rod, rocker arm note ○ install the needle bearings so that the marked side faces out. Needle bearing [a] grease seals [b] front [c] left side [d] right side [e] rocker arm [f] tie-rod [g] 6 ±1 mm (0.24 ±0.04 in.) [h] 11.5 ±1 mm (0.453 ±0.04 in.) [i] 5.5 ±1 mm (0.22 ±0.04 in.) [j...

  • Page 419: Steering

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

  • Page 420

    14-2 steering exploded view.

  • Page 421

    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 3 steering stem head nut 49 5.0 36 4 upper front fork clamp bolts 20 2.0 15 5 steering stem nut 4.9 0.50 43 in·lb 6 lower front fork clamp bolts 34 3.5 25 ...

  • Page 422

    14-4 steering special tools bearing puller: 57001-135 steering stem bearing driver: 57001-137 steering stem bearing driver adapter, 34.5: 57001-1074 head pipe outer race press shaft: 57001-1075 head pipe outer race driver, 51.5: 57001-1076 steering stem nut wrench: 57001-1100 head pipe outer race dr...

  • Page 423

    Steering 14-5 handlebar handlebar removal • remove: clutch lever assembly [a] left handlebar switch housing [b] • remove: front master cylinder [a] (see front master cylinder re- moval in the brakes chapter) right handlebar switch housing [b] throttle grip [c] • remove: caps [a] clamp bolts handleba...

  • Page 424

    14-6 steering handlebar ○ the front half of the right handlebar switch housing has a small projection [a]. • fit the projection into the small hole [b] in the handlebar, and install the housing. • set the left handlebar switch housing [a] to match its mat- ing surface [b] to the punched mark [c] of ...

  • Page 425

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

  • Page 426

    14-8 steering steering stem steering stem removal • remove the front wheel (see front wheel removal in the wheels/tires chapter). Caution be sure to put the rear wheel on the ground when removing the steering, or the motorcycle may fall over. The motorcycle could be damaged. Warning be sure to put t...

  • Page 427

    Steering 14-9 steering stem • remove: steering stem head nut [a] and washer front forks (see front fork removal (each fork leg) in the suspension chapter) steering stem head [b] • bend the claws [a] of the claw washer straighten. • remove: steering stem locknut [b] claw washer • remove: steering ste...

  • Page 428

    14-10 steering steering stem • replace the claw washer [a] with a new one. • install the claw washer so that its bent side [b] faces up- ward, and engage the bent claws with the grooves of stem locknut [c]. • hand tighten the stem locknut until it touches the claw washer. • tighten the stem locknut ...

  • Page 429

    Steering 14-11 steering stem steering stem warp • whenever the steering stem is removed, or if the steering cannot be adjusted for smooth action, check the steering stem for straightness. If the steering stem [a] is bent, replace the steering stem..

  • Page 430

    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, id > 37 mm [a]: 57001-1107 note ○ if either steering stem bearing is damaged, it is r...

  • Page 431

    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. Stem bearing lubrication in accordance with the periodic maintenance chart, lubri- cate the steering stem bearings. Refer to the...

  • Page 433: Frame

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

  • Page 434

    15-2 frame exploded view.

  • Page 435

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 downtube bolts 44 4.5 32 2 footboard bracket bolts 34 3.5 25 3 sidestand mounting nut 44 4.5 32 4 lower muffler bracket bolts 34 3.5 25 5 upper muffler bracket bolts 34 3.5 25 6 sidestand mounting bolt 44 4.5 32 7 footpeg bracket...

  • Page 436

    15-4 frame exploded view.

  • Page 437

    Frame 15-5 exploded view 1. Other than europe models.

  • Page 438

    15-6 frame exploded view vn900d models.

  • Page 439

    Frame 15-7 special tool jack: 57001-1238.

  • Page 440

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

  • Page 441

    Frame 15-9 side covers left side cover removal • remove: seat (see seat removal) screw [a] • pull [a] the left side cover evenly, and remove it. Left side cover installation • put the front stoppers [a] into the grommets [b] first, then put the rear stopper [c] into the grommet [d]. • tighten the sc...

  • Page 442

    15-10 frame side covers right side cover installation • put the stoppers [a] into the grommets [b]. • tighten the screw..

  • Page 443

    Frame 15-11 fenders front fender removal caution be careful not to scratch the painted surface during removal or installation. • remove the mounting bolts [a] and washers on both sides to separate the fender from the front fork. • move the fender forwards with the wheel installed and remove it. • re...

  • Page 444

    15-12 frame fenders • remove: bolt [a] seat lock cable lower end [b] • remove the rear fender bolts [a] on both sides. • remove the rear fender [b] rearwards. • remove: bolts [a] screws [b] reinforce [c] rear fender installation • installation is reverse of removal, note the following. ○ put the gro...

