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Kawasaki Z1000 Service Manual

Summary of Z1000

  • Page 1

    Z1000 z1000 abs motorcycle service manual.

  • Page 3: Quick Reference Guide

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

  • Page 5: Z1000

    Z1000 z1000 abs motorcycle service manual all rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of quality assuran...

  • 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

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

  • Page 9: Foreword

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

  • Page 11: General Information 1-1

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

  • Page 12: 1-2 General Information

    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

    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

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

  • Page 15: General Information 1-5

    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

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

  • Page 17: General Information 1-7

    General information 1-7 model identification zr1000da (united states and canada) left side view zr1000da (united states and canada) right side view frame number engine number.

  • Page 18: 1-8 General Information

    1-8 general information model identification zr1000da (europe) left side view zr1000da (europe) right side view.

  • Page 19: General Information 1-9

    General information 1-9 model identification zr1000ea left side view zr1000ea right side view.

  • Page 20: 1-10 General Information

    1-10 general information general specifications items zr1000da ∼ dd/ea ∼ ed dimensions overall length 2 095 mm (82.48 in.) overall width 805 mm (31.7 in.) overall height 1 085 mm (42.72 in.) wheelbase 1 440 mm (56.69 in.) road clearance 140 mm (5.51 in.) seat height 815 mm (32.1 in.) curb mass: zr10...

  • Page 21: General Information 1-11

    General information 1-11 general specifications items zr1000da ∼ dd/ea ∼ ed duration 276° exhaust: open 58° bbdc close 18° atdc duration 256° lubrication system forced lubrication (wet sump) engine oil: type api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity sae 10w-40 capacity 4.0 l (4.2 u...

  • Page 22: 1-12 General Information

    1-12 general information general specifications items zr1000da ∼ dd/ea ∼ ed rear suspension: type swingarm wheel travel 138 mm (5.43 in.) brake type: front dual discs rear single disc electrical equipment battery 12 v 8 ah headlight: type semi-sealed beam bulb 12 v 55 w × 2/55 w (hi/lo) tail/brake l...

  • Page 23: General Information 1-13

    General information 1-13 unit conversion table prefixes for units: prefix symbol power mega m × 1 000 000 kilo k × 1 000 centi c × 0.01 milli m × 0.001 micro µ × 0.000001 units of mass: kg × 2.205 = lb g × 0.03527 = oz units of volume: l × 0.2642 = gal (us) l × 0.2200 = gal (imp) l × 1.057 = qt (us)...

  • Page 25: Periodic Maintenance 2-1

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

  • Page 26: 2-2 Periodic Maintenance

    2-2 periodic maintenance steering stem bearing lubrication ................................................................................... 2-42 electrical system ................................................................................................................. 2-43 lights and swit...

  • Page 27: Periodic Maintenance 2-3

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

  • Page 28: 2-4 Periodic Maintenance

    2-4 periodic maintenance periodic maintenance chart frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) 1 6 12 18 24 30 36 item every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) see page final drive drive chain lubrication condition - inspect # every 600 km (400 mile) 2-3...

  • Page 29: Periodic Maintenance 2-5

    Periodic maintenance 2-5 periodic maintenance chart #: service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping. *: for higher odometer readings, repeat at the frequency interval established here..

  • Page 30: 2-6 Periodic Maintenance

    2-6 periodic maintenance periodic maintenance chart periodic replacement parts frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) 1 12 24 36 48 item every (0.6) (7.5) (15) (22.5) (30) see page air cleaner element # - replace every 18 000 km (11 250 mile) 2-51 fuel hose - re...

  • Page 31: Periodic Maintenance 2-7

    Periodic maintenance 2-7 torque and locking agent the following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “remarks” column mean: al: tighten the two clamp bolts alternately two times to ensure...

  • Page 32: 2-8 Periodic Maintenance

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks front camshaft chain guide bolt (upper) 25 2.5 18 plugs 19.6 2.0 14 l rear camshaft chain guide bolt 25 2.5 18 spark plugs 13 1.3 115 in·lb throttle body assy holder bolts 12 1.2 106 in·lb upper camshaft chain ...

  • Page 33: Periodic Maintenance 2-9

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks breather side plate bolt 5.9 0.60 52 in·lb connecting rod big end nuts see the text ← ← mo breather plate bolts 9.8 1.0 87 in·lb l shift drum bearing holder bolts 12 1.2 106 in·lb l oil passage plugs 20 2.0 15 ...

  • Page 34: 2-10 Periodic Maintenance

    2-10 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks rear brake disc mounting bolts 27 2.8 20 l rear caliper mounting bolts 25 2.5 18 rear master cylinder mounting bolts 25 2.5 18 rear master cylinder push rod locknut 17 1.7 12 suspension front fork bottom allen...

  • Page 35: Periodic Maintenance 2-11

    Periodic maintenance 2-11 torque and locking agent torque fastener n·m kgf·m ft·lb remarks meter unit mounting screws 1.2 0.12 11 in·lb oxygen sensor (equipped models) 44 4.5 32 switch housing screws 3.5 0.36 31 in·lb alternator cover bolts (engine no. ∼ zrt00de013356) 9.8 1.0 87 in·lb alternator co...

  • Page 36: 2-12 Periodic Maintenance

    2-12 periodic maintenance specifications item standard service limit fuel system (dfi) 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 1/2 (for reference) – – – throttle body vacuum 40.7 ±1.3 kpa (305 ±10 mmhg) at idle speed ...

  • Page 37: Periodic Maintenance 2-13

    Periodic maintenance 2-13 specifications item standard service limit final drive drive chain slack 20 ∼ 30 mm (0.8 ∼ 1.2 in.) – – – drive chain wear (20-link length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 319 mm (12.56 in.) standard chain: make enuma – – – type ek525zx – – – link 112 links – – – brake...

  • Page 38: 2-14 Periodic Maintenance

    2-14 periodic maintenance special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 jack: 57001-1238 oil filter wrench: 57001-1249 attachment jack: 57001-1252 spark plug wrench, hex 16: 57001-1262 vacuum gauge: 57001-1369 throttle sensor setting adapter: 57001-1538 fuel hos...

  • Page 39: Periodic Maintenance 2-15

    Periodic maintenance 2-15 periodic maintenance procedures fuel system (dfi) throttle control system inspection • check that the throttle grip [a] moves smoothly from full open to close, and the throttle closes quickly and com- pletely by the return spring in all steering positions. If the throttle g...

  • Page 40: 2-16 Periodic Maintenance

    2-16 periodic maintenance periodic maintenance procedures • plug the vacuum hose end [a]. • connect a vacuum gauge (special tool) and hoses [a] to the fittings on the throttle body. Special tool - vacuum gauge: 57001-1369 • connect a highly accurate tachometer [b] to one of the stick coil primary le...

  • Page 41: Periodic Maintenance 2-17

    Periodic maintenance 2-17 periodic maintenance procedures • start the engine and warm it up thoroughly. • check the idle speed, using a highly accurate tachometer [a]. Idle speed standard: 1 100 ±50 r/min (rpm) if the idle speed is out of the specified range, adjust it with the adjusting screw (see ...

  • Page 42: 2-18 Periodic Maintenance

    2-18 periodic maintenance periodic maintenance procedures if any one vacuum measurement is out of the specified range after left (#1, #2) and right (#2, #3) synchronization, adjust the bypass screws [a]. Special tool - pilot screw adjuster, a [b]: 57001-1239 • adjust the lower vacuum between #1 and ...

  • Page 43: Periodic Maintenance 2-19

    Periodic maintenance 2-19 periodic maintenance procedures • back out the same number of turns counted when first turned in. This is to set the screw to its original position. Note ○ a throttle body has different “turns out” of the bypass screw for each individual unit. On setting the bypass screw, u...

  • Page 44: 2-20 Periodic Maintenance

    2-20 periodic maintenance periodic maintenance procedures idle speed adjustment • start the engine and warm it up thoroughly. • turn the adjusting screw [a] until the idle speed is correct. ○ open and close the throttle a few times to make sure that the idle speed is within the specified range. Read...

  • Page 45: Periodic Maintenance 2-21

    Periodic maintenance 2-21 periodic maintenance procedures evaporative emission control system (cal, sea-b1 and th models) inspection • inspect the canister as follows. ○ remove the front seat (see front seat removal in the frame chapter). ○ remove the canister [a], and disconnect the hoses from the ...

  • Page 46: 2-22 Periodic Maintenance

    2-22 periodic maintenance periodic maintenance procedures cooling system coolant level inspection note ○ check the level when the engine is cold (room or ambi- ent temperature). • clear the clutch cable [a] from the clamp [b]. • check the coolant level in the reserve tank [c] with the motorcycle hel...

  • Page 47: Periodic Maintenance 2-23

    Periodic maintenance 2-23 periodic maintenance procedures engine top end valve clearance inspection note ○ valve clearance must be checked and adjusted when the engine is cold (room temperature). • remove: crankshaft sensor cover (see crankshaft sensor re- moval in the electrical system chapter) cyl...

  • Page 48: 2-24 Periodic Maintenance

    2-24 periodic maintenance periodic maintenance procedures ○ when positioning #4 piston tdc at the end of the compression stroke: intake valve clearance of #2 and #4 cylinders exhaust valve clearance of #3 and #4 cylinders measuring valve [a] ○ when positioning #1 piston tdc at the end of the compres...

  • Page 49: Periodic Maintenance 2-25

    Periodic maintenance 2-25 periodic maintenance procedures ○ besides the standard shims in the valve clearance adjust- ment charts, the following shims may be installed at the factory. Although they are not available as spare parts, they can be used to adjust valve clearance. Adjustment shims thickne...

  • Page 50: 2-26 Periodic Maintenance

    2-26 periodic maintenance periodic maintenance procedures valve clearance adjustment chart intake valve 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where t...

  • Page 51: Periodic Maintenance 2-27

    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 52: 2-28 Periodic Maintenance

    2-28 periodic maintenance periodic maintenance procedures notice be sure to remeasure the clearance after selecting a shim according to the table. If the clearance is out of the specified range, use the additional shim. ○ if there is no valve clearance, use a shim that is a few sizes smaller, and re...

  • Page 53: Periodic Maintenance 2-29

    Periodic maintenance 2-29 periodic maintenance procedures clutch clutch operation inspection • pull the clutch lever just enough to take up the free play [a]. • measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow,...

  • Page 54: 2-30 Periodic Maintenance

    2-30 periodic maintenance periodic maintenance procedures wheels/tires air pressure inspection • 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 55: Periodic Maintenance 2-31

    Periodic maintenance 2-31 periodic maintenance procedures tread depth standard: front: zr1000d 4.0 mm (0.16 in.) zr1000e 3.8 mm (0.15 in.) rear: zr1000d 5.5 mm (0.22 in.) zr1000e 5.4 mm (0.22 in.) service limit: front 1 mm (0.04 in.) (at, ch, de) 1.6 mm (0.06 in.) rear 2 mm (0.08 in.) up to 130 km/h...

  • Page 56: 2-32 Periodic Maintenance

    2-32 periodic maintenance periodic maintenance procedures final drive drive chain lubrication condition inspection • if a special lubricant is not available, a heavy oil such as sae 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. • if the cha...

  • Page 57: Periodic Maintenance 2-33

    Periodic maintenance 2-33 periodic maintenance procedures drive chain slack adjustment • loosen the left and right chain adjuster clamp bolts [a]. • using an allen wrench, turn the adjusters [b] forward or rearward until the drive chain has the correct amount of chain slack. • tighten: torque - chai...

  • Page 58: 2-34 Periodic Maintenance

    2-34 periodic maintenance periodic maintenance procedures drive chain wear inspection • remove the chain cover (see drive chain removal in the final drive chapter). • rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, repla...

  • Page 59: Periodic Maintenance 2-35

    Periodic maintenance 2-35 periodic maintenance procedures brakes brake fluid leak (brake hose and pipe) inspection • for abs equipped models, remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • apply the brake lever or pedal and inspect the brake fluid leak from the brak...

  • Page 60: 2-36 Periodic Maintenance

    2-36 periodic maintenance periodic maintenance procedures brake hose and pipe damage and installation condition inspection • for abs equipped models, remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • inspect the brake hoses and fittings for deterioration, cracks and si...

  • Page 61: Periodic Maintenance 2-37

    Periodic maintenance 2-37 periodic maintenance procedures • check that the brake fluid level in the rear brake reservoir [a] is above the lower level line [b]. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [c]. ○ remove the stopper [d]. Warning mix...

  • Page 62: 2-38 Periodic Maintenance

    2-38 periodic maintenance periodic maintenance procedures brake light switch operation inspection • turn on the ignition switch. • the brake light [a] should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm (0.39 in.). If it does not, adjust the brake light swi...

  • Page 63: Periodic Maintenance 2-39

    Periodic maintenance 2-39 periodic maintenance procedures suspension front forks/rear shock absorber operation inspection • pump the forks down and up [a] 4 or 5 times, and inspect the smooth stroke. If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see front...

  • Page 64: 2-40 Periodic Maintenance

    2-40 periodic maintenance periodic maintenance procedures tie-rod operation inspection • pump the seat down and up 4 or 5 times, and inspect the smooth stroke. If the tie-rod [a] does not smoothly stroke or noise is found, inspect the fasteners and tie-rod bearings (see rocker arm/tie-rod bearing, s...

  • Page 65: Periodic Maintenance 2-41

    Periodic maintenance 2-41 periodic maintenance procedures • bend the claws [a] of the claw washer back. • remove the steering stem locknut [b] and claw washer [c]. • adjust the steering. Special tool - steering stem nut wrench [a]: 57001-1100 if the steering is too tight, loosen the stem nut a fract...

  • Page 66: 2-42 Periodic Maintenance

    2-42 periodic maintenance periodic maintenance procedures steering stem bearing lubrication • remove the steering stem (see stem, stem bearing re- moval in the steering chapter). • using a high flash-point solvent, wash the upper and lower ball bearings in the cages, and wipe the upper and lower out...

  • Page 67: Periodic Maintenance 2-43

    Periodic maintenance 2-43 periodic maintenance procedures electrical system lights and switches operation inspection first step • turn on the ignition switch. • the following lights should go on according to below table. City light [a] goes on taillight [b] goes on license plate light [c] goes on me...

  • Page 68: 2-44 Periodic Maintenance

    2-44 periodic maintenance periodic maintenance procedures third step • turn on the turn signal switch [a] (left or right position). • the left or right turn signal lights [b] (front and rear) ac- cording to the switch position should flash. • the turn signal indicator light (led) [c] in the meter un...

  • Page 69: Periodic Maintenance 2-45

    Periodic maintenance 2-45 periodic maintenance procedures • set the dimmer switch to high beam position. • the low beam [a] and high beam [b] headlights should go on. • the high beam indicator light (led) [c] should go on. If the high beam headlight and/or high beam indicator light (led) does not go...

  • Page 70: 2-46 Periodic Maintenance

    2-46 periodic maintenance periodic maintenance procedures • to move the headlight beam leftward, turn the left ad- juster [a] clockwise and turn the right adjuster counter- clockwise same number as the left adjuster was turned until the beam points straight ahead. • to move the headlight beam rightw...

  • Page 71: Periodic Maintenance 2-47

    Periodic maintenance 2-47 periodic maintenance procedures if the sidestand switch operation does not work, inspect or replace the following item. Battery (see charging condition inspection in the elec- trical system chapter) main fuse 30 a (see fuse inspection in the electrical system chapter) ignit...

  • Page 72: 2-48 Periodic Maintenance

    2-48 periodic maintenance periodic maintenance procedures others chassis parts lubrication • before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • lubricate the points listed below with indicated lubricant. Note ○ whenever the vehic...

  • Page 73: Periodic Maintenance 2-49

    Periodic maintenance 2-49 periodic maintenance procedures • with the cable disconnected at both ends, the cable should move freely [a] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [b], or if the cable housing is kinked [c], replace the cable..

  • Page 74: 2-50 Periodic Maintenance

    2-50 periodic maintenance periodic maintenance procedures bolts, nuts and fasteners tightness inspection • check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. Note ○ for the engine fasteners, check the tightness of them wh...

  • Page 75: Periodic Maintenance 2-51

    Periodic maintenance 2-51 periodic maintenance procedures replacement parts air cleaner element replacement note ○ in dusty areas, the element should be replaced more frequently than the recommended interval. Warning if dirt or dust is allowed to pass through into the throttle body assy, the throttl...

  • Page 76: 2-52 Periodic Maintenance

    2-52 periodic maintenance periodic maintenance procedures • wipe off the dirt of the surface [a] around the connection using a cloth or a soft brush. When removing with standard tip screwdriver • insert the standard tip screwdriver [a] into slit on the joint lock [b]. • turn the driver to disconnect...

  • Page 77: Periodic Maintenance 2-53

    Periodic maintenance 2-53 periodic maintenance procedures • run the fuel hose correctly (see cable, wire, and hose routing section in the appendix chapter). • insert the fuel hose joint [a] straight onto the delivery pipe until the hose joint clicks. • push [b] the joint lock [c]. • push and pull [a...

  • Page 78: 2-54 Periodic Maintenance

    2-54 periodic maintenance periodic maintenance procedures • remove the right center fairing (see center fairing re- moval in the frame 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 ...

  • Page 79: Periodic Maintenance 2-55

    Periodic maintenance 2-55 periodic maintenance procedures • fill the reserve tank up to the “f” (full) level line [a] with coolant and install the cap [b]. • start the engine, warm it up thoroughly until the radiator fan turns on and then stop the engine. • check the coolant level in the reserve tan...

  • Page 80: 2-56 Periodic Maintenance

    2-56 periodic maintenance periodic maintenance procedures radiator hose and o-ring replacement • drain the coolant (see coolant change). • remove: thermostat housing [a] (see thermostat removal in the cooling system chapter) water pump cover [b] (see water pump removal in the cooling system chapter)...

  • Page 81: Periodic Maintenance 2-57

    Periodic maintenance 2-57 periodic maintenance procedures engine oil change • situate the motorcycle so that it is vertical after warming up the engine. • remove the engine oil drain bolt [a] to drain the oil. ○ the oil in the oil filter can be drained by removing the filter (see oil filter replacem...

  • Page 82: 2-58 Periodic Maintenance

    2-58 periodic maintenance periodic maintenance procedures brake hose replacement • remove: upper fairing (see upper fairing removal in the frame chapter) brake hose fitting bolt [a] notice brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediat...

  • Page 83: Periodic Maintenance 2-59

    Periodic maintenance 2-59 periodic maintenance procedures • for abs equipped models; note the following. • remove: air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter) battery case (see battery case removal in the frame chapter) brake pipe joint nuts [a] bolts [b] c...

  • Page 84: 2-60 Periodic Maintenance

    2-60 periodic maintenance periodic maintenance procedures brake fluid change note ○ the procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is the same as for the front brake. • level the brake fluid reservoir. • remove the reservoir cap. • remove the rubber cap ...

  • Page 85: Periodic Maintenance 2-61

    Periodic maintenance 2-61 periodic maintenance procedures master cylinder rubber parts replacement front master cylinder disassembly • remove the front master cylinder (see front master cylin- der removal in the brakes chapter). • remove: screws [a] cap [b] diaphragm plate [c] diaphragm [d] float [e...

  • Page 86: 2-62 Periodic Maintenance

    2-62 periodic maintenance periodic maintenance procedures master cylinder assembly • before assembly, clean all parts including the master cylinder with brake fluid or alcohol. Notice except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake...

  • Page 87: Periodic Maintenance 2-63

    Periodic maintenance 2-63 periodic maintenance procedures • remove: front caliper assembly bolts [a] • split the front caliper. • remove: pad spring o-ring [a] • using compressed air, remove the pistons. One way to remove the pistons is as follows. ○ install a rubber gasket [a] and a wooden board [b...

  • Page 88: 2-64 Periodic Maintenance

    2-64 periodic maintenance periodic maintenance procedures note ○ if compressed air is not available, do as follows for both calipers coincidentally, with the brake hose connected to the caliper. ○ prepare a container for brake fluid, and perform the work above it. ○ remove the pad springs and pads (...

  • Page 89: Periodic Maintenance 2-65

    Periodic maintenance 2-65 periodic maintenance procedures rear caliper disassembly • remove: rear caliper (see rear caliper removal in the brakes chapter) brake pads (see rear brake pad removal in the brakes chapter) caliper holder • using a rear caliper mounting bolt [a], screw the thread hole for ...

  • Page 90: 2-66 Periodic Maintenance

    2-66 periodic maintenance periodic maintenance procedures spark plug replacement • remove the stick coils (see stick coil removal in the electrical system chapter). • remove the spark plugs [a] using the plug wrench [b] vertically. Special tool - spark plug wrench, hex 16: 57001-1262 • replace the s...

  • Page 91: Fuel System (Dfi) 3-1

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

  • Page 92: 3-2 Fuel System (Dfi)

    3-2 fuel system (dfi) vehicle-down sensor installation ...................................................................................... 3-68 vehicle-down sensor input voltage inspection................................................................. 3-68 vehicle-down sensor output voltage ins...

  • Page 93: Fuel System (Dfi) 3-3

    Fuel system (dfi) 3-3 dfi power source .................................................................................................................. 3-108 ecu fuse removal .......................................................................................................... 3-108 ecu fuse i...

  • Page 94: 3-4 Fuel System (Dfi)

    3-4 fuel system (dfi) exploded view.

  • Page 95: Fuel System (Dfi) 3-5

    Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air cleaner duct clamp bolts 2.0 0.20 18 in·lb 2 delivery pipe assy mounting screws 3.4 0.35 30 in·lb 3 throttle body assy holder clamp bolts 2.9 0.30 26 in·lb 4 upper air cleaner housing screws 1.1 0.11 9.7 in·lb 5. A...

  • Page 96: 3-6 Fuel System (Dfi)

    3-6 fuel system (dfi) exploded view.

  • Page 97: Fuel System (Dfi) 3-7

    Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 intake air temperature sensor screw 1.2 0.12 11 in·lb 2 oxygen sensor (equipped models) 44 4.5 32 3 water temperature sensor 30 3.1 22 4 exhaust butterfly valve actuator mounting screws 1.2 0.12 11 in·lb 5 exhaust butt...

  • Page 98: 3-8 Fuel System (Dfi)

    3-8 fuel system (dfi) exploded view.

  • Page 99: Fuel System (Dfi) 3-9

    Fuel system (dfi) 3-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 fuel pump bolts 9.8 1.0 87 in·lb l 2. Other than cal, sea-b1 and th models 3. Cal, sea-b1 and th models 4. Separator 5. Canister 6. Blue hose 7. Green hose 8. Red hose 9. White hose 10. Frame no. ∼ jkazrt00da017291 11....

  • Page 100: 3-10 Fuel System (Dfi)

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

  • Page 101: Fuel System (Dfi) 3-11

    Fuel system (dfi) 3-11 dfi system 1. Ecu 2. Battery 12 v 8 ah 3. Air switching valve 4. Intake air pressure sensor #1 5. Intake air pressure sensor #2 6. Crankshaft sensor 7. Subthrottle valve actuator 8. Subthrottle sensor 9. Intake air temperature sensor 10. Main throttle sensor 11. Water temperat...

  • Page 102: 3-12 Fuel System (Dfi)

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

  • Page 103: Fuel System (Dfi) 3-13

    Fuel system (dfi) 3-13 dfi system part names 1. Ecu 2. Exhaust butterfly valve actuator 3. Water temperature sensor 4. Crankshaft sensor 5. Intake air pressure sensor #1 6. Frame ground 7. Meter ground 8. Intake air pressure sensor #2 9. Intake air temperature sensor 10. Speed sensor 11. Oxygen sens...

