1. DL manuals
  2. Kawasaki
  3. Other
  4. Z1000
  5. Service Manual

Kawasaki Z1000 Service Manual

Summary of Z1000

  • Page 1

    Z1000 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: Z1000

    Z1000 motorcycle service manual all rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of quality assurance departm...

  • Page 6

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

  • Page 7

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

  • Page 8

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

  • Page 9: Foreword

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

  • Page 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 bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating dia...

  • Page 15

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

  • Page 16

    1-6 general information before servicing direction of engine rotation when rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro- tate the crankshaft to positive direction (clockwise viewed from output side). Electrical wires a two-color wire is i...

  • Page 17

    General information 1-7 model identification zr1000–a1 left side view: zr1000–a1 right side view:.

  • Page 18

    1-8 general information general specifications items zr1000–a1 ∼ dimensions: overall length 2 080 mm (81.9 in.) overall width 770 mm (30.3 in.) overall height 1 055 mm (41.5 in.) wheelbase 1 420 mm (55.9 in.) road clearance 145 mm (5.7 in.) seat height 820 mm (32.3 in.) dry mass 198 kg (410.1 lb) cu...

  • Page 19

    General information 1-9 general specifications items zr1000–a1 ∼ lubrication system forced lubrication (wet sump with cooler) engine oil: type api se, sf or sg api sh or sj with jaso ma viscosity sae10w-40 capacity 3.8 l (4.0 us qt) drive train: primary reduction system: type gear reduction ratio 1....

  • Page 20

    1-10 general information general specifications items zr1000–a1 ∼ tail/brake light 12 v 0.5/3.8 w (led) (us, ca, cal) 12 v 0.5/5w (led) alternator: type three-phase ac rated output 24 a/ 14 v @5 000 r/min (rpm) specifications are subject to change without notice, and may not apply to every country. ...

  • Page 21

    General information 1-11 technical information – air inlet system subthrottle control system the zr1000–a1 ∼ employs large bore throttle bodies to increase power output. However, sudden changes in throttle opening can cause hesitation and jerky throttle response with a single butterfly valve in a la...

  • Page 22

    1-12 general information technical information – air inlet system operation the subthrottle control system consists of the subthrottle valve, subthrottle valve actuator with a stepping motor built in it, ecu, and subthrottle sensor. The subthrottle valve is built in the each throttle body. The subth...

  • Page 23

    General information 1-13 technical information – new ignition interlock sidestand outline the new ignition interlock sidestand system applied to zr1000–a1 models that cannot function if gears are engaged and/or the sidestand is not lifted upward even though clutch lever pulled in, which differs from...

  • Page 24

    1-14 general information technical information – tail/brake lights employing led outline this model employs a tail/brake light containing 21 light emitting diodes (led). The led emits luminous beams over a longer life span than those emitted from a traditional electric heated bulb (more than 5 times...

  • Page 25

    General information 1-15 technical information – tail/brake lights employing led the emitting color differs according to the materials of semi-conductors. Materials of semi-conductor and emitting color materials of semi-conductor emitting color gaasp, gaalas red gap green gan blue ga: gallium as: ar...

  • Page 26

    1-16 general information technical information - kleen (kawasaki low exhaust emission system) since the emission regulations become more severe, kawasaki has adopted a type of simplified kleen, which have no catalyst protection system, according to each regulation of different countries. The muffler...

  • Page 27

    General information 1-17 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 29: Periodic Maintenance

    Periodic maintenance 2-1 2 periodic maintenance table of contents periodic maintenance chart .............. 2-2 torque and locking agent................. 2-4 specifications .................................... 2-9 special tools ..................................... 2-11 periodic maintenance procedur...

  • Page 30

    2-2 periodic maintenance periodic maintenance chart the scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. Frequency whichever 1 000 km * odometer reading comes (60...

  • Page 31

    Periodic maintenance 2-3 periodic maintenance chart frequency whichever 1 000 km * odometer reading comes (600 mile) first 6 000 km → (4 000 mile) ↓ 12 000 km ( 7 500 mile) 18 000 km (12 000 mile) 24 000 km (15 000 mile) 30 000 km (20 000 mile) 36 000 km (24 000 mile) operation every clutch-adjust †...

  • Page 32

    2-4 periodic maintenance torque and locking agent the following tables list the tightening torque for the major fasteners requiring use of a non -permanent locking agent or liquid gasket. Letters used in the “remarks” column mean: l: apply a non-permanent locking agent to the threads. G: apply greas...

  • Page 33

    Periodic maintenance 2-5 torque and locking agent torque fastener n·m kgf·m ft·lb remarks water pump drain bolt 11 1.1 95 in·lb water pipe bolts 11 1.1 95 in·lb in/outlet thermostat housing ground bolt 7 0.7 61 in·lb thermostat bracket bolt 7 0.7 61 in·lb radiator upper bolts 7 0.7 61 in·lb radiator...

  • Page 34

    2-6 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks engine lubrication: oil filler plug 1.5 0.15 13 in·lb engine drain plug 20 2.0 14.5 oil filter (cartridge type, p/no.16097–1070) 26 2.7 20 r, eo oil filter (cartridge type, p/no.16097–0002) 31 3.2 23 r, eo oil ...

  • Page 35

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks wheels/tires: front axle clamp bolt 34 3.5 25 front axle 127 13 94 rear axle nut 127 13 94 final drive: engine sprocket nut 127 13 94 mo engine sprocket cover bolts 9.8 1.0 87 in·lb engine sprocket cover damper...

  • Page 36

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks handlebar lower clamp nuts 34 3.5 25 handlebar switch housing screws 3.4 0.35 30 in·lb frame: footpeg holder bolts 34 3.5 25 muffler mounting bolts 29 3.0 22 side stand bolt 44 4.5 33 side stand switch bolt 8.8...

  • Page 37

    Periodic maintenance 2-9 specifications item standard service limit fuel system: throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) idle speed 1 100 ± 50 r/min (rpm) bypass screws (turn out) 2 ± 1/4 (for reference) – – – engine vacuum 32.7 ± 1.333 kpa (245 ± 10 mm hg) air cleaner element paper filte...

  • Page 38

    2-10 periodic maintenance specifications item standard service limit air pressure: (when cold) front up to 180 kg (396 lb) load: 250 kpa (2.5 kgf/cm², 36 psi) – – – rear up to 180 kg (396 lb) load: 290 kpa (2.9 kgf/cm², 41 psi) – – – final drive: drive chain slack 20 ∼ 30 mm (0.8 ∼ 1.2 in.) – – – dr...

  • Page 39

    Periodic maintenance 2-11 special tools steering stem nut wrench: 57001–1100 jack: 57001–1238 oil filter wrench: 57001–1249 pilot screw adjuster, c: 57001–1292 hand tester: 57001–1394 spark plug wrench (owner’s tool): 92110–1132.

  • Page 40

    2-12 periodic maintenance periodic maintenance procedures fuel system (dfi) fuel hose and connection inspection ○ the fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure in- side the fuel l...

  • Page 41

    Periodic maintenance 2-13 periodic maintenance procedures throttle control system inspection throttle grip play inspection • check the throttle grip free play [a]. If the free play is incorrect, adjust the throttle cable (see below). Throttle grip free play standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) • che...

  • Page 42

    2-14 periodic maintenance periodic maintenance procedures throttle bore cleaning • check the throttle bore for cleanliness as follows: ○ remove the throttle body assy (see fuel system (dfi) chapter). ○ check the main throttle valves and throttle bores [a] for carbon deposits by opening the main valv...

  • Page 43

    Periodic maintenance 2-15 periodic maintenance procedures engine vacuum synchronization inspection note ○ these procedures are explained on the assumption that the inlet and exhaust systems of the engine are in good condition. • situate the motorcycle so that it is vertical. • remove the fuel tank (...

  • Page 44

    2-16 periodic maintenance periodic maintenance procedures • install the fuel tank (see fuel system (dfi) chapter). • start the engine and warm it up thoroughly. • check the idle speed. Tachometer [a] if the idle speed is out of the specified range, adjust it. Caution do not measure the idle speed by...

  • Page 45

    Periodic maintenance 2-17 periodic maintenance procedures if any one vacuum measurement is out of the standard measurement after synchronization, adjust the bypass screws [a]. Front [b] special tool - pilot screw adjuster, c: 57001-1292 • adjust the lowest vacuum between #1 and #2 to the high- est o...

  • Page 46

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

  • Page 47

    Periodic maintenance 2-19 periodic maintenance procedures air cleaner element cleaning note ○ in dusty areas, the element should be cleaned more frequently than the recommended interval. ○ after riding through rain or on muddily roads, the ele- ment should be cleaned immediately. Warning if dirt or ...

  • Page 48

    2-20 periodic maintenance periodic maintenance procedures • clean the element by tapping it lightly to loosen dust. • blow away the remaining dust by applying compressed air [a] from the outside to the inside (from the clean side to the dirty side). • visually inspect the element for no tears or no ...

  • Page 49

    Periodic maintenance 2-21 periodic maintenance procedures ○ disconnect the hoses from the separator, and remove the separator [a] from the motorcycle left side. Front [b] ○ visually inspect the separator for cracks and other dam- age. If the separator has any cracks or damage, replace it with a new ...

  • Page 50

    2-22 periodic maintenance periodic maintenance procedures • remove the fuel tank (see fuel system (dfi) chapter). • remove the radiator cap [a] in two steps. First turn the cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap. ○ the coolant w...

  • Page 51

    Periodic maintenance 2-23 periodic maintenance procedures • loosen the air bleeder bolt [a] on the thermostat housing. Front [b] • replenish the coolant into the radiator until the coolant begins to flow out the air bleeder bolt hole (that is, all the remaining air is forced out). • tap the radiator...

  • Page 52

    2-24 periodic maintenance periodic maintenance procedures valve clearance inspection note ○ valve clearance must be checked and adjusted when the engine is cold (at room temperature). • remove: lower fairings (see frame chapter) pickup coil cover cylinder head cover (see cylinder head cover re- mova...

  • Page 53

    Periodic maintenance 2-25 periodic maintenance procedures valve clearance adjustment • to change the valve clearance, remove the camshaft chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. Note ○ mark and record the valve lifter and shim locations so th...

  • Page 54

    2-26 periodic maintenance 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 55

    Periodic maintenance 2-27 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 56

    2-28 periodic maintenance periodic maintenance procedures clutch clutch adjust inspection • pull the clutch lever just enough to take up the free play [a]. • measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, th...

  • Page 57

    Periodic maintenance 2-29 periodic maintenance procedures engine lubrication system engine oil change • situate the motorcycle so that it is vertical after warming up the engine. • remove the engine drain plug [a] to drain the oil. ○ the oil in the oil filter can be drained by removing the filter (s...

  • Page 58

    2-30 periodic maintenance periodic maintenance procedures wheels/tires tire inspection as the tire tread wears down, the tire becomes more sus- ceptible to puncture and failure. An accepted estimate is that 90 % of all tire failures occur during the last 10 % of tread life (90 % worn). So it is fals...

  • Page 59

    Periodic maintenance 2-31 periodic maintenance procedures air pressure inspection/adjustment • remove the air valve cap. • 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)....

  • Page 60

    2-32 periodic maintenance periodic maintenance procedures • tighten both chain adjuster locknuts securely. • tighten the axle nut. Torque - rear axle nut: 127 n·m (13 kgf·m, 94 ft·lb) • turn the wheel, measure the chain slack again at the tight- est position, and readjust if necessary. • insert a ne...

  • Page 61

    Periodic maintenance 2-33 periodic maintenance procedures • rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry. • stretch the chain taut by hanging a 98 n...

  • Page 62

    2-34 periodic maintenance periodic maintenance procedures • apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the o-rings so that the o-rings will be coated with oil. • wipe off any excess oil. Oil applied areas [a] o-ring [b] brakes brake...

  • Page 63

    Periodic maintenance 2-35 periodic maintenance procedures if it does not, adjust and inspect 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 bod...

  • Page 64

    2-36 periodic maintenance periodic maintenance procedures master cylinder inspection (visual inspection) • disassemble the front and rear master cylinders. • check that there are no scratches, rust or pitting on the inner wall [a] of each master cylinder and on the outside of each piston [b]. If a m...

  • Page 65

    Periodic maintenance 2-37 periodic maintenance procedures level inspection • check that the brake fluid level in the front brake reservoir [a] is above the lower level line [b]. Note ○ hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid level is lower...

  • Page 66

    2-38 periodic maintenance periodic maintenance procedures • level the brake fluid reservoir. • remove the reservoir cap and diaphragm. • remove the rubber cap from the bleed valve [a] on the caliper. • attach a clear plastic hose [b] to the bleed valve, and run the other end of the hose into a conta...

  • Page 67

    Periodic maintenance 2-39 periodic maintenance procedures brake line bleeding the brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air ent...

  • Page 68

    2-40 periodic maintenance periodic maintenance procedures • bleed the brake line and the caliper: ○ repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [a]. 2. Quickly open and close [b...

  • Page 69

    Periodic maintenance 2-41 periodic maintenance procedures 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 ...

  • Page 70

    2-42 periodic maintenance periodic maintenance procedures suspension front fork oil leak check • visually inspect the front forks [a] for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace or repair any defective parts, if necessary. Rear shock absorber oil leak check...

  • Page 71

    Periodic maintenance 2-43 periodic maintenance procedures steering steering inspection • lift the front wheel off the ground using the jack. Special tool - jack: 57001–1238 • with the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully l...

  • Page 72

    2-44 periodic maintenance periodic maintenance procedures • adjust the steering. Special tool - steering stem nut wrench: 57001–1100 [b] if the steering is too tight, loosen the stem nut [a] a fraction of a turn. If the steering is too loose, tighten the stem nut a fraction of a turn. Note ○ turn th...

  • Page 73

    Periodic maintenance 2-45 periodic maintenance procedures • unscrew the thermostat bracket bolt [a]. ○ if removing the spark plug #2 or #3. • disconnect: stick coil connectors [a] • pull out the stick coil #1 [b]. • take out the camshaft position sensor connector [c] from the bracket. • pull out the...

  • Page 74

    2-46 periodic maintenance periodic maintenance procedures • clean the spark plug, preferably in a sandblasting device, and then clean off any abrasive particles. The plug may also be cleaned using a high-flash point solvent and a wire brush or other tool. If the spark plug center electrode [a] and/o...

  • Page 75

    Periodic maintenance 2-47 periodic maintenance procedures general lubrication 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 vehicl...