  • Page 445

    Frame 15-13 battery case battery case removal • remove: seat (see seat removal) battery (see battery removal in the electrical system chapter) ecu [a] (see ecu removal in the fuel system (dfi) chapter) relay box (see relay box removal in the electrical sys- tem chapter) fuse box (see electrical syst...

  • Page 446

    15-14 frame tool box tool box removal • clear the seat lock cable [a] from the hook [b]. • remove: seat (see seat removal) screws [c] tool box [d].

  • Page 447

    Frame 15-15 footboard footboard removal/installation left side: • remove: shift pedal clamp bolt [a] footboard bracket bolts [b] left footboard assembly [c] • install the shift pedal to the front shift lever so that the punch mark [a] on the pedal align to the punch mark [b] on the shift lever. • ti...

  • Page 448

    15-16 frame footboard • install: right footboard assembly • tighten: torque - footboard bracket bolts: 34 n·m (3.5 kgf·m, 25 ft·lb) rear master cylinder mounting bolts: 25 n·m (2.5 kgf·m, 18 ft·lb) • install the brake pedal so that the punch mark [a] on the brake lever shaft align to the brake lever...

  • Page 449

    Frame 15-17 sidestand sidestand removal • raise the rear wheel [a] off the ground, using the jack [b]. Special tool - jack: 57001-1238 • remove the alternator outer cover (see alternator outer cover removal in the electrical system chapter). • disconnect the sidestand switch lead connector [a]. • re...

  • Page 450

    15-18 frame windshield (vn900d models) windshield height adjustment ○ the windshield [a] can be adjusted within 50 mm (2.0 in.) in height to suit the rider’s preference. • loosen the upper and lower bolts [b] on both sides and slide the windshield up or down. • check to see that the position marks [...

  • Page 451

    Frame 15-19 windshield (vn900d models) • install: brackets (both sides) [a] bolts [b] • install the windshield [a] on the brackets with the bolt [b]..

  • Page 452

    15-20 frame saddlebags (vn900d models) saddlebag removal • open the lid. • remove: bolt [a] nuts [b] saddlebag saddlebag installation • be sure that the washers [a] are in place. • install: saddlebag • tighten: nuts [a] bolt [b].

  • Page 453

    Frame 15-21 rear view mirrors rear view mirror removal (other than europe models) • 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 (europe models) • loosen the lower hexagonal area [a]. • tu...

  • Page 454

    15-22 frame rear view mirrors rear view mirror installation (europe models) • 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] w...

  • Page 455

    Frame 15-23 downtube downtube removal • raise the rear wheel [a] off the ground, using the jack [b]. Special tool - jack: 57001-1238 • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) • disconnect the rear brake light switch connector [a]. • remove: bolt [a] clamps [b] • re...

  • Page 456

    15-24 frame downtube • clear the brake hose [a] from the clamps [b]. • remove: radiator mounting bolt [a] • remove: regulator/rectifier (see regulator/rectifier removal in the electrical system chapter) front cross pipe bolts [a] front cross pipe [b] • remove: engine mounting bracket bolts [a] caps ...

  • Page 457

    Frame 15-25 back rest (vn900d models) back rest removal/installation • remove: bolts (both sides) [a] back rest assy [b] • remove: bolts [a] plate [b] back rest pad [c] • install: back rest side stays (both sides) [a] saddlebag brackets (both sides) [b] • tighten: nuts (both sides) [c] • install: ba...

  • Page 458

    15-26 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 459: Electrical System

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

  • Page 460

    16-2 electrical system armature inspection.......................................................................................................... 16-53 brush lead inspection ...................................................................................................... 16-53 brush plate an...

  • Page 461

    Electrical system 16-3 exploded view dummy page.

  • Page 462

    16-4 electrical system exploded view.

  • Page 463

    Electrical system 16-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 alternator outer cover bolts 9.8 1.0 87 in·lb 2 alternator cover bolts 9.8 1.0 87 in·lb 3 timing inspection plate bolts 9.8 1.0 87 in·lb 4 alternator lead holder plate bolts 5.9 0.60 52 in·lb 5 sator coil bolts 12 1.2...

  • Page 464

    16-6 electrical system exploded view.

  • Page 465

    Electrical system 16-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 tail/brake light unit mounting nuts 5.9 0.60 52 in·lb 2 headlight rim screws 2.9 0.30 26 in·lb.

  • Page 466

    16-8 electrical system exploded view.