  • Page 104: 3-14 Fuel System (Dfi)

    3-14 fuel system (dfi) dfi system terminal numbers of ecu connectors terminal names 1. Subthrottle valve actuator: lg/r 2. Exhaust butterfly valve actuator (–): gl 3. Exhaust butterfly valve actuator (+): g/r 4. Fuel pump relay: br/y 5. Power supply to sensors: bl 6. Power supply to ecu (from ecu ma...

  • Page 105: Fuel System (Dfi) 3-15

    Fuel system (dfi) 3-15 dfi system 35. Starter button: bk/r 36. Fuel injector #1: bl/r 37. Engine stop switch: r 38. Stick coil #4: bk/o 39. Stick coil #3: bk/w 40. Stick coil #1: bk 41. External communication line (immobilizer system, equipped models/*kds): lg/bk 42. Unused 43. Neutral switch: lg 44...

  • Page 106: 3-16 Fuel System (Dfi)

    3-16 fuel system (dfi) dfi parts location main throttle sensor [a] subthrottle sensor [b] crankshaft sensor [a] oxygen sensor [b] (equipped models) ignition key (transponder, equipped models) [a] ignition switch [b] immobilizer antenna [c] (equipped models) warning indicator light (led) [d] stick co...

  • Page 107: Fuel System (Dfi) 3-17

    Fuel system (dfi) 3-17 dfi parts location immobilizer amplifier [a] (equipped models) intake air temperature sensor [a] frame ground [b] exhaust butterfly valve actuator [a] battery 12 v 8 ah [b] vehicle-down sensor [c] fi fuse 15 a [d] relay box (ecu main relay, radiator fan relay, fuel pump relay)...

  • Page 108: 3-18 Fuel System (Dfi)

    3-18 fuel system (dfi) specifications item standard digital fuel injection system idle speed 1 100 ±50 r/min (rpm) throttle body assy: throttle valve dual throttle valve bore 38 mm (1.42 in.) throttle body vacuum 40.7 ±1.3 kpa (305 ±10 mmhg) bypass screws (turn out) 2 1/2 (for reference) ecu: make d...

  • Page 109: Fuel System (Dfi) 3-19

    Fuel system (dfi) 3-19 specifications item standard subthrottle sensor: input voltage dc 4.75 ∼ 5.25 v output voltage dc 1.08 ∼ 1.12 v at subthrottle valve full close position dc 4.2 ∼ 4.4 v at subthrottle valve full open position (for reference) resistance 4 ∼ 6 k Ω exhaust butterfly valve actuator...

  • Page 110: 3-20 Fuel System (Dfi)

    3-20 fuel system (dfi) special tools and sealant oil pressure gauge, 5 kgf/cm²: 57001-125 carburetor drain plug wrench, hex 3: 57001-1269 fork oil level gauge: 57001-1290 vacuum gauge: 57001-1369 hand tester: 57001-1394 throttle sensor setting adapter #1: 57001-1400 peak voltage adapter: 57001-1415 ...

  • Page 111: Fuel System (Dfi) 3-21

    Fuel system (dfi) 3-21 special tools and sealant fuel hose: 57001-1607 measuring adapter: 57001-1700 liquid gasket, tb1211: 56019-120

  • Page 112: 3-22 Fuel System (Dfi)

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

  • Page 113: Fuel System (Dfi) 3-23

    Fuel system (dfi) 3-23 dfi servicing precautions ○ if the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see fuel tank removal) and check the fuel hose [a]. Replace the fuel hose if any fraying, cracks o...

  • Page 114: 3-24 Fuel System (Dfi)

    3-24 fuel system (dfi) troubleshooting the dfi system the warning indicator light (led) [a] is used for the fi indicator, immobilizer indicator (equipped models) and oil pressure warning indicator. Outline when a problem occurs with dfi system, the warning in- dicator light (led) [a] and fi warning ...

  • Page 115: Fuel System (Dfi) 3-25

    Fuel system (dfi) 3-25 troubleshooting the dfi system when the service code [a] is displayed, for first ask the rider about the conditions [b] of trouble, and then start to determine the cause [c] of problem. As a pre-diagnosis inspection, check the ecu for ground and power supply, the fuel line for...

  • Page 116: 3-26 Fuel System (Dfi)

    3-26 fuel system (dfi) troubleshooting the dfi system • when checking the dfi parts, use a digital meter which can be read two decimal place voltage or resistance. ○ the dfi part connectors [a] have seals [b], including the ecu. When measuring the input or output voltage with the connector joined, u...

  • Page 117: Fuel System (Dfi) 3-27

    Fuel system (dfi) 3-27 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 118: 3-28 Fuel System (Dfi)

    3-28 fuel system (dfi) 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 119: Fuel System (Dfi) 3-29

    Fuel system (dfi) 3-29 troubleshooting the dfi system sample diagnosis sheet rider name: registration no. (license plate no.): year of initial registration: model: engine no.: frame no.: date problem occurred: mileage: environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ al...

  • Page 120: 3-30 Fuel System (Dfi)

    3-30 fuel system (dfi) troubleshooting the dfi system □ very low idle speed, □ very high idle speed, □ rough idle speed. □ battery voltage is low (charge the battery). □ spark plug loose (tighten it). □ spark plug dirty, broken, or gap maladjusted (remedy it). □ backfiring. □ afterfiring. □ hesitati...

  • Page 121: Fuel System (Dfi) 3-31

    Fuel system (dfi) 3-31 dfi system troubleshooting guide note ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in dfi system. ○ the ecu may be involved in t...

  • Page 122: 3-32 Fuel System (Dfi)

    3-32 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) fuel pressure regulator trouble inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged inspect and repair (see chapter 3). Intake air pressure sensor #1 trouble inspect (see ...

  • Page 123: Fuel System (Dfi) 3-33

    Fuel system (dfi) 3-33 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). Intake air pressure sensor #1 trouble inspect (see chapter 3). Intake air pressure sen...

  • Page 124: 3-34 Fuel System (Dfi)

    3-34 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) other: intermittent any dfi fault and its recovery check that dfi connectors are clean and tight, and examine leads for signs of burning or fraying (see chapter 3). Poor running or no power at high ...

  • Page 125: Fuel System (Dfi) 3-35

    Fuel system (dfi) 3-35 dfi system troubleshooting guide symptoms or possible causes actions (chapter) intake air temperature sensor trouble inspect (see chapter 3). Miscellaneous: subthrottle sensor trouble inspect (see chapter 3). Subthrottle valve actuator trouble inspect (see chapter 3). Speed se...

  • Page 126: 3-36 Fuel System (Dfi)

    3-36 fuel system (dfi) self-diagnosis the warning indicator light (led) [a] is used for the fi indicator, immobilizer indicator (equipped models) and oil pressure warning indicator. Self-diagnosis outline the self-diagnosis system has two modes and can be switched to another mode by operating the me...

  • Page 127: Fuel System (Dfi) 3-37

    Fuel system (dfi) 3-37 self-diagnosis dealer mode the lcd (liquid crystal display) display the service code(s) [a] to show the problem(s) which the dfi system, ignition system and immobilizer system has at the moment of diagnosis. Self-diagnosis procedures ○ when a problem occurs with the dfi system...

  • Page 128: 3-38 Fuel System (Dfi)

    3-38 fuel system (dfi) self-diagnosis • turn the ignition switch on. • push the left button [a] to display the odometer. • push the left button [a] for more than two seconds. • the service code [b] is displayed on the lcd by the num- ber of two digits. • any of the following procedures ends self-dia...

  • Page 129: Fuel System (Dfi) 3-39

    Fuel system (dfi) 3-39 self-diagnosis self-diagnosis flow chart service code reading ○ the service code(s) is displayed on the lcd by the num- ber of two digits. ○ when there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number serv...

  • Page 130: 3-40 Fuel System (Dfi)

    3-40 fuel system (dfi) self-diagnosis service code erasing ○ when repair has been done, fi and/or immobilizer warning symbols go off and service code is not displayed. But the service codes stored in memory of the ecu are not erased to preserve the problem history. In this model, the problem history...

  • Page 131: Fuel System (Dfi) 3-41

    Fuel system (dfi) 3-41 self-diagnosis backups ○ the ecu takes the following measures to prevent engine damage when the dfi, ignition or immo- bilizer system parts have troubles. Service codes parts output signal usable range or criteria backups by ecu 11 main throttle sensor output voltage 0.2 ∼ 4.8...

  • Page 132: 3-42 Fuel System (Dfi)

    3-42 fuel system (dfi) self-diagnosis service codes parts output signal usable range or criteria backups by ecu 34 exhaust butterfly valve actuator sensor output voltage 0.1 ∼ 4.8 v if the exhaust butterfly valve sensor system fails (the output voltage is out of the usable range, wiring short or ope...

  • Page 133: Fuel System (Dfi) 3-43

    Fuel system (dfi) 3-43 self-diagnosis service codes parts output signal usable range or criteria backups by ecu 67 oxygen sensor heater (equipped models) the oxygen sensor heater raise temperature of the sensor for its earlier activation. If the oxygen sensor heater fails (wiring short or open), the...

  • Page 134: 3-44 Fuel System (Dfi)

    3-44 fuel system (dfi) main throttle sensor (service code 11) the main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ecu senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm,...

  • Page 135: Fuel System (Dfi) 3-45

    Fuel system (dfi) 3-45 main throttle sensor (service code 11) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main harness connectors. ○ disconnect the ecu and sensor connectors. Wiring inspection ecu connector [a] ←→ main throttle sensor connector [...

  • Page 136: 3-46 Fuel System (Dfi)

    3-46 fuel system (dfi) main throttle sensor (service code 11) • turn the ignition switch off. • measure the output voltage with the engine stopped and with the connector joined. • turn the ignition switch on. Output voltage standard: dc 1.02 ∼ 1.06 v at idle throttle opening dc 4.22 ∼ 4.42 v at full...

  • Page 137: Fuel System (Dfi) 3-47

    Fuel system (dfi) 3-47 main throttle sensor (service code 11) main throttle sensor resistance inspection • turn the ignition switch off. • disconnect the main throttle sensor connector. ○ disconnect the main throttle sensor connector and con- nect the harness adapter [a] to the sensor connector only...

  • Page 138: 3-48 Fuel System (Dfi)

    3-48 fuel system (dfi) intake air pressure sensor #1 (service code 12) intake air pressure sensor #1 removal notice never drop the intake air pressure sensor #1 espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove: air cleaner housing (see air cleaner housing removal) i...

  • Page 139: Fuel System (Dfi) 3-49

    Fuel system (dfi) 3-49 intake air pressure sensor #1 (service code 12) intake air pressure sensor #1 input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the air cleaner housing (see air cleaner housing removal). • disconnect the intake air p...

  • Page 140: 3-50 Fuel System (Dfi)

    3-50 fuel system (dfi) intake air pressure sensor #1 (service code 12) intake air pressure sensor #1 output voltage inspection • measure the output voltage at the intake air pressure sen- sor #1 in the same way as input voltage inspection, note the following. ○ disconnect the intake air pressure sen...

  • Page 141: Fuel System (Dfi) 3-51

    Fuel system (dfi) 3-51 intake air pressure sensor #1 (service code 12) if the wiring is good, check the sensor for various vacuum. • remove the intake air pressure sensor #1 [a] and discon- nect the vacuum hose from the sensor. • connect an auxiliary hose [b] to the intake air pressure sensor #1. • ...

  • Page 142: 3-52 Fuel System (Dfi)

    3-52 fuel system (dfi) intake air pressure sensor #1 (service code 12) id: idling ps: standard atmospheric pressure (absolute) pv: throttle vacuum pressure (absolute) st: standard of sensor output voltage (v) to: throttle full open ur: usable range of sensor output voltage (v) vv: intake air pressur...

  • Page 143: Fuel System (Dfi) 3-53

    Fuel system (dfi) 3-53 intake air pressure sensor #1 (service code 12) intake air pressure sensor #1 circuit 1. Ecu 2. Intake air pressure sensor #1.

  • Page 144: 3-54 Fuel System (Dfi)

    3-54 fuel system (dfi) intake air temperature sensor (service code 13) intake air temperature sensor removal/instal- lation notice never drop the intake air temperature sensor espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove the fuel tank (see fuel tank removal). • ...

  • Page 145: Fuel System (Dfi) 3-55

    Fuel system (dfi) 3-55 intake air temperature sensor (service code 13) • turn the ignition switch off. If the reading is within the standard, check the ecu for its ground, and power supply (see ecu power supply inspection). If the ground and power supply are good, replace the ecu (see ecu removal/in...

  • Page 146: 3-56 Fuel System (Dfi)

    3-56 fuel system (dfi) intake air temperature sensor (service code 13) intake air temperature sensor circuit 1. Ecu 2. Intake air temperature sensor.

  • Page 147: Fuel System (Dfi) 3-57

    Fuel system (dfi) 3-57 water temperature sensor (service code 14) water temperature sensor removal/installation notice never drop the water temperature sensor especially on a hard surface. Such a shock to the sensor can damage it. • drain the coolant (see coolant change in the periodic maintenance c...

  • Page 148: 3-58 Fuel System (Dfi)

    3-58 fuel system (dfi) water temperature sensor (service code 14) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main and sub harness connectors. ○ disconnect the ecu and sensor connectors. Wiring inspection ecu connector [a] ←→ sub harness connecto...

  • Page 149: Fuel System (Dfi) 3-59

    Fuel system (dfi) 3-59 intake air pressure sensor #2 (service code 16) intake air pressure sensor #2 removal notice never drop the intake air pressure sensor #2 espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove the air cleaner housing (see air cleaner housing removal...

  • Page 150: 3-60 Fuel System (Dfi)

    3-60 fuel system (dfi) intake air pressure sensor #2 (service code 16) intake air pressure sensor #2 input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the air cleaner housing (see air cleaner housing removal). • disconnect the intake air p...

  • Page 151: Fuel System (Dfi) 3-61

    Fuel system (dfi) 3-61 intake air pressure sensor #2 (service code 16) intake air pressure sensor #2 output voltage inspection • measure the output voltage at the intake air pressure sen- sor #2 in the same way as input voltage inspection, note the following. ○ disconnect the intake air pressure sen...

  • Page 152: 3-62 Fuel System (Dfi)

    3-62 fuel system (dfi) intake air pressure sensor #2 (service code 16) intake air pressure sensor #2 circuit 1. Ecu 2. Intake air pressure sensor #2.

  • Page 153: Fuel System (Dfi) 3-63

    Fuel system (dfi) 3-63 crankshaft sensor (service code 21) the crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no sig- nals. Crankshaft sensor removal/installation • refer to the crankshaft sensor removal/installation in the electrical system chapter...

  • Page 154: 3-64 Fuel System (Dfi)

    3-64 fuel system (dfi) speed sensor (service code 24, 25) speed sensor removal/installation • refer to the speed sensor removal/installation in the electrical system chapter. Speed sensor input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • disconne...

  • Page 155: Fuel System (Dfi) 3-65

    Fuel system (dfi) 3-65 speed sensor (service code 24, 25) speed sensor output voltage inspection • using the stand, raise the rear wheel off the ground. • measure the output voltage at the speed sensor in the same way as input voltage inspection, note the following. ○ disconnect the speed sensor con...

  • Page 156: 3-66 Fuel System (Dfi)

    3-66 fuel system (dfi) speed sensor (service code 24, 25) speed sensor circuit 1. Ecu 2. Speed sensor 3. Meter unit.

  • Page 157: Fuel System (Dfi) 3-67

    Fuel system (dfi) 3-67 vehicle-down sensor (service code 31) this sensor has a weight [a] with two magnets inside, and sends a signal to the ecu. But when the motorcycle banks 60 ∼ 70° or more to either side (in fact falls down), the weight turns and the signal changes. The ecu senses this change, a...

  • Page 158: 3-68 Fuel System (Dfi)

    3-68 fuel system (dfi) vehicle-down sensor (service code 31) vehicle-down sensor installation • be sure to install the rubber dampers [a] and collars [b] on the battery case. • the up mark [a] of the sensor should face upward. Warning incorrect installation of the vehicle-down sensor could cause sud...

  • Page 159: Fuel System (Dfi) 3-69

    Fuel system (dfi) 3-69 vehicle-down sensor (service code 31) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main harness connectors. ○ disconnect the ecu and sensor connections. Wiring inspection ecu connector [a] ←→ vehicle-down sensor connector [b...

  • Page 160: 3-70 Fuel System (Dfi)

    3-70 fuel system (dfi) vehicle-down sensor (service code 31) • hold the sensor vertically. • measure the output voltage with the engine stopped and with the connector joined. • turn the ignition switch on. • tilt the sensor 60 ∼ 70° or more [a] right or left, then hold the sensor almost vertical wit...

  • Page 161: Fuel System (Dfi) 3-71

    Fuel system (dfi) 3-71 vehicle-down sensor (service code 31) vehicle-down sensor circuit 1. Ecu 2. Vehicle-down sensor.

  • Page 162: 3-72 Fuel System (Dfi)

    3-72 fuel system (dfi) subthrottle sensor (service code 32) the subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ecu senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and...

  • Page 163: Fuel System (Dfi) 3-73

    Fuel system (dfi) 3-73 subthrottle sensor (service code 32) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main harness connectors. ○ disconnect the ecu and sensor connectors. Wiring inspection ecu connector [a] ←→ subthrottle sensor connector [b] b...

  • Page 164: 3-74 Fuel System (Dfi)

    3-74 fuel system (dfi) subthrottle sensor (service code 32) • measure the output voltage with the engine stopped with the connector joined. • turn the ignition switch on. • measure the output voltage when the subthrottle valve is completely closed by turning the lever [a] fully clockwise [b]. Output...

  • Page 165: Fuel System (Dfi) 3-75

    Fuel system (dfi) 3-75 subthrottle sensor (service code 32) subthrottle sensor resistance inspection • turn the ignition switch off. • disconnect the subthrottle sensor connector. ○ disconnect the subthrottle sensor connector and connect the harness adapter [a] to the sensor connector only. Special ...

  • Page 166: 3-76 Fuel System (Dfi)

    3-76 fuel system (dfi) oxygen sensor - not activated (service code 33, equipped models) oxygen sensor removal/installation • refer to the oxygen sensor removal/installation in the electrical system chapter. Oxygen sensor inspection • warm up the engine thoroughly until the radiator fan starts. • tur...

  • Page 167: Fuel System (Dfi) 3-77

    Fuel system (dfi) 3-77 oxygen sensor - not activated (service code 33, equipped models) • separate the air switching valve hoses [a] from the air suction valve covers. ○ do not disconnect the air switching valve connector [b]. • install the suitable plugs [a] on the fitting of the air suction valve ...

  • Page 168: 3-78 Fuel System (Dfi)

    3-78 fuel system (dfi) oxygen sensor - not activated (service code 33, equipped models) if the reading is out of the standard (with plugs: dc 0.7 v or more, without plugs: dc 0.2 v or less), remove the ecu and check the wiring for continuity between main harness connectors. ○ disconnect the ecu and ...

  • Page 169: Fuel System (Dfi) 3-79

    Fuel system (dfi) 3-79 exhaust butterfly valve actuator sensor (service code 34) exhaust butterfly valve actuator sensor removal/installation the exhaust butterfly valve actuator sensor is built in the exhaust butterfly valve actuator. So, the sensor itself can not be removed. Remove the exhaust but...

  • Page 170: 3-80 Fuel System (Dfi)

    3-80 fuel system (dfi) exhaust butterfly valve actuator sensor (service code 34) exhaust butterfly valve actuator sensor output voltage inspection note ○ before this inspection, confirm the pulley [a] is original position (see exhaust butterfly valve actuator installa- tion). • disconnect: 2 pins co...

  • Page 171: Fuel System (Dfi) 3-81

    Fuel system (dfi) 3-81 exhaust butterfly valve actuator sensor (service code 34) exhaust butterfly valve actuator sensor resistance inspection • turn the ignition switch off. • disconnect the exhaust butterfly valve actuator sensor connector (3 pins connector) [a]. • connect a digital meter [b] to t...

  • Page 172: 3-82 Fuel System (Dfi)

    3-82 fuel system (dfi) immobilizer amplifier (service code 35, equipped models) antenna resistance inspection • turn the ignition switch off. • remove the left center fairing (see center fairing re- moval in the frame chapter). • remove the band [a]. • disconnect the antenna lead connector [a]. • me...

  • Page 173: Fuel System (Dfi) 3-83

    Fuel system (dfi) 3-83 immobilizer amplifier (service code 35, equipped models) amplifier input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the left center fairing (see center fairing re- moval in the frame chapter). ○ do not disconnect th...

  • Page 174: 3-84 Fuel System (Dfi)

    3-84 fuel system (dfi) blank key detection (service code 36, equipped models) the master key exists in zr1000da/ea only. • this code appears in the following conditions. ○ the transponder [a] in the master and/or user key (ignition key) is malfunction. ○ when the spare key of unregistration is used....

  • Page 175: Fuel System (Dfi) 3-85

    Fuel system (dfi) 3-85 ecu communication error (service code 39) ecu communication line inspection ○ when the data is not sent from the ecu to the meter unit for more than about 10 seconds, the service code 39 is displayed. ○ the service code 39 is detected with meter unit. • remove the ecu and mete...

  • Page 176: 3-86 Fuel System (Dfi)

    3-86 fuel system (dfi) stick coils #1, #2, #3, #4 (service code 51, 52, 53, 54) stick coil #1: service code 51 stick coil #2: service code 52 stick coil #3: service code 53 stick coil #4: service code 54 stick coil removal/installation • refer to the stick coil removal/installation in the electri- c...

  • Page 177: Fuel System (Dfi) 3-87

    Fuel system (dfi) 3-87 stick coils #1, #2, #3, #4 (service code 51, 52, 53, 54) • turn the ignition switch off. If the input voltage is out of the standard, check the wiring for continuity (see wiring diagram in this section). If the wiring is good, check the ecu for its ground and power supply (see...

  • Page 178: 3-88 Fuel System (Dfi)

    3-88 fuel system (dfi) radiator fan relay (service code 56) radiator fan relay removal/installation ○ the radiator fan relay is built in the relay box [a]. • refer to the relay box removal in the electrical system chapter. Radiator fan relay inspection • refer to the relay circuit inspection in the ...

  • Page 179: Fuel System (Dfi) 3-89

    Fuel system (dfi) 3-89 subthrottle valve actuator (service code 62) subthrottle valve actuator removal notice do not remove the subthrottle valve actuator [a] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy especially on a hard surface. Such a shoc...

  • Page 180: 3-90 Fuel System (Dfi)

    3-90 fuel system (dfi) subthrottle valve actuator (service code 62) subthrottle valve actuator input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • disconnect the subthrottle valve actuator connector and connect the harness adapter [a] between these...

  • Page 181: Fuel System (Dfi) 3-91

    Fuel system (dfi) 3-91 subthrottle valve actuator (service code 62) subthrottle valve actuator circuit 1. Ecu 2. Subthrottle valve actuator.

  • Page 182: 3-92 Fuel System (Dfi)

    3-92 fuel system (dfi) exhaust butterfly valve actuator (service code 63) exhaust butterfly valve actuator removal notice never drop the exhaust butterfly valve actuator es- pecially on a hard surface. Such a shock to the ac- tuator can damage it. • remove: exhaust butterfly valve cables (see exhaus...