  • Page 76

    2-48 periodic maintenance periodic maintenance procedures nut, bolt, and fastener tightness 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...

  • Page 77: Fuel System (Dfi)

    Fuel system (dfi) 3-1 3 fuel system (dfi) table of contents exploded view................................... 3-3 dfi parts location............................. 3-8 dfi wiring diagram ........................... 3-10 specifications .................................... 3-12 special tools ...............

  • Page 78

    3-2 fuel system (dfi) ecu installation ........................... 3-71 ecu power supply inspection..... 3-72 dfi power source ............................. 3-74 ecu fuse removal ..................... 3-74 ecu fuse installation .................. 3-74 ecu fuse inspection ................... 3-74 ecu...

  • Page 79

    Fuel system (dfi) 3-3 exploded view clifornia evaporative emission control system 1. Canister 2. Separator 3. Right fitting of throttle body #2 4. Right fitting of throttle body #3 5. Canister purge hose (green) 6. Fuel return hose (left, red) 7. Fuel tank breather hose (right, blue) 8. Separator br...

  • Page 80

    3-4 fuel system (dfi) exploded view.

  • Page 81

    Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 throttle cable plate bolt 6 0.6 52 in·lb 2 throttle body cover bolts 7 0.7 61 in·lb 3 throttle assy holder clamp bolts 2 0.2 17 in·lb 4 choke link holder screws 2.1 0.21 18 in·lb 5 delivery pipe screws 3.4 0.35 30 in·l...

  • Page 82

    3-6 fuel system (dfi) exploded view.

  • Page 83

    Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 inlet air pressure sensor bolt 12 1.2 104 in·lb 2 water temperature sensor 25 2.5 18 3 vehicle downsensor bolts 2 0.2 17 in·lb 4 camshaft position sensor bolt 12 1.2 104 in·lb 5 camshaft position sensor rotor bolt 12 1...

  • Page 84

    3-8 fuel system (dfi) dfi parts location dfi: dfi parts (this chapter) 8. Ecu fuse 15a 19. Turn signal relay f: front 9. Ecu (dfi) 20. Subthrottle sensor (dfi) 1. Water temperature 10. Stick coils 21. Main throttle sensor (dfi) sensor (dfi) 11. Throttle body assy 22. Ignition switch 2. Inlet air pre...

  • Page 85

    Fuel system (dfi) 3-9 dfi parts location [1], [2], [10], [13], [22] and [24] are not included..

  • Page 86

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

  • Page 87

    Fuel system (dfi) 3-11 dfi wiring diagram terminal names 1. Power supply to sensors (inlet air pres- sure, atmospheric pressure, and throttle sensors) from ecu. 2. Main throttle sensor signal 3. Subthrottle sensor signal for ecu 4. Atmospheric pressure sensor signal 5. Water temperature sensor signa...

  • Page 88

    3-12 fuel system (dfi) specifications item standard digital fuel injection system idle speed 1 100 ± 50 r/min (rpm) throttle assy: type four barrel type bore 38 mm (1.5 in.) ecu (electronic control unit): make denso type digital memory type, with built in ic igniter, sealed with resin usable engine ...

  • Page 89

    Fuel system (dfi) 3-13 specifications item standard detection time within 0.5 ∼ 1.0 sec. Output voltage with the sensor tilted 60 ∼ 70° or more: 3.7 ∼ 4.4 v with sensor arrow mark pointed up: 0.4 ∼ 1.4 v subthrottle sensor: non-adjustable and non-removal input voltage 4.75 ∼ 5.25 v dc between br and...

  • Page 90

    3-14 fuel system (dfi) special tools oil pressure gauge: 57001–125 carburetor drain plug wrench, hex 3: 57001–1269 fork oil level gauge: 57001–1290 hand tester: 57001–1394 throttle sensor setting adapter: 57001–1400 fuel pressure gauge adapter: 57001–1417 needle adapter set: 57001–1457 throttle sens...

  • Page 91

    Fuel system (dfi) 3-15 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 12 v sealed battery as a p...

  • Page 92

    3-16 fuel system (dfi) dfi servicing precautions ○ to maintain the correct fuel/air mixture (f/a), there must be no inlet air leaks in the dfi system. Be sure to install the oil filler plug [a] after filling the engine oil. Clutch cover [b] front [c] torque - oil filler plug: 1.5 n·m (0.15 kgf·m, 13...

  • Page 93

    Fuel system (dfi) 3-17 troubleshooting the dfi system 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 control ...

  • Page 94

    3-18 fuel system (dfi) troubleshooting the dfi system ○ the dfi part connectors [a] have seals [b], including the ecu. • join the connector and insert the needle adapters (special tool) [c] inside the seal [b] from behind the connector until the adapter reaches the terminal. Special tool - needle ad...

  • Page 95

    Fuel system (dfi) 3-19 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 96

    3-20 fuel system (dfi) troubleshooting the dfi system ○ there are two ways to inspect the dfi system. One is voltage check method and the other is resistance check method. (voltage check method) ○ this method is conducted by measuring the input voltage [b] to a sensor [a] first, and then the output ...

  • Page 97

    Fuel system (dfi) 3-21 troubleshooting the dfi system dfi diagnosis flow chart inquiries to rider ○ each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ try to find out exactly what problem occurred under exactly what condi...

  • Page 98

    3-22 fuel system (dfi) troubleshooting the dfi system sample diagnosis sheet rider name: registration no. (license plate no.): year of initial registration: model: engine no.: frame no.: date problem occurred: mileage: environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ al...

  • Page 99

    Fuel system (dfi) 3-23 troubleshooting the dfi system poor running □ choke lever pulled out fully (push it in fully) at low speed □ very low choke speed (adjust choke cable) □ very low idle speed, □ very high idle speed, □ rough idle speed □ battery voltage is low (charge the battery) □ spark plug l...

  • Page 100

    3-24 fuel system (dfi) dfi system troubleshooting guide note ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. ○ the ecu may be involved in the dfi electri...

  • Page 101

    Fuel system (dfi) 3-25 dfi system troubleshooting guide symptoms or possible causes actions (chapter) 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 gear in neutral. Thoug...

  • Page 102

    3-26 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) piston ring /groove clearance excessive inspect and replace (see chapter 5). Cylinder head gasket damaged replace (see chapter 5). Cylinder head warped inspect and replace (see chapter 5). No valve ...

  • Page 103

    Fuel system (dfi) 3-27 dfi system troubleshooting guide symptoms or possible causes actions (chapter) atmospheric pressure sensor trouble inspect (see chapter 3). Fuel pressure too low or too high inspect (see chapter 3). Battery voltage low inspect and charge (see chapter 16). Incorrect idle speed ...

  • Page 104

    3-28 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) subthrottle sensor trouble inspect (see chapter 3). Subthrottle valve actuator trouble inspect (see chapter 3). Water temperature sensor trouble inspect (see chapter 3). Atmospheric pressure sensor ...

  • Page 105

    Fuel system (dfi) 3-29 dfi system troubleshooting guide symptoms or possible causes actions (chapter) spark plug dirty, broken or gap maladjusted clean spark plugs and adjust plug gap (see chapter 2). Too low fuel pressure inspect (see chapter 3). Fuel pump trouble inspect (see chapter 3). Main thro...

  • Page 106

    3-30 fuel system (dfi) dfi system troubleshooting guide poor running or no power at high speed: symptoms or possible causes actions (chapter) firing incorrect : spark plug dirty, broken or maladjusted clean spark plug and adjust plug gap (see chapter 2). Spark plug cap trouble inspect stick coil (se...

  • Page 107

    Fuel system (dfi) 3-31 dfi system troubleshooting guide symptoms or possible causes actions (chapter) fuel poor quality or incorrect (use the gasoline recommended in the owner’s manual) change fuel (see chapter 3). Spark plug incorrect replace it with the correct plug (see chapter 16). Stick coil tr...

  • Page 108

    3-32 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) too low fuel pressure inspect fuel line and fuel pump (see chapter 3). Water temperature sensor trouble inspect and replace (see chapter 3). Inlet air temperature sensor trouble inspect and replace ...

  • Page 109

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

  • Page 110

    3-34 fuel system (dfi) self-diagnosis • to enter the self-diagnosis dealer mode 2, open [b] and ground [a] the lead more than five times [f] within 2 sec- onds [c] after the lead is first grounded, and then keep it grounded continuously [d] for more than 2 seconds. ○ count the blinks of the led ligh...

  • Page 111

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

  • Page 112

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

  • Page 113

    Fuel system (dfi) 3-37 self-diagnosis service code table service code fi indicator led light 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 or short 14 water te...

  • Page 114

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

  • Page 115

    Fuel system (dfi) 3-39 self-diagnosis service codes parts output signal usable range or criteria backups by ecu 51 stick coil #1 (ignition coil)* the stick coil primary winding must send signals (output voltage) continuously to the ecu. If the ignition primary winding #1 has failures (no signal, wir...

  • Page 116

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

  • Page 117

    Fuel system (dfi) 3-41 main throttle sensor (service code 11) output voltage inspection • measure the output voltage at the main throttle sensor in the same way as input voltage inspection, note the following. • disconnect the main throttle sensor (gray) [a] and con- nect the harness adapter [b] bet...

  • Page 118

    3-42 fuel system (dfi) main throttle sensor (service code 11) resistance inspection • turn the ignition switch off. • disconnect the main throttle sensor connector. • connect a digital meter [a] to the main throttle sensor connector [b]. • measure the main throttle sensor resistance. Main throttle s...

  • Page 119

    Fuel system (dfi) 3-43 inlet air pressure sensor (service code 12) caution never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Removal • remove: fuel tank (see fuel system chapter) water temperature sensor connector [a] inlet air pressure sensor bolt [b] • ra...

  • Page 120

    3-44 fuel system (dfi) inlet air pressure sensor (service code 12) output voltage inspection note ○ the output voltage changes according to the local at- mospheric pressure. • measure the output voltage at the ecu in the same way as input voltage inspection. Note the following. Inlet air pressure se...

  • Page 121

    Fuel system (dfi) 3-45 inlet air pressure sensor (service code 12) ○ turn the ignition switch on. ○ measure the inlet air pressure sensor output voltage from various vacuum readings, while pulling the handle of the fork oil level gauge. ○ check the inlet air pressure sensor output voltage, using the...

  • Page 122

    3-46 fuel system (dfi) inlet air pressure sensor (service code 12) pv = 24 ∼ 55 cmhg.

  • Page 123

    Fuel system (dfi) 3-47 inlet air pressure sensor (service code 12) pv = 55 ∼ 86 cmhg vv: inlet air pressure sensor output volt- age (v) (digital meter reading) id: idling to: throttle full open pv: throttle vacuum pressure (absolute) st: standard of sensor output voltage (v) ps: standard atmospheric...

  • Page 124

    3-48 fuel system (dfi) inlet air temperature sensor (service code 13) removal/installation caution never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove the fuel tank (see fuel tank removal). • disconnect the connector [a] from the inlet air tempera-...

  • Page 125

    Fuel system (dfi) 3-49 inlet air temperature sensor (service code 13) sensor resistance inspection • remove the inlet air temperature sensor (see this sec- tion). • suspend the sensor [a] in a container of machine oil so that the heat-sensitive portion is submerged. • suspend a thermometer [b] with ...

  • Page 126

    3-50 fuel system (dfi) 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 about 200 ml (6.76 us oz). • disconnect th...

  • Page 127

    Fuel system (dfi) 3-51 water temperature sensor (service code 14) a. Ecu d. Water temperature sensor v. Coolant temperature gauge in tachometer sensor resistance inspection • remove the water temperature sensor (see this section). • refer to the electrical system chapter for water temper- ature sens...

  • Page 128

    3-52 fuel system (dfi) atmospheric pressure sensor (service code 15) caution never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Note ○ the atmospheric pressure sensor is the same part as the inlet air pressure sensor except that the inlet air pressure sens...

  • Page 129

    Fuel system (dfi) 3-53 atmospheric pressure sensor (service code 15) output voltage inspection • measure the output voltage at the ecu in the same way as input voltage inspection. Note the following. Digital meter [a] ecu connector [b] atmospheric pressure sensor output voltage connections to ecu me...

  • Page 130

    3-54 fuel system (dfi) atmospheric pressure sensor (service code 15) va: atmospheric pressure sensor output voltage (v) st: standard of sensor output voltage (v) ur: usable range of sensor output voltage (v) h: altitude (m or feet) a. Ecu e. Atmospheric pressure sensor.

  • Page 131

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

  • Page 132

    3-56 fuel system (dfi) camshaft position sensor (service code 23) 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- t...

  • Page 133

    Fuel system (dfi) 3-57 speed sensor (service code 24, 25) speed sensor removal/installation • see the switches and sensors section in the electrical system chapter. Speed sensor inspection • see the switches and sensors section in the electrical system chapter. Input voltage inspection note ○ be sur...

  • Page 134

    3-58 fuel system (dfi) speed sensor (service code 24, 25) • disconnect the speed sensor connector [a] and connect the harness adapter [b] between the harness connector and speed sensor connector. Engine sprocket cover [c] • connect a digital meter to the harness adapter leads. Special tool - throttl...

  • Page 135

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

  • Page 136

    3-60 fuel system (dfi) vehicle-down sensor (service code 31) • turn the ignition switch off. • remove the sensor. • connect a digital volt meter [a] to the connector with nee- dle adapter set [b]. Special tool - needle adapter set: 57001–1457 vehicle-down sensor output voltage connections to sensor ...

  • Page 137

    Fuel system (dfi) 3-61 vehicle-down sensor (service code 31) a. Ecu s. Ecu main relay t. Ignition switch a. Ecu fuse 15a b. Vehicle-down sensor d. Starter relay f. Sealed battery j. Joint connector b k. Main fuse 30 a.

  • Page 138

    3-62 fuel system (dfi) subthrottle sensor (service code 32) subthrottle sensor removal/adjustment caution do not remove or adjust the subthrottle sensor [a] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sens...

  • Page 139

    Fuel system (dfi) 3-63 subthrottle sensor (service code 32) output voltage inspection • remove the throttle body assy (see throttle body assy removal). • measure the output voltage at the subthrottle sensor in the same way as input voltage inspection. Note the fol- lowing. • disconnect the subthrott...

  • Page 140

    3-64 fuel system (dfi) subthrottle sensor (service code 32) resistance inspection • turn the ignition switch off. • disconnect the subthrottle sensor connector. • connect a digital meter [a] to the subthrottle sensor con- nector [b]. • measure the subthrottle sensor resistance. Throttle sensor resis...