  • Page 467

    Electrical system 16-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 sidestand switch mounting bolt 8.8 0.90 78 in·lb l 2 fuel level sensor mounting bolts 6.9 0.70 61 in·lb l l: apply a non-permanent locking agent. R: replacement parts.

  • Page 468

    16-10 electrical system electrical parts location left handlebar switches [a] starter lockout switch [b] headlight [c] front brake light switch [d] right handlebar switches [e] meter unit [f] spark plug [a] (front) fuel pump [b] ignition coil [c] (front) ignition coil [d] (rear) spark plug [e] (rear...

  • Page 469

    Electrical system 16-11 electrical parts location speed sensor [a] battery [a] ecu (electronic control unit) [b] turn signal control relay [c] relay box [a] starter relay and main fuse 30 a [b] frame ground terminal [c] natural switch [a] air switching valve [a].

  • Page 470

    16-12 electrical system electrical parts location fuel level sensor [a] rear brake light switch [a] water temperature sensor [a] sidestand switch [a].

  • Page 471

    Electrical system 16-13 wiring diagram dummy page.

  • Page 472

    16-14 electrical system wiring diagram united states and canada models.

  • Page 473

    Electrical system 16-15 wiring diagram.

  • Page 474

    16-16 electrical system wiring diagram europe models.

  • Page 475

    Electrical system 16-17 wiring diagram.

  • Page 476

    16-18 electrical system wiring diagram australia model.

  • Page 477

    Electrical system 16-19 wiring diagram.

  • Page 478

    16-20 electrical system specifications item standard service limit battery type sealed battery – – – model name ytx12-bs – – – capacity 12 v 10 ah – – – voltage 12.8 v or more – – – charging system type three-phase ac – – – charging voltage (regulator/rectifier output voltage) 14.2 ∼ 15.2 v – – – al...

  • Page 479

    Electrical system 16-21 special tools and sealant rotor puller, m16/m18/m20/m22 × 1.5: 57001-1216 jack: 57001-1238 spark plug wrench, hex 16: 57001-1262 hand tester: 57001-1394 flywheel puller assembly, m38 × 1.5/m35 × 1.5: 57001-1405 peak voltage adapter: 57001-1415 needle adapter set: 57001-1457 g...

  • Page 480

    16-22 electrical system precautions there are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○ always check battery con...

  • Page 481

    Electrical system 16-23 precautions ○ electrical connectors female connectors [a] male connectors [b].

  • Page 482

    16-24 electrical system 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 483

    Electrical system 16-25 battery battery removal • remove: tool box (see tool box removal in the frame chapter) • disconnect the negative (–) cable [a]. • slide out the positive (+) terminal cap [b] and then discon- nect the positive (+) cable. Caution be sure to disconnect the negative (–) cable fir...

  • Page 484

    16-26 electrical system battery • remove the electrolyte container from the vinyl bag. • detach the strip of caps [a] from the container and set aside, these will be used later to seal the battery. Note ○ do not pierce or otherwise open the sealed cells [b] of the electrolyte container. Do not attem...

  • Page 485

    Electrical system 16-27 battery initial charge • place the strip [a] of caps loosely over the filler ports. • newly activated sealed batteries require an initial charge. Standard charge: 1.2 a × 5 ∼ 10 hours if using a recommended battery charger, follow the charger’s instructions for newly activate...

  • Page 486

    16-28 electrical system battery precautions 1) no need of topping-up no topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that. 2) refreshing charge. If an engine will not start, a horn sounds we...

  • Page 487

    Electrical system 16-29 battery charging condition inspection ○ battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter [a]. • remove: seat (see seat removal in the frame chapter) battery cable cap (see battery removal) • disconnect the battery termin...

  • Page 488

    16-30 electrical system battery terminal voltage: 11.5 ∼ less than 12.8 v standard charge 1.2 a × 5 ∼ 10 h (see following chart) quick charge 5 a × 1 h caution if possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on. Terminal voltage: less than 11.5 v charg...

  • Page 489

    Electrical system 16-31 charging system alternator outer cover removal • remove: bolts [a] alternator outer cover [b] alternator outer cover installation • install the alternator outer cover. • tighten: torque - alternator outer cover bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) alternator cover removal • d...

  • Page 490

    16-32 electrical system charging system • remove: bolts [a] alternator cover [b] alternator cover installation • replace the alternator cover gasket with a new one. • check to see that the knock pins [a] are in place. • tighten: torque - alternator cover bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • instal...

  • Page 491

    Electrical system 16-33 charging system alternator rotor removal • remove: alternator cover (see alternator cover removal). • wipe oil off the outer circumference of the rotor. • hold the alternator rotor steady with the rotor holder [a], and remove the rotor bolt [b]. Special tools - rotor holder: ...