  • Page 183: Fuel System (Dfi) 3-93

    Fuel system (dfi) 3-93 exhaust butterfly valve actuator (service code 63) • after tightening the pulley bolt, confirm whether pulley [a] is an angle shown in the figure. 41.7° ±7° [b] ○ this position is original position of the pulley. Note ○ correct the position electrically after confirming the us...

  • Page 184: 3-94 Fuel System (Dfi)

    3-94 fuel system (dfi) exhaust butterfly valve actuator (service code 63) • be sure to install the washers [a] on the exhaust butterfly valve actuator [b]. • tighten: torque - exhaust butterfly valve actuator mounting screws [c]: 1.2 n ·m (0.12 kgf ·m, 11 in·lb) • install the close cable first and t...

  • Page 185: Fuel System (Dfi) 3-95

    Fuel system (dfi) 3-95 exhaust butterfly valve actuator (service code 63) if the reading is in specification, remove the ecu and check the wiring for continuity between main harness con- nectors. ○ disconnect the ecu and actuator connectors. Wiring inspection ecu connector [a] ←→ exhaust butterfly v...

  • Page 186: 3-96 Fuel System (Dfi)

    3-96 fuel system (dfi) air switching valve (service code 64) air switching valve removal/installation • refer to the air switching valve removal/installation in the engine top end chapter. Air switching valve inspection • refer to the air switching valve unit test in the electrical system chapter. I...

  • Page 187: Fuel System (Dfi) 3-97

    Fuel system (dfi) 3-97 oxygen sensor heater (service code 67, equipped models) oxygen sensor heater removal/installation the oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see oxygen sensor removal (equipped mod- els) in the ...

  • Page 188: 3-98 Fuel System (Dfi)

    3-98 fuel system (dfi) oxygen sensor heater (service code 67, equipped models) oxygen sensor heater power source voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • disconnect the oxygen sensor lead connector and con- nect the harness adapter [a] between...

  • Page 189: Fuel System (Dfi) 3-99

    Fuel system (dfi) 3-99 oxygen sensor heater (service code 67, equipped models) oxygen sensor circuit 1. Ecu 2. Frame ground 3. Meter ground 4. Oxygen sensor 5. Ignition switch 6. Relay box 7. Ecu main relay 8. Starter relay 9. Fi fuse 15 a 10. Main fuse 30 a 11. Battery 12 v 8 ah 12. Water-proof joi...

  • Page 190: 3-100 Fuel System (Dfi)

    3-100 fuel system (dfi) oxygen sensor - incorrect output voltage (service code 94, equipped models) oxygen sensor removal/installation • refer to the oxygen sensor removal/installation in the electrical system chapter. Oxygen sensor inspection • warm up the engine thoroughly until the radiator fan s...

  • Page 191: Fuel System (Dfi) 3-101

    Fuel system (dfi) 3-101 oxygen sensor - incorrect output voltage (service code 94, equipped models) • separate the air switching valve hoses [a] from the air suction valve covers. ○ do not disconnect the air switching valve connector [b]. • install the suitable plugs [a] on the fitting of the air su...

  • Page 192: 3-102 Fuel System (Dfi)

    3-102 fuel system (dfi) oxygen sensor - incorrect output voltage (service code 94, equipped models) if the reading is out of the standard (with plugs: dc 0.7 v or more, without plugs: dc 0.2 v or less), check the following. Fuel pressure (see fuel pressure inspection) fuel injector (see fuel injecto...

  • Page 193: Fuel System (Dfi) 3-103

    Fuel system (dfi) 3-103 warning indicator light (led) light (led) inspection ○ the warning indicator light (led) [a] is used for the fi indicator, immobilizer indicator (immobilizer models) and oil pressure warning indicator. ○ in this model, the warning indicator light (led) (fi/immo- bilizer) blin...

  • Page 194: 3-104 Fuel System (Dfi)

    3-104 fuel system (dfi) ecu ecu identification ○ most countries have their own regulations, so each ecu has different characteristic. So, do not confuse ecu with each other and use only the ecu for your model. Other- wise, the motorcycle cannot clear the regulation. Ecu identification model part num...

  • Page 195: Fuel System (Dfi) 3-105

    Fuel system (dfi) 3-105 ecu • remove: relay box (see relay box removal in the electrical sys- tem chapter) ecu connectors [a] ecu [b] ecu installation • connect the ecu connectors [a]. • install the ecu [b] into the rubber protector [c]. • insert the slits of the rubber protector to the projections ...

  • Page 196: 3-106 Fuel System (Dfi)

    3-106 fuel system (dfi) ecu if the wiring is good, check the power source voltage of the ecu. Note ○ be sure the battery is fully charged. • connect the ecu and relay box connectors. • connect a digital meter [a] to the connectors [b] with the needle adapter set. Special tool - needle adapter set: 5...

  • Page 197: Fuel System (Dfi) 3-107

    Fuel system (dfi) 3-107 ecu ecu power source circuit 1. Ecu 2. Frame ground 3. Meter ground 4. Ignition switch 5. Relay box 6. Ecu main relay 7. Starter relay 8. Fi fuse 15 a 9. Main fuse 30 a 10. Battery 12 v 8 ah 11. Water-proof joint c.

  • Page 198: 3-108 Fuel System (Dfi)

    3-108 fuel system (dfi) dfi power source ecu fuse removal • refer to the 15 a fi fuse removal in the electrical sys- tem chapter. 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 ...

  • Page 199: Fuel System (Dfi) 3-109

    Fuel system (dfi) 3-109 fuel line fuel pressure inspection note ○ be sure the battery is fully charged. • remove: fuel tank (see fuel tank removal) fuel hose (see fuel tank removal) ○ be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of the throttle...

  • Page 200: 3-110 Fuel System (Dfi)

    3-110 fuel system (dfi) fuel line • start the engine, and let it idle. • measure the fuel pressure with the engine idling. Fuel pressure (with engine idling) standard: 294 kpa (3.0 kgf/cm², 43 psi) note ○ the gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum in...

  • Page 201: Fuel System (Dfi) 3-111

    Fuel system (dfi) 3-111 fuel line • open the fuel tank cap [a] to lower the pressure in the tank. • remove the fuel hose from the fuel pump (see fuel tank removal). ○ be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump. Warning fuel is flammable and explosive under certain...

  • Page 202: 3-112 Fuel System (Dfi)

    3-112 fuel system (dfi) fuel pump fuel pump removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a...

  • Page 203: Fuel System (Dfi) 3-113

    Fuel system (dfi) 3-113 fuel pump fuel pump installation • remove dirt or dust from the fuel pump [a] by lightly ap- plying compressed air. • replace the fuel pump gasket with a new one. • check that the fuel pump terminal [a] and band [b] are in place. • apply a non-permanent locking agent to the t...

  • Page 204: 3-114 Fuel System (Dfi)

    3-114 fuel system (dfi) fuel pump fuel pump operating voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the front seat (see front seat removal in the frame chapter). • disconnect the fuel pump lead connector and connect the harness adapter [a] b...

  • Page 205: Fuel System (Dfi) 3-115

    Fuel system (dfi) 3-115 fuel pump pump screen, fuel filter cleaning ○ the pump screen [a] and fuel filter [b] are built into the pump and can not be cleaned or checked. If the pump screen or fuel filter is suspected of clogging or being damaged, replace it with the fuel pump as a set. Fuel pump rela...

  • Page 206: 3-116 Fuel System (Dfi)

    3-116 fuel system (dfi) fuel pump fuel pump circuit 1. Ecu 2. Frame ground 3. Meter ground 4. Engine stop switch 5. Fuel pump/fuel level sensor 6. Fuse box 7. Ignition fuse 15 a 8. Ignition switch 9. Meter unit 10. Relay box 11. Ecu main relay 12. Fuel pump relay 13. Starter relay 14. Fi fuse 15 a 1...

  • Page 207: Fuel System (Dfi) 3-117

    Fuel system (dfi) 3-117 fuel injectors fuel injector removal/installation • refer to the throttle body assy disassembly/assembly. Fuel injector audible inspection note ○ be sure the battery is fully charged. • start the engine, and let it idle. • apply the tip of a screwdriver [a] to the fuel inject...

  • Page 208: 3-118 Fuel System (Dfi)

    3-118 fuel system (dfi) fuel injectors fuel injector power source voltage inspection note ○ be sure the battery is fully charged. • remove the air cleaner housing (see air cleaner housing removal). • turn the ignition switch off. • disconnect the injector connector and connect the har- ness adapter ...

  • Page 209: Fuel System (Dfi) 3-119

    Fuel system (dfi) 3-119 fuel injectors fuel injector output voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the ecu (see ecu removal). ○ do not disconnect the ecu connector. ○ connect the relay box connectors. • connect a digital meter [a] to ...

  • Page 210: 3-120 Fuel System (Dfi)

    3-120 fuel system (dfi) fuel injectors fuel injector fuel line inspection • remove: fuel tank (see fuel tank removal) fuel hose (see fuel tank removal) ○ be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of the throttle body assy. Warning fuel is fl...

  • Page 211: Fuel System (Dfi) 3-121

    Fuel system (dfi) 3-121 fuel injectors fuel injector circuit 1. Ecu 2. Frame ground 3. Meter ground 4. Fuel injectors 5. Engine stop switch 6. Fuse box 7. Ignition fuse 15 a 8. Ignition switch 9. Meter unit 10. Ecu main relay 11. Fuel pump relay 12. Starter relay 13. Fi fuse 15 a 14. Main fuse 30 a ...

  • Page 212: 3-122 Fuel System (Dfi)

    3-122 fuel system (dfi) throttle grip and cables free play inspection • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Free play adjustment • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Cable installation • install th...

  • Page 213: Fuel System (Dfi) 3-123

    Fuel system (dfi) 3-123 throttle body assy idle speed inspection/adjustment • refer to the idle speed inspection/adjustment in the pe- riodic maintenance chapter. Synchronization inspection/adjustment • refer to the engine vacuum synchronization inspection in the periodic maintenance chapter. Thrott...

  • Page 214: 3-124 Fuel System (Dfi)

    3-124 fuel system (dfi) throttle body assy • slide the dust covers [a]. • loosen the locknuts [b]. • turn the adjusters [c] to give the more free play. • remove: bolts [a] throttle pulley cover [b] • remove: throttle cable holder clamp [a] throttle cable lower ends [b] • loosen the throttle body ass...

  • Page 215: Fuel System (Dfi) 3-125

    Fuel system (dfi) 3-125 throttle body assy • remove the throttle body assy [a] from the throttle body assy holders. • disconnect the injector connectors [b]. • remove the clamps [c]. • after removing the throttle body assy, stuff pieces of lint -free, clean cloth into the throttle body assy holders....

  • Page 216: 3-126 Fuel System (Dfi)

    3-126 fuel system (dfi) throttle body assy throttle body assy disassembly 1. Subthrottle valve actuator 2. Subthrottle sensor 3. Main throttle sensor 4. Throttle body assy 5. Fuel injectors 6. Delivery pipe assy notice do not remove, disassemble or adjust the main throttle sensor, subthrottle sensor...

  • Page 217: Fuel System (Dfi) 3-127

    Fuel system (dfi) 3-127 throttle body assy • pull out the fuel injectors [a] from the delivery pipe assy [b]. Note ○ do not damage the insertion portions of the injectors when they are pulled out from the delivery pipe assy. Notice never drop the primary fuel injector, especially on a hard surface. ...

  • Page 218: 3-128 Fuel System (Dfi)

    3-128 fuel system (dfi) air cleaner air cleaner element removal/installation • refer to the air cleaner element replacement in the pe- riodic maintenance chapter. Air cleaner element inspection • remove the air cleaner element (see air cleaner element replacement in the periodic maintenance chapter)...

  • Page 219: Fuel System (Dfi) 3-129

    Fuel system (dfi) 3-129 air cleaner • loosen the both air cleaner duct clamp bolts [a]. • lift up the air cleaner housing, and remove the air switch- ing valve hose [a]. • after removing the air cleaner housing, cover the clean cloth on the throttle body assy. Warning if dirt or dust is allowed to p...

  • Page 220: 3-130 Fuel System (Dfi)

    3-130 fuel system (dfi) fuel tank fuel tank removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a...

  • Page 221: Fuel System (Dfi) 3-131

    Fuel system (dfi) 3-131 fuel tank • open the fuel tank cap [a] to lower the pressure in the tank. ○ during tank removal, keep the tank cap open to release pressure in the tank. This makes fuel spillage less. • draw the fuel out from the fuel tank with a commercially available pump [a]. ○ use a soft ...

  • Page 222: 3-132 Fuel System (Dfi)

    3-132 fuel system (dfi) fuel tank • wipe off the dirt of the surface [a] around the connection using a cloth or a soft brush. When removing with standard tip screwdriver • insert the standard tip screwdriver [a] into slit on the joint lock [b]. • turn the driver to disconnect the joint lock. When re...

  • Page 223: Fuel System (Dfi) 3-133

    Fuel system (dfi) 3-133 fuel tank • for the cal, sea-b1 and th models, remove the follow- ing. Fuel return hose [a] (red) fuel tank breather hose [b] (blue) rear fuel tank bolt [c] • remove the fuel tank, and place a it on a flat surface. ○ do not apply the load to the fuel pipe of the fuel pump. • ...

  • Page 224: 3-134 Fuel System (Dfi)

    3-134 fuel system (dfi) fuel tank fuel tank installation • note the above warning (see fuel tank removal). • run the hoses correctly (see cable, wire, and hose rout- ing section in the appendix chapter). • check that the dampers [a], pad [b] and trims [c] are in place on the frame and the fuel tank....

  • Page 225: Fuel System (Dfi) 3-135

    Fuel system (dfi) 3-135 fuel tank • insert the fuel hose joint [a] straight onto the fuel outlet pipe until the hose joint clicks. • push [b] the joint lock [c] until the hose joint clicks. • push and pull [a] the hose joint [b] back and forth more than two times, and make sure it is locked and does...

  • Page 226: 3-136 Fuel System (Dfi)

    3-136 fuel system (dfi) fuel tank fuel tank cleaning warning gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the tank in a well-ventilated area, and take care that there are no sparks or flame any- where near the working area. Do not use gasoline...

  • Page 227: Fuel System (Dfi) 3-137

    Fuel system (dfi) 3-137 evaporative emission control system (cal, sea-b1 and th models) the evaporative emission control system routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a t...

  • Page 228: 3-138 Fuel System (Dfi)

    3-138 fuel system (dfi) evaporative emission control system (cal, sea-b1 and th models) 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 an...

  • Page 229: Fuel System (Dfi) 3-139

    Fuel system (dfi) 3-139 evaporative emission control system (cal, sea-b1 and th models) 1. Fuel tank 2. Green hose (purge) 3. Clamps 4. White hose (vacuum) 5. Blue hose (breather) 6. Canister 7. Blue hose (breather) 8. Separator 9. Damper (for separator) 10. Bracket (for separator) 11. Red hose (ret...

  • Page 231: Cooling System 4-1

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

  • Page 232: 4-2 Cooling System

    4-2 cooling system exploded view.

  • Page 233: Cooling System 4-3

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 coolant by-pass fitting bolt 8.8 0.90 78 in·lb l 2 coolant drain bolt 11 1.1 97 in·lb 3 radiator (water) hose clamp screws 2.9 0.30 26 in·lb 4 thermostat housing bolts 5.9 0.60 52 in·lb l 5 water pipe bolts 12 1.2 106 in·...

  • Page 234: 4-4 Cooling System

    4-4 cooling system coolant flow chart 1. Radiator cap 2. Radiator fan 3. Radiator 4. Oil cooler 5. Cylinder head jacket 6. Cylinder jacket 7. Inlet pipe 8. Water pump 9. Outlet pipe 10. Water temperature sensor 11. Thermostat housing 12. Reserve tank overflow hose 13. Reserve tank 14. Hot coolant 15...

  • Page 235: Cooling System 4-5

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

  • Page 236: 4-6 Cooling System

    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 237: Cooling System 4-7

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

  • Page 238: 4-8 Cooling System

    4-8 cooling system coolant coolant deterioration inspection • remove the right center fairing (see center fairing re- moval in the frame chapter). • visually inspect the coolant [a] in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If ...

  • Page 239: Cooling System 4-9

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

  • Page 240: 4-10 Cooling System

    4-10 cooling system water pump water pump removal • drain: coolant (see coolant change in the periodic mainte- nance chapter) engine oil (see engine oil change in the periodic main- tenance chapter) • remove the engine sprocket cover (see engine sprocket cover removal in the final drive chapter). • ...

  • Page 241: Cooling System 4-11

    Cooling system 4-11 water pump • be sure to install the dowel pins [a]. • install: water pump housing [a] water pump impeller [b] • tighten: torque - water pump impeller bolt [c]: 9.8 n·m (1.0 kgf·m, 87 in·lb) • be sure to install the dowel pins [d]. • replace the o-ring [a] with a new one, and inst...

  • Page 242: 4-12 Cooling System

    4-12 cooling system water pump water pump inspection • remove the left lower fairing (see lower fairing removal in the frame chapter). • check the drainage outlet passage [a] at the bottom of the water pump body for coolant leaks. If the mechanical seal is damaged, the coolant leaks through the seal...

  • Page 243: Cooling System 4-13

    Cooling system 4-13 water pump • take the oil seal [a] out of the housing [b] with a hook [c]. Water pump housing assembly notice do not reuse the mechanical seal and oil seal. • apply high-temperature grease to the oil seal lips [a]. • press the new oil seal into the housing with a bearing driver [...

  • Page 244: 4-14 Cooling System

    4-14 cooling system radiator radiator and radiator fan removal • remove: center fairings (see center fairing removal in the frame chapter) coolant (drain, see coolant change in the periodic maintenance chapter) • remove: radiator hose clamp [a] radiator cap mounting bolt [b] radiator hose [c] • remo...

  • Page 245: Cooling System 4-15

    Cooling system 4-15 radiator • slide the connector cover [a] to disconnect the radiator fan motor lead connector [b]. • remove: radiator hose clamp screw [a] (loosen) radiator hose [b] radiator lower bolt [c] notice do not touch the radiator core. This could damage the radiator fins, resulting in lo...

  • Page 246: 4-16 Cooling System

    4-16 cooling system radiator radiator and radiator fan installation • installation is the reverse of removal. • install the rubber dampers [a] and radiator bracket collars [b] as shown in the figure. [c] larger [d] smaller • fit the slits [a] of the heat insulation rubber plate to the up- per mounti...

  • Page 247: Cooling System 4-17

    Cooling system 4-17 radiator notice when cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage: keep the steam gun [a] away more than 0.5 m (1.6 ft) [b] from the radiator core. Hold the steam gun perpendicular [c] (not oblique [d]) to the core surface. Run ...

  • Page 248: 4-18 Cooling System

    4-18 cooling system thermostat thermostat removal • remove: coolant (drain, see coolant change in the periodic maintenance chapter) engine sprocket cover (see engine sprocket removal in the final drive chapter) harness holder clamp [a] water hose clamp [b] water hose [c] water pipe bolts [d] water p...

  • Page 249: Cooling System 4-19

    Cooling system 4-19 thermostat • replace the o-ring [a] with a new one. • apply grease to the o-ring, and install it. • install the thermostat housing cover. Note ○ note that the thermostat does not move at the place when installing the thermostat housing cover. • tighten: torque - thermostat housin...

  • Page 250: 4-20 Cooling System

    4-20 cooling system hose and pipes hose installation • install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • run the hoses (see cable, wire, and hose routing sec- tion in the appendix chapter). • install the clamp [a] as nea...

  • Page 251: Cooling System 4-21

    Cooling system 4-21 water temperature sensor notice the water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it. Water temperature sensor removal/installation • refer to the water temperature sensor removal/instal- lati...

  • Page 253: Engine Top End 5-1

    Engine top end 5-1 5 engine top end table of contents exploded view................................... 5-2 exhaust system identification ........... 5-6 specifications .................................... 5-9 special tools and sealant ................. 5-11 clean air system.............................

  • Page 254: 5-2 Engine Top End

    5-2 engine top end exploded view.

  • Page 255: Engine Top End 5-3

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air suction valve cover bolts 9.8 1.0 87 in·lb l 2 camshaft cap bolts 12 1.2 106 in·lb s 3 camshaft chain tensioner cap bolt 20 2.0 15 4 camshaft chain tensioner mounting bolts 11 1.1 97 in·lb 5 camshaft sprocket bolts 15...

  • Page 256: 5-4 Engine Top End

    5-4 engine top end exploded view.

  • Page 257: Engine Top End 5-5

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 exhaust butterfly valve actuator bolts 4.3 0.44 38 in·lb 2 exhaust butterfly valve actuator pulley bolt 5.0 0.51 44 in·lb 3 muffler body mounting bolts 34 3.5 25 4 premuffler chamber mounting bolt 34 3.5 25 5 muffler body...

  • Page 258: 5-6 Engine Top End

    5-6 engine top end exhaust system identification.

  • Page 259: Engine Top End 5-7

    Engine top end 5-7 exhaust system identification exhaust pipe mark position [a] left muffler body mark position [a] right muffler body mark position [a].

  • Page 260: 5-8 Engine Top End

    5-8 engine top end exhaust system identification exhaust pipe [a] with hole [b] for oxygen sensor [c] (equipped models) honeycomb type catalyst positions [a].

  • Page 261: Engine Top End 5-9

    Engine top end 5-9 specifications item standard service limit camshafts cam height: exhaust 33.743 ∼ 33.857 mm (1.3285 ∼ 1.3330 in.) 33.64 mm (1.324 in.) intake 34.743 ∼ 34.857 mm (1.3678 ∼ 1.3723 in.) 34.64 mm (1.364 in.) camshaft journal, camshaft cap clearance 0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in...

  • Page 262: 5-10 Engine Top End

    5-10 engine top end specifications item standard service limit cylinder, pistons cylinder inside diameter 76.994 ∼ 77.006 mm (3.0313 ∼ 3.0317 in.) 77.09 mm (3.035 in.) piston diameter 76.974 ∼ 76.984 mm (3.0305 ∼ 3.0309 in.) 76.82 mm (3.024 in.) piston/cylinder clearance 0.010 ∼ 0.032 mm (0.0004 ∼ 0...

  • Page 263: Engine Top End 5-11

    Engine top end 5-11 special tools and sealant compression gauge, 20 kgf/cm²: 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 sea...

  • Page 264: 5-12 Engine Top End

    5-12 engine top end special tools and sealant valve guide reamer, 4.5: 57001-1333 valve seat cutter, 60° - 33: 57001-1334 valve seat cutter, 60° - 27: 57001-1409 engine mount nut wrench: 57001-1450 valve guide driver: 57001-1564 valve spring compressor adapter, 24: 57001-1586 compression gauge adapt...

  • Page 265: Engine Top End 5-13

    Engine top end 5-13 clean air system air suction valve removal • remove: left center fairing (see center fairing removal in the frame chapter) air switching valve (see air switching valve removal) connector [a] (from bracket [b] at left side) air suction valve cover bolts [c] and bracket air suction...

  • Page 266: 5-14 Engine Top End

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

  • Page 267: Engine Top End 5-15

    Engine top end 5-15 clean air system air switching valve installation • install the air switching valve [a] as shown in the figure. [b] viewed left side [c] about 40° air switching valve operation test • refer to the air suction system damage inspection in the periodic maintenance chapter. Air switc...

  • Page 268: 5-16 Engine Top End

    5-16 engine top end cylinder head cover cylinder head cover removal • remove: right center fairing (see center fairing removal in the frame chapter) radiator cap mounting bolt [a] • remove: throttle pulley cover bolts [a] throttle pulley cover [b] • remove: air suction valve (see air suction valve r...