  • Page 141

    Fuel system (dfi) 3-65 stick coils (#1, #2, #3, #4: service code 51, 52, 53, 54) stick coil #1: ignition coil (service code 51) stick coil #2: ignition coil (service code 52) stick coil #3: ignition coil (service code 53) stick coil #4: ignition coil (service code 54) removal/installation caution ne...

  • Page 142

    3-66 fuel system (dfi) stick coils (#1, #2, #3, #4: service code 51, 52, 53, 54) a. Ecu m. Stick coils n. Engine stop switch t. Ignition switch x. Ignition fuse 10 a y. Junction box d. Starter relay e. Joint connector d f. Sealed battery k. Main fuse 30 a.

  • Page 143

    Fuel system (dfi) 3-67 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 144

    3-68 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 throttle body assy (see throttle body assy removal). • connect the peak voltage adapter [a] and a digital meter [b] t...

  • Page 145

    Fuel system (dfi) 3-69 fi indicator led light inspection flow chart.

  • Page 146

    3-70 fuel system (dfi) fi indicator led light led light inspection • remove the meter unit (see electrical system chapter). • using two auxiliary leads, supply battery power to the fi indicator led light [a]. 12 v battery [b] fi indicator led light check connector: meter connector [c] (disconnected)...

  • Page 147

    Fuel system (dfi) 3-71 ecu caution never drop the ecu, especially on a hard surface. Such a shock to the ecu can damage it. Ecu identification ○ most countries have their own regulations, so each ecu has different characteristic. So, do not confuse ecu’s with each other and use only the ecu’s for yo...

  • Page 148

    3-72 fuel system (dfi) ecu if the rubber protector [a] is removed, install it. Ecu [b] ecu power supply inspection • visually inspect the terminals [a] of the ecu connectors. If the connector is clogged with mud or dust, blow it off with compressed air. Replace the main harness if the terminals of t...

  • Page 149

    Fuel system (dfi) 3-73 ecu • check the ecu power source voltage with a digital meter [a]. ○ position the terminal in accordance with terminal numbers of ecu connectors [b] in this chapter figure. Battery [c] ecu power source inspection meter between terminal 13 (w/y) and connections: battery (–) ter...

  • Page 150

    3-74 fuel system (dfi) dfi power source ecu fuse removal • refer to the electrical system chapter for the ecu fuse removal. Ecu fuse installation if a fuse fails during operation, inspect the dfi system to determine the cause, and then replace it with a new fuse of proper amperage. • refer to the el...

  • Page 151

    Fuel system (dfi) 3-75 fuel line fuel pressure inspection note ○ this inspection can determine which trouble the dfi system has, mechanical or electrical trouble. ○ it is preferable to measure the fuel pressure while run- ning the motorcycle just when trouble occurred in order to know symptom well. ...

  • Page 152

    3-76 fuel system (dfi) fuel line • start the engine, and let it idle. • measure the fuel pressure with the engine idling. Fuel pressure (idling) standard: 310 kpa (3.2 kgf/cm², 46 psi) note ○ the gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. If...

  • Page 153

    Fuel system (dfi) 3-77 fuel line • open the fuel tank cap [a] to lower the pressure in the tank. Front [b] • be sure to place a piece of cloth around the fuel pump outlet hose. • remove the fuel pump outlet hose [a] from the fuel pump [b] and the delivery pipe [c] (see fuel pump removal). Front [d] ...

  • Page 154

    3-78 fuel system (dfi) fuel pump fuel pump removal caution never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. Warning gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from an...

  • Page 155

    Fuel system (dfi) 3-79 fuel pump • replace the fuel pump gasket [a] with a new one. • check that the fuel pump (–) terminal [a] and band [b] are in place. Front [c] • apply a non-permanent locking agent to the threads of the fuel pump bolts. • tighten the fuel pump bolts to a snug fit, following the...

  • Page 156

    3-80 fuel system (dfi) fuel pump • connect the hand tester (25 v dc) to the fuel pump con- nector [a] with needle adapter set. Front [b] special tools - hand tester: 57001–1394 needle adapter set: 57001–1457 ○ measure the operating voltage with the engine stopped, and with the connector joined. • tu...

  • Page 157

    Fuel system (dfi) 3-81 fuel pump fuel pump relay removal caution never drop the relay, especially on a hard surface. Such a shock to the relay can damage it. • remove the seat cover (see frame chapter). • remove the fuel pump relay [a] from the tongue of the storage compartment. • disconnect the con...

  • Page 158

    3-82 fuel system (dfi) fuel injectors removal/installation • refer to the throttle body assy disassembly/assembly. Audible inspection • start the engine. • apply the tip of a screwdriver [a] to the injector [c]. Put the grip end onto your ear, and listen whether the injector is clicking or not. ○ a ...

  • Page 159

    Fuel system (dfi) 3-83 fuel injectors output voltage inspection • turn the ignition switch off. • remove the ecu (see ecu section). • connect a digital voltmeter [a] to the ecu connector [b] with the needle adapter set [c]. Special tool - needle adapter set: 57001–1457 injector output voltage connec...

  • Page 160

    3-84 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 (0.071 in.) terminal thickness [c]: 0.8 mm (0.031 in.) caution do not use larger terminals than specified above. A la...

  • Page 161

    Fuel system (dfi) 3-85 fuel injectors injector resistance inspection • remove the fuel tank (see fuel tank removal). • disconnect the connector from the injector [a] (see throt- tle body assy disassembly/assembly). • measure the injector resistance with the hand tester [b]. Front [c] special tool - ...

  • Page 162

    3-86 fuel system (dfi) fuel injectors • check the injector fuel line for leakage as follows: ○ connect a commercially available vacuum/pressure pump [a] to the nipple of the delivery pipe [b] with a high-pressure fuel hose [c] (both ends connected with the clamps [d]) as shown. Torque - fuel hose cl...

  • Page 163

    Fuel system (dfi) 3-87 fuel injectors a. Ecu k. Fuel injectors n. Engine stop switch t. Ignition switch x. Ignition fuse 10 a y. Junction box z. Fuel pump relay (for fuel pump an injectors) d. Starter relay e. Joint connector c f. Sealed battery j. Joint connector b k. Main fuse 30 a.

  • Page 164

    3-88 fuel system (dfi) throttle grip and cables throttle grip play inspection/adjustment • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Choke lever operation ○ do not use the choke lever except when the engine has a starting difficulty like in cold weather (...

  • Page 165

    Fuel system (dfi) 3-89 throttle body assy idle speed inspection/adjustment • refer to the idle speed inspection in the periodic main- tenance chapter . Throttle bore cleaning • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Engine vacuum synchronization inspec...

  • Page 166

    3-90 fuel system (dfi) throttle body assy • loosen: throttle assy holder clamp bolts [a] air cleaner duct clamp bolts [b] special tool - carburetor drain plug wrench, hex 3: 57001–1269 • remove: right and left side covers (see frame chapter) coolant reserve tank (see coolant change in the peri- odic...

  • Page 167

    Fuel system (dfi) 3-91 throttle body assy • remove the bolt [a] and the throttle cable plate [b] from the throttle body front side. • remove the throttle cable lower ends from the throttle pulley. • remove: choke cable upper end (from choke lever) choke cable lower end [a] throttle body #2 [b] • aft...

  • Page 168

    3-92 fuel system (dfi) 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 (see throttle body assy removal). • fit the projection [a] of the right switch housing into the hole [b] of the handlebar (front vi...

  • Page 169

    Fuel system (dfi) 3-93 throttle body assy caution never drop the injector, especially on a hard sur- face. Such a shock to the injector can damage it. • pull out [a] the injectors along with the delivery pipe [b]. If necessary, remove the injectors from the delivery pipe. Replace the o-rigs of the i...

  • Page 170

    3-94 fuel system (dfi) air cleaner element removal/installation • refer to the air cleaner element cleaning in the periodic maintenance chapter. Air cleaner oil draining a drain hose is connected to the bottom of the air cleaner to drain water or oil accumulated in the cleaner part. • visually check...

  • Page 171

    Fuel system (dfi) 3-95 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 igniti...

  • Page 172

    3-96 fuel system (dfi) fuel tank • be sure to place a piece of cloth [a] around the fuel hose pump outlet joint [b]. • while pinching the hose joint locks [c] with fingers, pull the joint out along the delivery pipe. Front [d] warning be prepared for fuel spillage; any spilled fuel must be completel...

  • Page 173

    Fuel system (dfi) 3-97 fuel tank fuel tank installation • note the above warning (see fuel tank removal). • route the hoses correctly (see appendix chapter). • check that the rubber dampers [a] are on the frame and the fuel tank. Front [b] • check that the dampers [a] are in place on the fuel tank a...

  • Page 174

    3-98 fuel system (dfi) fuel tank fuel tank and cap inspection • visually inspect the gasket [a] on the tank cap for any damage. Replace the gasket if it is damaged. • check to see if the water drain pipe [b] and fuel breather pipe [c] in the tank are not clogged. Check the tank cap breather also. If...

  • Page 175

    Fuel system (dfi) 3-99 evaporative emission control system parts removal/installation warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch off. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks...

  • Page 176

    3-100 fuel system (dfi) evaporative emission control system separator operation test warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch off. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...

  • Page 177: Cooling System

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

  • Page 178

    4-2 cooling system exploded view.

  • Page 179

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 radiator hose clamp screws 2 0.2 17 in·lb 2 thermostat air bleeder bolt 7.8 0.80 69 in·lb 3 radiator fan bolts 8.3 0.85 74 in·lb 4 water pump impeller bolt 9.8 1.0 87 in·lb 5 water pump cover bolts 11 1.1 95 in·lb 6 water...

  • Page 180

    4-4 cooling system coolant flow chart.

  • Page 181

    Cooling system 4-5 coolant flow chart 1. Drain bolt 2. Water pump 3. Cylinder jacket 4. Cylinder head jacket 5. Thermostat housing 6. Thermostat air bleeder bolt 7. Radiator cap 8. Radiator 9. Oil filter 10. Outlet hose 11. Inlet hose 12. Oil cooler 13. Reserve tank 14. Reserve tank hose 15. Reserve...

  • Page 182

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

  • Page 183

    Cooling system 4-7 special tool bearing driver set: 57001–1129 bearing driver: 57001–382 kawasaki bond (silicone sealant): 56019–120

  • Page 184

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

  • Page 185

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

  • Page 186

    4-10 cooling system water pump water pump removal • refer to oil pump removal in the engine lubrication sys- tem chapter. Water pump [a] front [b] water pump installation • refer to oil pump installation in the engine lubrication system chapter. Water pump inspection • check the drainage outlet pass...

  • Page 187

    Cooling system 4-11 water pump • be sure to replace the mechanical seal, oil seal, and o -ring with new ones because these parts will be damaged by removal. • apply plenty of high temperature grease to the oil seal lips. • apply oil to the outer circumference of the oil seal. • press the oil seal [a...

  • Page 188

    4-12 cooling system radiator radiator 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 fan before the connector is disc...

  • Page 189

    Cooling system 4-13 radiator • if necessary, remove: radiator fan mounting bolts [a] radiator fan [b] radiator inspection • check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [a] are deformed, carefully straighten them. If the air passages of the radi...

  • Page 190

    4-14 cooling system radiator • install the cap [a] on a cooling system pressure tester [b]. Note ○ wet the cap sealing surfaces with water or coolant to prevent pressure leaks. • watching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gauge ne...

  • Page 191

    Cooling system 4-15 thermostat thermostat removal • remove: coolant : drain about 200 ml fuel tank (see fuel system (dfi) chapter) thermostat bracket bolt [a] water temperature sensor connector [b] three water hoses [c] • remove the thermostat housing [d]. Front [e] • remove the screws [a], take off...

  • Page 192

    4-16 cooling system 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 193

    Cooling system 4-17 hose and pipes hose installation • install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • run the hoses in accordance with the cable, wire, and hose routing section in the appendix chapter. • wet the inter...

  • Page 194

    4-18 cooling system radiator fan switch, water temperature sensor caution the fan switch or the water temperature sensor should never be allowed to fall on a hard surface. Such a shock to their parts can damage them. Radiator fan switch removal • drain the coolant (see coolant change in the periodic...

  • Page 195: Engine Top End

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

  • Page 196

    5-2 engine top end exploded view.

  • Page 197

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air suction valve cover bolts 10 1.0 87 in·lb 2 cylinder head cover bolts 10 1.0 87 in·lb 3 camshaft cap bolts (l=45 mm) 12 1.2 104 in·lb 4 camshaft cap bolts (l=40 mm) 12 1.2 104 in·lb 5 cylinder head bolts (m10 new bolt...

  • Page 198

    5-4 engine top end exploded view.

  • Page 199

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 coolant drain plug (cylinder) 10 1.0 87 in·lb 2 exhaust pipe manifold holder nuts 17 1.7 12 3 muffler body clamp bolts 17 1.7 12 4 muffler body mounting bolts and nuts 34 35 25 5 crankshaft sensor cover bolts 11 1.1 95 in...

  • Page 200

    5-6 engine top end specifications item standard service limit clean air system: vacuum switch valve closing open → close pressure: 45 ∼ 53 kpa - - - (340 ∼ 400 mmhg, 6.5 ∼ 7.7 psi) camshafts: cam height: exhaust 36.146 ∼ 36.254 mm 36.05 mm (1.4231 ∼ 1.4273 in.) (1.419 in.) inlet 36.746 ∼ 36.854 mm 3...

  • Page 201

    Engine top end 5-7 specifications item standard service limit valve/valve guide clearance (wobble method): exhaust 0.09 ∼ 0.18 mm 0.40 mm (0.0035 ∼ 0.0071 in.) (0.016 in.) inlet 0.03 ∼ 0.12 mm 0.33 mm (0.0012 ∼ 0.0047 in.) (0.013 in.) valve seat cutting angle 45°, 32°, 60° - - - valve seating surfac...

  • Page 202

    5-8 engine top end special tools and sealant compression gauge: 57001–221 valve spring compressor assembly: 57001–241 piston pin puller assembly: 57001–910 valve seat cutter, 45° - 27.5: 57001–1114 valve seat cutter, 45° - 32: 57001–1115 valve seat cutter, 32° - 28: 57001–1119 valve seat cutter, 32°...

  • Page 203

    Engine top end 5-9 special tools and sealant valve spring compressor adapter, 22: 57001–1202 spark plug wrench, hex 16: 57001–1262 fork oil level gauge: 57001–1290 compression gauge adapter, m10 × 1.0: 57001–1317 valve guide arbor, 4.5: 57001–1331 valve seat cutter holder, 4.5: 57001–1330 valve guid...