  • Page 492

    16-34 electrical system charging system • when installing the alternator rotor, align the rotor mark [a] with the left crankcase projection [b]. • apply molybdenum disulfide oil solution to the threads and seating surface of the alternator rotor bolt. • install the washer. Note ○ confirm the alterna...

  • Page 493

    Electrical system 16-35 charging system • to check the alternator output voltage, do the following procedures. ○ remove the regulator/rectifier and disconnect the con- nector [a]. ○ connect the hand tester to the connector as shown. Special tool - hand tester: 57001-1394 ○ start the engine. ○ run it...

  • Page 494

    16-36 electrical system charging system regulator/rectifier removal • remove: bolts [a] regulator/rectifier cover [b] • remove: bolts [a] regulator/rectifier [b] connector [c] (disconnect) regulator/rectifier inspection rectifier circuit check • remove the regulator/rectifier (see regulator/rectifie...

  • Page 495

    Electrical system 16-37 charging system • do the 1st step regulator circuit test. ○ connect the test light and the 12 v battery to the regula- tor/rectifier as shown. ○ check w1, w2 and w3 terminal respectively. If the test light turns on, the regulator/rectifier is defective. Replace it. If the tes...

  • Page 496

    16-38 electrical system charging system charging voltage inspection • check the battery condition (see charging condition in- spection). • warm up the engine to obtain actual alternator operating conditions. • remove: seat (see seat removal in the frame chapter) tool box (see tool box removal in the...

  • Page 497

    Electrical system 16-39 charging system charging system circuit 1. Ignition switch 2. Regulator/rectifier 3. Alternator 4. Frame ground 5. Battery 6. Main fuse 30 a 7. Load.

  • Page 498

    16-40 electrical system ignition system.

  • Page 499

    Electrical system 16-41 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 500

    16-42 electrical system ignition system ignition coil installation • connect the primary leads to the ignition coil terminals and run the secondary cables according to the cable, wire and hose routing section in the appendix chapter. [a] front ignition coil [b] rear ignition coil [c] dampers [d] bra...

  • Page 501

    Electrical system 16-43 ignition system • measure the primary winding resistance as follows. ○ connect the hand tester between the coil terminals. ○ set the tester to the × 1 Ω range, and read the tester. • measure the secondary winding resistance as follows. ○ remove the plug caps by turning them c...

  • Page 502

    16-44 electrical system ignition system spark plug condition inspection • remove the spark plugs (see spark plug removal). • visually inspect the spark plugs. If the spark plug center electrode [a] and/or side elec- trode [b] are corroded or damaged, or if the insulator [c] is cracked, replace the p...

  • Page 503

    Electrical system 16-45 ignition system warning to avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • 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 measur...

  • Page 504

    16-46 electrical system ignition system crankshaft sensor inspection • remove: alternator outer cover (see alternator outer cover re- moval) crankshaft sensor lead connector [a] (disconnect) • set the hand tester to the × 100 Ω range and connect it between the terminals in the connector. Special too...

  • Page 505

    Electrical system 16-47 ignition system crankshaft sensor peak voltage inspection • remove: alternator outer cover (see alternator outer cover re- moval) • remove all the spark plug caps but do not remove the spark plugs. • disconnect the crankshaft sensor lead connector. • connect a commercially pe...

  • Page 506

    16-48 electrical system ignition system 2nd check • start the engine to the following conditions. Condition transmission gear → 1st position clutch lever → pulled in sidestand → up ○ turn the ignition switch on and push the starter button. ○ then the starter motor should turn when the starter sys- t...

  • Page 507

    Electrical system 16-49 ignition system ignition system circuit 1. Ignition switch 2. Engine stop switch 3. Spark plugs 4. Ignition coil #1 (front cylinder) 5. Ignition coil #2 (rear cylinder) 6. Sidestand switch 7. Subthrottle sensor 8. Main throttle sensor 9. Joint connector b 10. Crankshaft senso...

  • Page 508

    16-50 electrical system electric starter system starter motor removal • remove: regulator/rectifier (see regulator/rectifier removal) bolts [a] front cross pipe [b] • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove the starter motor cable nut [a] and the ...

  • Page 509

    Electrical system 16-51 electric starter system • remove: terminal locknut and washers o-ring • remove the brush plate assy [a] from the yoke [b]. • remove the brush plate [a] from the terminal bolt assem- bly [b]. Note ○ do not remove the negative carbon brushes form the brush plate. Starter motor ...