  • Page 269: Engine Top End 5-17

    Engine top end 5-17 cylinder head cover • using a cleaning fluid, clean off any oil or dirt on the cylin- der head [a] as shown and dry them with a clean cloth. • apply liquid gasket to the cylinder head as shown. Sealant - liquid gasket, tb1216b: 92104-1064 note ○ make the application finish within...

  • Page 270: 5-18 Engine Top End

    5-18 engine top end camshaft chain tensioner camshaft chain tensioner removal notice this is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below. When removing the tens...

  • Page 271: Engine Top End 5-19

    Engine top end 5-19 camshaft, camshaft chain camshaft removal • remove: cylinder head cover (see cylinder head cover re- moval) crankshaft sensor cover (see crankshaft sensor re- moval in the electrical system chapter) • turn the crankshaft clockwise, align the #1, 4 mark on the timing rotor with th...

  • Page 272: 5-20 Engine Top End

    5-20 engine top end camshaft, camshaft chain camshaft installation note ○ the crankshaft, camshaft chain and camshaft sprock- ets are different between the early production models (engine number: ∼ zrt00de016592), the late produc- tion models (engine number: zrt00de016593 ∼ ) and zr1000dd/ed. ○ do n...

  • Page 273: Engine Top End 5-21

    Engine top end 5-21 camshaft, camshaft chain • using a wrench on the timing rotor bolt [a], turn the crank- shaft clockwise until the line [b] (tdc mark for #1,4 pis- tons) on the timing rotor is aligned with the timing mark [c] (crankcase halves mating surface). Notice the crankshaft may be turned ...

  • Page 274: 5-22 Engine Top End

    5-22 engine top end camshaft, camshaft chain ○ the timing marks must be aligned with the cylinder head upper surface [b] (engine number: zrt00de016593 ∼ ). Ex mark [c] in mark [d] #1 pin [e] #2 pin [f] #29 pin [g] #30 pin [h].

  • Page 275: Engine Top End 5-23

    Engine top end 5-23 camshaft, camshaft chain • before installing the camshaft caps and upper chain guide, install the camshaft chain tensioner body tem- porarily (see camshaft chain tensioner installation). • install the camshaft caps and upper camshaft chain guide [a] as shown in the figure. Identi...

  • Page 276: 5-24 Engine Top End

    5-24 engine top end camshaft, camshaft chain camshaft, camshaft cap wear inspection • remove: upper chain guide (see camshaft removal) camshaft caps (see camshaft removal) • cut strips of plastigage (press gauge) to journal width. Place a strip on each journal parallel to the camshaft in- stalled in...

  • Page 277: Engine Top End 5-25

    Engine top end 5-25 camshaft, camshaft chain camshaft chain removal • split the crankcase (see crankcase splitting in the crank- shaft/transmission chapter). • remove the camshaft chain [a] from the crankshaft sprocket. Camshaft chain installation note ○ the crankshaft, camshaft chain and camshaft s...

  • Page 278: 5-26 Engine Top End

    5-26 engine top end cylinder head cylinder compression measurement note ○ use the battery which is fully charged. • warm up the engine thoroughly. • stop the engine. • remove: stick coils (see stick coil removal in the electrical sys- tem chapter) spark plugs (see spark plug replacement in the peri-...

  • Page 279: Engine Top End 5-27

    Engine top end 5-27 cylinder head cylinder head removal • remove: coolant (drain, see coolant change in the periodic maintenance chapter) camshafts (see camshaft removal) throttle body assy (see throttle body assy removal in the fuel system (dfi) chapter) exhaust pipe (see exhaust pipe removal) • di...

  • Page 280: 5-28 Engine Top End

    5-28 engine top end cylinder head • replace the cylinder head gasket [a] with a new one. • install the dowel pins [b] and cylinder head gasket. • replace the cylinder head bolt washers [a] with new ones. • apply molybdenum disulfide oil solution to both sides [b] of the cylinder head bolt washers an...

  • Page 281: Engine Top End 5-29

    Engine top end 5-29 cylinder head • install: front camshaft chain guide [a] rear camshaft chain guide [b] new o-rings [c] collar [d] ○ apply grease to the new o-ring. • tighten: torque - front camshaft chain guide bolt (upper) [e]: 25 n·m (2.5 kgf·m, 18 ft·lb) front camshaft chain guide bolt (lower)...

  • Page 282: 5-30 Engine Top End

    5-30 engine top end valves valve clearance inspection • refer to the valve clearance inspection in the periodic maintenance chapter. Valve clearance adjustment • refer to the valve clearance adjustment in the periodic maintenance chapter. Valve removal • remove: cylinder head (see cylinder head remo...

  • Page 283: Engine Top End 5-31

    Engine top end 5-31 valves valve guide installation • apply oil to the valve guide outer surface before installa- tion. • heat the area around the valve guide hole to about 120 ∼ 150°c (248 ∼ 302°f). Notice do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylind...

  • Page 284: 5-32 Engine Top End

    5-32 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 285: Engine Top End 5-33

    Engine top end 5-33 valves seat cutter operation care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. 3. Do not fai...

  • Page 286: 5-34 Engine Top End

    5-34 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 287: Engine Top End 5-35

    Engine top end 5-35 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 288: 5-36 Engine Top End

    5-36 engine top end valves.

  • Page 289: Engine Top End 5-37

    Engine top end 5-37 cylinder, pistons cylinder removal • remove: lower radiator bolt [a] radiator bracket bolt [b] radiator bracket [c] cylinder head (see cylinder head removal) engine bracket (see engine removal in the engine re- moval/installation chapter) • remove: water hose clamp screw (loosen)...

  • Page 290: 5-38 Engine Top End

    5-38 engine top end cylinder, pistons • the piston ring openings must be positioned as shown in the figure. The openings of the oil ring steel rails must be about 30 ∼ 40° of angle from the opening of the top ring. Top ring [a] second ring [b] upper oil ring steel rail [c] oil ring expander [d] lowe...

  • Page 291: Engine Top End 5-39

    Engine top end 5-39 cylinder, pistons piston installation • apply molybdenum disulfide oil solution to the oil ring ex- pander, and install the oil ring expander [a] in the bottom piston ring groove so the ends [b] not butt together. • apply molybdenum disulfide oil solution to the oil ring steel ra...

  • Page 292: 5-40 Engine Top End

    5-40 engine top end cylinder, pistons piston wear inspection • measure the outside diameter [a] of each piston 11 mm (0.43 in.) [b] up from the bottom of the piston at a right angle to the direction of the piston pin. If the measurement is under service limit, replace the pis- ton. Piston diameter s...

  • Page 293: Engine Top End 5-41

    Engine top end 5-41 cylinder, pistons piston ring thickness inspection • measure the piston ring thickness. ○ use the micrometer to measure at several points around the ring. Piston ring thickness standard: top [a] 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) second [b] 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) ...

  • Page 294: 5-42 Engine Top End

    5-42 engine top end throttle body assy holder throttle body assy holder removal • remove: throttle body assy (see throttle body assy removal in the fuel system (dfi) chapter) clamps [a] bolts [b] throttle body assy holders [c] throttle body assy holder installation • replace the o-rings [a] with new...

  • Page 295: Engine Top End 5-43

    Engine top end 5-43 muffler warning the exhaust pipe or muffler body can become ex- tremely hot during normal operation and cause se- vere burns. Do not remove the exhaust pipe or muf- fler body while it is hot. Muffler body removal left muffler body • loosen the muffler body clamp bolt [a]. • remov...

  • Page 296: 5-44 Engine Top End

    5-44 engine top end muffler • remove: clamp bolt [a] (loosen) right muffler body mounting bolt [b] and nut right muffler body [c] (with the cable installed) • remove: bolts [a] exhaust butterfly valve pulley cover [b] • loosen the locknuts [a]. • remove the cable lower ends [b]. Muffler body install...

  • Page 297: Engine Top End 5-45

    Engine top end 5-45 muffler • thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts and nuts. • install the removed parts (see appropriate chapters). ○ when installing, run the cables correctly (see cable, wire, and hose routing section in the appendix chapter)..

  • Page 298: 5-46 Engine Top End

    5-46 engine top end muffler exhaust pipe removal • remove: muffler bodies (see muffler body removal) oxygen sensor (see oxygen sensor removal (equipped models) in the electrical system chap- ter) • support the premuffler chamber with the suitable stand [a]. • loosen the premuffler chamber mounting b...

  • Page 299: Engine Top End 5-47

    Engine top end 5-47 muffler • remove: clamp [a] exhaust butterfly valve cable upper ends [b] exhaust butterfly valve cables [c] exhaust butterfly valve cable installation • confirm whether pulley [a] is an angle as shown in the figure. 41.7° ±7° [b] ○ this position is original position of the pulley...

  • Page 300: 5-48 Engine Top End

    5-48 engine top end muffler • install the upper ends of the exhaust butterfly valve ca- bles to the pulley of the exhaust butterfly valve actuator, following the specified installing sequence. ○ first, install the close cable (black) [a]. ○ second, install the open cable (white) [b]. ○ third, stretc...

  • Page 301: Clutch 6-1

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

  • Page 302: 6-2 Clutch

    6-2 clutch exploded view.

  • Page 303: Clutch 6-3

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 clutch lever assembly clamp bolts 7.8 0.80 69 in·lb s 2 clutch spring bolts 8.8 0.90 78 in·lb 3 clutch cover bolts 9.8 1.0 87 in·lb 4 clutch hub nut 135 13.8 99.6 r 5 oil filler plug 2.0 0.20 18 in·lb cl: apply cable lubricant. E...

  • Page 304: 6-4 Clutch

    6-4 clutch specifications item standard service limit clutch lever free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – clutch clutch plate assembly length 51.1 ∼ 51.7 mm (2.01 ∼ 2.04 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 0.15 m...

  • Page 305: Clutch 6-5

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

  • Page 306: 6-6 Clutch

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

  • Page 307: Clutch 6-7

    Clutch 6-7 clutch cover clutch cover removal • remove: rear lower fairing (see rear lower fairing removal in the frame chapter) engine oil (drain, see engine oil change in the periodic maintenance chapter) clutch cable lower end clutch cover mounting bolts [a] • turn the release lever [a] toward the...

  • Page 308: 6-8 Clutch

    6-8 clutch clutch cover • fit the spring [a] as shown in the figure. Viewed from rear [b] release shaft [c] clutch cover [d] clutch cover disassembly • remove: clutch cover (see clutch cover removal) release lever and shaft assembly (see release shaft removal) oil filler plug [a] oil seal [b] needle...

  • Page 309: Clutch 6-9

    Clutch 6-9 clutch cover • replace the o-ring [a] of the oil filler plug [b] with a new one. • apply grease to the o-ring. • tighten: torque - oil filler plug: 2.0 n·m (0.20 kgf·m, 18 in·lb).

  • Page 310: 6-10 Clutch

    6-10 clutch clutch clutch removal • remove: clutch cover (see clutch cover removal) clutch spring bolts [a] clutch springs clutch spring plate [b] (with washer, needle bearing and pusher [c]) • remove: friction plates and steel plates spring and spring seat note ○ the two plates at both ends are dif...

  • Page 311: Clutch 6-11

    Clutch 6-11 clutch • install the clutch housing [a] to the drive shaft. • while holding the clutch housing, install the needle bear- ing [b] and sleeve [c]. ○ the holes [d] of the sleeve face outward. • install the following parts to the drive shaft. Spacer ( 47 × 25.5) [a] clutch hub • install the ...

  • Page 312: 6-12 Clutch

    6-12 clutch clutch • install the friction plates and steel plates, starting with a friction plate and alternating them. Note ○ install the both ends marked two friction plates at dis- assembled to the their original position. ○ when replace the friction plates with new ones, mark the both end two fr...

  • Page 313: Clutch 6-13

    Clutch 6-13 clutch clutch plate assembly inspection • inspect the friction plate thickness (see clutch plate, wear, damage inspection). • measure the length [a] of the clutch plate assembly as shown in the figure. ○ assemble: clutch hub [b] spring seat [c] spring [d] friction plates [e] steel plates...

  • Page 314: 6-14 Clutch

    6-14 clutch clutch clutch plate, wear, damage inspection • visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. • measure the thickness of each friction plate [a] at several points. If any plates show signs of damage, or if they have worn ...

  • Page 315: Engine Lubrication System

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

  • Page 316

    7-2 engine lubrication system exploded view.

  • Page 317

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine oil drain bolt 29 3.0 21 2 lower fairing bracket bolts 12 1.2 106 in·lb 3 oil cooler bolts 12 1.2 106 in·lb 4 oil filler plug 2.0 0.20 18 in·lb 5 oil filter 17 1.7 13 g, r 6 oil filter pipe 25 2.5 18 l 7...

  • Page 318

    7-4 engine lubrication system engine oil flow chart 1. Oil screen 2. Oil pump 3. Output shaft oil passage 4. Drive shaft oil passage 5. Crankshaft oil passage 6. Oil pipe 7. Camshaft oil passage 8. Balancer oil passage 9. Oil pressure switch 10. Main oil passage 11. Oil cooler 12. Oil filter 13. Oil...

  • Page 319

    Engine lubrication system 7-5 specifications item standard engine oil type api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity sae 10w-40 capacity: 3.2 l (3.4 us gt) (when filter is not removed) 3.8 l (4.0 us gt) (when filter is removed) 4.0 l (4.2 us gt) (when engine is completely dry) leve...

  • Page 320

    7-6 engine lubrication system special tools and sealants outside circlip pliers: 57001-144 oil pressure gauge, 10 kgf/cm²: 57001-164 oil pressure gauge adapter, pt3/8: 57001-1233 liquid gasket, tb1211: 56019-120 liquid gasket, tb1207b: 92104-2068.

  • Page 321

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

  • Page 322

    7-8 engine lubrication system oil pan oil pan removal • remove: exhaust pipe (see exhaust pipe removal in the engine top end chapter) oil filter (see oil filter replacement in the periodic maintenance chapter) oil pan bolts [a] oil pan [b] • remove the following parts if necessary. Oil screen (see o...

  • Page 323

    Engine lubrication system 7-9 oil pan note ○ make the application finish within 7 minutes when the liquid gasket to the mating surface of the oil pan is ap- plied. ○ moreover fit the oil pan and tighten the bolts just after application of the liquid gasket. • tighten the oil pan bolts following sequ...

  • Page 324

    7-10 engine lubrication system oil screen oil screen removal • remove: oil pan (see oil pan removal) oil screen [a] oil screen installation • clean the oil screen (see oil screen cleaning). • replace the o-ring [a] with a new one, and install it. • apply grease to the o-ring. • install the rubber da...

  • Page 325

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

  • Page 326

    7-12 engine lubrication system oil pump oil pump removal • remove: water pump (see water pump removal in the cooling system chapter) oil pump cover [a] • remove: oil (water) pump shaft [a] with inner rotor [b] outer rotor [c] oil pump installation • install the outer rotor [a] into the crankcase. • ...

  • Page 327

    Engine lubrication system 7-13 oil pump • pack grease into the cavity [a] between the inner rotor and outer rotor for improve the oil pump initial priming. • install the dowel pin [b]. • install the oil pump cover [c] so that the dowel pin fit into the hole [d] of the oil pump cover. • install the w...

  • Page 328

    7-14 engine lubrication system oil cooler oil cooler removal • remove: coolant (drain, see coolant change in the periodic maintenance chapter) engine oil (drain, see engine oil change in the periodic maintenance chapter) water hose clamp screws (loosen) [a] water hoses [b] oil cooler bolts [c] oil c...

  • Page 329

    Engine lubrication system 7-15 oil pressure measurement oil pressure measurement • remove the right lower fairing (see lower fairing re- moval in the frame chapter). • remove the oil passage plug [a]. • aattach the adapter [a] and gauge [b] to the plug hole. Special tools - oil pressure gauge, 10 kg...

  • Page 330

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

  • Page 331

    Engine lubrication system 7-17 oil pipe oil pipe removal • remove: oil pan (see oil pan removal) oil pipe [a] oil pipe installation • replace the o-rings [a] with new ones. • apply grease to the o-rings, and install them..

  • Page 333: Engine Removal/installation

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

  • Page 334

    8-2 engine removal/installation exploded view.

  • Page 335

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 lower adjusting collar locknut 49 5.0 36 s 2 lower adjusting collar 9.8 1.0 87 in·lb s 3 lower engine bracket bolts 59 6.0 44 s 4 lower engine mounting nut 44 4.5 32 s 5 middle engine bracket bolts 25 2.5 18 ...

  • Page 336

    8-4 engine removal/installation special tool engine mount nut wrench: 57001-1450

  • Page 337

    Engine removal/installation 8-5 engine removal/installation engine removal • support the rear part of the swingarm with a stand. • squeeze the brake lever slowly and hold it with a band [a]. Warning motorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to hold the front b...

  • Page 338

    8-6 engine removal/installation engine removal/installation • remove the connector [a] from the bracket on the air suc- tion valve cover. • disconnect the connector. • disconnect: starter motor cable (see starter motor removal in the electrical system chapter) alternator lead connector (see alternat...

  • Page 339

    Engine removal/installation 8-7 engine removal/installation • support the engine with a suitable stand [a]. ○ put a plank [b] onto the suitable stand for engine balance. • remove: upper engine mounting bolt [a] (both sides) middle engine mounting nut [b] and bolt lower engine mounting nut [c] • usin...

  • Page 340

    8-8 engine removal/installation engine removal/installation engine installation • support the engine with a suitable stand. ○ put a plank onto the suitable stand for engine balance. • apply 2-stroke oil to the upper adjusting collar [a]. • screw the upper adjusting collar and lower adjusting col- la...

  • Page 341

    Engine removal/installation 8-9 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, apply a non-parmane...

  • Page 342

    8-10 engine removal/installation engine removal/installation • run the leads, cables and hoses correctly (see cable, wire, and hose routing section in the appendix chapter). • install the removed parts (see appropriate chapters). Torque - engine ground cable terminal bolt: 9.8 n·m (1.0 kgf·m, 87 in·...

  • Page 343

    Engine removal/installation 8-11 engine removal/installation • fill the engine with engine oil (see engine oil change in the periodic maintenance chapter). • fill the engine with coolant (see coolant change in the periodic maintenance chapter)..

  • Page 345: Crankshaft/transmission 9-1

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

  • Page 346: 9-2 Crankshaft/transmission

    9-2 crankshaft/transmission exploded view.

  • Page 347: Crankshaft/transmission 9-3

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 balancer shaft clamp bolt 9.8 1.0 87 in·lb 2 balancer shaft clamp lever bolt 25 2.5 18 l 3 breather side plate bolt 5.9 0.60 52 in·lb l 4 connecting rod big end nuts see the text ← ← mo 5 breather plate bolts 9.8...

  • Page 348: 9-4 Crankshaft/transmission

    9-4 crankshaft/transmission exploded view.

  • Page 349: Crankshaft/transmission 9-5

    Crankshaft/transmission 9-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 gear positioning lever bolt 12 1.2 106 in·lb 2 neutral switch 15 1.5 11 3 shift drum cam bolt 12 1.2 106 in·lb l 4 shift pedal mounting bolt 25 2.5 18 5 shift shaft return spring pin 39 4.0 29 l eo: apply engine ...

  • Page 350: 9-6 Crankshaft/transmission

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

  • Page 351: Crankshaft/transmission 9-7

    Crankshaft/transmission 9-7 specifications item standard service limit crankshaft main bearing insert thickness: brown 1.491 ∼ 1.495 mm (0.0587 ∼ 0.0589 in.) – – – black 1.495 ∼ 1.499 mm (0.0589 ∼ 0.0590 in.) – – – blue 1.499 ∼ 1.503 mm (0.0590 ∼ 0.0592 in.) – – – transmission shift fork ear thickne...

  • Page 352: 9-8 Crankshaft/transmission

    9-8 crankshaft/transmission special tools and sealants bearing puller: 57001-135 outside circlip pliers: 57001-144 bearing puller adapter: 57001-317 bearing driver, 32: 57001-382 bearing driver set: 57001-1129 flywheel holder: 57001-1313 liquid gasket, tb1216b: 92104-1064 liquid gasket, tb1207b: 921...

  • Page 353: Crankshaft/transmission 9-9

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

  • Page 354

    9-10 crankshaft/transmission crankcase splitting • remove the lower crankcase bolts, following the specified sequence. ○ first, loosen the m7 bolts [a]. ○ lastly, loosen the m9 bolts as shown sequence [1 ∼ 10] in the figure. • tap lightly around the crankcase mating surface with a plastic mallet, an...

  • Page 355

    Crankshaft/transmission 9-11 crankcase splitting • apply a non-permanent locking agent to the threads of the breather plate bolts [a] and tighten them. Torque - breather plate bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install the breather side plate [a] so that the plate hole [b] fit the projection [c]...

  • Page 356

    9-12 crankshaft/transmission crankcase splitting • apply a non-parmanent locking agent to the oil passage plugs [a], and tighten them. Torque - oil passage plugs: 20 n·m (2.0 kgf·m, 15 ft·lb) • install the oil passage plug [b] in the lower crankcase, and tighten it. Torque - oil passage plug: 9.8 n·...

  • Page 357

    Crankshaft/transmission 9-13 crankcase splitting • apply liquid gasket [a] to the mating surface of the lower crankcase half. Sealant - liquid gasket, tb1216b: 92104-1064 note ○ especially, apply a sealant so that it shall be filled up on the grooves [b]. ○ do not apply liquid gasket to the inside o...

  • Page 358

    9-14 crankshaft/transmission crankcase splitting • apply molybdenum disulfide oil solution to the lower seating surface [a] on the copper plated washer [b] and threads [c] of the m9 bolts [d]. • tighten the lower crankcase bolts using the following steps. ○ following the sequence numbers on the lowe...

  • Page 359

    Crankshaft/transmission 9-15 crankcase splitting • after tightening all crankcase bolts, check the following items. ○ wipe up the liquid gasket that seeps out around the crankcase mating surface. ○ crankshaft and transmission shafts turn freely. ○ while spinning the output shaft, gears shift smoothl...

  • Page 360

    9-16 crankshaft/transmission crankshaft and connecting rods crankshaft removal • split the crankcase (see crankcase splitting). • remove: balancer (see balancer removal) crankshaft [a] crankshaft installation note ○ the crankshaft, camshaft chain and camshaft sprock- ets are different between the ea...

  • Page 361

    Crankshaft/transmission 9-17 crankshaft and connecting rods connecting rod installation notice to minimize vibration, the connecting rods should have the same weight mark. Big end cap [a] connecting rod [b] weight mark, alphabet [c] diameter mark [d]: “ ○ ” or no mark notice if the connecting rods, ...

  • Page 362

    9-18 crankshaft/transmission crankshaft and connecting rods • install the crankshaft (see crankshaft installation). • install each connecting rod on its original crankpin. ○ the connecting rod big end is bolted using the “plastic region fastening method”. ○ this method precisely achieves the needed ...

  • Page 363

    Crankshaft/transmission 9-19 crankshaft and connecting rods • install new bolts and nuts in reused connecting rod. If the connecting rod assy was replaced, use the bolts and nuts attached to the new connecting rod assy. • apply a small amount of molybdenum disulfide oil solution to the following por...

  • Page 364

    9-20 crankshaft/transmission crankshaft and connecting rods • install new bolts and nuts in reused connecting rods. If the connecting rod assy was replaced, use the bolts and nuts attached to the new connecting rod assy. • apply a small amount of molybdenum disulfide oil solution to the following po...