  • Page 204

    5-10 engine top end clean air system air suction valve removal • remove: fuel tank (see fuel system (dfi) chapter) connector [a] (from clamp [b]) air suction valve cover bolts [c] and clamp air suction valve cover [d] air suction valve air suction valve installation • install the air suction valve [...

  • Page 205

    Engine top end 5-11 clean air system vacuum switch valve test • remove: fuel tank (see fuel system (dfi) chapter) vacuum switch valve • connect a vacuum gauge [a] and syringe [b] or fork oil level gauge to the vacuum hoses as shown. Special tool - fork oil level gauge: 57001–1290 air flow [c] • grad...

  • Page 206

    5-12 engine top end cylinder head cover cylinder head cover removal • remove: fuel tank (see fuel system (dfi) chapter) vacuum switch valve and hoses stick coils (see electrical system chapter) air suction valve covers [a] • remove the cylinder head cover bolts [a] and take off the cover. Cylinder h...

  • Page 207

    Engine top end 5-13 cylinder head cover • install the washer [a] with the metal side faces upward. • tighten: torque - cylinder head cover bolts [b]: 10 n·m (1.0 kgf·m, 87 in·lb).

  • Page 208

    5-14 engine top end camshaft chain tensioner camshaft chain tensioner removal caution this is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: when removing the ten...

  • Page 209

    Engine top end 5-15 camshaft, camshaft chain camshaft removal • remove: fuel tank (see fuel system (dfi) chapter) stick coils (see electrical system) cylinder head cover (see cylinder head cover re- moval) pickup coil cover • position the crankshaft at #1, 4 piston tdc. [a] tdc mark for #1, 4 piston...

  • Page 210

    5-16 engine top end camshaft, camshaft chain • apply engine oil to all cam parts and journals. • if a new camshaft is to be used, apply a thin coat of molyb- denum disulfide grease to the cam surfaces. Note ○ the exhaust camshaft has a 030 ex mark [a] and the inlet camshaft has a 030 in mark [b]. Be...

  • Page 211

    Engine top end 5-17 camshaft, camshaft chain camshaft, camshaft cap wear • remove: camshaft chain guide camshaft cap • cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position. • measure each clearance between the camshaft jo...

  • Page 212

    5-18 engine top end camshaft, camshaft chain camshaft chain removal • split the crankcase (see crankshaft/transmission chap- ter). • remove the camshaft chain [a] from the crankshaft sprocket..

  • Page 213

    Engine top end 5-19 cylinder head cylinder compression measurement note ○ use the battery which is fully charged. • warm up the engine thoroughly. • stop the engine. • remove: seats (see frame chapter) fuel tank (see fuel system (dfi) chapter) stick coils spark plugs owners tool - spark plug wrench,...

  • Page 214

    5-20 engine top end cylinder head cylinder head removal • drain the coolant (see cooling system chapter). • remove: exhaust pipes (see exhaust pipe removal) coolant drain bolt [a] (cylinder) • remove: cylinder head cover (see cylinder head cover re- moval) camshaft position sensor (see electrical sy...

  • Page 215

    Engine top end 5-21 cylinder head • install: front camshaft chain guide [a] o-ring [b] collar [c] • tighten: torque - front camshaft chain guide bolt (upper) [d]: 25 n·m (2.5 kgf·m, 18 ft·lb) front camshaft chain guide bolt (lower) [e]: 12 n·m (1.2 kgf·m, 104 in·lb) • install: rear camshaft chain gu...

  • Page 216

    5-22 engine top end valves valve clearance inspection • refer to the engine top end in the periodic maintenance chapter. Valve clearance adjustment • refer to the engine top end in the periodic maintenance chapter. Valve removal • remove the cylinder head (see cylinder head removal). • remove the va...

  • Page 217

    Engine top end 5-23 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). • drive the valve guide in from the top of the head using the valve guide arbor. The flange stops ...

  • Page 218

    5-24 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 219

    Engine top end 5-25 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 fa...

  • Page 220

    5-26 engine top end valves • measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range. Widened width [a] of engagement by machining with 45° cutter ...

  • Page 221

    Engine top end 5-27 valves if the seat width is too wide, make the 60° [a] grind de- scribed below. If the seat width is within the specified range, lap the valve to the seat as described below. • grind the seat at a 60° angle until the seat width is within the specified range. ○ to make the 60° gri...

  • Page 222

    5-28 engine top end valves.

  • Page 223

    Engine top end 5-29 cylinder, pistons cylinder removal • remove: cylinder head (see cylinder head removal) water hose [a] • remove the cylinder [b]. Cylinder installation note ○ if a new cylinder is used, use new piston ring. • install the pins [a] and new cylinder gasket [b]. • apply engine oil to ...

  • Page 224

    5-30 engine top end cylinder, pistons • remove the piston pins. Special tool - piston pin puller assembly: 57001–910 [a] • remove the pistons. • carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [a] to remove it. • remove the 3-piece oil ring with y...

  • Page 225

    Engine top end 5-31 cylinder, pistons note ○ if a new piston is used, use new piston ring. • install the piston with its hollow facing forward. • fit a new piston pin snap ring into the side of the piston so that the ring opening [a] does not coincide with the slit [b] of the piston pin hole. ○ appl...

  • Page 226

    5-32 engine top end cylinder, pistons piston ring groove width • measure the piston ring groove width. ○ use a vernier caliper at several points around the piston. Piston ring groove width standard service limit top [a] 0.83 ∼ 0.85 mm 0.93 mm (0.0327 ∼ 0.0335 in.) (0.037 in.) second [b] 0.82 ∼ 0.84 ...

  • Page 227

    Engine top end 5-33 throttle body holder throttle body holder installation • be sure to install the o-rings [a]. • install the clamps [b] as shown and so that its hole fit on the projection [c] of the holder. • tighten: torque - throttle body holder bolts [d]: 12 n·m (1.2 kgf·m, 104 in·lb) throttle ...

  • Page 228

    5-34 engine top end muffler warning to avoid a serious burn, do not remove the mufflers when the engine is still hot. Wait until the mufflers cool down. Muffler body removal • remove: muffler body clamp bolts [a] muffler body mounting bolts [b] muffler body [c] exhaust pipe removal • remove: muffler...

  • Page 229

    Engine top end 5-35 muffler ○ install the muffler body clamp bolts as shown. [l] upper side [m] inside [n] connection part detail • thoroughly warm up the engine, wait until the engine cools down, and retighten all the bolts and nuts..

  • Page 231: Clutch

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

  • Page 232

    6-2 clutch exploded view.

  • Page 233

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 clutch lever clamp bolts 7.9 0.8 69 in·lb s 2 clutch cover bolts (l = 32 mm) 11 1.1 95 in·lb 3 clutch cover bolts (l = 45 mm) 11 1.1 95 in·lb 4 clutch cover bolts (l = 30 mm) 11 1.1 95 in·lb 5 clutch cover bolts 11 1.1 95 in·lb 6...

  • Page 234

    6-4 clutch specifications item standard service limit clutch lever free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) - - - clutch: clutch plate assembly 48.4 ∼ 49.0 mm (1.91 ∼ 1.93 in.) - - - friction plate thickness 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) 2.4 mm (0.094 in.) friction and steel plate warp 0.2 mm (0.00...

  • Page 235

    Clutch 6-5 special tools and sealant inside circlip pliers: 57001–143 clutch holder: 57001–1243 kawasaki bond (silicone sealant): 56019–120

  • Page 236

    6-6 clutch clutch lever and cable clutch lever free play inspection • refer to the clutch adjust inspection in the periodic main- tenance chapter. Clutch lever free play adjustment • refer to the clutch adjust inspection in the periodic main- tenance chapter. Cable removal • slide the dust cover [a]...

  • Page 237

    Clutch 6-7 clutch cover clutch cover removal • remove: engine oil (drain, see engine oil change section in the periodic maintenance chapter) clutch cable lower end [a] clutch cover mounting bolts [b] clutch cable bracket [c] • turn the release lever [a] toward the rear as shown, and remove the clutc...

  • Page 238

    6-8 clutch clutch cover • fit the spring [a] as shown. [b] viewed from rear [c] release shaft [d] clutch cover clutch cover disassembly • remove: oil seal [a] needle bearings • remove: circlip [a] special tool - inside circlip pliers [b]: 57001–143 • remove: oil level gauge [c] clutch cover assembly...

  • Page 239

    Clutch 6-9 clutch clutch removal • remove: engine oil (drain, see engine oil change section in the periodic maintenance chapter) clutch cover (see clutch cover removal) clutch spring bolts [a] clutch springs clutch spring plate [b] (with thrust bearing and pusher [c]) • remove: friction plates, stee...

  • Page 240

    6-10 clutch clutch ○ install the spacer [a] so that the tapered side [b] faces inward. ○ install the washer [a] so that the out side mark faces outward. ○ replace the clutch hub nut with a new one. ○ holding the clutch hub, tighten the clutch hub nut. Special tool - clutch holder: 57001–1243 torque ...

  • Page 241

    Clutch 6-11 clutch • apply molybdenum disulfide grease to the pusher ends [a] and install the pusher [b]. • apply engine oil to the needle bearing [c] and install it. • install the washer [d]. • align the mark [a] of the clutch spring plate [b] with the groove [c] of the clutch hub. • install the cl...

  • Page 242

    6-12 clutch clutch clutch plate assembly adjustment • inspect the clutch plate assembly length, and then re- place the steel plate(s) which brings the length within the specified range. • remove: spring bolts spring holders springs spring plate • replace the following steel plate(s). Part no. Thickn...

  • Page 243: Engine Lubrication System

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

  • Page 244

    7-2 engine lubrication system exploded view.

  • Page 245

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oil filler plug 1.5 0.15 13 in·lb 2 engine drain plug 20 2.0 14.5 3 oil filter (cartridge type, p/no. 16097–1070) 26 2.7 20 eo, r 3 oil filter (cartridge type, p/no. 16097–0002) 31 3.2 23 eo, r 4 oil cooler mou...

  • Page 246

    7-4 engine lubrication system engine oil flow chart.

  • Page 247

    Engine lubrication system 7-5 engine oil flow chart 1. Camshaft oil passage 2. Oil passage hole in alternator rotor bolt 3. Starter clutch oil passage hole 4. Main oil passage 5. Crankshaft oil passage 6. Oil filter 7. Oil cooler 8. Oil pressure switch 9. Oil pipe 10. Oil pump 11. To drive shaft 12....

  • Page 248

    7-6 engine lubrication system specifications item standard engine oil: type api se, sf or sg api sh or sj with jaso ma viscosity sae 10w-40 capacity: 3.1 l (3.3 us gt) (when filter is not removed) 3.3 l (3.5 us gt) (when filter is removed) 3.8 l (4.0 us gt) (when engine is completely dry) level betw...

  • Page 249

    Engine lubrication system 7-7 special tools and sealant oil pressure gauge, 10 kgf/cm²: 57001–164 oil pressure gauge adapter, pt3/8: 57001–1233 kawasaki bond (silicone sealant): 56019–120 oil filter wrench: 57001–1249.

  • Page 250

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

  • Page 251

    Engine lubrication system 7-9 oil pan oil pan removal • remove: engine oil (drain, see periodic maintenance chapter) muffler (see engine top end chapter) oil pan bolts [a] oil pan [b] ○ remove the oil pipe [a], oil pressure relief valve [b] and oil screen [c] as necessary. Oil pan installation • cle...

  • Page 252

    7-10 engine lubrication system oil pressure relief valve oil pressure relief valve removal • see oil pan removal. Oil pressure relief valve installation • see oil pan installation. Oil pressure relief valve inspection • check to see if the valve [a] slides smoothly when push- ing it in with a wooden...

  • Page 253

    Engine lubrication system 7-11 oil pump oil pump removal • drain: coolant (see periodic maintenance chapter) engine oil (see periodic maintenance chapter) • remove: water hose [a] water pipe fitting bolts [b] water pipes [c] • remove: water pump cover bolts [a] clamp [b] water pump cover [c] • remov...

  • Page 254

    7-12 engine lubrication system oil pump • fit the pin [a] of the oil pump cover [b] into the hole [c] in the crankcase. • install: pins [a] water pump body [b] • install: impeller [a] and bolt [b] • tighten: torque - water pump impeller bolt: 10 n·m (1.0 kgf·m, 87 in·lb) • install: pins [c] water pu...

  • Page 255

    Engine lubrication system 7-13 oil pump oil pump drive gear removal • remove: clutch (see clutch chapter) oil pan (see oil pan removal) circlip [a] and washer [b] oil pump drive gear [c] oil pump drive gear installation • apply molybdenum disulfide oil solution to the journal por- tions [a] on the o...

  • Page 256

    7-14 engine lubrication system oil cooler oil cooler removal • drain: coolant (see periodic maintenance chapter) engine oil (see periodic maintenance chapter) • remove: oil filter (see periodic maintenance chapter) water hose [a] oil cooler mounting bolt [b] and washer oil cooler [c] and water hose ...

  • Page 257

    Engine lubrication system 7-15 oil pressure measurement oil pressure measurement • remove the oil passage plug, and attach the adapter [a] and gauge [b] to the plug hole. Special tools - oil pressure gauge, 10 kgf/cm²: 57001–164 oil pressure gauge adapter, pt 3/8: 57001–1233 • start the engine and w...

  • Page 258

    7-16 engine lubrication system oil pressure switch oil pressure switch removal • remove: engine oil (drain, see periodic maintenance chapter) switch cover [a] switch terminal [b] oil pressure switch [c] oil pressure switch installation • apply silicone sealant to the threads of the oil pressure swit...

  • Page 259: Engine Removal/installation

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

  • Page 260

    8-2 engine removal/installation exploded view.

  • Page 261

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 adjusting collar locknut 49 5.0 36 s 2 upper engine mounting bolts 44 4.5 32 s 3 rear engine bracket bolts 25 2.5 18 s 4 front engine bracket bolts 44 4.5 32 s 5 middle engine mounting nut 44 4.5 32 s 6 lower...

  • Page 262

    8-4 engine removal/installation special tools carburetor drain plug wrench, hex3: 57001–1269 engine mount nut wrench: 57001–1450

  • Page 263

    Engine removal/installation 8-5 engine removal/installation engine removal • support the rear part of the swingarm with a stand [a]. • 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 cou...