  • Page 510

    16-52 electrical system electric starter system • install the new o-ring [a] as shown. • install: washers [b] and terminal locknut [c] • tighten: torque - starter motor terminal locknut: 11 n·m (1.1 kgf·m, 97 in·lb) • align the lines [a] on the yoke with the end cover lines [b]. • tighten the throug...

  • Page 511

    Electrical system 16-53 electric starter system armature inspection • using the × 1 Ω hand tester range, measure the resis- tance between any two commutator segments [a]. Special tool - hand tester: 57001-1394 if there is a high resistance or no reading ( ∞ ) between any two segments, a winding is o...

  • Page 512

    16-54 electrical system electric starter system • disconnect the connector [a]. • disconnect the starter motor cable [b] and battery positive (+) cable [c] from the starter relay [d]. Caution the battery positive (+) cable with the rubber cap is connected directly to the battery positive (+) termi- ...

  • Page 513

    Electrical system 16-55 electric starter system electric starter circuit 1. Ignition switch 2. Engine stop switch 3. Starter button 4. Neutral switch 5. Sidestand switch 6. Ecu 7. Battery 8. Main fuse 30 a 9. Starter relay 10. Starter motor 11. Frame ground 12. Relay box 13. Starter circuit relay 14...

  • Page 514

    16-56 electrical system lighting system this models adopt the daylight system and has a head- light relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on u...

  • Page 515

    Electrical system 16-57 lighting system • take out the bulb [a]. Caution when handling the quartz-halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode. ○ clean off any conta...

  • Page 516

    16-58 electrical system lighting system • remove the wedge-base type bulb [a], pull the bulb straight out of the socket [b]. • replace the bulb with a new one. Caution do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage than the specified ...

  • Page 517

    Electrical system 16-59 lighting system • with the front pin [a] up and the rear pin [b] down, in- sert the new bulb by aligning the front pin with the upper groove [c] in the walls of the socket [d]. • push the bulb in, turn it clockwise, and release it. It should lock in position. • put the hooks ...

  • Page 518

    16-60 electrical system lighting system • insert the new bulb [a] by aligning the pins [b] with the groove in the walls of the socket [c]. Headlight/taillight circuit 1. Ignition switch 2. Rear brake switch 3. License plate light 4. Tail/brake light 5. Relay box 6. Headlight relay 7. Frame ground 8....

  • Page 519

    Electrical system 16-61 lighting system turn signal light bulb replacement • remove the turn signal light lens screws [a] and remove the lens [b]. • push the bulb [a] in the socket and turn the bulb counter- clockwise. • replace the bulb. Turn signal relay inspection • remove: tool box (see tool box...

  • Page 520

    16-62 electrical system lighting system turn signal light circuit 1. Ignition switch 2. Frame ground 3. Main fuse 30 a 4. Battery 5. Rear right turn signal light 6. Rear left turn signal light 7. Turn signal relay 8. Turn signal lights fuse 10 a 9. Turn signal switch 10. Front left turn signal light...

  • Page 521

    Electrical system 16-63 radiator fan system fan motor inspection • remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • disconnect the 2-pin connector [a] in the fan motor leads. • using two auxiliary wires, supply battery [b] power to the fan motor. If the fan does not r...

  • Page 522

    16-64 electrical system meter unit meter unit removal • remove the bolt [a], and lift up the tail of the cover [b]. • push the cover forward a little, and remove the meter cover. • remove the meter unit [a]. ○ pull out the meter unit end from the pin [b] on the fuel tank, and then pull out the front...

  • Page 523

    Electrical system 16-65 meter unit • remove the screw [a] on the lower cover to free the speedometer. • remove the screw [a] on the indicator panel to remove the panel..

  • Page 524

    16-66 electrical system meter unit • lifting the speedometer [a] with the indicator panel [b] attached, pull out the fi indicator led light [c] and oil pressure warning led light [d] from the lower cover [e]. Note ○ the water temperature warning led light, oil pressure warning led light and fi indic...

  • Page 525

    Electrical system 16-67 meter unit • fit the speedometer and indicator panel onto the lower cover. ○ put the holes [b] onto the projections [a] of the lower cover. • tighten the screws. • install the upper cover. Meter unit inspection mode selection and reset button checks • when the ignition switch...

  • Page 526

    16-68 electrical system meter unit • push the mode select button to clock. • push the reset button [a] more than 2 seconds, then the display turns to the hour/minute mode [b]. ○ in the hour/minute mode, the numbers flash on the display. • check that the flashing number changes to the hour or minute ...

  • Page 527

    Electrical system 16-69 meter unit lcd segment inspection • remove the meter unit [a] (see meter unit removal). Caution do not drop the meter unit. Such a shock to the meter unit can damage it. Place the meter facing up. If a meter is left upside down or sideways for any length of time, it will malf...