  • Page 365

    Crankshaft/transmission 9-21 crankshaft and connecting rods connecting rod twist inspection • with the big-end arbor [a] still on v block [c], hold the connecting rod horizontally and measure the amount that the arbor [b] varies from being paralleled with the surface plate over a 100 mm (3.94 in.) l...

  • Page 366

    9-22 crankshaft/transmission crankshaft and connecting rods if the clearance is within the standard, no bearing replace- ment is required. If the clearance is between 0.061 mm (0.0024 in.) and the service limit (0.10 mm, 0.0039 in.), replace the bear- ing inserts [a] with inserts painted blue [b]. C...

  • Page 367

    Crankshaft/transmission 9-23 crankshaft and connecting rods • measure the connecting rod big end inside diameter, and mark each connecting rod big end in accordance with the inside diameter. • tighten the connecting rod big end nuts to the specified torque (see connecting rod installation). Note ○ t...

  • Page 368

    9-24 crankshaft/transmission crankshaft and connecting rods crankshaft runout inspection • measure the crankshaft runout. If the measurement exceeds the service limit, replace the crankshaft. Crankshaft runout standard: tir 0.02 mm (0.0008 in.) or less service limit: tir 0.05 mm (0.0020 in.) cranksh...

  • Page 369

    Crankshaft/transmission 9-25 crankshaft and connecting rods • measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. Crankcase main bearing inside diameter marks: “ ○ ” or no mark. • tighten the crankcase bolts to the specified torque (s...

  • Page 370

    9-26 crankshaft/transmission balancer balancer removal • split the crankcase (see crankcase splitting). • unscrew: balancer shaft clamp bolt [a] balancer shaft lever [b] oil seal [c] • remove the balancer [d] from the upper crankcase half. Balancer installation • check that the rubber dampers [a] ar...

  • Page 371

    Crankshaft/transmission 9-27 balancer • assemble the crankcase (see crankcase assembly). • fill the oil seal lips with grease. • install the new oil seal [a] so that its surface is flush with the surface of the crankcase. • turn the balancer shaft so that its mark [b] faces down- ward. • install the...

  • Page 372

    9-28 crankshaft/transmission starter motor clutch starter motor clutch removal/installation • refer to the alternator rotor removal/installation in the electrical system chapter. Starter motor clutch inspection • remove: alternator cover (see alternator cover removal in the electrical system chapter...

  • Page 373

    Crankshaft/transmission 9-29 external shift mechanism shift pedal removal • remove: shift lever bolt [a] shift lever [b] shift pedal mounting bolt [c] shift pedal [d] with tie-rod [e] shift pedal installation • tighten: torque - shift pedal mounting bolt [a]: 25 n·m (2.5 kgf·m, 18 ft·lb) shift pedal...

  • Page 374

    9-30 crankshaft/transmission external shift mechanism • pull out the shift shaft assembly [a]. • remove: gear positioning lever bolt [a] gear positioning lever [b] collar and spring [c] • remove: shift drum cam bolt [a] shift drum cam [b] external shift mechanism installation • be sure to install th...

  • Page 375

    Crankshaft/transmission 9-31 external shift mechanism • while prying the gear positioning lever [a], tighten the gear positioning lever bolt [b]. Torque - gear positioning lever bolt: 12 n·m (1.2 kgf·m, 106 in·lb) • install the shift shaft [a] so that the return spring pin [a] fits between the sprin...

  • Page 376

    9-32 crankshaft/transmission external shift mechanism • check the gear positioning lever [a] and its spring for breaks or distortion. If the lever or spring are damaged in any way, replace them. • visually inspect the shift drum cam [b]. If it is badly worn or shows any damage, replace it..

  • Page 377

    Crankshaft/transmission 9-33 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 378

    9-34 crankshaft/transmission transmission • remove the ball bearing [a] from each shafts. Special tools - bearing puller [c]: 57001-135 bearing puller adapter [d]: 57001-317 • discard the bearing. ○ for output shaft, remove the collar [b] together with the ball bearing. Transmission shaft assembly •...

  • Page 379

    Crankshaft/transmission 9-35 transmission • the drive shaft gears can be recognized by size: the gear with the smallest diameter is 1st gear, and the largest one is 6th gear. Be sure that all parts are put back in the cor- rect sequence and all circlips and washers are properly in place. • install t...

  • Page 380

    9-36 crankshaft/transmission transmission.

  • Page 381

    Crankshaft/transmission 9-37 transmission 1. Output shaft 2. Collar 3. Bearing 4. Bushing 5. 2nd gear (39 t) 6. Washer ( 34 × 28.1) 7. Circlips ( 33 × 25.9) 8. Top gear (25 t) 9. Toothed washer ( 34) 10. 4th/3rd gear (25 t/24 t) 11. Bushing 12. Toothed washer ( 40.5) 13. Toothed washer ( 37) 14. Ste...

  • Page 382

    9-38 crankshaft/transmission transmission shift drum and fork removal • remove: lower crankcase half (see crankcase splitting) transmission shafts (see transmission shaft removal) gear positioning lever (see external shift mechanism removal) bolts [a] shift drum bearing holder [b] • pull out the shi...

  • Page 383

    Crankshaft/transmission 9-39 transmission shift fork/gear groove wear inspection • measure the thickness of the shift fork ears [a], and mea- sure the width of the gear grooves [b]. If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced. Shift fork ear t...

  • Page 384

    9-40 crankshaft/transmission ball bearing, needle bearing, and oil seal ball and needle bearing replacement notice do not remove the ball or needle bearings unless it is necessary. Removal may damage them. • using a press or puller, remove the ball bearing and/or needle bearings. Note ○ in the absen...

  • Page 385: Wheels/tires 10-1

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

  • Page 386: 10-2 Wheels/tires

    10-2 wheels/tires exploded view.

  • Page 387: Wheels/tires 10-3

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front axle 108 11.0 79.7 2 front axle clamp bolt 20 2.0 15 3 rear axle nut 98 10 72 hg: apply high-temperature grease. R: replacement parts wl: apply soap and water solution or rubber lubricant..

  • Page 388: 10-4 Wheels/tires

    10-4 wheels/tires specifications item standard service limit wheels (rims) rim runout: axial tir 0.5 mm (0.02 in.) or less tir 1.0 mm (0.04 in.) radial tir 0.8 mm (0.03 in.) or less tir 1.0 mm (0.04 in.) axle runout/100 mm (3.94 in.) tir 0.1 mm (0.004 in.) or less tir 0.2 mm (0.008 in.) wheel balanc...

  • Page 389: Wheels/tires 10-5

    Wheels/tires 10-5 specifications item standard service limit replacement tires: make, type size front bridgestone, battlax bt003f racing street 120/70 zr 17m/c (58w) bridgestone, battlax bt016f hypersport 120/70 zr 17m/c (58w) bridgestone, battlax bt023f 120/70 zr 17m/c (58w) continental, contiracea...

  • Page 390: 10-6 Wheels/tires

    10-6 wheels/tires special tools inside circlip pliers: 57001-143 bearing driver set: 57001-1129 jack: 57001-1238 attachment jack: 57001-1252 bearing remover head, 20 × 22: 57001-1293 bearing remover shaft, 13: 57001-1377 jack attachment: 57001-1608.

  • Page 391: Wheels/tires 10-7

    Wheels/tires 10-7 wheels (rims) front wheel removal • remove: front caliper mounting bolts [a] (both sides) front calipers [b] (both sides) rear lower fairing (see rear lower fairing removal in the frame chapter) front fender (see front fender removal in the frame chapter) • for the abs equipped mod...

  • Page 392: 10-8 Wheels/tires

    10-8 wheels/tires wheels (rims) • apply high-temperature grease to the grease seal lips. • fit the collars [a] on the both sides of the hub. ○ the collars are identical. • insert the front axle. • tighten: torque - front axle: 108 n·m (11.0 kgf·m, 79.7 ft·lb) • before tightening the axle clamp bolt ...

  • Page 393: Wheels/tires 10-9

    Wheels/tires 10-9 wheels (rims) • remove: rear caliper mounting bolts [a] rear caliper [b] • for abs equipped models, remove the bolt [a] and rear wheel rotation sensor [b]. • loosen the chain adjuster clamp bolts [a] (both sides). • turn the chain adjuster [b] to make the chain slack. • remove: ret...

  • Page 394: 10-10 Wheels/tires

    10-10 wheels/tires wheels (rims) rear wheel installation • apply high-temperature grease to the grease seal lips. • fit the collars on the both sides of the hub. Left side collar [a] ( 40 × 35) right side collar [b] ( 44 × 28) • engage the drive chain with the rear sprocket. • insert the axle from t...

  • Page 395: Wheels/tires 10-11

    Wheels/tires 10-11 wheels (rims) wheel inspection • raise the front/rear wheel off the ground. Special tools - jack: 57001-1238 jack attachment: 57001-1608 attachment jack: 57001-1252 • spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bear...

  • Page 396: 10-12 Wheels/tires

    10-12 wheels/tires wheels (rims) balance inspection • remove the front and rear wheels (see front/rear wheel removal). • support the wheel so that it can be spun freely. • spin the wheel lightly, and mark [a] the wheel at the top when the wheel stops. ○ repeat this procedure several times. If the wh...

  • Page 397: Wheels/tires 10-13

    Wheels/tires 10-13 wheels (rims) balance weight part number weight 41075-0007 10 g (0.35 oz.) 41075-0008 20 g (0.71 oz.) 41075-0009 30 g (1.06 oz.) note ○ balance weights are available from kawasaki dealers in 10, 20 and 30 grams (0.35, 0.71 and 1.06 oz.) sizes. An imbalance of less than 10 grams (0...

  • Page 398: 10-14 Wheels/tires

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

  • Page 399: Wheels/tires 10-15

    Wheels/tires 10-15 tires • install a new valve in the rim. ○ remove the valve cap, lubricate the stem seal [a] with a soap and water solution or rubber lubricant, and pull [b] the valve stem through the rim from the inside out until it snaps into place. Notice do not use engine oil or petroleum dist...

  • Page 400: 10-16 Wheels/tires

    10-16 wheels/tires 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 401: Wheels/tires 10-17

    Wheels/tires 10-17 hub bearing hub bearing removal • remove the wheels (see front/rear wheel removal), and take out the following. Collars [a] coupling [b] (out of rear hub) grease seals [c] circlip [d] special tool - inside circlip pliers: 57001-143 • use the bearing remover to remove the hub beari...

  • Page 402: 10-18 Wheels/tires

    10-18 wheels/tires hub bearing • replace the circlip with a new one. Special tool - inside circlip pliers: 57001-143 • replace the grease seals with new ones. • press in the grease seals [a] so that the seal surface flush [b] with the end of the hole. ○ apply high-temperature grease to the grease se...

  • Page 403: Final Drive 11-1

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

  • Page 404: 11-2 Final Drive

    11-2 final drive exploded view.

  • Page 405: Final Drive 11-3

    Final drive 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 chain adjuster clamp bolts 64 6.5 47 2 drive chain guide bolts 9.8 1.0 87 in·lb 3 engine sprocket nut 125 12.7 92.2 mo 4 rear sprocket nuts 59 6.0 44 5 speed sensor mounting bolt 6.9 0.70 61 in·lb l hg: apply high-temperatu...

  • Page 406: 11-4 Final Drive

    11-4 final drive specifications item standard service limit drive chain drive chain slack 25 ∼ 30 mm (1.0 ∼ 1.2 in.) – – – drive chain wear (20-link length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 319 mm (12.56 in.) standard chain: make enuma – – – type ek525zx – – – link 112 links – – – link pin outsi...

  • Page 407: Final Drive 11-5

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

  • Page 408: 11-6 Final Drive

    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 409: Final Drive 11-7

    Final drive 11-7 drive chain drive chain installation • install the drive chain to the engine sprocket. • install: swingarm (see swingarm installation in the suspension chapter) rear wheel (see rear wheel installation in the wheels/tires chapter) • insert the projection [a] on the chain cover into t...

  • Page 410: 11-8 Final Drive

    11-8 final drive drive chain • screw the pin holder until it touches chain pin. • be sure that the cutting pin hits center of chain pin. • screw the handlebar [a] into body. • turn the pin holder with wrench [b] clockwise to extract chain pin. • replace the link pin, link plate and grease seals. • a...

  • Page 411: Final Drive 11-9

    Final drive 11-9 drive chain • turn the pin holder [a] by wrench clockwise until two pins of link come into groove of plate holders [b]. • take off the plate holder. • set the plate holder (b) [a] and cutting and riveting pin [b] as shown in the figure. • turn the pin holder until riveting pin touch...

  • Page 412: 11-10 Final Drive

    11-10 final drive drive chain • after staking, check the staked area of the link pin for cracks. • measure the outside diameter [a] of the link pin and link plates width [b]. Link pin outside diameter standard: 5.6 ∼ 6.0 mm (0.22 ∼ 0.24 in.) link plates outside width standard: 20.35 ∼ 20.55 mm (0.80...

  • Page 413: Final Drive 11-11

    Final drive 11-11 sprocket, coupling engine sprocket cover removal • remove: engine sprocket inner cover bolts [a] engine sprocket inner and outer cover [b] • remove the engine sprocket outer cover screws [a] to sparate the outer and inner cover [b]. • remove the speed sensor bolt [a]. Engine sproke...

  • Page 414: 11-12 Final Drive

    11-12 final drive sprocket, coupling engine sprocket removal • remove the engine sprocket cover (see engine sprocket cover removal). • flatten out the bended washer [a]. • remove the engine sprocket nut [b] and washer. Note ○ when loosening the engine sprocket nut, hold the rear brake on. • raise th...

  • Page 415: Final Drive 11-13

    Final drive 11-13 sprocket, coupling rear sprocket installation • install the sprocket facing the tooth number marking [a] outward. • replace the rear sprocket nuts with new ones. • tighten: torque - rear sprocket nuts: 59 n·m (6.0 kgf·m, 44 ft·lb) • install the rear wheel (see rear wheel installati...

  • Page 416: 11-14 Final Drive

    11-14 final drive sprocket, coupling coupling bearing installation • replace the bearing with a new one. • press in the bearing [a] until it is bottomed. Special tool - bearing driver set [b]: 57001-1129 • pack the bearing with high-temperature grease. • replace the circlip with a new one. Special t...

  • Page 417: Final Drive 11-15

    Final drive 11-15 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 in the periodic maintenance chapter)....

  • Page 419: Brakes 12-1

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

  • Page 420: 12-2 Brakes

    12-2 brakes abs servicing precautions ............................................................................................... 12-33 abs troubleshooting outline............................................................................................ 12-35 inquiries to rider...................

  • Page 421: Brakes 12-3

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

  • Page 422: 12-4 Brakes

    12-4 brakes exploded view.

  • Page 423: Brakes 12-5

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bleed valves 7.8 0.80 69 in·lb 2 brake hose banjo bolts 25 2.5 18 3 brake lever pivot bolt 1.0 0.10 8.8 in·lb si 4 brake lever pivot bolt locknut 5.9 0.60 52 in·lb 5 front brake disc mounting bolts 27 2.8 20 l 6 front brake ligh...

  • Page 424: 12-6 Brakes

    12-6 brakes exploded view.

  • Page 425: Brakes 12-7

    Brakes 12-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bleed valve 7.8 0.8 69 in·lb 2 brake hose banjo bolts 25 2.5 18 3 brake pedal bolt 8.8 0.90 78 in·lb l 4 rear brake disc mounting bolts 27 2.8 20 l 5 rear caliper mounting bolts 25 2.5 18 6 rear master cylinder mounting bolts 25...

  • Page 426: 12-8 Brakes

    12-8 brakes exploded view abs equipped models.

  • Page 427: Brakes 12-9

    Brakes 12-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake hose banjo bolts 25 2.5 18 2 brake pipe joint nuts 18 1.8 13 3 front brake disc mounting bolts 27 2.8 20 l 4 rear brake disc mounting bolts 27 2.8 20 l 5. Front wheel rotation sensor 6. Rear wheel rotation sensor 7. Abs hy...

  • Page 428: 12-10 Brakes

    12-10 brakes specifications item standard service limit brake lever, brake pedal brake lever position 6-way adjustable (to suit rider) – – – brake lever free play non-adjustable – – – pedal free play non-adjustable – – – pedal position about 62 mm (2.4 in.) below footpeg top – – – brake pads lining ...

  • Page 429: Brakes 12-11

    Brakes 12-11 special tools jack: 57001-1238 attachment jack: 57001-1252 jack attachment: 57001-1608.

  • Page 430: 12-12 Brakes

    12-12 brakes brake lever, brake pedal brake lever position adjustment the brake lever adjuster has 6 positions so that the brake lever position can be adjusted to suit the operator’s hand. • push the lever forward and turn the adjuster [a] to align the number with the arrow mark [b] on the lever hol...

  • Page 431: Brakes 12-13

    Brakes 12-13 brake lever, brake pedal • remove: cotter pin [a] joint pin [b] rear brake light switch spring [c] return spring [d] brake pedal bolt [e] brake pedal [f] brake pedal installation • apply grease to the footpeg pivot shaft [a]. • install: washer [b] brake pedal [c] washer [d] • apply a no...

  • Page 432: 12-14 Brakes

    12-14 brakes calipers front caliper removal • loosen the banjo bolt [a] at the brake hose lower end, and tighten it loosely. • unscrew the caliper mounting bolts [b], and detach the caliper [c] from the disc. Notice do not loosen the caliper assembly bolts [d]. Take out only the caliper mounting bol...

  • Page 433: Brakes 12-15

    Brakes 12-15 calipers caliper installation • install the caliper and brake hose lower end. ○ for the front caliper, install the collars [a] on the fork leg and fit the holes [b] of the front caliper to the collars. ○ replace the washers on each side of hose fitting with new ones. • tighten: torque -...

  • Page 434: 12-16 Brakes

    12-16 brakes calipers caliper fluid seal damage inspection the fluid seal (piston seal) [a] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- p...

  • Page 435: Brakes 12-17

    Brakes 12-17 calipers rear caliper holder shaft wear inspection the caliper body must slide smoothly on the caliper holder shafts [a]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and con- stant drag on the disc will raise brake and brake fluid ...

  • Page 436: 12-18 Brakes

    12-18 brakes brake pads front brake pad removal • loosen the pad pins [a]. • remove the front caliper with the hose installed (see front caliper removal). • remove: pad pins [a] brake pads [b] front brake pad installation • check that the pad spring [a] is in place on the caliper. • push the caliper...

  • Page 437: Brakes 12-19

    Brakes 12-19 brake pads rear brake pad removal • remove the rear caliper with the hose installed (see rear caliper removal). • remove: clip [a] pad pin [b] • remove the brake pad [c] of the jaw side from the holder shaft [d], then remove the other pad [e]. Rear brake pad installation • check that th...

  • Page 438: 12-20 Brakes

    12-20 brakes master cylinder front master cylinder removal • remove the rear view mirror (see rear view mirror re- moval in the frame chapter). • remove the banjo bolt [a] to disconnect the brake hose from the master cylinder (see brake hose removal/in- stallation). • unscrew the clamp bolts [b], an...

  • Page 439: Brakes 12-21

    Brakes 12-21 master cylinder rear master cylinder installation • replace the cotter pin [a] with a new one. • insert the cotter pin and bend the pin ends [b]. • replace the washers on each side of hose fitting with new ones. • tighten the following bolts. Torque - front footpeg bracket bolts: 25 n·m...

  • Page 440: 12-22 Brakes

    12-22 brakes master cylinder master cylinder inspection (visual inspection) • remove the master cylinders (see front/rear master cylinder removal). • disassemble the front and rear master cylinders (see master cylinder rubber parts replacement in the peri- odic maintenance chapter). • check that the...

  • Page 441: Brakes 12-23

    Brakes 12-23 brake disc brake disc removal • remove the wheels (see front/rear wheel removal in the wheels/tires chapter). • unscrew the mounting bolts [a], and take off the disc [b]. • remove the gaskets. Brake disc installation • replace the gaskets with new ones. • install the brake disc on the w...

  • Page 442: 12-24 Brakes

    12-24 brakes brake fluid brake fluid level inspection • refer to the brake fluid level inspection in the periodic maintenance chapter. Brake fluid change • refer to the brake fluid change in the periodic mainte- nance chapter. Brake line bleeding the brake fluid has a very low compression coefficien...

  • Page 443: Brakes 12-25

    Brakes 12-25 brake fluid • bleed the brake line and the master cylinder. ○ repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [a]. 2. Quickly open and close [b] the bleed valve while h...

  • Page 444: 12-26 Brakes

    12-26 brakes brake fluid • follow the procedure below to install the rear brake fluid reservoir cap correctly. ○ first, tighten the brake fluid reservoir cap [b] clockwise [c] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an add...

  • Page 445: Brakes 12-27

    Brakes 12-27 brake fluid warning when working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types and brands of fluid for use in th...

  • Page 446: 12-28 Brakes

    12-28 brakes brake hose brake hose removal/installation • refer to the brake hose replacement in the periodic maintenance chapter. Brake hose and pipe inspection • refer to the brake hose and pipe damage and instal- lation condition inspection in the periodic maintenance chapter..

  • Page 447: Brakes 12-29

    Brakes 12-29 anti-lock brake system (equipped models) parts location front wheel rotation sensor [a] front wheel rotation sensor rotor [b] rear wheel rotation sensor [a] rear wheel rotation sensor rotor [b] abs indicator light [a] abs hydraulic unit [a] abs fuse box [a].

  • Page 448: 12-30 Brakes

    12-30 brakes anti-lock brake system (equipped models) abs kawasaki diagnostic system connector [a] abs self-diagnosis terminal [b].

  • Page 449: Brakes 12-31

    Brakes 12-31 anti-lock brake system (equipped models) abs system wiring diagram 1. Abs self-diagnosis terminal 2. Abs fuse box 3. Abs motor relay fuse 30 a 4. Abs solenoid valve relay fuse 20 a 5. Abs ecu fuse 10 a 6. Fuse box 7. Ignition fuse 10 a 8. Front brake light switch 9. Meter ground 10. Fra...

  • Page 450: 12-32 Brakes

    12-32 brakes anti-lock brake system (equipped models) abs hydraulic unit terminal names 1. Power supply to abs motor 2. Power supply to abs solenoid valve relay 3. Ground 4. Ground 5. Abs self-diagnosis terminal 6. Unused 7. Unused 8. Front and rear brake light switch 9. Unused 10. Unused 11. Unused...

  • Page 451: Brakes 12-33

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

  • Page 452: 12-34 Brakes

    12-34 brakes anti-lock brake system (equipped models) warning air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If any of the brake line fittings, including the abs hydraulic unit joint nuts, or the bleed valve is opened at any time, the air ...

  • Page 453: Brakes 12-35

    Brakes 12-35 anti-lock brake system (equipped models) ○ the abs indicator light (led) may come on if the engine is run with the motorcycle on its stand and the transmis- sion in gear. If the indicator light comes on, just turn the ignition switch off, then clear service code 42, which in- dicates a ...

  • Page 454: 12-36 Brakes

    12-36 brakes anti-lock brake system (equipped models) even when the abs is operating normally, the abs indi- cator light (led) may light up under the conditions listed be- low. Turn the ignition switch off to stop the indicator light. If the motorcycle runs without erasing the service code, the ligh...

  • Page 455: Brakes 12-37

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

  • Page 456: 12-38 Brakes

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

  • Page 457: Brakes 12-39

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

  • Page 458: 12-40 Brakes

    12-40 brakes anti-lock brake system (equipped models) pre-diagnosis inspection 2 self-diagnosis outline when the indicator light has blinked or come on, the abs hydraulic unit memorizes and stores the service code (17 codes including “normal code”) for the service person to troubleshoot easily. The ...