  • Page 264

    8-6 engine removal/installation engine removal/installation • remove: radiator hose clamp [a] (loosen) radiator hose [b] oil cooler water hose clamp [c] (loosen) oil cooler water hose [d] radiator bolt [e] (loosen) radiator bracket bolt [f] • disconnect crankshaft sensor lead connector (see electric...

  • Page 265

    Engine removal/installation 8-7 engine removal/installation • remove: camshaft position sensor connector [a] injector harness connector [b] coolant reserve tank [a] (see cooling system chapter) air cleaner housing bolt [b] vacuum switch valve hose [c] • remove: vacuum switch valve tube [a] inlet air...

  • Page 266

    8-8 engine removal/installation engine removal/installation • support the engine with a suitable stand [a]. ○ put a plank [b] onto the suitable stand for engine balance. • remove: right and left engine upper mounting bolts [a] front engine bracket bolts [b] front engine bracket [c] • remove the midd...

  • Page 267

    Engine removal/installation 8-9 engine removal/installation • using the hexagon wrench, turn the adjusting collar [a] counter clockwise to mark the gap between the engine and flame adjusting collar. • remove the drive chain [a] from the output shaft [b]. • down the rear portion of the engine a littl...

  • Page 268

    8-10 engine removal/installation engine removal/installation • install the engine mounting bolts and nuts, following the specified installing sequence. ○ first, hang the drive chain over the output shaft just before moving the engine into its final position in the frame. ○ second, insert the lower e...

  • Page 269

    Engine removal/installation 8-11 engine removal/installation ○ ninth, temporarily install: front engine bracket [a] front right engine mounting bolt [b] ○ tenth, tighten the rear bracket bolts. Torque - rear engine bracket bolts: 25 n·m (2.5 kgf·m, 18 ft·lb) ○ eleventh, tighten securely: middle engi...

  • Page 271: Crankshaft/transmission

    Crankshaft/transmission 9-1 9 crankshaft/transmission table of contents exploded view................................... 9-2 specifications .................................... 9-6 special tools and sealant ................. 9-8 crankcase splitting............................ 9-9 crankcase splitting...

  • Page 272

    9-2 crankshaft/transmission exploded view.

  • Page 273

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 breather plate bolts 10 1.0 87 in·lb l 2 crankcase bolts (m9, l=81 mm) 42 4.3 31 mo,s 3 crankcase bolts (m9, l=95 mm) 49 5.0 36 mo,s 4 crankcase bolts (m8) 27 2.8 20 s 5 crankcase bolts (m7) 20 2.0 14.5 s 6 crank...

  • Page 274

    9-4 crankshaft/transmission exploded view.

  • Page 275

    Crankshaft/transmission 9-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 shift pedal mounting bolt 34 3.5 25 l 2 gear positioning lever bolt 12 1.2 104 in·lb 3 shift shaft return spring pin 29 3.0 22 l 4 shift drum cam holder bolt 12 1.2 104 in·lb l 5 footpeg bracket bolts 34 3.5 25 l...

  • Page 276

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

  • Page 277

    Crankshaft/transmission 9-7 specifications item standard service limit crankshaft runout tir 0.02 mm (0.0008 in.) or less tir 0.05 mm (0.0020 in.) crankshaft main bearing insert/journal clearance 0.020 ∼ 0.044 mm 0.07 mm (0.0008 ∼ 0.0017 in.) (0.0028 in.) crankshaft main journal diameter: 32.984 ∼ 3...

  • Page 278

    9-8 crankshaft/transmission special tools and sealant bearing puller: 57001–135 bearing puller adapter: 57001–317 kawasaki bond (silicone sealant): 56019–120 kawasaki bond (silicone sealant): 92104–1063.

  • Page 279

    Crankshaft/transmission 9-9 crankcase splitting crankcase splitting • remove the engine (see engine removal/installation chapter). • set the engine on a clean surface and hold the engine steady while parts are being removed. • remove: crankshaft sensor (see electrical system chapter) clutch (see clu...

  • Page 280

    9-10 crankshaft/transmission crankcase splitting • apply liquid gasket to the breather plate mating surface [a] 1 to 1.5 mm (0.04 to 0.06 in.) thick, and then install the breather plate. Sealant - three bond: 1207b • apply a non-permanent locking agent to the threads and tighten the bolts [a]. Torqu...

  • Page 281

    Crankshaft/transmission 9-11 crankcase splitting • apply liquid gasket [a] to the mating surface of the lower crankcase half. Sealant - kawasaki bond (silicone sealant): 92104–1063 caution do not apply liquid gasket around the crankshaft main bearing inserts, and oil passage holes. • fit the lower c...

  • Page 282

    9-12 crankshaft/transmission crankshaft and connecting rods crankshaft removal • split the crankcase (see crankcase splitting). • remove the crankshaft [a]. Crankshaft installation caution if the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing insert...

  • Page 283

    Crankshaft/transmission 9-13 crankshaft and connecting rods • apply molybdenum disulfide grease [a] to the outer sur- face of the upper insert and the inner surface of the con- necting rod big end. • apply molybdenum disulfide oil [b] to the inner surfaces of upper and lower bearing inserts. ○ the m...

  • Page 284

    9-14 crankshaft/transmission crankshaft and connecting rods (1) bolt length measurement method • be sure to clean the bolts, nuts, and connecting rods thoroughly with a high-flash point solvent, because the new connecting rods, bolts, and nuts are treated with an anti-rust solution. Warning clean th...

  • Page 285

    Crankshaft/transmission 9-15 crankshaft and connecting rods (2) rotation angle method if you don’t have a point micrometer, you may tighten the nuts using the “rotation angle method”. • be sure to clean the bolts and nuts thoroughly with a high -flash point solvent, because the new bolts and nuts ar...

  • Page 286

    9-16 crankshaft/transmission crankshaft and connecting rods connecting rod bend • remove the connecting rod big end bearing inserts, 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...

  • Page 287

    Crankshaft/transmission 9-17 crankshaft and connecting rods connecting rod big end bearing insert/crankpin wear • measure the bearing insert/crankpin [b] clearance with plastigage [a]. ○ tighten the big end nuts to the specified torque (see con- necting rod installation). Note ○ do not move the conn...

  • Page 288

    9-18 crankshaft/transmission crankshaft and connecting rods connecting rod big end inside diameter marks none 38.000mm ∼ 38.008mm (1.4961 ∼ 1.4964 in.) 38.009 ∼ 38.016 mm (1.4964 ∼ 1.4967 in.) big end cap [a] connecting rod [b] weight mark, alphabet [c] diameter mark (around weight mark) [d]: “ ” or...

  • Page 289

    Crankshaft/transmission 9-19 crankshaft and connecting rods crankshaft main bearing insert/journal wear • using a plastigage (press gauge) [a], measure the bear- ing insert/journal [b] clearance. Note ○ tighten the crankcase bolts to the specified torque (see crankcase assembly). ○ do not turn the c...

  • Page 290

    9-20 crankshaft/transmission crankshaft and connecting rods • measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. Crankcase main bearing inside diameter marks : " " or no mark. • tighten the crankcase bolts to the specified torque (se...

  • Page 291

    Crankshaft/transmission 9-21 starter motor clutch starter motor clutch removal/installation • refer to the alternator rotor removal and installation in the electrical system chapter. Starter motor clutch assembly • be sure to install the one-way clutch [a] so that its flange [b] fits in the holder r...

  • Page 292

    9-22 crankshaft/transmission transmission shift pedal removal • mark [a] the position of the shift lever [b] on the shift shaft so that it can be installed later in the same position. • remove: shift lever bolt [c] shift lever • remove: footpeg bracket bolts [a] muffler mounting bolt [b] footpeg bra...

  • Page 293

    Crankshaft/transmission 9-23 transmission • install the footpeg bracket [a]. • apply a non-permanent locking agent to the footpeg bracket bolts [b]. • tighten: torque - footpeg bracket bolts: 34 n·m (3.5 kgf·m, 25 ft·lb) muffler mounting bolt and nut [c]: 29 n·m (3.0 kgf·m, 22 ft·lb) • install the s...

  • Page 294

    9-24 crankshaft/transmission transmission • remove: gear positioning lever bolt [a] gear positioning lever [b], collar and spring external shift mechanism installation • install the gear positioning lever [a] as shown. Spring [b] collar [c] bolt [d] • tighten: torque - gear positioning lever bolt: 1...

  • Page 295

    Crankshaft/transmission 9-25 transmission transmission shaft removal • split the crankcase (see crankcase splitting). • remove the drive shaft [a] and output shaft [b]. Transmission shaft installation • check to see that the set pins [a] and set rings [b] are in place. • install the drive shaft and ...

  • Page 296

    9-26 crankshaft/transmission transmission • remove the ball bearing [a] from each shafts. Special tools - bearing puller: 57001–135 [b] bearing puller adapter: 57001–317 [c] • discard the bearing. Transmission shaft assembly • apply engine oil to the sliding surfaces on the transmis- sion shafts, ge...

  • Page 297

    Crankshaft/transmission 9-27 transmission note ○ when the toothed washers [28] [29] are assembled onto the output shaft, note the following. ○ when the tangs [a] of the toothed washer [29] shall be assembled, they should be installed into the notch [b] of the toothed washer [28]. ○ fit the steel bal...

  • Page 298

    9-28 crankshaft/transmission transmission 1. 1st gear 2. 2nd gear 3. 3rd gear 4. 4th gear 5. 5th gear 6. 6th (top) gear 7. Toothed washer, 31 mm (1.22 in.) 8. Thrust washer, 30 mm (1.18 in.) 9. Circlip 10. Circlip 11. Bushing 12. Bushing 13. Needle bearing 14. Needle bearing 15. Bearing outer race 1...

  • Page 299

    Crankshaft/transmission 9-29 transmission shift drum and fork installation • install the shift rods [a], noting the groove position. The rods are identical. • position the one with shortest ears [b] on the drive shaft and place the pin in the center groove in the shift drum [c]. ○ the two forks [d] ...

  • Page 300

    9-30 crankshaft/transmission transmission shift fork/gear groove wear • measure the thickness of the shift fork ears [a], and mea- sure the width [b] of the gear grooves. If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced. Shift fork ear thickness st...

  • Page 301: Wheels/tires

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

  • Page 302

    10-2 wheels/tires exploded view.

  • Page 303

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front axle clamp bolt 20 2.0 15 2 front axle 127 13 94 3 rear axle nut 127 13 94 g: apply grease. R: replacement parts wl: apply soap and water solution or rubber lubricant..

  • Page 304

    10-4 wheels/tires specifications item standard service limit wheels (rims): rim runout: axial - - - tir 0.5 mm (0.020 in.) radial - - - tir 0.8 mm (0.031 in.) axle runout/100 mm (3.94 in.) tir 0.05 mm (0.0020 in.) or less tir 0.2 mm (0.008 in.) wheel balance 10 g (0.35 us oz) or less - - - balance w...

  • Page 305

    Wheels/tires 10-5 special tools bearing driver set: 57001–1129 jack: 57001–1238 bearing remover head, 25 × 28: 57001–1346 bearing remover shaft, 13: 57001–1377.

  • Page 306

    10-6 wheels/tires wheels (rims) front wheel removal • remove: brake caliper mounting bolts [a] • loosen: right side axle clamp bolt [a] axle [b] • raise the front wheel off the ground. Special tool - jack: 57001–1238 • pull out the axle to the right and drop the front wheel out of the forks. Caution...

  • Page 307

    Wheels/tires 10-7 wheels (rims) • tighten the axle. Torque - front axle: 127 n·m (13 kgf·m, 94 ft·lb) • before tightening the clamp bolt on the right front fork leg, pump the front fork up and down 4 or 5 times to allow the right front fork leg to seat on the front axle. Note ○ put a block in front ...

  • Page 308

    10-8 wheels/tires wheels (rims) • remove: caliper mounting bolts [a] caliper [b] • remove the drive chain [a] from the rear sprocket toward the left. • move the rear wheel back and remove the wheel from the rear caliper. • remove the rear wheel. Caution do not lay the wheel on the ground with the di...

  • Page 309

    Wheels/tires 10-9 wheels (rims) • bend the cotter pin [a] over the nut [b]. Warning if the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condi- tion may result. • adjust the drive chain slack after installation (see final drive chapter). • check the rea...

  • Page 310

    10-10 wheels/tires wheels (rims) axle inspection • visually inspect the front and rear axle for damages. If the axle is damaged or bent, replace it. • place the axle in v blocks that are 100 mm (3.94 in.) [a] apart, and set a dial gauge [b] on the axle at a point halfway between the blocks. Turn [c]...

  • Page 311

    Wheels/tires 10-11 wheels (rims) (b) when the tire is on the rim. • pry [a] the balance weight off the rim flange using a reg- ular tip screwdriver as shown in the figure. ○ insert a tip of the screwdriver between the tire bead [b] and weight blade [c] until the end of the tip reaches the end of the...

  • Page 312

    10-12 wheels/tires wheels (rims) • when required total weight exceeds 20 g (0.71 us oz), in- stall balance weight at both sides of rim flange as shown. Weight selection: g (us oz) required total weight: g (us oz) one side [a] other side [b] 20 (0.71) 10 (0.35) 10 (0.35) 30 (1.06) 20 (0.71) 10 (0.35)...

  • Page 313

    Wheels/tires 10-13 tires air pressure inspection/adjustment • refer to the air pressure inspection/adjustment in the pe- riodic maintenance chapter. Tire inspection • refer to the tire inspection in the periodic maintenance chapter. Tire removal • remove: wheel (see front wheel removal, rear wheel r...

  • Page 314

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

  • Page 315

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

  • Page 316

    10-16 wheels/tires hub bearing hub bearing removal • remove the wheel, and take out the following. Collars coupling (out of rear hub) grease seals circlips • use the bearing remover to remove the hub bearings [a]. Caution do not lay the wheel on the ground with the disc facing down. This can damage ...

  • Page 317: Final Drive

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

  • Page 318

    11-2 final drive exploded view.

  • Page 319

    Final drive 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine sprocket cover bolts 9.8 1.0 87 in·lb 2 engine sprocket nut 127 13 94 mo 3 rear sprocket nut 59 6.0 43 4 engine sprocket cover damper bolts 6.9 0.7 61 in·lb l 5 speed sensor bolt 6.9 0.7 61 in·lb l 6 rear axle nut 12...

  • Page 320

    11-4 final drive specifications item standard service limit drive chain: chain slack 20 ∼ 30 mm (0.8 ∼ 1.2 in.) - - - 20-link length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) standard chain make enuma - - - type ek525uvxl2, endless - - - link 112 links - - - sprockets: rear sprocket war...