  • Page 528

    16-70 electrical system meter unit speedometer inspection • if an oscillator is unavailable, check the speedometer as follows. ○ install the meter unit. ○ use the jack to lift the rear wheel. Special tool - jack: 57001-1238 ○ turn the ignition switch on. ○ turn the rear wheel by hand to see if the s...

  • Page 529

    Electrical system 16-71 meter unit trip meter inspection • turn the display [a] into trip. • during the speedometer inspection with an oscillator, ver- ify that the trip meter reading increases. • stop the short wave form, press the reset button more than 2 seconds and check that the display shows “...

  • Page 530

    16-72 electrical system meter unit oil pressure warning led light connections battery negative wire (–) to terminal [3] • connect the terminal [3]. ○ the oil pressure warning led light lights. • disconnect the terminal [3]. ○ the oil pressure warning led light disappears. If there is any problem, re...

  • Page 531

    Electrical system 16-73 meter unit turn signal indicator lights connections battery positive wire (+) to terminal [17] or [18] • connect the terminal [17] or [18]. ○ the turn signal indicator light lights. • disconnect the terminal [17] or [18]. ○ the signal indicator light disappears. If there is a...

  • Page 532

    16-74 electrical system meter unit if there is any problem, inspect the bulb, bulb socket [a] and wiring of the indicator panel [b] for continuity. If they are normal, replace the speedometer assembly. Special tools - hand tester: 57001-1394 needle adapter set: 57001-1457.

  • Page 533

    Electrical system 16-75 meter unit 1. Ignition switch 2. Fuel level sensor 3. Speed sensor 4. Joint connector b 5. Water temperature sensor 6. Oil pressure switch 7. Neutral switch 8. Ecu 9. Fuel reserve switch 10. Frame ground 11. Battery 12. Main fuse 30 a 13. Ignition fuse 10 a 14. Tail light fus...

  • Page 534

    16-76 electrical system meter unit fuel gauge operation inspection • remove: fuel tank bolts (see fuel tank removal in the fuel sys- tem (dfi) chapter) • lift the fuel tank front part a little and pull the fuel gauge connector forward. • disconnect the fuel gauge connector. • prepare an auxiliary wi...

  • Page 535

    Electrical system 16-77 air switching valve air switching valve operation test • refer to the air suction system damage inspection in the periodic maintenance chapter. Air switching valve unit test • remove the air switching valve (see air switching valve removal in the engine top end chapter). • se...

  • Page 536

    16-78 electrical system switch and sensors fuel level sensor inspection • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) • open the clamps on the fuel tank. • remove: bolts [a] fuel level sensor [b] • check that the float moves up and down smoothly without binding. It sho...

  • Page 537

    Electrical system 16-79 switch and sensors fuel reserve switch inspection • fill the fuel tank with fuel. • close the fuel tank cap surely. • remove: ignition coil cover (see ignition coil removal) fuel pump lead connector [a] • connect the test light [b] (12 v 3.4 w bulb in a socket with leads) and...

  • Page 538

    16-80 electrical system switch and sensors speed sensor installation • apply grease to the o-ring [a] on the speed sensor [b]. • tighten: torque - speed sensor mounting bolt: 9.8 n·m (1.0 kgf·m, 87 in·lb) speed sensor inspection • remove: speed sensor (see speed sensor removal) • connect the speed s...

  • Page 539

    Electrical system 16-81 switch and sensors oxygen sensor installation (europe models) caution never drop the oxygen sensor [a], especially on a hard surface. Such a shock to the unit can damage it. Do not touch the sensing part [b] to prevent oil con- tact. Oil contamination from hands can reduce se...

  • Page 540

    16-82 electrical system switch and sensors water temperature sensor inspection • remove the water temperature sensor (see water tem- perature sensor removal). • suspend the sensor [a] in a container of machine oil so that the heat-sensitive portion and threaded portion are submerged. • suspend an ac...

  • Page 541

    Electrical system 16-83 switch and sensors switch inspection • using the hand tester, check to see that only the con- nections shown in the table have continuity (about zero ohms). ○ for the handlebar switches and the ignition switch, refer to the tables in the wiring diagram. If the switch has an o...

  • Page 542

    16-84 electrical system relay box the relay box [a] has relays and diodes. The relays and diodes can not be removed. Relay box removal • remove: right side cover (see right side cover removal in the frame chapter) • take out the relay box [a] and disconnect the connectors [b]. Relay circuit inspecti...