  • Page 459: Brakes 12-41

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

  • Page 460: 12-42 Brakes

    12-42 brakes anti-lock brake system (equipped models).

  • Page 461: Brakes 12-43

    Brakes 12-43 anti-lock brake system (equipped models) self-diagnosis flow chart.

  • Page 462: 12-44 Brakes

    12-44 brakes anti-lock brake system (equipped models) how to read service codes ○ service codes are shown by a series of long and short blinks of the abs indicator light (led) as shown below. ○ read 10th digit and unit digit as the abs indicator light (led) blinks. ○ when there are a number of fault...

  • Page 463: Brakes 12-45

    Brakes 12-45 anti-lock brake system (equipped models) service code table service code abs indicator light (led) problems light state 11 rise in heat of solenoid coil by abs continuousness operation on 12 start code (not fault) after starts, turn off 13 rear inlet solenoid valve trouble (shorted or o...

  • Page 464: 12-46 Brakes

    12-46 brakes anti-lock brake system (equipped models) abs indicator light (led) inspection ○ in this model, the abs indicator light (led) [a] goes on or blinks by the control of the abs hydraulic unit. • turn the ignition switch on. If the abs indicator light (led) lights, it is normal. If the abs i...

  • Page 465: Brakes 12-47

    Brakes 12-47 anti-lock brake system (equipped models) abs solenoid valve relay inspection (service code 19) • remove: front seat (see front seat removal in the frame chap- ter) • check the abs solenoid valve relay fuse (20 a) [a] (see fuse inspection in the electrical system chapter). If the fuse is...

  • Page 466: 12-48 Brakes

    12-48 brakes anti-lock brake system (equipped models) if the abs indicator light (led) [a] lights, the abs hy- draulic unit has trouble. Replace the abs hydraulic unit. If the abs indicator light (led) does not light, abs system is normal (service code is not stored; temporary failure.). Abs motor r...

  • Page 467: Brakes 12-49

    Brakes 12-49 anti-lock brake system (equipped models) • check that there is iron or other magnetic deposits be- tween the sensor [a] and sensor rotor [b], and the sensor rotor slots for obstructions. • check the installation condition of the sensor for loose- ness. • check the sensor rotor tip for d...

  • Page 468: 12-50 Brakes

    12-50 brakes anti-lock brake system (equipped models) rear wheel rotation sensor signal abnormal (service code 44) • measure the air gap between the rear wheel rotation sen- sor and sensor rotor (see wheel rotation sensor air gap inspection). • check the rear wheel rotation sensor (see rear wheel ro...

  • Page 469: Brakes 12-51

    Brakes 12-51 anti-lock brake system (equipped models) • recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the abs indicator light (led) [a] lights, replace the rear wheel rotation sensor (see rear wheel rotati...

  • Page 470: 12-52 Brakes

    12-52 brakes anti-lock brake system (equipped models) ecu inspection (service code 55) • recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the abs indicator light (led) [a] lights, the abs hy- draulic unit has...

  • Page 471: Brakes 12-53

    Brakes 12-53 anti-lock brake system (equipped models) • remove: battery case (see battery case removal in the frame chapter) brake hose (see brake hose replacement in the peri- odic maintenance chapter) • clean the abs hydraulic unit. Notice clean all fittings on the abs hydraulic unit and the rear ...

  • Page 472: 12-54 Brakes

    12-54 brakes anti-lock brake system (equipped models) • remove: bolts [a] abs hydraulic unit [b] notice the abs hydraulic unit [a] has been adjusted and set with precision at the factory. Do not try to dis- assemble and repair the abs hydraulic unit. Abs hydraulic unit installation • install the abs...

  • Page 473: Brakes 12-55

    Brakes 12-55 anti-lock brake system (equipped models) • visually inspect the connector terminals [a]. Replace the abs hydraulic unit or main harness if either of the terminals are cracked, bent, or otherwise damaged. If the abs hydraulic unit connector is clogged with mud or dust, blow it off with c...

  • Page 474: 12-56 Brakes

    12-56 brakes anti-lock brake system (equipped models) rear wheel rotation sensor removal notice the wheel rotation sensor should be handled care- fully, never struck sharply, as with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made. Be careful not ...

  • Page 475: Brakes 12-57

    Brakes 12-57 anti-lock brake system (equipped models) wheel rotation sensor inspection • remove the front wheel rotation sensor [a] from the front fork. • remove the rear wheel rotation sensor [b] from the caliper bracket. • visually inspect the wheel rotation sensors. Replace the wheel rotation sen...

  • Page 476: 12-58 Brakes

    12-58 brakes anti-lock brake system (equipped models) wheel rotation sensor rotor inspection • remove: wheels (see front/rear wheel removal in the wheels/tires chapter) brake disc mounting bolts [a] sensor rotor [b] front wheel [c] rear wheel [d] • visually inspect the wheel rotation sensor rotor. I...

  • Page 477: Brakes 12-59

    Brakes 12-59 anti-lock brake system (equipped models) fuse installation • if a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage (see fuse installation in the electrical system chapter). Fuse inspection • remov...

  • Page 479: Suspension 13-1

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

  • Page 480: 13-2 Suspension

    13-2 suspension exploded view.

  • Page 481: Suspension 13-3

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fork bottom allen bolts 35 3.6 26 2 front fork top plugs 34 3.5 25 3 lower front fork clamp bolts 25 2.5 18 al 4 piston rod nuts 20 2.0 15 5 upper front fork clamp bolts 20 2.0 15 al: tighten the two clamp bolts altern...

  • Page 482: 13-4 Suspension

    13-4 suspension exploded view.

  • Page 483: Suspension 13-5

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear shock absorber nut (lower) 34 3.5 25 r 2 rear shock absorber bolt (upper) 34 3.5 25 3 swingarm pivot shaft 20 2.0 15 4 swingarm pivot adjusting collar locknut 98 10 72 5 swingarm pivot shaft nut 108 11.0 79.7 6 tie-rod ...

  • Page 484: 13-6 Suspension

    13-6 suspension specifications item standard front fork (per one unit) fork inner tube diameter 41 mm (1.6 in.) air pressure atmospheric pressure (non-adjustable) rebound damper setting 2 turns out from the fully clockwise position (usable range: 0 ←→ 3 1/2 turns out) compression damper setting 1 3/...

  • Page 485: Suspension 13-7

    Suspension 13-7 special tools inside circlip pliers: 57001-143 oil seal & bearing remover: 57001-1058 bearing driver set: 57001-1129 jack: 57001-1238 fork oil seal driver, 41: 57001-1288 fork oil level gauge: 57001-1290 bearing remover head, 15 × 17: 57001-1267 fork piston rod puller, m10 × 1.0: 570...

  • Page 486: 13-8 Suspension

    13-8 suspension special tools hook wrench t=3.2 r37: 57001-1539 fork spring compressor: 57001-1587 swingarm pivot nut wrench: 57001-1597 jack attachment: 57001-1608 needle bearing driver, 17/ 18: 57001-1609 needle bearing driver, 28: 57001-1610 clamp: 57001-1693 bar: 57001-1751.

  • Page 487: Suspension 13-9

    Suspension 13-9 front fork rebound damping force adjustment • to adjust the rebound damping force, turn the rebound damping adjuster [a] until you feel a click. ○ the standard adjuster setting is the 2 turns out from the fully clockwise position. Warning if both adjusters are not adjusted equally, h...

  • Page 488: 13-10 Suspension

    13-10 suspension front fork compression damping force adjustment • to adjust the compression damping force, turn the com- pression damping adjuster [a] until you feel a click. ○ the standard adjuster setting is the 1 3/4 turns out from the fully clockwise position. Warning if both adjusters are not ...

  • Page 489: Suspension 13-11

    Suspension 13-11 front fork ○ if fork leg is to be disassembled, loosen the upper and lower front fork clamp bolts to lower the fork leg [a] as shown. And retighten the lower front fork clamp bolts. Then, loosen the top plug beforhand. Note ○ loosen the top plug after loosening the upper front fork ...

  • Page 490: 13-12 Suspension

    13-12 suspension front fork • holding the top plug [a] with a wrench [b], tighten the spring preload adjuster [c]. Note ○ after tightening, lift the top plug to make the space. • side down the damper [d]. • install the clamps [a] as shown in the figure. Note ○ set the cutout [b] of the clamp to the ...

  • Page 491: Suspension 13-13

    Suspension 13-13 front fork • screw the adjust nut [a] onto the compression shaft as shown in the figure. • screw the locknut [b]. About 20 mm (0.79 in.) [c] • set the other side compression shaft same process. • set the holder bar [a] and compression shafts [b]. • screw in the nuts [a] until the pi...

  • Page 492: 13-14 Suspension

    13-14 suspension front fork • remove: top plug with the rebound damping adjuster rod damper [a] slider [b] collar [c] fork spring [d] • drain the fork oil into a suitable container. ○ pump the piston rod [a] up and down at least ten times to expel the oil from the fork. Special tool - fork piston ro...

  • Page 493: Suspension 13-15

    Suspension 13-15 front fork oil level (fully compressed, without spring) standard: 100 ±2 mm (3.94 ±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 level gauge [a]: 57001-1290 ○ with the fork fully compress...

  • Page 494: 13-16 Suspension

    13-16 suspension front fork • check the distance between the upper end [a] of the spring preload adjuster [b] and rebound damping adjuster [c] with a pair of vernier caliper. 1.5 mm (0.059 in.) [d] • set the fork spring compressor on the slider [a] using the outer tube as a guide. Special tools - fo...

  • Page 495: Suspension 13-17

    Suspension 13-17 front fork front fork disassembly • remove the front fork (see front fork removal). • drain the fork oil (see fork oil change). • install the suitable pipe ( 26 ∼ 32) [a] into the cylinder unit. • set the fork leg inverted. • while pushing down [b] the fork leg, loosen the bottom al...

  • Page 496: 13-18 Suspension

    13-18 suspension front fork front fork assembly • replace the following parts with new one. Oil seal [a] outer tube guide bushing [b] inner tube guide bushing [c] dust seal [d] retaining [e] bottom allen bolt gasket • install the following parts onto the inner tube. Dust seal retaining ring oil seal...

  • Page 497: Suspension 13-19

    Suspension 13-19 front fork inner tube, outer tube inspection • visually inspect the inner tube [a]. If there is any damage, replace the inner tube. Since damage to the inner tube damages the oil seal and dust seal, replace the oil seal and dust seal whenever the inner tube is replaced. Notice if th...

  • Page 498: 13-20 Suspension

    13-20 suspension rear shock absorber rebound damping force adjustment • to adjust the rebound damping force, turn the lower damping adjuster [a] to the desired position, until you feel a click. Zr1000da/ea ○ the standard adjuster setting is the 1 3/4 turns out from the fully clockwise position. Rebo...

  • Page 499: Suspension 13-21

    Suspension 13-21 rear shock absorber • remove the bolts [a] and footpeg bracket (both side) [b] for turning the hook wrench easily. • to adjust the spring preload, turn in the adjusting nut to the desired position and tighten the locknut by using hook wrenches [a] with the rear shock absorber attach...

  • Page 500: 13-22 Suspension

    13-22 suspension rear shock absorber • raise the rear wheel off the ground with the jack. Special tools - jack [a]: 57001-1238 jack attachment [b]: 57001-1608 warning be sure to hold the front brake when removing the shock absorber, or the motorcycle may fall over. It could cause an accident and inj...

  • Page 501: Suspension 13-23

    Suspension 13-23 rear shock absorber rear shock absorber bearing removal • remove: rear shock absorber (see rear shock absorber re- moval) sleeve [a] grease seals [b] • remove the needle bearing [a], using the bearing re- mover head [b] and bearing remover shaft [c]. Special tools - bearing remover ...

  • Page 502: 13-24 Suspension

    13-24 suspension swingarm swingarm removal • remove: rear brake hose lower end (see rear caliper removal in the brakes chapter) rear wheel (see rear wheel removal in the wheels/tires chapter) mud guard (see mad guard removal in the frame chapter) rocker arm (see rocker arm removal) • remove: cotter ...

  • Page 503: Suspension 13-25

    Suspension 13-25 swingarm • turn the swingarm pivot shaft [a] counterclockwise to free the adjusting collar from the swingarm. ○ make the gap between the adjusting collar and swingarm. • pull out the pivot shaft to the right side and remove the swingarm. Swingarm installation • visually inspect the ...

  • Page 504: 13-26 Suspension

    13-26 suspension swingarm • tighten the swingarm pivot shaft nut. Torque - swingarm pivot shaft nut: 108 n·m (11.0 kgf·m, 79.7 ft·lb) • move the swingarm up and down to check for abnormal friction. • install the removed parts (see appropriate chapters). Swingarm bearing removal • remove: swingarm (s...

  • Page 505: Suspension 13-27

    Suspension 13-27 swingarm swingarm bearing, sleeve inspection notice do not remove the bearings for inspection. Re- moval may damage them. • inspect the needle bearings [a] and ball bearing [b] in- stalled in the swingarm. ○ the rollers and ball in a bearing normally wear very little, and wear is di...

  • Page 506: 13-28 Suspension

    13-28 suspension tie-rod, rocker arm tie-rod removal • remove: mud guard (see mud guard removal in the frame chapter) • squeeze the brake lever slowly and hold it with a band [a]. • raise the rear wheel off the ground with the jack (see rear shock absorber removal). Special tools - jack: 57001-1238 ...

  • Page 507: Suspension 13-29

    Suspension 13-29 tie-rod, rocker arm tie-rod and rocker arm bearing removal • remove: tie-rods (see tie-rod removal) rocker arm (see rocker arm removal) sleeves [a] oil seals [b] swingarm [c] (see swingarm removal) • remove the needle bearings [d], using the bearing re- mover head and bearing remove...

  • Page 508: 13-30 Suspension

    13-30 suspension tie-rod, rocker arm note ○ install the needle bearings so that the marked side faces in. Rocker arm/tie-rod bearing, sleeve inspection notice do not remove the bearings for inspection. Re- moval may damage them. • visually inspect the rocker arm, or tie-rod sleeves [a] and needle be...

  • Page 509: Steering 14-1

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

  • Page 510: 14-2 Steering

    14-2 steering exploded view.

  • Page 511: Steering 14-3

    Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 handlebar holder bolts 25 2.5 18 2 handlebar holder nuts 34 3.5 25 r 3 left switch housing screws 3.5 0.36 31 in·lb 4 right switch housing screws 3.5 0.36 31 in·lb 5 steering stem head bolt 108 11.0 79.7 6 steering stem nut 25...

  • Page 512: 14-4 Steering

    14-4 steering special tools head pipe outer race press shaft: 57001-1075 head pipe outer race driver, 54.5: 57001-1077 steering stem nut wrench: 57001-1100 steering stem bearing driver, 42.5: 57001-1344 steering stem bearing driver adapter, 41.5: 57001-1345 head pipe outer race driver, 55: 57001-144...

  • Page 513: Steering 14-5

    Steering 14-5 steering steering inspection • refer to the steering play inspection in the periodic main- tenance chapter. Steering adjustment • refer to the steering play adjustment in the periodic maintenance chapter..

  • Page 514: 14-6 Steering

    14-6 steering steering stem stem, stem bearing removal • remove: upper fairing (see upper fairing removal in the frame chapter) upper fairing bracket (see upper fairing bracket re- moval in the frame chapter) meter unit (see meter unit removal in the electrical sys- tem chapter) handlebar (see handl...

  • Page 515: Steering 14-7

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

  • Page 516: 14-8 Steering

    14-8 steering steering stem • install the stem [a] through the head pipe and install the ball bearing [b] and inner race [c] on it. • install: stem cap [d] steering stem nut [e] • settle the bearings in place as follows. ○ tighten the steering stem nut with 55 n·m (5.6 kgf·m, 41 ft·lb) of torque fir...

  • Page 517: Steering 14-9

    Steering 14-9 steering stem steering stem bearing lubrication • refer to the steering stem bearing lubrication in the pe- riodic maintenance chapter. Steering stem warp inspection • whenever the steering stem is removed, or if the steering can not be adjusted for smooth action, check the steering st...

  • Page 518: 14-10 Steering

    14-10 steering handlebar handlebar removal • remove: rear view mirrors (see rear view mirrors removal in the frame chapter) clutch lever clamp bolts [a] clutch lever assembly [b] left switch housing [c] handlebar weight [d] • remove: front master cylinder [a] (see front master cylinder re- moval in ...

  • Page 519: Steering 14-11

    Steering 14-11 handlebar • side the dust cover [a] to disconnect the meter unit con- nector. • remove: meter unit mounting screws [a] meter unit [b] handlebar installation • assemble the meter unit bracket [a] and handlebar holder [b] as shown. ○ insert the pins [c] with the gap [d] of the pin and h...

  • Page 520: 14-12 Steering

    14-12 steering handlebar • for other than us and ca models, align the punch mark [a] on the handlebar and the corner edge [b] on the upper holder. • tighten: torque - handlebar holder bolts [a]: 25 n·m (2.5 kgf·m, 18 ft·lb) • install the handlebar holder plugs [b]. • apply adhesive cement to the ins...

  • Page 521: Frame 15-1

    Frame 15-1 15 frame table of contents exploded view................................... 15-2 seats ................................................. 15-9 rear seat removal...................... 15-9 rear seat installation................... 15-9 front seat removal ..................... 15-9 front sea...

  • Page 522: 15-2 Frame

    15-2 frame exploded view zr1000da/ea.

  • Page 523: Frame 15-3

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 center fairing assembly screws 1.2 0.12 11 in·lb 2 front fender assembly screws 1.2 0.12 11 in·lb 3 front fender mounting bolts 3.9 0.40 35 in·lb 4. Reflectors (us, ca, and cal models) 5. Zr1000da/ea early model.

  • Page 524: 15-4 Frame

    15-4 frame exploded view zr1000db ∼ /eb ∼.

  • Page 525: Frame 15-5

    Frame 15-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 center fairing assembly screws 1.2 0.12 11 in·lb 2 front fender assembly screws 1.2 0.12 11 in·lb 3 front fender mounting bolts 3.9 0.40 35 in·lb 4 rear view mirror (lower hexagonal area) 30 3.1 22 5 rear view mirror (upper hexag...

  • Page 526: 15-6 Frame

    15-6 frame exploded view.

  • Page 527: Frame 15-7

    Frame 15-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front footpeg bracket bolts 25 2.5 18 2 rear footpeg bracket bolts 25 2.5 18 3 rear frame bolts 25 2.5 18 l 4 rear frame bracket bolts 44 4.5 32 5 sidestand bolt 44 4.5 32 s 6 sidestand locknut 29 3.0 21 r, s 7 sidestand bracket ...

  • Page 528: 15-8 Frame

    15-8 frame exploded view 1. Reflectors (us, ca, and cal models) 2. Zr1000dc/ec late models ∼ r: replacement parts.

  • Page 529: Frame 15-9

    Frame 15-9 seats rear seat removal • insert the ignition switch key [a] into the seat lock, turning the key clockwise, pulling the front part of the seat [b] up, and pull the seat forward. Rear seat installation • insert the rear seat hook [a] under the rear frame [b]. • insert the seat hooks [c] in...

  • Page 530: 15-10 Frame

    15-10 frame fairings lower fairing removal • remove: quick rivets [a] bolts [b] • pull out the lower fairing [c]. Lower fairing installation • be sure to install the dampers [a]. • for left lower fairing installation, insert the stopper [a] into the damper [b] on the oil pan bracket. • for right low...

  • Page 531: Frame 15-11

    Frame 15-11 fairings rear lower fairing installation • insert the projection [a] into the damper [b] on the right lower fairing. • insert the projection [c] into the damper [d]. Center fairing removal • remove: bolt [a] • clear the clutch cable from the holder [a]. • remove: bolt [b] and washer bolt...

  • Page 532: 15-12 Frame

    15-12 frame fairings windshield removal • remove: bolts [a] with washers windshield [b] windshield installation • installation is the reverse of removal. Upper fairing removal • remove: windshield (see windshield removal) quick rivets [a] (both sides) • remove: bolts [a] • pull out the upper fairing...

  • Page 533: Frame 15-13

    Frame 15-13 fairings upper fairing disassembly • remove: upper fairing (see upper fairing removal) bolts [a] quick rivets [b] headlight [c] • remove: bolts [a] • separate the upper fairing. Upper fairing assembly • fit the projection [a] into the slit [b]. Upper fairing installation • connect: city ...

  • Page 534: 15-14 Frame

    15-14 frame fairings • remove: upper fairing (see upper fairing removal) throttle cables [a] meter unit lead [b] right switch housing lead [c] left switch housing lead [d] bolts [e] upper fairing bracket [f] upper fairing bracket installation • installation is the reverse of removal. ○ run the cable...

  • Page 535: Frame 15-15

    Frame 15-15 side covers side cover removal • remove: seat (see seat removal) bolts [a] • pull the side cover [b] outward to clear the stopper [c]. Side cover installation • be sure to install the pads [a]. • hang the hooks [a] to the frame. • insert the projections [b] into the holes [c]. • install ...

  • Page 536: 15-16 Frame

    15-16 frame seat covers seat cover removal • remove: seats (see rear/front seat removal) bolts [a] and washers seat cover [b] ○ pull out the seat cover rearward to clear the craws. Seat cover installation • fit the craws [a] into the slits [b] on the rear fender..

  • Page 537: Frame 15-17

    Frame 15-17 fenders front fender removal • remove: brake hose clamps [a] (both sides) front fender mounting bolts [b] with washers (both sides) front fender assy [c] • remove the front fender assembly screws [a]. • separate the front fender side covers [b] and front fender. Front fender installation...

  • Page 538: 15-18 Frame

    15-18 frame fenders • install the brake hose clamps to the front fender holes. • for zr1000dc ∼ /ec ∼ , face the lock [a] of the brake hose clamp backward. Flap and rear fender removal • remove: seat covers (see seat cover removal) owner’s tool [a] and pad • disconnect: turn signal lead connectors [...

  • Page 539: Frame 15-19

    Frame 15-19 fenders • remove: bolts [a] screw [b] • push the rear fender [a] downward. • remove: relay box [b] ecu [c] turn signal relay [d] • remove the rear fender rearward. Flap and rear fender installation • installation is the reverse of removal. • install the removed parts (see appropriate cha...

  • Page 540: 15-20 Frame

    15-20 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 resulting in injury or death. If the frame is bent, dented, cracked, or warpe...

  • Page 541: Frame 15-21

    Frame 15-21 battery case battery case removal • remove: battery (see battery removal in the electrical system chapter) exhaust butterfly valve actuator [a] (see exhaust but- terfly valve actuator removal in the fuel system (dfi) chapter) seat bracket • disconnect: vehicle-down sensor connector [b] s...

  • Page 542: 15-22 Frame

    15-22 frame guard mud guard removal • remove: rear lower fairing (see rear lower fairing removal) right front footpeg bracket bolts [a] • remove: bolts [a] • remove: quick rivets [a] mud guard [b] mud guard installation • installation is the reverse of removal. Note the following. Torque - front foo...

  • Page 543: Frame 15-23

    Frame 15-23 sidestand sidestand removal • raise the rear wheel off the ground with the stand. • remove: sidestand switch bolt [a] and nut [b] sidestand switch [c] • remove: spring [a] sidestand nut [b] sidestand bolt [c] sidestand [d] sidestand installation • apply grease to the sliding area [a] of ...