  • Page 321

    Final drive 11-5 special tools bearing driver set: 57001–1129 jack: 57001–1238.

  • Page 322

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

  • Page 323

    Final drive 11-7 drive chain ek joint tool #50 body [a] handlebar [b] cutting and riveting pin [c] for cutting [d] for riveting [e] plate holder (a) [f] plate holder (b) [g] gauge [h] • grind [a] pin head to make it flat. • set cutting and riveting pin [b] as shown. • screw pin holder until it touch...

  • Page 324

    11-8 final drive drive chain • set plate holder (a) [a] and plate holder (b) [b] on the body. • fit plate holder (a) to link plate. • turn pin holder by hand until plate holder (b) touches the other link plate. • turn pin holder by wrench clockwise until two pins of link come into groove of plate ho...

  • Page 325

    Final drive 11-9 drive chain • turn wrench clockwise until tip of riveting pin hits of link pin. • rivet it. • some work for the other link pin. • after staking, check the staked area of the link pin for cracks. • measure the outside diameter [a] of the link pin and link plates outside width [b]. Li...

  • Page 326

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

  • Page 327

    Final drive 11-11 sprocket, coupling rear sprocket removal • remove the rear wheel (see wheels/tires chapter). 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. • remove the...

  • Page 328

    11-12 final drive sprocket, coupling • replace the grease seal with a new one. • press in the grease seal so that the seal surface is flush with the end of the hole. ○ apply high temperature grease to the grease seal lips. Special tool - bearing driver set : 57001–1129 coupling installation • grease...

  • Page 329

    Final drive 11-13 sprocket, coupling sprocket wear inspection • visually inspect the engine and rear sprocket teeth for wear and damage. If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see drive chain wear inspection). [a] worn tooth (engine sprocket) [b...

  • Page 331: Brakes

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

  • Page 332

    12-2 brakes exploded view.

  • Page 333

    Brakes 12-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front caliper mounting bolts 25 2.5 18 2 brake hose banjo bolt 25 2.5 18 3 bleed valve 7.8 0.80 69 in·lb 4 front caliper assembly bolts 22 2.2 16 l 5 front brake pad pin bolt 17 1.7 12 6 brake lever pivot bolt 1.0 0.10 9 in·lb s...

  • Page 334

    12-4 brakes exploded view.

  • Page 335

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

  • Page 336

    12-6 brakes specifications item standard service limit brake lever, brake pedal: brake lever position 5-way adjustable (to suit rider) - - - brake lever free play non-adjustable - - - pedal free play non-adjustable - - - pedal position about 47 mm (1.85 in.) below footpeg top - - - brake fluid: grad...

  • Page 337

    Brakes 12-7 special tool jack: 57001–1238.

  • Page 338

    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 339

    Brakes 12-9 calipers front caliper removal • loosen the banjo bolt [a] at the brake hose lower end, and tighten it loosely. • unscrew the caliper mounting bolts [b], and detach the caliper [c] from the disc. Caution do not loosen the caliper assembly bolts [d]. Take out only the caliper mounting bol...

  • Page 340

    12-10 brakes calipers caliper installation • install the caliper and brake hose lower end. ○ replace the washers on each side of hose fitting with new ones. • tighten: torque - caliper mounting bolts (front): 25 n·m (2.5 kgf·m, 18 ft·lb) caliper mounting bolts (rear): 25 n·m (2.5 kgf·m, 18 ft·lb) br...

  • Page 341

    Brakes 12-11 calipers warning to avoid serious injury, never place your fingers or palm in front of the piston. If you apply compressed air into the caliper, the piston may crush your hand or fingers. ○ pull out the pistons by hand. • remove the dust seals [a] and fluid seals [b]. • remove the bleed...

  • Page 342

    12-12 brakes calipers • replace the fluid seals [a] with new ones. ○ apply brake fluid to the fluid seals, and install them into the cylinders by hand. • replace the dust seals [b] with new ones if they are dam- aged. ○ apply brake fluid to the dust seals, and install them into the cylinders by hand...

  • Page 343

    Brakes 12-13 calipers rear caliper assembly • clean the caliper parts except for the pads. Caution for cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • install the bleed valve and rubber cap. Torque - bleed valve: 7.8 n·m (0.80 kgf·m, 69 in·lb) • replace the flui...

  • Page 344

    12-14 brakes calipers caliper piston and cylinder damage • visually inspect the piston [a] and cylinder surfaces. Replace the caliper if the cylinder and piston are badly scores or rusty. Front caliper [b] rear caliper [c] caliper holder shaft wear the caliper body must slide smoothly on the caliper...

  • Page 345

    Brakes 12-15 brake pads front brake pad removal • remove: mounting bolts [a] • remove: pad pin bolt [a] pad spring [b] brake pads [c] front brake pad installation • push the caliper pistons in by hand as far as they will go. • apply silicone grease to the stopper ring [a]. • install: brake pads pad ...

  • Page 346

    12-16 brakes brake pads rear brake pad installation • push the caliper piston in by hand as far as it will go. • install: brake pads pad pin clip • install the caliper (see caliper installation). Warning do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake...

  • Page 347

    Brakes 12-17 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 [c] (see brake hose removal/in- stallation). • remove the rear view mirror (see steering chapter). • ...

  • Page 348

    12-18 brakes master cylinder rear master cylinder removal • unscrew the brake hose banjo bolt [a] on the master cylin- der (see brake hose removal/installation). • pull off the reservoir hose lower end [b], and drain the brake fluid into a container. • loosen the master cylinder mounting bolts [c] l...

  • Page 349

    Brakes 12-19 master cylinder rear master cylinder disassembly note ○ do not remove the push rod clevis for master cylinder disassembly since removal requires brake position ad- justment. • remove the rear master cylinder (see rear master cylin- der removal). • slide the dust cover on the push rod ou...

  • Page 350

    12-20 brakes brake disc brake disc removal • remove the wheel (see wheels/tires chapter). • unscrew the mounting bolts, and take off the disc. Brake disc installation • install the brake disc on the wheel so that the marked side [a] faces out. • apply a non-permanent locking agent to the threads of ...

  • Page 351

    Brakes 12-21 brake fluid brake fluid level inspection • refer to the brake fluid level in the periodic maintenance chapter. Brake fluid change • refer to the brake fluid change in the periodic mainte- nance chapter. Brake line bleeding • refer to the brake line bleeding in the periodic mainte- nance...

  • Page 352

    12-22 brakes brake hose brake hose removal/installation caution brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wiped up immediately with wet cloth. • when removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts....

  • Page 353: Suspension

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

  • Page 354

    13-2 suspension exploded view.

  • Page 355

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fork clamp bolts (upper) 8.8 0.90 78 in·lb al front fork clamp bolts (upper): zr1000–a2 ∼ 13 1.3 113 in·lb 2 front fork clamp bolts (lower) 20 2.0 15 al front fork clamp bolts (lower): zr1000–a2 ∼ 30 3.1 22 3 front for...

  • Page 356

    13-4 suspension exploded view.

  • Page 357

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear shock absorber nuts (upper and lower) 34 3.5 25 2 swingarm pivot shaft nut 127 13 94 3 swingarm pivot shaft locknut 98 10 72 4 rocker arm nut 34 3.5 25 5 tie-rod nuts 59 6.0 43 g: apply or add grease..

  • Page 358

    13-6 suspension specifications item standard front fork (per one unit): fork inner tube outside diameter 41 mm (1.61 in.) air pressure atmospheric pressure (non-adjustable) rebound damper setting 1 turns out from the fully clockwise position (only right fork leg) (usable range: 0 ←→ 1 4/5 ∼ 2 2/5 tu...

  • Page 359

    Suspension 13-7 special tools oil seal and bearing remover: 57001–1058 bearing driver set: 57001–1129 jack: 57001–1238 front fork oil seal driver: 57001–1288 fork oil level gauge: 57001–1290 fork piston rod puller, m10 × 1.0: 57001–1298 front fork spring compressor: 57001–1338 socket wrench: 57001–1...

  • Page 360

    13-8 suspension front fork rebound damping force adjustment (only right fork leg) • to adjust the rebound damping force, turn the rebound damping adjuster [a] on top of the right front fork leg to the desired position. ○ the standard adjuster setting for the average-build rider of 68 kg (150 lb) wit...

  • Page 361

    Suspension 13-9 front fork front fork removal (each fork leg) • remove: front wheel (see wheels/tires chapter.) front fender (see frame chapter.) windshield and bracket (see frame chapter.) inner cover (see frame chapter.) fairing and bracket (see frame chapter.) loosen the upper fork clamp bolts [a...

  • Page 362

    13-10 suspension front fork fork oil change • remove the front fork (see front fork removal). ○ turn the spring preload adjuster [a] counterclockwise until the fully position. • unscrew the top plug [b] out of the inner tube. • avoiding the pins [a], set the front fork spring compressor set [b] on t...

  • Page 363

    Suspension 13-11 front fork • drain the fork oil into a suitable container. • remove the fork spring [a]. ○ pump the piston rod [b] up and down at least ten times to expel the oil from the fork. • hold the fork tube upright, press the inner tube and the piston rod all the way down. • pour in the typ...

  • Page 364

    13-12 suspension front fork oil level (fully compressed, without spring) standard: right fork leg 62 ± 2 mm (2.44 ± 0.08 in.) left fork leg 47 ± 2 mm (1.85 ± 0.08 in.) (from the top of the outer tube) note ○ fork oil level may also be measured using the fork oil level gauge. Special tool - fork oil ...

  • Page 365

    Suspension 13-13 front fork • check the o-ring on the top plug and replace it with a new one if damaged. • for the right fork leg, check the distance [c] between the bottom end [a] of the top plug and rebound damping ad- juster [b] with a pair of vernier caliper. [c] 20 mm (0.79 in.) • holding the t...

  • Page 366

    13-14 suspension front fork ○ holding the inner tube [a] by hand, pull the outer tube [b] several times to pull out the outer tube. • remove the inner tube guide bushing [a], outer tube guide bushing [b], washer [c], oil seal [d] from the inner tube. Front fork assembly • replace the following parts...

  • Page 367

    Suspension 13-15 front fork • install the cente ring plate on the cylinder unit. • insert the cente ring plate and cylinder unit as a set into the inner tube. Cylinder unit [a] and center ring plate [c] for right fork leg cylinder unit [b] and center ring plate [c] for left fork leg • hold the front...

  • Page 368

    13-16 suspension front fork spring tension • since a spring becomes shorter as it weakens, check its free length [a] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the remaining sp...

  • Page 369

    Suspension 13-17 rear shock absorber rebound damping force adjustment • to adjust the rebound damping force, turn the rebound damping adjuster [a] to the desired position. ○ the standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories 3/4 turns out ...

  • Page 370

    13-18 suspension rear shock absorber special tools - hook wrench: 57001–1539 [a] spring adjustment adjuster damping position force setting load road speed 193.4 mm weak soft light good low (7.61 in.) ↑ ↑ ↑ ↑ ↑ ↑ ↓ ↓ ↓ ↓ ↓ ↓ 183.4 mm strong hard heavy bad high (7.22 in.) rear shock absorber removal •...

  • Page 371

    Suspension 13-19 rear shock absorber • remove the shock absorber [a] from upside. Rear shock absorber installation • tighten: torque - rear shock absorber nuts: 34 n·m (3.5 kgf·m, 25 ft·lb) rear shock absorber inspection • remove the rear shock absorber. • visually inspect the following items. Smoot...

  • Page 372

    13-20 suspension swingarm swingarm removal • remove the muffler bodies (see engine top end chapter.) • raise the rear wheel off the ground with jack. Special tool - jack: 57001–1238 • remove: rear wheel (see wheels/tires chapter.) chain cover (see final drive chapter.) mud guard (see frame chapter.)...

  • Page 373

    Suspension 13-21 swingarm swingarm installation • apply plenty of grease to the ball bearing, needle bearings and grease seals, and add plenty of grease to the grease nipple. • install the collars [a]. ○ place the right collar [a] on the stopper [b] inside the frame [c]. • insert the pivot shaft int...

  • Page 374

    13-22 suspension swingarm • remove the ball bearing and needle bearings. Special tool - oil seal and bearing remover: 57001–1058 [a] swingarm bearing installation • apply plenty of grease to the ball bearing and needle bearings. • install the needle bearings so that the manufacturer’s marks face in....

  • Page 375

    Suspension 13-23 tie-rod, rocker arm tie-rod removal • remove the muffler bodies (see engine top end chapter.) • remove the side stand (see frame chapter.) • using the jack, raise the rear wheel off the ground. Special tool - jack: 57001–1238 • squeeze the brake lever slowly and hold it with a band ...

  • Page 376

    13-24 suspension tie-rod, rocker arm rocker arm installation • apply grease to the inside of the needle bearings and oil seal lips, and add grease to the grease nipple. • tighten: torque - rocker arm bolt: 34 n·m (3.5 kgf·m, 25 ft·lb) tie-rod nut: 59 n·m (6.0 kgf·m, 43 ft·lb) rear shock absorber nut...

  • Page 377: Steering

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

  • Page 378

    14-2 steering exploded view.

  • Page 379

    Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 steering stem nut 27 2.75 20 2 steering stem head bolt 108 11 80 3 front fork clamp bolts (upper) 8.8 0.90 78 in·lb al front fork clamp bolts (upper): zr1000–a2 ∼ 13 1.3 113 in·lb 4 front fork clamp bolts (lower) 20 2.0 15 al ...

  • Page 380

    14-4 steering special tools steering stem nut wrench: 57001–1100 bearing driver set: 57001–1129 jack: 57001–1238 steering stem bearing driver: 57001–1344 steering stem bearing driver adapter: 57001–1345.

  • Page 381

    Steering 14-5 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 382

    14-6 steering steering stem stem, stem bearing removal • remove: windshield and bracket (see frame chapter.) inner cover (see frame chapter.) fairing and bracket (see frame chapter.) front wheel (see wheels/tires chapter.) handlebar (see handlebar removal.) steering stem head bolt plug steering stem...

  • Page 383

    Steering 14-7 steering stem • to remove the bearing outer races [c] pressed into the head pipe [b], insert a bar [a] into the recesses [d] of head pipe, and applying it to both recess alternately hammer it to drive the race out. Note ○ if either steering stem bearing is damaged, it is recom- mended ...