  • Page 543

    Electrical system 16-85 relay box relay circuit inspection (with the battery connected) battery connection (+) (–) tester connection tester reading ( Ω ) 2-11 1-3 0 ecu main relay 4-5 7-6 0 fuel pump relay 9-10 7-8 0 fan relay 18-19 17-20 0 battery connection (+) (–) tester connection dc 25 v range ...

  • Page 544

    16-86 electrical system relay box relay box internal circuit a: headlight relay b: ecu main relay c: fuel pump relay d: starter circuit relay e: fan relay.

  • Page 545

    Electrical system 16-87 fuse 30 a main fuse removal • remove: right side cover (see right side cover removal in the frame chapter) connector [a] • pull out the main fuse [b] from the starter relay with needle nose pliers. Fuse box fuse removal • remove the right side cover (see right side cover re- ...

  • Page 546

    16-88 electrical system fuse fuse installation • if a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage. • install the fuse box fuses on the original position as spec- ified on the lid. Fuse inspection • remove...

  • Page 547: Appendix

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

  • Page 548

    17-2 appendix cable, wire and hose routing.

  • Page 549

    Appendix 17-3 cable, wire and hose routing 1. Right switch housing harness 2. Left switch housing harness 3. Clutch cable 4. Clamp the right switch housing harness. 5. Through the clutch cable and left switch housing harness. 6. Run the clutch cable through the brake hose front side. 7. Through the ...

  • Page 550

    17-4 appendix cable, wire and hose routing.

  • Page 551

    Appendix 17-5 cable, wire and hose routing 1. Clamp the left and right switch housing harness and clutch cable. 2. Run the water temperature sensor connector over the reserve tank hose. 3. Run the clutch cable between the frame and radiator hose. 4. Throttle cables 5. Fuel level sensor lead 6. Clamp...

  • Page 552

    17-6 appendix cable, wire and hose routing.

  • Page 553

    Appendix 17-7 cable, wire and hose routing 1. Right switch housing harness connector 2. Left switch housing harness connector 3. Left switch housing harness connector 4. Radiator fan harness connector 5. Rear brake light switch lead connector 6. Clamp the main harness. 7. Clamp the clutch cable, rea...

  • Page 554

    17-8 appendix cable, wire and hose routing.

  • Page 555

    Appendix 17-9 cable, wire and hose routing 1. Subthrottle valve actuator connector 2. Subthrottle sensor connector 3. Injector #2 connector 4. Injector #1 connector 5. Inlet air pressure sensor hose 6. Inlet air temperature sensor lead 7. Vacuum hose (california model) 8. Purge hose (california mode...

  • Page 556

    17-10 appendix cable, wire and hose routing.

  • Page 557

    Appendix 17-11 cable, wire and hose routing 1. Run the alternator lead and sidestand switch lead through the clamp of the engine bracket. 2. Fuse box 3. Run the seat lock cable through the guide of the tool box. 4. Seat lock cable 5. Stator coil lead 6. Sidestand switch lead 7. Sidestand switch lead...

  • Page 558

    17-12 appendix cable, wire and hose routing.

  • Page 559

    Appendix 17-13 cable, wire and hose routing 1. Fuel pump lead connector 2. Black/green lead 3. Red lead 4. Black lead 5. Red lead 6. Clamp the ignition coil #2 lead connector with the air switching valve hose clamp. 7. Air switching valve hose.

  • Page 560

    17-14 appendix cable, wire and hose routing.

  • Page 561

    Appendix 17-15 cable, wire and hose routing 1. Speed sensor connector 2. Neutral switch connector 3. Run the starter motor lead through the engine bracket clamp..

  • Page 562

    17-16 appendix cable, wire and hose routing.

  • Page 563

    Appendix 17-17 cable, wire and hose routing 1. Connect the battery negative (–) lead connector to the main harness. 2. Vehicle-down sensor 3. Ecu 4. Ignition switch lead connector 5. Kawasaki diagnostic system connector 6. Battery 7. Turn signal relay 8. Insert the harness attached clamp to the batt...

  • Page 564

    17-18 appendix cable, wire and hose routing.

  • Page 565

    Appendix 17-19 cable, wire and hose routing 1. Rear fender harness connector 2. Run the rear fender harness through the guide of the tool box. 3. Run the rear fender harness through the guide of the frame. 4. Rear fender harness 5. Seat lock cable 6. Run the seat lock cable through the guide of the ...

  • Page 566

    17-20 appendix cable, wire and hose routing.

  • Page 567

    Appendix 17-21 cable, wire and hose routing 1. Reserve tank hose 2. Breather hose 3. Breather check valve 4. Other than europe models 5. Run the breather hose to the inside of the engine bracket and frame cross pipe front. 6. Breather hose 7. View from the front 8. Clamp 9. Main harness.