  • Page 544: 15-24 Frame

    15-24 frame rear view mirrors rear view mirrors removal (zr1000da/ea) • slide the cover [a] upward. • loosen the lower hexagonal area [b] to remove the rear view mirror from the holder. Notice do not force to tighten and/or loosen the upper hexagonal area (adapter) [c] with a pair of span- ners. Dis...

  • Page 545: Frame 15-25

    Frame 15-25 rear view mirrors rear view mirrors installation (zr1000db ∼ /eb ∼ ) • tighten: torque - lower hexagonal area [b]: 30 n·m (3.1 kgf·m, 22 ft·lb) upper hexagonal area [a]: 18 n·m (1.8 kgf·m, 13 ft·lb) ○ the lock nut and rear view mirror are left-hand thread. ○ turn the stay [c] to assure t...

  • Page 547: Electrical System 16-1

    Electrical system 16-1 16 electrical system table of contents exploded view........................................................................................................................ 16-4 specifications .......................................................................................

  • Page 548: 16-2 Electrical System

    16-2 electrical system commutator cleaning and inspection............................................................................... 16-52 armature inspection.......................................................................................................... 16-53 brush lead inspection ......

  • Page 549: Electrical System 16-3

    Electrical system 16-3 fuse installation................................................................................................................ 16-127 fuse inspection................................................................................................................. 16-128.

  • Page 550: 16-4 Electrical System

    16-4 electrical system exploded view.

  • Page 551: Electrical System 16-5

    Electrical system 16-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front brake light switch screw 1.2 0.12 11 in·lb 2 front turn signal light mounting screws 1.2 0.12 11 in·lb 3 licence plate light mounting screws 1.2 0.12 11 in·lb 4 meter unit mounting screws 1.2 0.12 11 in·lb 5 oxy...

  • Page 552: 16-6 Electrical System

    16-6 electrical system exploded view.

  • Page 553: Electrical System 16-7

    Electrical system 16-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks alternator cover bolts (engine no. ∼ zrt00de013356) 9.8 1.0 87 in·lb 1 alternator cover bolts 12 1.2 106 in·ib 2 alternator lead holding plate bolt 12 1.2 106 in·ib l 3 alternator rotor bolt 155 15.8 114 4 brush holder ...

  • Page 554: 16-8 Electrical System

    16-8 electrical system exploded view.

  • Page 555: Electrical System 16-9

    Electrical system 16-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine ground cable terminal bolt 9.8 1.0 87 in·lb 2 neutral switch 15 1.5 11 3 sidestand switch bolt 8.8 0.90 78 in·lb l 4 speed sensor mounting bolt 6.9 0.70 61 in·lb l 5. Air switching valve 6. Fuel box 7. Relay bo...

  • Page 556: 16-10 Electrical System

    16-10 electrical system specifications item standard battery type sealed battery model name ytx9-bs capacity 12 v 8 ah voltage 12.8 v or more gross weight 2.9 kg (6.4 lb) electrolyte volume 0.40 l (24 cu in.) charging system type three-phase ac alternator output voltage 43 v or more at 4 000 rpm sta...

  • Page 557: Electrical System 16-11

    Electrical system 16-11 special tools and sealant hand tester: 57001-1394 peak voltage adapter: 57001-1415 lead wire - peak voltage adapter: 57001-1449 needle adapter set: 57001-1457 key registration unit: 57001-1582 grip: 57001-1591 flywheel & pulley holder: 57001-1605 flywheel puller assembly, m38...

  • Page 558: 16-12 Electrical System

    16-12 electrical system special tools and sealant key registration adapter: 57001-1746 liquid gasket, tb1211f: 92104-0004.

  • Page 559: Electrical System 16-13

    Electrical system 16-13 parts location 1. Timing rotor 2. Crankshaft sensor 3. Horn 4. Oxygen sensor (equipped models) 5. Relay box 6. Ecu 7. Turn signal relay 8. Rear brake light switch 9. Regulator/rectifier 10. Water temperature sensor 11. Speed sensor 12. Alternator 13. Stator coil 14. Radiator ...

  • Page 560: 16-14 Electrical System

    16-14 electrical system parts location 15. Neutral switch 16. Oil pressure switch 17. Sidestand switch 18. Fuse box 19. Battery 12 v 8 ah 20. Starter relay 21. Air switching valve 22. Stick coils 23. Spark plugs 24. Immobilizer amplifier (immobilizer mod- els) 25. Starter lockout switch 26. Ignition...

  • Page 561: Electrical System 16-15

    Electrical system 16-15 parts location this page intentionally left blank..

  • Page 562: 16-16 Electrical System

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

  • Page 563: Electrical System 16-17

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

  • Page 564: 16-18 Electrical System

    16-18 electrical system wiring diagram (other than us and ca models).

  • Page 565: Electrical System 16-19

    Electrical system 16-19 wiring diagram (other than us and ca models).

  • Page 566: 16-20 Electrical System

    16-20 electrical system wiring diagram (abs equipped models).

  • Page 567: Electrical System 16-21

    Electrical system 16-21 wiring diagram (abs equipped models).

  • Page 568: 16-22 Electrical System

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

  • Page 569: Electrical System 16-23

    Electrical system 16-23 electrical wiring wiring inspection • visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clea...

  • Page 570: 16-24 Electrical System

    16-24 electrical system battery battery removal • turn off the ignition switch. • remove: front seat (see front seat removal in the frame chap- ter) • disconnect the negative (–) cable [a]. Notice be sure to disconnect the negative (–) cable first. • slide out the positive (+) terminal cap [b] and d...

  • Page 571: Electrical System 16-25

    Electrical system 16-25 battery notice do not remove the aluminum sealing sheet [a] from the filler ports [b] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. Danger sulfuric acid in battery electrolyte can cause severe burns. To prevent bur...

  • Page 572: 16-26 Electrical System

    16-26 electrical system battery • check the electrolyte flow. If no air bubbles [a] are coming up from the filler ports, or if the container cells have not emptied completely, tap the container [b] a few times. Note ○ be careful not to have the battery fall down. • keep the container in place. Don’t...

  • Page 573: Electrical System 16-27

    Electrical system 16-27 battery initial charge • newly activated sealed batteries require an initial charge. Standard charge: 0.9 a × 5 ∼ 10 hours if using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers: battery mate...

  • Page 574: 16-28 Electrical System

    16-28 electrical system battery danger batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri- ous injury and burns if ignited. Keep the battery away from sparks and open flames during charging. When using a battery charger, connect the battery to the charger before tu...

  • Page 575: Electrical System 16-29

    Electrical system 16-29 battery terminal voltage: 11.5 ∼ less than 12.8 v standard charge 0.9 a × 5 ∼ 10 h (see following chart) quick charge 4 a × 1 h notice if possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on. Terminal voltage: less than 11.5 v chargi...

  • Page 576: 16-30 Electrical System

    16-30 electrical system charging system alternator cover removal • remove: left lower fairing (see lower fairing removal in the frame chapter) • support the fuel tank with a suitable bar (see fuel tank removal in the fuel system (dfi) chapter). • pull up the connector bracket [a]. • remove the alter...

  • Page 577: Electrical System 16-31

    Electrical system 16-31 charging system stator coil removal • remove: alternator cover (see alternator cover removal) holding plate bolt [a] and plate alternator lead grommet [b] stator coil bolts [c] • remove the stator coil [d] from the alternator cover. Stator coil installation • apply a non-perm...

  • Page 578: 16-32 Electrical System

    16-32 electrical system charging system • using the flywheel puller [a], remove the alternator rotor [b] from the crankshaft. Special tool - flywheel puller assembly, m38 × 1.5/m35 × 1.5: 57001-1615 notice do not attempt to strike the alternator rotor itself. Striking the rotor can cause the magnets...

  • Page 579: Electrical System 16-33

    Electrical system 16-33 charging system • remove the rotor bolt and washer. • check the tightening torque with flywheel puller [a]. Special tool - flywheel puller assembly, m38 × 1.5/m35 × 1.5: 57001-1615 if the rotor is not pulled out with 20 n·m (2.0 kgf·m, 15 ft·lb) of drawing torque, it is insta...

  • Page 580: 16-34 Electrical System

    16-34 electrical system charging system • to check the alternator output voltage, do the following procedures. ○ turn off the ignition switch. ○ support the fuel tank with a suitable bar [a] (see fuel tank removal in the fuel system (dfi) chapter). ○ disconnect the alternator lead connector [b] (see...

  • Page 581: Electrical System 16-35

    Electrical system 16-35 charging system regulator/rectifier inspection abs non-equipment models • remove: bolts [a] and nuts [b] connector [c] (disconnect) regulator/rectifier [d] abs equipment models • remove: abs hydraulic unit (see abs hydraulic unit removal in the brakes chapter) bolts [a] and n...

  • Page 582: 16-36 Electrical System

    16-36 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 in the figure. ○ check the bk1, bk2 and bk3 terminal respectively. If the test light turns on, the regulator/rectifier is defective. R...

  • Page 583: Electrical System 16-37

    Electrical system 16-37 charging system charging voltage inspection • check the battery condition (see charging condition in- spection). • warm up the engine to obtain actual alternator operating conditions. • check that the ignition switch is turned off, and connect the hand tester [a] to the batte...

  • Page 584: 16-38 Electrical System

    16-38 electrical system charging system charging system circuit 1. Regulator/rectifier 2. Alternator 3. Ignition switch 4. Load 5. Main fuse 30 a 6. Battery 12 v 8 ah.

  • Page 585: Electrical System 16-39

    Electrical system 16-39 ignition system warning the ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. Notice do not disconnect the battery cables or any ot...

  • Page 586: 16-40 Electrical System

    16-40 electrical system ignition system • remove: crankshaft sensor bolts [a] crankshaft sensor [b] crankshaft sensor installation • route the crankshaft sensor lead correctly (see cable, wire, and hose routing section in the appendix chapter). • tighten: torque - crankshaft sensor bolts: 5.9 n·m (0...

  • Page 587: Electrical System 16-41

    Electrical system 16-41 ignition system crankshaft sensor inspection • remove: crankshaft sensor lead connector [a] (see crankshaft sensor removal) • set the hand tester [b] to the × 100 Ω range and connect (+) lead to the yellow lead and (–) lead to the black lead in the connector. Special tools - ...

  • Page 588: 16-42 Electrical System

    16-42 electrical system ignition system timing rotor removal • remove the crankshaft sensor (see crankshaft sensor removal). • remove the timing rotor [a]. ○ holding the timing rotor with the flywheel & pulley holder [b] and remove the rotor bolt [c]. Special tool - flywheel & pulley holder: 57001-1...

  • Page 589: Electrical System 16-43

    Electrical system 16-43 ignition system stick coil inspection • remove the stick coils (see stick coil removal). • measure the primary winding resistance [a] as follows. ○ connect the hand tester between the coil terminals. ○ set the tester to the × 1 Ω range, and read the tester. • measure the seco...

  • Page 590: 16-44 Electrical System

    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 591: Electrical System 16-45

    Electrical system 16-45 ignition system 2nd check • start the engine to the following conditions. Condition: transmission gear → 1st position clutch lever → pulled in sidestand → up ○ turn the ignition switch on and push the starter button. ○ then the starter motor should turn when the starter sys- ...

  • Page 592: 16-46 Electrical System

    16-46 electrical system ignition system.

  • Page 593: Electrical System 16-47

    Electrical system 16-47 ignition system ignition system circuit 1. Ignition switch 2. Fuse box 3. Ignition fuse 15 a 4. Engine stop switch 5. Stick coils 6. Spark plugs 7. Subthrottle sensor 8. Main throttle sensor 9. Oxygen sensor (equipped models) 10. Speed sensor 11. To meter unit 12. Meter groun...

  • Page 594: 16-48 Electrical System

    16-48 electrical system electric starter system starter motor removal notice do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: engine sprocket cover (see engine sprocke...

  • Page 595: Electrical System 16-49

    Electrical system 16-49 electric starter system starter motor installation notice do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • when installing the starter motor, clean the starter mo- tor legs [a] and crankcase [b] where the starter motor is grounde...

  • Page 596: 16-50 Electrical System

    16-50 electrical system electric starter system • remove the starter motor terminal locknut [a]. • pull out the brushes from the brush holder [a]. • remove: brush springs [b] starter motor terminal [c] positive brush assy [d] screw [e] negative brush assy [f] brush holder starter motor assembly • al...

  • Page 597: Electrical System 16-51

    Electrical system 16-51 electric starter system • replace the o-ring [a] with a new one. • install the following parts to the starter motor terminal [b]. New o-ring collar [c] washer [d] starter motor terminal locknut [e] ○ install the collar so that stepped side faces outward. • tighten: torque - s...

  • Page 598: 16-52 Electrical System

    16-52 electrical system electric starter system • align the marks [a] to assemble the yoke and the end cover [b]. • tighten: torque - starter motor through bolts [a]: 4.9 n·m (0.50 kgf·m, 43 in·lb) brush inspection • measure the length of each brushes [a]. If any is worn down to the service limit, r...

  • Page 599: Electrical System 16-53

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

  • Page 600: 16-54 Electrical System

    16-54 electrical system electric starter system • remove the cable terminal cover [a]. • disconnect: connector [a] cable terminals [b] • remove: starter relay [c] • connect the hand tester [a] and 12 v battery [b] to the starter relay [c] as shown in the figure. Special tool - hand tester: 57001-139...

  • Page 601: Electrical System 16-55

    Electrical system 16-55 electric starter system electric starter circuit 1. Ignition switch 2. Fuse box 3. Ignition fuse 15 a 4. Engine stop switch 5. Starter button 6. Frame ground 7. Sidestand switch 8. Neutral switch 9. Starter lockout switch 10. Relay box 11. Starter circuit relay 12. Starter mo...

  • Page 602: 16-56 Electrical System

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

  • Page 603: Electrical System 16-57

    Electrical system 16-57 lighting system • fit the projection [a] of the bulb in the hollow [b] of the headlight. • install the hook [a]. • install the dust covers [a] so that align the arrow marks [b] and slits [c] on the headlight body. • be sure to fit the dust cover [a] onto the bulb [b] firmly a...

  • Page 604: 16-58 Electrical System

    16-58 electrical system lighting system city light bulb replacement • remove the headlight (see headlight removal). • pull out the socket [a] and remove it with the bulb. • pull out the bulb [a] straight from the socket. Notice do not turn the bulb. Pull the bulb out to prevent damage to the bulb. D...

  • Page 605: Electrical System 16-59

    Electrical system 16-59 lighting system license plate light bulb replacement • remove: screws [a] license plate light cover [b] and lens • pull out the bulb [a]. • replace the bulb with a new one. • insert the new bulb into the socket. • fit the projections [a] on the lens to the cover grooves [b]. ...

  • Page 606: 16-60 Electrical System

    16-60 electrical system lighting system headlight/tail light circuit 1. Fuse box 2. Turn signal relay fuse 10 a 3. Headlight fuse 10 a 4. Alternator 5. Meter ground 6. Frame ground 7. Ignition switch 8. Meter unit 9. High beam indicator light (led) 10. Headlight (high) 12 v 55 w 11. Headlight (low) ...

  • Page 607: Electrical System 16-61

    Electrical system 16-61 lighting system turn signal light bulb replacement front turn signal light • remove: center fairings (see center fairing removal in the frame chapter) inner fairings (see inner fairing removal in the frame chapter) • turn the socket [a] counterclockwise and pull out the socke...

  • Page 608: 16-62 Electrical System

    16-62 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°. • fit the projection [a]...

  • Page 609: Electrical System 16-63

    Electrical system 16-63 lighting system • connect one 12 v battery and turn signal lights as indi- cated in the figure, and count how may times the lights flash for one minute. Turn signal relay [a] turn signal light 21 w [b] turn signal light 10 w [c] 12 v battery [d] if the lights do not flash as ...

  • Page 610: 16-64 Electrical System

    16-64 electrical system lighting system turn signal light circuit 1. Fuse box 2. Turn signal relay fuse 10 a 3. Meter ground 4. Frame ground 5. Ignition switch 6. Meter unit 7. Right turn signal indicator light (led) 8. Left turn signal indicator light (led) 9. Front right turn signal light 12 v 21 ...

  • Page 611: Electrical System 16-65

    Electrical system 16-65 air switching valve air switching valve operation test • refer to the air suction system damage inspection in the periodic maintenance chapter. Air switching valve unit test • remove the air switching valve (see air switching valve removal in the engine top end chapter). • se...

  • Page 612: 16-66 Electrical System

    16-66 electrical system air switching valve air switching valve circuit 1. Ignition switch 2. Fuse box 3. Ignition fuse 15 a 4. Engine stop switch 5. Air switching valve 6. Meter ground 7. Ecu 8. Relay box 9. Ecu main relay 10. Fuel pump relay 11. Fi fuse 15 a 12. Main fuse 30 a 13. Battery 12 v 8 a...

  • Page 613: Electrical System 16-67

    Electrical system 16-67 radiator fan system fan motor inspection • remove the left center fairing (see center fairing re- moval in the frame chapter). • remove the band [a]. • slide the dust cover [a]. • disconnect the connector [b]. • using an auxiliary leads, supply battery power to the fan motor....

  • Page 614: 16-68 Electrical System

    16-68 electrical system radiator fan system radiator fan circuit 1. Radiator fan motor 2. Fuse box 3. Fan fuse 15 a 4. Meter gruond 5. Frame ground 6. Water temperature sensor 7. Ecu 8. Ignition switch 9. Water-proof joint a 10. Relay box 11. Radiator fan relay 12. Fi fuse 15 a 13. Main fuse 30 a 14...

  • Page 615: Electrical System 16-69

    Electrical system 16-69 meter, gauge, indicator unit meter unit removal/installation • remove: upper fairing (see upper fairing removal in the frame chapter) • slide the dust cover [a] and remove the connector [b]. • remove the meter unit by taking off the mounting screws [c] with the washers. Notic...

  • Page 616: 16-70 Electrical System

    16-70 electrical system meter, gauge, indicator unit • separate the meter assembly [a] and upper meter cover [b]. Meter unit assembly • assembly the following parts. Upper meter cover meter assembly lower meter cover • tighten the meter assembly screws. • replace the caps [a] with new ones, and put ...

  • Page 617: Electrical System 16-71

    Electrical system 16-71 meter, gauge, indicator unit notice do not drop the meter unit. Place the meter unit so that it faces upward. If the meter assembly is left up- side down or sideways for a long time or dropped, it will malfunction. Do not short each terminals. Liquid crystal display (lcd) seg...

  • Page 618: 16-72 Electrical System

    16-72 electrical system meter, gauge, indicator unit • connect the terminal [2] to the terminal [1] again. ○ about 3 seconds after, the all fuel level gauge segments starts flashing [a]. If the fuel level gauge does not flash, replace the meter assembly. Note ○ this meter unit has a failure detectio...

  • Page 619: Electrical System 16-73

    Electrical system 16-73 meter, gauge, indicator unit • indicate the odo mode. • check that when the right button [a] in odo mode is pushed for more than 2 seconds, the meter display turns to the clock set mode. ○ both the hour and minute display start flashing. • in the hour/minute setting mode, pre...

  • Page 620: 16-74 Electrical System

    16-74 electrical system meter, gauge, indicator unit speedometer check • connect the 12 v battery and terminals in the same man- ner as specified in the “liquid crystal display (lcd) seg- ments check”. • the speed equivalent to the input frequency is indicated in the oscillator [a], if the square wa...

  • Page 621: Electrical System 16-75

    Electrical system 16-75 meter, gauge, indicator unit trip a/b meter check • check the trip a or b meters by the same way as the speedometer check. If value indicated in the trip a/b meters is not added, re- place the meter unit. • check that when the right button is pushed for more than 2 seconds, t...

  • Page 622: 16-76 Electrical System

    16-76 electrical system meter, gauge, indicator unit • check that the number of segments [a] matches the re- sistance value of the variable rheostat. ○ when the terminal [16] is connected, one segment in the fuel level gauge should appear about every 15 seconds. Variable rheostat resistance ( Ω) dis...

  • Page 623: Electrical System 16-77

    Electrical system 16-77 meter, gauge, indicator unit neutral indicator light (led) battery negative (–) terminal to terminal [11] water temperature warning indicator light (led) battery negative (–) terminal to terminal [8] ○ the water temperature indicator light (led) goes on about 2 seconds after ...

  • Page 624: 16-78 Electrical System

    16-78 electrical system meter, gauge, indicator unit meter circuit 1. Meter unit 2. To turn signal switch (right) 3. To turn signal switch (left) 4. To dimmer switch and passing button (equipped models) 5. Ignition switch 6. Abs hydrauric unit (equipped models) 7. To france ground 8. Fuel level gaug...

  • Page 625: Electrical System 16-79

    Electrical system 16-79 immobilizer system (equipped models), zr1000da/ea this motorcycle is equipped with an immobilizer system to protect the motorcycle from theft. This system provides a theft proof device by means of matching a code between the inbuilt key transponder and ecu (electronic control...

  • Page 626: 16-80 Electrical System

    16-80 electrical system immobilizer system (equipped models), zr1000da/ea • insert the master key into the ignition switch, and turn it to on. Verified ○ the warning indicator light (led) and the immobilizer warning symbol [a] blink to display the registration mode (go to the next step). Not verifie...

  • Page 627: Electrical System 16-81

    Electrical system 16-81 immobilizer system (equipped models), zr1000da/ea ○ if there is any problem in the registration, the warning indicator light (led) and the immobilizer warning symbol [a] blink to display the collation error. Immobilizer amplifier failure when registered user key is inserted. ...

  • Page 628: 16-82 Electrical System

    16-82 electrical system immobilizer system (equipped models), zr1000da/ea ○ if there is any problem in the registration, the warning indicator light (led) and the immobilizer warning symbol [a] blink to display the collation error. Immobilizer amplifier failure when registered user key is inserted. ...

  • Page 629: Electrical System 16-83

    Electrical system 16-83 immobilizer system (equipped models), zr1000da/ea • the warning indicator light (led) [a] goes off. • remove the key registration unit, key registration adapter and install the immobilizer/kawasaki diagnostic system connector cap. Note ○ turn the ignition switch to on with th...

  • Page 630: 16-84 Electrical System

    16-84 electrical system immobilizer system (equipped models), zr1000da/ea spare user key registration flow chart.

  • Page 631: Electrical System 16-85

    Electrical system 16-85 immobilizer system (equipped models), zr1000da/ea case 2: when the ignition switch is faulty and to be replaced. • prepare a new ignition switch [a] and two new user keys [b]. ○ these parts are available as a set. Prepare the current master key [c]. • remove: ignition switch ...

  • Page 632: 16-86 Electrical System

    16-86 electrical system immobilizer system (equipped models), zr1000da/ea verified ○ the warning indicator light (led) and the immobilizer warning symbol [a] blink to display the ecu is in the registration mode (go to the next step). Not verified ○ the warning indicator light (led) and the immobiliz...

  • Page 633: Electrical System 16-87

    Electrical system 16-87 immobilizer system (equipped models), zr1000da/ea ○ if there is any problem in the registration, the warning indicator light (led) and the immobilizer warning symbol [a] blink to display the collation error. Immobilizer amplifier failure when registered user key is inserted. ...

  • Page 634: 16-88 Electrical System

    16-88 electrical system immobilizer system (equipped models), zr1000da/ea ○ if there is any problem in the registration, the warning indicator light (led) and the immobilizer warning symbol [a] blink to display the collation error. Immobilizer amplifier failure when registered user key is inserted. ...