  • Page 384

    14-8 steering steering stem • apply grease the lower ball bearing [a] and install it onto the stem. • apply grease to the upper ball bearing [b] and inner race [c]. • install the stem [a] through the head pipe and install the ball bearing [b] and inner race [c] on it. • install the stem cap [d] and ...

  • Page 385

    Steering 14-9 steering stem note ○ tighten the fork upper clamp bolts first, next the stem head nut, last the fork lower clamp bolts. Torque - steering stem head bolt : 108 n·m (11 kgf·m, 80 ft·lb) front fork clamp bolts (upper): 8.8 n·m (0.90 kgf·m, 78 in·lb) 13 n·m (1.3 kgf·m, 113 in·lb): zr1000–a...

  • Page 386

    14-10 steering handlebar handlebar removal • remove: clutch lever assembly [a] left handlebar switch housing [b] front brake master cylinder [c] right handlebar switch housing [d] handlebar holder bolts [e] • remove the handlebar holders [f] and then pull out the handlebar [g]. • remove the cotter p...

  • Page 387

    Steering 14-11 handlebar rear view mirrors removal • loosen the lower hexagonal area [a] for tightening to re- move the rear view mirror from the holder. Caution do not force to tighten and/or loosen the upper hexagonal area (adapter) [b] with a pair of span- ners. Disassembly of this area is not av...

  • Page 389: Frame

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

  • Page 390

    15-2 frame exploded view.

  • Page 391

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 footpeg holder bolts 34 3.5 25 2 muffler mounting nuts 29 3.0 22 3 side stand bolt 44 4.5 33 4 side stand switch bolt 8.8 0.9 78 in·lb g: apply grease..

  • Page 392

    15-4 frame exploded view.

  • Page 393

    Frame 15-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 windshield screws 0.35 ∼ 0.50 0.035 ∼ 0.050 3 ∼ 4 in·lb 2 front fender bolts 3.9 0.4 34.7 in·lb l.

  • Page 394

    15-6 frame exploded view.

  • Page 395

    Frame 15-7 seats rear seat removal • insert the ignition switch key into the seat lock [a], turning the key counterclockwise, pulling up on the rear of the seat [b], and pulling the seat backward. Warning the muffler surface is hot once the engine has been started. When operating the seat lock be ca...

  • Page 396

    15-8 frame side covers side cover removal • remove the bolt [a]. • pull the side cover [b] evenly outward to clear the stop- pers. Side cover installation • insert the tabs [a] into the holes [b]. • install the bolt..

  • Page 397

    Frame 15-9 fairings windshield removal • remove: bolts [a] windshield [b] windshield installation • windshield installation is the reverse of removal. Torque - windshield screw: 0.35 ∼ 0.50 n·m (0.035 ∼ 0.050 kgf·m, 3 ∼ 4 in·lb) inner cover removal • remove: inner cover screws [a] (both side) inner ...

  • Page 398

    15-10 frame fairings • remove: fairing mounting bolts [a] (both side) headlight connectors fairing installation • fairing installation is the reverse of removal. Faring bracket removal • remove: fairing (see fairing removal) turn signal lights (see electrical system chapter) meter unit [a] (see elec...

  • Page 399

    Frame 15-11 seat covers seat cover removal • remove: seats screws [a] • push the central pin, and then remove the quick rivets [a]. • pull the front portions [a] of the seat cover outside [b], and then remove the seat cover backward. Seat cover installation • installation is reverse of removal. • pu...

  • Page 400

    15-12 frame mud guard mud guard removal • remove: chain cover (see final drive chapter) bolt [a] clamp [b] • lift up the mud guard [a], and then pull it out backward. Mud guard installation • put the projections [a] into the grommets [b]..

  • Page 401

    Frame 15-13 fenders front fender removal • remove: brake hose clamps [a] bolts [b] (both side) • remove the front fender [c]. Front fender installation • install the brake hose clamps to the front fender holes. Rear fender rear removal • remove: seats seat cover canister (california model only) diod...

  • Page 402

    15-14 frame fenders • remove: quick rivets [a] rear fender rear [b] rear fender rear installation • put the projection [a] into the hole [b]. • put the projections [a] into the holes [b]. • installation is reverse of removal..

  • Page 403

    Frame 15-15 frame cover frame cover removal • remove: bolts [a] frame cover [b] (both side).

  • Page 404

    15-16 frame battery case battery case removal • remove: seats seat cover rear fender assy side covers battery left side screw [a] (with reserver tank) • pull out the battery case [b] backward [c]. Battery case installation • put the battery case attachments [a] at the projections [b] on the frame..

  • Page 405

    Frame 15-17 side stand side stand removal • raise the rear wheel off the ground with the stand. • remove: muffler (both side) exhaust pipe side stand switch bolt [a] side stand switch [b] spring [c] side stand nut [d] side stand bolt [e] side stand [f] side stand installation • apply grease to the s...

  • Page 406

    15-18 frame frame frame inspection • visually inspect the frame 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 407: Electrical System

    Electrical system 16-1 16 electrical system table of contents parts location.................................... 16-3 exploded view................................... 16-4 specifications .................................... 16-10 special tools and sealant ................. 16-11 wiring diagram (u.S....

  • Page 408

    16-2 electrical system fan motor inspection ................... 16-63 meter, gauge, indicator unit.............. 16-65 meter unit removal ..................... 16-65 meter, gauge disassembly.......... 16-65 electronic combination meter unit inspection .......................... 16-66 switches and se...

  • Page 409

    Electrical system 16-3 parts location [a] starter lockout switch [b] camshaft position sensor [c] radiator fan switch [d] starter motor [e] alternator [f] speed sensor [g] neutral switch [h] side stand switch [i] water temperature sensor [j] battery [k] junction box [l] front brake light switch [m] ...

  • Page 410

    16-4 electrical system exploded view.

  • Page 411

    Electrical system 16-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 meter mounting screws 1.2 0.12 11 in·lb 2 tail/brake light mounting screws 1.2 0.12 11 in·lb 3 license plate light mounting screws 1.2 0.12 11 in·lb 4 front brake light switch screw 1.2 0.12 11 in·lb 5 starter locknut...

  • Page 412

    16-6 electrical system exploded view.

  • Page 413

    Electrical system 16-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 water temperature sensor 25 2.5 18 ss 2 spark plugs 13 1.3 115 in·lb 3 alternator lead holding plate bolts 11 1.1 95 in·lb l 4 starter motor mounting bolts 11 1.1 95 in·lb 5 stator motor coil bolts 11 1.1 95 in·lb 6 a...

  • Page 414

    16-8 electrical system exploded view.

  • Page 415

    Electrical system 16-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 regulator/rectifier bolts 6.9 0.7 62 in·lb 2 fuel level sensor bolts 6.9 0.7 62 in·lb 3 side stand switch bolt 8.8 0.9 78 in·lb 4 neutral switch 15 1.5 11 5 speed sensor bolt 6.9 0.7 62 in·lb l 6 speed sensor cover bo...

  • Page 416

    16-10 electrical system specifications item standard battery: type sealed battery capacity 12 v 8 ah voltage 12.6 v or more charging system: type three–phase ac alternator output voltage 42 v or more stator coil resistance 0.3 ∼ 0.4 Ω charging voltage 14.7 ± 0.5 v (regulator/rectifier output voltage...

  • Page 417

    Electrical system 16-11 special tools and sealant hand tester: 57001–1394 flywheel puller, m38 × 1.5: 57001–1405 rotor holder: 57001–1543 lead wire-peak voltage adapter: 57001–1449 kawasaki bond (silicone sealant): 56019–120 rotor puller, m16/m18/m20/m22 × 1.5: 57001–1216 flywheel and pulley holder:...

  • Page 418

    16-12 electrical system wiring diagram (u.S.A. And canada).

  • Page 419

    Electrical system 16-13 wiring diagram (u.S.A. And canada).

  • Page 420

    16-14 electrical system wiring diagram (australia).

  • Page 421

    Electrical system 16-15 wiring diagram (australia).

  • Page 422

    16-16 electrical system wiring diagram (other than u.S.A., canada, australia, and malaysia).

  • Page 423

    Electrical system 16-17 wiring diagram (other than u.S.A., canada, australia, and malaysia).

  • Page 424

    16-18 electrical system wiring diagram (malaysia).

  • Page 425

    Electrical system 16-19 wiring diagram (malaysia).

  • Page 426

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

  • Page 427

    Electrical system 16-21 precautions male connectors [b].

  • Page 428

    16-22 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 429

    Electrical system 16-23 battery battery removal caution do not disconnect the battery cables or any other electrical connections when the ignition switch is on, as this could damage the ecu (electronic con- trol unit). Never reverse the connections of the battery, this could damage the ecu. • remove...

  • Page 430

    16-24 electrical system battery caution do not remove the aluminum seal sheet [a] sealing the filler ports [b] until just before use. • check to see that there is no peeling, tears or holes in the seal sheet on the top of the battery. • place the battery on a level surface. • remove the seal sheet. ...

  • Page 431

    Electrical system 16-25 battery • fit the seal caps [a] tightly into the filler ports until the seal caps are at the same level as the top of the battery. Note ○ do not hammer. Press down evenly with both hands. Caution once you installed the seal caps after filling the bat- tery, never remove it, n...

  • Page 432

    16-26 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 sealing plug to add water is very dangerous. Never do that. 2) refreshing charge if an engine will not start, a horn sounds...

  • Page 433

    Electrical system 16-27 battery interchange the sealed battery can fully display its performance only when combined with a proper vehicle electric system. Therefore, replace the sealed battery only on a motorcycle which was originally equipped with the sealed battery. Be careful, if a sealed battery...

  • Page 434

    16-28 electrical system battery terminal voltage: 11.5 ∼ less than 12.6 v standard charge 0.9 a × 5 ∼ 10 h quick charge 4.0 a × 1.0 h battery terminal voltage (v) [a] charge time (h) [b] caution if possible, do not quick charge. If the quick charge is done due to unavoidable circumstances, do stan- ...

  • Page 435

    Electrical system 16-29 charging system alternator cover removal • remove: frame cover bolts [a] left frame cover [b] clamp (open) [a] alternator lead connector [b] ○ for california model, remove the separator. • place a suitable container under the alternator cover [a], and remove the cover bolts [...

  • Page 436

    16-30 electrical system charging system stator coil installation • apply a non-permanent locking agent to the stator coil bolts and tighten it. Torque - stator coil bolts: 11 n·m (1.1 kgf·m, 95 in·lb) • secure the alternator lead with a holding plate, and tighten the bolt. ○ apply a non-permanent lo...

  • Page 437

    Electrical system 16-31 charging system • install the starter gear [a]. • again, clean the crankshaft tapered portion [b] and dry there. • fit the woodruff key [c] securely in the slot in the crank- shaft before installing the alternator rotor. • install the alternator rotor [a] while turning [b] th...

  • Page 438

    16-32 electrical system charging system • apply a thin coat of molybdenum disulfide grease to the shaft [a], and install it and starter idle gear [b]. • install the alternator cover (see alternator cover installa- tion). Alternator inspection there are three types of alternator failures: short, open...

  • Page 439

    Electrical system 16-33 charging system if there is more resistance than shown in the table, or no hand tester reading (infinity) for any two leads, the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced. • using the highest...

  • Page 440

    16-34 electrical system 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 bk1, bk2, and bk3 terminal respectively. If the test light turns on, the regulator/rectifier is defective. Replace it. If the...

  • Page 441

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

  • Page 442

    16-36 electrical system charging system charging system circuit 1. Ignition switch 2. To starter circuit relay 3. Alternator 4. Regulator/rectifier 5. Joint connector c 6. Battery 12 v 8 ah 7. Main fuse 30a 8. Load.

  • Page 443

    Electrical system 16-37 ignition system warning the ignition system produces extremely high volt- age. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock. Caution do not disconnect the battery cables or any other electrical connect...

  • Page 444

    16-38 electrical system ignition system crankshaft sensor installation • route the crankshaft sensor lead correctly (see cable, wire, and hose routing in appendix chapter). • tighten: torque - crankshaft sensor bolts: 5.9 n·m (0.6 kgf·m, 53 in·lb) • apply silicone sealant [a] to the crankshaft senso...

  • Page 445

    Electrical system 16-39 ignition system crankshaft sensor resistance: 375 ∼ 565 Ω • using the highest resistance range of the tester, measure the resistance between the crankshaft sensor leads and chassis ground. Any tester reading less than infinity (∞) indicates a short, necessitating replacement ...

  • Page 446

    16-40 electrical system ignition system camshaft position sensor removal • remove: fuel tank (see fuel system (dfi) chapter) camshaft position sensor lead connector [a] (discon- nect) ○ push the tongue [b] upside and take out the connector from the bracket. • remove: camshaft position sensor bolt [a...

  • Page 447

    Electrical system 16-41 ignition system camshaft position sensor peak voltage inspection • remove: fuel tank (see fuel system (dfi) chapter) camshaft position sensor lead connector [a] (discon- nect) • set the hand tester [b] to the 10 v dc range. • connect the peak voltage adapter [c] to the hand t...

  • Page 448

    16-42 electrical system ignition system • remove the stick coil harness [a] from the bracket. • remove: stick coil connector #4 [b] (disconnect) stick coil #4 [c] stick coil connector #3 [d] (disconnect) • disconnect: water temperature sensor connector [a] left switch housing connector [b] • pull th...

  • Page 449

    Electrical system 16-43 ignition system stick coil (ignition coil together with spark plug cap) inspection • remove the stick coils (see this chapter). • measure the primary winding resistance [a] as follows. ○ connect the hand tester between the coil terminals. ○ set the tester to the × 1 Ω range, ...

  • Page 450

    16-44 electrical system 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 451

    Electrical system 16-45 ignition system interlock operation inspection • remove: seats (see frame chapter) junction box (see this chapter) ○ do not disconnect the connectors. 1st check • measure the terminal voltage of the g/bk lead in the junc- tion box connector [a] in accordance with the followin...

  • Page 452

    16-46 electrical system ignition system ic igniter inspection ○ the ic igniter is built in the ecu [a]. • refer to the interlock operation inspection, ignition system troubleshooting chapter and fuel system (dfi) chapter for ecu inspection..

  • Page 453

    Electrical system 16-47 ignition system.

  • Page 454

    16-48 electrical system ignition system ignition system circuit 1. Ignition switch 2. Engine stop switch 3. Starter button 4. Spark plugs 5. Stick coils 6. Side stand switch 7. Crankshaft sensor 8. Camshaft position sen- sor 9. Throttle sensor 10. Neutral switch 11. Junction box 12. Ignition fuse 10...