  • Page 568

    17-22 appendix cable, wire and hose routing.

  • Page 569

    Appendix 17-23 cable, wire and hose routing 1. View from the outside 2. Roll the taillight lead to the pin. 3. Through the rear fender harness to the fender hole. 4. Through the rear fender harness to the guide. 5. Clamp the rear fender harness with the reinforce attached clamps. 6. Clamp the fuel l...

  • Page 570

    17-24 appendix cable, wire and hose routing 1. Clamps (clamp the sidestand switch lead.).

  • Page 571

    Appendix 17-25 cable, wire and hose routing 1. Starter motor lead 2. Clamp 3. Clamp (bent the clamp as shown.).

  • Page 572

    17-26 appendix cable, wire and hose routing 1. Air switching valve 2. Face the white mark right side. 3. Clamp (for ignition coil #2 lead) 4. Air switching valve hose.

  • Page 573

    Appendix 17-27 cable, wire and hose routing 1. Stator coil lead 2. Oil pressure switch lead 3. Clamp the stator coil lead and oil pressure switch lead. After installed, bend the clamp to the alternator cover. 4. Clamp the sidestand switch lead only. 5. Clamp the oil pressure switch lead and sidestan...

  • Page 574

    17-28 appendix cable, wire and hose routing 1. Main harness 2. Clamp (wrap the connectors.) 3. Sidestand switch lead 4. Oil pressure switch lead 5. Crankshaft sensor lead 6. Engine pulley cover.

  • Page 575

    Appendix 17-29 cable, wire and hose routing 1. Clamp the stator coil lead and main harness. 2. Stator coil lead.

  • Page 576

    17-30 appendix cable, wire and hose routing 1. Reserve tank hose 2. Inlet air pressure sensor hose 3. Air switching valve hose 4. Run the inlet air pressure hose over the air switching valve hose. 5. Run the reserve tank hose into the frame hose. 6. Reserve tank 7. Clamp.

  • Page 577

    Appendix 17-31 cable, wire and hose routing 1. Clamp 2. Reserve tank hose 3. Reserve tank.

  • Page 578

    17-32 appendix cable, wire and hose routing.

  • Page 579

    Appendix 17-33 cable, wire and hose routing 1. Front caliper 2. Brake hose 3. Clamp (insert the clamp in to the handlebar.) 4. Clamp 5. Through the brake hose. 6. Front master cylinder.

  • Page 580

    17-34 appendix cable, wire and hose routing.

  • Page 581

    Appendix 17-35 cable, wire and hose routing 1. Rear caliper 2. Brake hose 3. Clamp 4. Rear master cylinder 5. Reservoir tank 6. Swingarm 7. Cotter pin 8. Brake hose holder 9. Run the brake hose between the swingarm and frame..

  • Page 582

    17-36 appendix cable, wire and hose routing california model 1. Reserve tank hose 2. Clamp the air switching valve hose, vacuum hose (white) and purge hose (green). 3. Breather hose 4. Purge hose (green) 5. Fuel return hose (red) 6. Vacuum hose (white) 7. Through the breather hose (blue) to the engi...

  • Page 583

    Appendix 17-37 troubleshooting guide note ○ refer to the fuel system chapter for most of dfi trouble shooting guide. ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common di...

  • Page 584

    17-38 appendix troubleshooting guide air cleaner duct loose compression low: spark plug loose cylinder head not sufficiently tightened down no valve clearance cylinder, piston worn piston ring bad (worn, weak, broken, or sticking) piston ring/groove clearance excessive cylinder head warped cylinder ...

  • Page 585

    Appendix 17-39 troubleshooting guide air cleaner o-ring damaged air cleaner clogged compression high: carbon built up in combustion chamber engine load faulty: clutch slipping engine oil level too high engine oil viscosity too high drive train trouble brake dragging lubrication inadequate: engine oi...

  • Page 586

    17-40 appendix troubleshooting guide exhaust pipe leaking at cylinder head con- nection crankshaft runout excessive engine mount loose crankshaft bearing worn primary gear worn or chipped camshaft chain tensioner trouble camshaft chain, sprocket, guide worn air suction valve damaged air switching va...

  • Page 587

    Appendix 17-41 troubleshooting guide front fork oil viscosity too low rear shock adjustment too soft front fork, rear shock absorber spring weak rear shock absorber oil leaking brake doesn’t hold: air in the brake line pad or disc worn brake fluid leakage disc warped contaminated pad brake fluid det...

  • Page 588

    Model application year model beginning frame no. 2006 vn900b6f jkavn2b1 □ 6a000001 or jkavn900bba000001 2006 vn900d6f jkavn900bba000001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1366-01 printed in japan.