  • Page 455

    Electrical system 16-49 electric starter system starter motor removal caution do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • remove the mounting bolts [a]. • pull out the starter motor [b]. • slide back the rubber cap [a]. • remove the starter motor t...

  • Page 456

    16-50 electrical system electric starter system ○ the brush plate [a] and brushes come off with the right–hand end cover [b]. • remove the terminal locknut [a] and terminal bolt [b], and then remove the brush with the brush plate [c] from the right–hand end cover. Starter motor assembly • install th...

  • Page 457

    Electrical system 16-51 electric starter system • align the line [a] marked on the yoke with the through bolt hole [b]. Brush inspection • measure the length [a] of each brush. If any is worn down to the service limit, replace the carbon brush holder assembly [b] and the terminal bolt assembly [c]. ...

  • Page 458

    16-52 electrical system electric starter system note ○ even if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with the hand tester. If all other starter motor and starter motor circuit components check good, but the starter motor still do...

  • Page 459

    Electrical system 16-53 electric starter system • connect the hand tester [a] and 12 v battery [b] to the starter relay [c] as shown. Special tool - hand tester: 57001–1394 if the relay does not work as specified, the relay is defec- tive. Replace the relay. Testing relay tester range: × 1 Ω range c...

  • Page 460

    16-54 electrical system lighting system this models adopt the daylight system and have a head- light relay in the junction box. In these models, the head- light 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 ...

  • Page 461

    Electrical system 16-55 lighting system headlight bulb replacement • remove: headlight connector [a] headlight bulb dust cover [b] • remove: hook [a] headlight bulb [b] caution when handling the quartz–halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contami...

  • Page 462

    16-56 electrical system lighting system • fit the dust cover [a] with the arrow mark upward onto the bulb [b] firmly as shown. Good [c] bad [d] arrow mark [e] • after installation, adjust the headlight aim (see this chap- ter). Headlight removal/installation • remove: fairing (see frame chapter) • d...

  • Page 463

    Electrical system 16-57 lighting system • pull the bulb [a] out of the socket [b]. Caution do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage then the specified valve. • replace the bulb with a new one..

  • Page 464

    16-58 electrical system lighting system headlight/tail light circuit (us, ca, as) headlight/tail light circuit (other than us, ca, as) us: united states of america ca: canada as: australia 1. Ignition switch 2. Meter ground 3. Alternator 4. Headlight diodes 5. Taillight fuse 10a 6. Headlight fuse 10...

  • Page 465

    Electrical system 16-59 lighting system turn signal light circuit us: u.S.A. Model ca: canada model my: malaysia model 1. Joint connector d 2. Meter unit 3. Right turn signal indicator light (led) 4. Left turn signal indicator light (led) 5. Front right turn signal light 6. Front left turn signal li...

  • Page 466

    16-60 electrical system lighting system • push and turn the bulb [a] counterclockwise and remove it. • insert the new bulb [a] by aligning its upper and lower pins [b] with the upper and lower grooves [c] in the socket, and turn the bulb clockwise. ○ turn the bulb about 15° degrees. For the u.S.A. A...

  • Page 467

    Electrical system 16-61 lighting system • insert the new bulb [a] by aligning its upper and lower pins [b] with the upper and lower grooves [c] in the socket, and turn the bulb clockwise. Caution the front turn signal/running position lights use a vibration resistant bulb. Replacement of the front t...

  • Page 468

    16-62 electrical system lighting system • unscrew the bolts [a]. • loosen the bolts [b]. • unscrew the mounting screws [a]. • remove the tail/brake light (led) [b]. ○ pull out the mount portion [c]. Tail/brake light (led) installation • tighten the tail/brake light mounting screws. Torque - tail/bra...

  • Page 469

    Electrical system 16-63 radiator fan system fan system circuit inspection • disconnect the lead connector [a] from the radiator fan switch. • using an auxiliary wire [a], connect the radiator fan switch leads. If the fan rotates, inspect the fan switch. If the fan does not rotate, inspect the follow...

  • Page 470

    16-64 electrical system radiator fan system radiator fan circuit 1. Radiator fan 2. Radiator fan switch 3. Joint connector a 4. Joint connector d 5. Meter ground 6. Frame ground 7. Joint connector b 8. Junction box 9. Fan fuse 10a 10. Main fuse 30a 11. Battery 12 v 8 ah.

  • Page 471

    Electrical system 16-65 meter, gauge, indicator unit meter unit removal • remove: wind sealed (see frame chapter) • slide the dust cover [a] and remove the wiring connector [b]. • remove the meter unit by taking off the mounting screws [c] with the washers. Caution place the meter or gauge so that t...

  • Page 472

    16-66 electrical system meter, gauge, indicator unit electronic combination meter unit inspection • remove the meter unit [a]. [1] ignition [10] battery (+) [2] fuel reserve switch [11] oil pressure warning [3] unused indicator light (led) [4] fuel level sensor ground (–) [5] neutral indicator light...

  • Page 473

    Electrical system 16-67 meter, gauge, indicator unit mode and reset button operation check: • connect the 12 v battery and terminals in the same man- ner as specified in the "liquid crystal display (lcd) seg- ments check". • check that the display change to the odo, trip, and clock displays each tim...

  • Page 474

    16-68 electrical system meter, gauge, indicator unit • in the hour setting mode, press the reset button to effect the minute setting mode. ○ the minute display flashes on the display. • press the mode button to set the minute. • in the minute setting mode, press the reset button to return to the hou...

  • Page 475

    Electrical system 16-69 meter, gauge, indicator unit • if the oscillator is not available, the speedometer can be checked as follows. ○ install the meter unit. ○ raise the rear wheel off the ground, using the jack. ○ turn on the ignition switch. ○ rotate the rear wheel by hand. ○ check that the spee...

  • Page 476

    16-70 electrical system meter, gauge, indicator unit water temperature meter check: • connect the 12 v battery and terminals in the same man- ner as specified in the "liquid crystal display (lcd) seg- ments check". • connect the variable rheostat [a] to the terminal [8] as shown. • check that the nu...

  • Page 477

    Electrical system 16-71 meter, gauge, indicator unit fuel level gauge inspection: • connect the 12 v battery and terminals in the same man- ner as specified in the “liquid crystal display (lcd) seg- ments check”. • connect a variable rheostat [a] to terminal [4] and [9] as shown. • check that the nu...

  • Page 478

    16-72 electrical system meter, gauge, indicator unit • if the oscillator is not available, the tachometer can be checked as follows. ○ connect the 12 v battery and terminals in the same man- ner as specified in the "liquid crystal display (lcd) seg- ments check". ○ using an auxiliary wire, quick ope...

  • Page 479

    Electrical system 16-73 meter, gauge, indicator unit right and left turn signal indicator light (led): for right turn signal indicator light (led) battery positive (+) terminal to terminal [13] for left turn signal indicator light (led) battery positive (+) terminal to terminal [14] high beam indica...

  • Page 480

    16-74 electrical system meter, gauge, indicator unit meter circuit 1. Right turn signal indicator light (led) 2. High beam indicator light (led) 3. Neutral indicator light (led) 4. Oil pressure warning indicator light (led) 5. Fi indicator light (led) 6. Odometer/trip meter/clock/fuel indicator 7. W...

  • Page 481

    Electrical system 16-75 switches and sensors brake light timing inspection • refer to the brakes in the periodic maintenance chapter. Brake light timing adjustment • refer to the brakes in the periodic maintenance chapter. Switch inspection • using a hand tester, check to see that only the con- nect...

  • Page 482

    16-76 electrical system switches and sensors • disconnect the connector [a]. • remove the fan switch [b]. • suspend the switch [a] in a container of coolant so that the temperature–sensing projection and threaded portion are submerged. • suspend an accurate thermometer [b] in the coolant so that the...

  • Page 483

    Electrical system 16-77 switches and sensors • suspend the sensor [a] in a container of coolant so that the temperature-sensing projection [e] and threaded por- tion [e] are submerged. • suspend an accurate thermometer [b] in the coolant. Note ○ the sensor and thermometer must not touch the con- tai...

  • Page 484

    16-78 electrical system switches and sensors • remove: bolts [a] speed sensor cover • remove: bolt [a] • take out the speed sensor [b]. • connect the speed sensor connector [a] with the battery [b], 10 kΩ resistor [c] and hand tester [d] as shown. • set the tester to the dc 25 v range. Special tool ...

  • Page 485

    Electrical system 16-79 switches and sensors fuel level sensor inspection • remove: fuel tank (see fuel system (dfi) chapter) • open the clamps [a]. • remove: bolts [b] fuel level sensor [c] • check that the float moves up and down smoothly without binding. It should go down under its own weight. If...

  • Page 486

    16-80 electrical system switches and sensors • connect the test light [a] (12 v 3.4 w bulb a socket with leads) and the 12 v battery [b] to the fuel level sensor connector [c]. Connections: battery (+) → 12 v 3.4 w bulb (one side) 12 v 3.4 w bulb (other side) → blue lead terminal battery (–) → bk/y ...

  • Page 487

    Electrical system 16-81 junction box the junction box [a] has fuses [b], relays, and diodes. The relays and diodes can not be removed. Junction box fuse circuit inspection • remove the seats (see frame chapter). • remove the junction box [a]. • pull off the connectors [a] from the junction box [b]. ...

  • Page 488

    16-82 electrical system junction box starter circuit/headlight relay inspection • remove the junction box (see junction box fuse circuit inspection). • check conductivity of the following numbered terminals by connecting the hand tester and one 12 v battery to the junction box as shown. ○ refer to t...

  • Page 489

    Electrical system 16-83 junction box diode circuit inspection • remove the junction box. • check conductivity of the following pairs of terminals. Diode circuit inspection tester connection 13–8, 13–9, 12–11, 12–14, 15–14, 16–14 the resistance should be low in one direction and more than ten times a...

  • Page 490

    16-84 electrical system fuse 30a main fuse removal • remove: right side cover (see frame chapter) 30a main fuse connector [a] • pull out the main fuse [b] from the starter relay with needle nose pliers. Junction box fuse removal • remove the seats (see frame chapter). • unlock the hook to lift up th...

  • Page 491: Appendix

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

  • Page 492

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

  • Page 493

    Appendix 17-3 cable, wire, and hose routing 1. Fixes by the left side clamp of the tank. 2. Tank drain hose passes the side cover installation under the bracket. 3. Air cleaner drain hose 4. Fuel tank drain hose 5. Cooling reserve tank hose 6. Fixes by the swingarm clamp 7. Fuel level sensor 8. Fixe...

  • Page 494

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

  • Page 495

    Appendix 17-5 cable, wire, and hose routing 1. Clutch cable 2. Meter ground 3. Clamp (ignition switch connector) 4. Ignition switch connector 5. Inlet air pressure sensor 6. To ignition coil 7. Fan motor connector (connect the con- nector on the inlet air pressure sensor.) 8. Clamp 9. To fuel pump 1...

  • Page 496

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

  • Page 497

    Appendix 17-7 cable, wire, and hose routing 1. Run the main harness through lower and right side of the thermostat. 2. Frame ground (with thermostat bracket) 3. Ignition switch connector 4. Meter ground (with thermostat) 5. Engine harness (connect the harness on the cross pipe.) 6. Water temperature...

  • Page 498

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

  • Page 499

    Appendix 17-9 cable, wire, and hose routing 1. Tail light 2. Clamp 3. Atmospheric pressure sensor 4. To ecu fuse 5. Junction box 6. To self-diagnosis indicator terminal 7. Pickup coil and oil pressure switch 8. Fuel pump 9. Fuel level gauge and fuel reserve switch 10. To inlet air temperature sensor...

  • Page 500

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

  • Page 501

    Appendix 17-11 cable, wire, and hose routing 1. Clamp all the wires as shown in the encircled area. 2. Meter 3. Take out the lead of the meter from the right side of the tie lap to connect with the meter. 4. Clutch cable 5. Starter cable 6. To front left turn signal light (run the harness above the ...

  • Page 502

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

  • Page 503

    Appendix 17-13 cable, wire, and hose routing 1. Clamp 2. Brake hose 3. Punch mark 4. Run the brake hose through the inside of the frame. 5. Tight the bolt to the specified torque with the stopper (for turning prevention) applied..

  • Page 504

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

  • Page 505

    Appendix 17-15 cable, wire, and hose routing 1. Cam sensor lead (run the lead between the convex area of cap center and bolt head to secure the coupler.) 2. Radiator fan switch lead (run the lead through into the water hose.) 3. Cap 4. Catch cable (run the cable through forward the water hose.) 5. A...

  • Page 506

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

  • Page 507

    Appendix 17-17 cable, wire, and hose routing 1. Bend the bracket as shown to secure the lead. 2. Bend the bracket. 3. Run the lead end till it touches the boss of the crankcase. 4. Install the exterior of the lead with staking area facing downward..

  • Page 508

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

  • Page 509

    Appendix 17-19 cable, wire, and hose routing 1. Run the hose (cap – reserve) through upside of the throttle cable. 2. Run the hose (white) through into the throttle cables. 3. Run the throttle body harness throttle upside of the hose (white) and hose (throttle – fitting). 4. Run the harness through ...

  • Page 510

    17-20 appendix troubleshooting guide note ○ refer to the fuel system chapter for most of dfi trouble shooting guide. ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common di...

  • Page 511

    Appendix 17-21 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 512

    17-22 appendix troubleshooting guide muffler overheating: for kleen, do not run the engine even if with only one cylinder misfiring or poor running (request the nearest service fa- cility to correct it) for kleen, do not push-start with a dead battery (connect another full-charged battery with jumpe...

  • Page 513

    Appendix 17-23 troubleshooting guide abnormal engine noise: knocking: ic igniter in ecu trouble carbon built up in combustion chamber fuel poor quality or incorrect spark plug incorrect overheating piston slap: cylinder/piston clearance excessive cylinder, piston worn connecting rod bent piston pin,...

  • Page 514

    17-24 appendix troubleshooting guide handling and/or stability unsatisfactory: handlebar hard to turn: cable routing incorrect hose routing incorrect wiring routing incorrect steering stem nut too tight steering stem bearing damaged steering stem bearing lubrication inade- quate steering stem bent t...

  • Page 515

    Model application year model beginning frame no. 2003 zr1000–a1 jkazrca1 □ 3a000001 zrt00a–000001 jkazrt00aaa000001 2004 zr1000–a2 jkazrca1 □ 4a015001 jkazrt00aaa015001 zrt00a–015001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1310-03 printed in japan.