  • Page 635: Electrical System 16-89

    Electrical system 16-89 immobilizer system (equipped models), zr1000da/ea • remove the key registration unit, key registration adapter and install the immobilizer/kawasaki diagnostic system connector cap. Note ○ turn the ignition switch to on with the registered user key. ○ check that the engine can...

  • Page 636: 16-90 Electrical System

    16-90 electrical system immobilizer system (equipped models), zr1000da/ea • the master key is successfully registered in the ecu. ○ the warning indicator light (led) and the immobilizer warning symbol [a] blink 1 time and stop for 1 second and then repeat this cycle. • turn off the ignition switch a...

  • Page 637: Electrical System 16-91

    Electrical system 16-91 immobilizer system (equipped models), zr1000da/ea user key collation error • the user key 1 is registered in the ecu. ○ the warning indicator light (led) and the immobilizer warning symbol [a] blink 2 times and stop for 1 second and then repeat this cycle. • turn off the igni...

  • Page 638: 16-92 Electrical System

    16-92 electrical system immobilizer system (equipped models), zr1000da/ea when registered user key is inserted. User key collation error • the user key 2 is successfully registered in the ecu. ○ the warning indicator light (led) and the immobilizer warning symbol [a] blink 3 times and stop for 1 sec...

  • Page 639: Electrical System 16-93

    Electrical system 16-93 immobilizer system (equipped models), zr1000da/ea • prepare a new ecu [a], new master key [b] and current user keys [c]. Note ○ the key registration unit is not required. ○ the key registration process is same as the case 3. Case 5: when replacing the antenna. • prepare a new...

  • Page 640: 16-94 Electrical System

    16-94 electrical system immobilizer system (equipped models), zr1000da/ea all keys initial registration flow chart.

  • Page 641: Electrical System 16-95

    Electrical system 16-95 immobilizer system (equipped models), zr1000da/ea immobilizer system parts replacement immobilizer antenna replacement • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) left center fairing (see center fairing removal in the frame chapter) • disconne...

  • Page 642: 16-96 Electrical System

    16-96 electrical system immobilizer system (equipped models), zr1000da/ea • tighten a new torx bolt [a] until the bolt head [b] is broken [c]. • run the leads correctly (see cable, wire, and hose rout- ing section in the appendix chapter). Immobilizer amplifier replacement • remove: left center fair...

  • Page 643: Electrical System 16-97

    Electrical system 16-97 immobilizer system (equipped models), zr1000da/ea • remove: relay box (see relay box removal) ecu connectors [a] ecu [b] • connect the connectors to the ecu. • install the ecu guard [a]. Notice do not pinch the leads. • tighten the new screws [b] using the kawasaki genuine sc...

  • Page 644: 16-98 Electrical System

    16-98 electrical system immobilizer system (equipped models), zr1000db ∼ /eb ∼ this motorcycle is equipped with an immobilizer system to protect the motorcycle from theft. This system provides a theft proof device by means of matching a code between the inbuilt key transponder and ecu (electronic co...

  • Page 645: Electrical System 16-99

    Electrical system 16-99 immobilizer system (equipped models), zr1000db ∼ /eb ∼ • insert the registered ignition key into the ignition switch, and turn it to on. Verified ○ the warning indicator light (led) and the immobilizer warning symbol [a] blink to display the registration mode (go to the next ...

  • Page 646: 16-100 Electrical System

    16-100 electrical system immobilizer system (equipped models), zr1000db ∼ /eb ∼ ○ if there is any problem in the registration, the warning indicator light (led) and the immobilizer warning symbol [a] blink to display the collation error. Immobilizer amplifier failure when registered ignition key is ...

  • Page 647: Electrical System 16-101

    Electrical system 16-101 immobilizer system (equipped models), zr1000db ∼ /eb ∼ ○ if there is any problem in the registration, the warning indicator light (led) and the immobilizer warning symbol [a] blink to display the collation error. Immobilizer amplifier failure when registered ignition key is ...

  • Page 648: 16-102 Electrical System

    16-102 electrical system immobilizer system (equipped models), zr1000db ∼ /eb ∼ • the warning indicator light (led) [a] goes off. • remove the key registration unit, key registration adapter and install the immobilizer/kawasaki diagnostic system connector cap. Note ○ turn the ignition switch to on w...

  • Page 649: Electrical System 16-103

    Electrical system 16-103 immobilizer system (equipped models), zr1000db ∼ /eb ∼ spare ignition key registration flow chart.

  • Page 650: 16-104 Electrical System

    16-104 electrical system immobilizer system (equipped models), zr1000db ∼ /eb ∼ case 2: when the ignition switch is faulty and to be replaced. • prepare a new ignition switch [a] and two new ignition keys [b]. ○ these parts are available as a set. Prepare the current registered ignition key [c]. • r...

  • Page 651: Electrical System 16-105

    Electrical system 16-105 immobilizer system (equipped models), zr1000db ∼ /eb ∼ verified ○ the warning indicator light (led) and the immobilizer warning symbol [a] blink to display the ecu is in the registration mode (go to the next step). Not verified ○ the warning indicator light (led) and the imm...

  • Page 652: 16-106 Electrical System

    16-106 electrical system immobilizer system (equipped models), zr1000db ∼ /eb ∼ ○ if there is any problem in the registration, the warning indicator light (led) and the immobilizer warning symbol [a] blink to display the collation error. Immobilizer amplifier failure when registered ignition key is ...

  • Page 653: Electrical System 16-107

    Electrical system 16-107 immobilizer system (equipped models), zr1000db ∼ /eb ∼ ○ if there is any problem in the registration, the warning indicator light (led) and the immobilizer warning symbol [a] blink to display the collation error. Immobilizer amplifier failure when registered ignition key is ...

  • Page 654: 16-108 Electrical System

    16-108 electrical system immobilizer system (equipped models), zr1000db ∼ /eb ∼ • remove the key registration unit, key registration adapter and install the immobilizer/kawasaki diagnostic system connector cap. Note ○ turn the ignition switch to on with the registered ignition key. ○ check that the ...

  • Page 655: Electrical System 16-109

    Electrical system 16-109 immobilizer system (equipped models), zr1000db ∼ /eb ∼ • the registered ignition key is successfully registered in the ecu. ○ the warning indicator light (led) and the immobilizer warning symbol [a] blink 1 time and stop for 1 second and then repeat this cycle. • turn off th...

  • Page 656: 16-110 Electrical System

    16-110 electrical system immobilizer system (equipped models), zr1000db ∼ /eb ∼ ignition key collation error • the other remaining ignition key is registered in the ecu. ○ the warning indicator light (led) and the immobilizer warning symbol [a] blink 2 times and stop for 1 second and then repeat thi...

  • Page 657: Electrical System 16-111

    Electrical system 16-111 immobilizer system (equipped models), zr1000db ∼ /eb ∼ when registered ignition key is inserted. Ignition key collation error • the ignition key 1 is successfully registered in the ecu. ○ the warning indicator light (led) and the immobilizer warning symbol [a] blink 3 times ...

  • Page 658: 16-112 Electrical System

    16-112 electrical system immobilizer system (equipped models), zr1000db ∼ /eb ∼ case 4: when all registered ignition keys are faulty or lost. The all registered ignition keys replacement is considered very rare case. However if it is required, the following is necessary. Note ○ the ecu must be repla...

  • Page 659: Electrical System 16-113

    Electrical system 16-113 immobilizer system (equipped models), zr1000db ∼ /eb ∼ • the first ignition key is successfully registered in the ecu. ○ the warning indicator light (led) and the immobilizer warning symbol [a] blink 1 time and stops for 1 second and the repeats this cycle to indicate succes...

  • Page 660: 16-114 Electrical System

    16-114 electrical system immobilizer system (equipped models), zr1000db ∼ /eb ∼ ignition key collation error • the second ignition key is registered in the ecu. ○ the warning indicator light (led) and the immobilizer warning symbol [a] blinks 2 time and stops for 1 second and the repeats this cycle ...

  • Page 661: Electrical System 16-115

    Electrical system 16-115 immobilizer system (equipped models), zr1000db ∼ /eb ∼ all keys initial registration flow chart.

  • Page 662: 16-116 Electrical System

    16-116 electrical system immobilizer system (equipped models), zr1000db ∼ /eb ∼ immobilizer system parts replacement immobilizer antenna replacement • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) left center fairing (see center fairing removal in the frame chapter) • di...

  • Page 663: Electrical System 16-117

    Electrical system 16-117 immobilizer system (equipped models), zr1000db ∼ /eb ∼ • tighten a new torx bolt [a] until the bolt head [b] is broken [c]. • run the leads correctly (see cable, wire, and hose rout- ing section in the appendix chapter). Immobilizer amplifier replacement • remove: left cente...

  • Page 664: 16-118 Electrical System

    16-118 electrical system immobilizer system (equipped models), zr1000db ∼ /eb ∼ • remove: relay box (see relay box removal) ecu connectors [a] ecu [b] • connect the connectors to the ecu. • install the ecu guard [a]. Notice do not pinch the leads. • tighten the new screws [b] using the kawasaki genu...

  • Page 665: Electrical System 16-119

    Electrical system 16-119 immobilizer system (equipped models) immobilizer system circuit 1. Fuse box 2. Ignition fuse 15 a 3. Meter ground 4. Ecu 5. Ignition switch 6. Immobilizer antenna 7. Immobilizer amplifier 8. Meter unit 9. Oil pressure/fi/immobilizer warning indicator light (led) 10. Relay bo...

  • Page 666: 16-120 Electrical System

    16-120 electrical system switches and sensors brake light timing inspection • refer to the brake light switch operation inspection in the periodic maintenance chapter. Brake light timing adjustment • refer to the brake light switch operation inspection in the periodic maintenance chapter. Switch ins...

  • Page 667: Electrical System 16-121

    Electrical system 16-121 switches and sensors water temperature sensor inspection • remove the water temperature sensor (see water tem- perature sensor removal/installation in the fuel system (dfi) chapter). • suspend the sensor [a] in a container of coolant so that the threaded portion is submerged...

  • Page 668: 16-122 Electrical System

    16-122 electrical system switches and sensors speed sensor installation • apply a non-parmanent locking agent to the speed sensor mounting bolt [a]. • install the speed sensor [b] to the inner engine sprocket cover. • tighten: torque - speed sensor mounting bolt: 6.9 n·m (0.70 kgf·m, 61 in·lb) • ins...

  • Page 669: Electrical System 16-123

    Electrical system 16-123 switches and sensors • clear the oxygen sensor lead from the clamp [a]. • remove the oxygen sensor [b]. Oxygen sensor installation (equipped models) notice never drop the oxygen sensor [a] especially on a hard surface. Such a shock to the unit can damage it. Do not touch the...

  • Page 670: 16-124 Electrical System

    16-124 electrical system relay box the relay box [a] has relays and diodes. The relays and diodes can not be removed. Relay box removal notice never drop the relay box especially on a hard sur- face. Such a shock to the relay box can damage it. • remove the rear fender from the battery case and rear...

  • Page 671: Electrical System 16-125

    Electrical system 16-125 relay box relay circuit inspection (with the battery connected) battery connection (+) (–) tester connection tester reading ( Ω) 2-11 1-3 0 ecu main relay 4-5 7-6 0 fuel pump relay 9-10 7-8 0 fan relay 18-19 17-20 0 battery connection (+) (–) tester connection dc 25 v range ...

  • Page 672: 16-126 Electrical System

    16-126 electrical system relay box relay box internal circuit a: headlight relay b: ecu main relay c: fuel pump relay d: starter circuit relay e: fan relay.

  • Page 673: Electrical System 16-127

    Electrical system 16-127 fuse 30 a main fuse removal • remove: starter cable terminal cover (see starter relay inspec- tion) • pull out the main fuse [a] from the starter relay with a needle nose pliers. Fuse box fuse removal • remove: front seat (see front seat removal in the frame chap- ter) • unl...

  • Page 674: 16-128 Electrical System

    16-128 electrical system fuse fuse inspection • remove the fuse. • inspect the fuse element. If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and relat...

  • Page 675: Appendix 17-1

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

  • Page 676: 17-2 Appendix

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

  • Page 677: Appendix 17-3

    Appendix 17-3 cable, wire, and hose routing 1. Throttle cable (accelerator) 2. Throttle cable (decelerator) 3. Brake hose 4. Right switch housing lead 5. Clutch cable 6. Run the clutch cable to the front side of the other leads and cables. 7. Run the brake hose to the rear side of the headlight lead...

  • Page 678: 17-4 Appendix

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

  • Page 679: Appendix 17-5

    Appendix 17-5 cable, wire, and hose routing 1. Front 2. Clutch cable 3. Run the clutch cable under the radiator fan motor lead, horn lead, and front right turn signal light lead. 4. Radiator fan motor lead 5. Throttle cables 6. Run the throttle cables under the main harness. 7. Run the clutch cable ...

  • Page 680: 17-6 Appendix

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

  • Page 681: Appendix 17-7

    Appendix 17-7 cable, wire, and hose routing 1. Run the clutch cable to the rear side of the coolant reserve tank as shown. 2. Hold the clutch cable with the clamp. 3. Hook the heat insulation rubber plate to the boss of the upper engine bracket..

  • Page 682: 17-8 Appendix

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

  • Page 683: Appendix 17-9

    Appendix 17-9 cable, wire, and hose routing 1. Front 2. Immobilizer antenna lead (equipped models) 3. Ignition switch lead 4. Air switching valve 5. Run the horn lead and front right turn signal light lead through the clamp of the air switching valve. 6. Stick coil connectors 7. Subthrottle sensor c...

  • Page 684: 17-10 Appendix

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

  • Page 685: Appendix 17-11

    Appendix 17-11 cable, wire, and hose routing 1. Fuel injector lead 2. Front 3. Hold the fuel injector lead with the clamp. 4. Hold the alternator lead and crankshaft sensor lead with the bracket. 5. Crankshaft sensor lead 6. Alternator lead 7. Run the intake air temperature sensor to the upside of t...

  • Page 686: 17-12 Appendix

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

  • Page 687: Appendix 17-13

    Appendix 17-13 cable, wire, and hose routing 1. Insert the clamps of the main harness to the ribs of the inside of the frame. 2. Hold the rear brake light switch connector with the clamp. 3. Run the main harness under the pin. 4. Hold the fuel pump lead (main harness side) with the clamp and insert ...

  • Page 688: 17-14 Appendix

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

  • Page 689: Appendix 17-15

    Appendix 17-15 cable, wire, and hose routing 1. Relay box 2. Kawasaki diagnostic system connector 3. Turn signal relay 4. Ecu 5. Front 6. Rear left and right turn signal light lead connectors 7. Run the main harness and rear left and right turn signal light leads between the rear fender and the ecu....

  • Page 690: 17-16 Appendix

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

  • Page 691: Appendix 17-17

    Appendix 17-17 cable, wire, and hose routing 1. Front 2. Rear brake light switch lead 3. Crankshaft sensor lead 4. Hold the rear brake light switch lead, crankshaft sensor lead, and oxygen sensor lead (equipped models) with the clamp. 5. Oxygen sensor lead (equipped models) 6. Hold the oxygen sensor...

  • Page 692: 17-18 Appendix

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

  • Page 693: Appendix 17-19

    Appendix 17-19 cable, wire, and hose routing 1. Reserve tank hose 2. Front right turn signal light lead 3. Front 4. Run the horn lead under the reserve tank hose, to the outside of the upper engine bracket, and to the inside of the radiator hose. 5. Run the horn lead to the rear side of the coolant ...

  • Page 694: 17-20 Appendix

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

  • Page 695: Appendix 17-21

    Appendix 17-21 cable, wire, and hose routing 1. Water temperature sensor lead connector 2. Air cleaner drain hose 3. Starter motor cable 4. Breather hose 5. Speed sensor lead 6. Run the speed sensor lead and sidestand switch lead to the outside of the starter motor cable and to the front side of the...

  • Page 696: 17-22 Appendix

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

  • Page 697: Appendix 17-23

    Appendix 17-23 cable, wire, and hose routing 1. Run the fuel hose, starter motor cable, and alternator lead in order from the inside of the frame. 2. Run the fuel tank breather hose (other than cal, sea-b1 and th models) and fuel tank drain hose to the outside of the sidestand lead and speed sensor ...

  • Page 698: 17-24 Appendix

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

  • Page 699: Appendix 17-25

    Appendix 17-25 cable, wire, and hose routing 1. Turn signal relay 2. Seat lock cable 3. Run the seat lock cable to the outside of the turn signal relay and to the upside of the other leads. 4. Front 5. Stick the damper to the lower side of the front seat as shown..

  • Page 700: 17-26 Appendix

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

  • Page 701: Appendix 17-27

    Appendix 17-27 cable, wire, and hose routing 1. Air cleaner housing 2. Air switching valve hose 3. Air switching valve 4. Tighten the clamp bolt from left side. 5. Tighten the clamp bolt from right side. 6. Intake air temperature sensor 7. Install the clamp so that knob of the clamp faces rear side ...

  • Page 702: 17-28 Appendix

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

  • Page 703: Appendix 17-29

    Appendix 17-29 cable, wire, and hose routing 1. Insert the subharness connector to the clamp on the air suction valve cover. 2. Run the subharness under the hose. 3. Hose 4. Subharness 5. Run the subharness between the #1 and #2 throttle body holders so as not to pinch the lead with the throttle bod...

  • Page 704: 17-30 Appendix

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

  • Page 705: Appendix 17-31

    Appendix 17-31 cable, wire, and hose routing 1. Front 2. Exhaust butterfly valve open cable (white) 3. Exhaust butterfly valve close cable (black) 4. Run the exhaust butterfly valve cables to the inside of the rear brake light switch lead. 5. Rear brake light switch lead 6. Run the exhaust butterfly...

  • Page 706: 17-32 Appendix

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

  • Page 707: Appendix 17-33

    Appendix 17-33 cable, wire, and hose routing 1. Install the clamps as shown in the direction. 2. Reserve tank hose 3. Radiator hose 4. Water hose 5. Water hose 6. Reserve tank 7. Reserve tank overflow hose 8. Thermostat 9. Radiator 10. Radiator hose 11. Water pipe 12. Oil cooler 13. Water hose 14. W...

  • Page 708: 17-34 Appendix

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

  • Page 709: Appendix 17-35

    Appendix 17-35 cable, wire, and hose routing 1. Install the clamp as shown in the direction. 2. Install the clamp as shown in the direction. 3. Front 4. Viewed from a 5. About 45° 6. Viewed from b 7. About 60° 8. Run the reserve tank overflow hose to the upside of the horn lead and front right turn ...

  • Page 710: 17-36 Appendix

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

  • Page 711: Appendix 17-37

    Appendix 17-37 cable, wire, and hose routing 1. Radiator hose 2. Install the clamps as shown in the direction. 3. White paint mark (install the water hose so that the white paint mark faces upside of the engine.) 4. Water hose 5. White paint mark (install the water hose so that the white paint mark ...

  • Page 712: 17-38 Appendix

    17-38 appendix cable, wire, and hose routing abs equipped models (zr1000ea).

  • Page 713: Appendix 17-39

    Appendix 17-39 cable, wire, and hose routing 1. Brake hoses 2. Run the left and right switch housing leads into the upper fairing bracket. 3. Run the brake hose to the rear side of the headlight harness. 4. Clamp (clamp the grommet on the front wheel rotation sensor lead.) 5. Front wheel rotation se...

  • Page 714: 17-40 Appendix

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

  • Page 715: Appendix 17-41

    Appendix 17-41 cable, wire, and hose routing 1. Brake hoses 2. Brake hoses (brake pipes) 3. Hold the brake pipes at the rubber portions with the clamps. 4. Run the brake pipes under the harnesses. Run the rear wheel rotation sensor lead to the outside of the main harness and upper the intake air tem...

  • Page 716: 17-42 Appendix

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

  • Page 717: Appendix 17-43

    Appendix 17-43 cable, wire, and hose routing 1. Rear wheel rotation sensor 2. Run the rear wheel rotation sensor lead upper the brake hose. 3. Clamp (for brake hose and rear wheel rotation sensor lead) 4. Run the rear brake light switch lead and rear wheel rotation sensor lead to the outside of the ...

  • Page 718: 17-44 Appendix

    17-44 appendix cable, wire, and hose routing abs equipped models.

  • Page 719: Appendix 17-45

    Appendix 17-45 cable, wire, and hose routing 1. Clamp (for brake pipes) 2. Clamp (for rear brake light switch lead and rear wheel rotation sensor lead) 3. Rear wheel rotation sensor connector 4. Clamp (for brake pipe) 5. Run the brake hose inside of the harnesses and under the frame ground lead. 6. ...

  • Page 720: 17-46 Appendix

    17-46 appendix cable, wire, and hose routing abs equipped models 1. Hold the brake pipes at the rubber portions with the clamp. 2. Run the brake hoses under the harnesses. 3. Clamp (for brake pipes).

  • Page 721: Appendix 17-47

    Appendix 17-47 cable, wire, and hose routing 1. Clamp (hold the regulator/rectifier harness.) 2. Run the regulator/rectifier harness to the hollow on the battery case..

  • Page 722: 17-48 Appendix

    17-48 appendix cable, wire, and hose routing abs equipped models.

  • Page 723: Appendix 17-49

    Appendix 17-49 cable, wire, and hose routing 1. Abs hydraulic unit 2. Clamps 3. Brake hose (between front master cylinder and abs hydraulic unit) 4. Brake hose (between abs hydraulic unit and right front caliper) 5. Hold the front brake hose and the front wheel rotation sensor lead with the clamp at...

  • Page 724: 17-50 Appendix

    17-50 appendix cable, wire, and hose routing abs equipped models.

  • Page 725: Appendix 17-51

    Appendix 17-51 cable, wire, and hose routing 1. Abs hydraulic unit 2. Clamps 3. Brake hose (between rear master cylinder and abs hydraulic unit) 4. Brake hose (between abs hydraulic unit and rear caliper) 5. Rear wheel rotation sensor 6. Rear wheel rotation sensor lead 7. Clamp (hold the rear wheel ...

  • Page 726: 17-52 Appendix

    17-52 appendix cable, wire, and hose routing.

  • Page 727: Appendix 17-53

    Appendix 17-53 cable, wire, and hose routing 1. Brake hose 2. Right switch housing lead 3. Throttle cables 4. Clamp of the upper fairing bracket. 5. Run the brake hose to the most outside of the other leads and cables, and through it to the clamp. 6. Run the brake hose to the rear side of the headli...

  • Page 728: 17-54 Appendix

    17-54 appendix cable, wire, and hose routing.

  • Page 729: Appendix 17-55

    Appendix 17-55 cable, wire, and hose routing 1. Brake hose 2. Brake hose 3. (zr1000da ∼ db) hold the brake hose with the clamp, and insert it to the front fender. (zr1000dc ∼ ) hold the brake hose with the clamp at the grommet of the brake hose. Face the lock of the clamp backward. 4. Fit the brake ...

  • Page 730: 17-56 Appendix

    17-56 appendix cable, wire, and hose routing.

  • Page 731: Appendix 17-57

    Appendix 17-57 cable, wire, and hose routing 1. Brake hose 2. Clamp 3. Brake hose 4. Clamp 5. Fit the brake pipe to the stopper of the caliper as shown, and tighten the brake hose banjo bolt to the specified torque. 6. Hold the brake hose with the clamp. 7. Hold the rear brake light switch lead with...

  • Page 732: 17-58 Appendix

    17-58 appendix cable, wire, and hose routing.

  • Page 733: Appendix 17-59

    Appendix 17-59 cable, wire, and hose routing 1. Run the brake hose (between rear master cylinder and rear caliper) to the inside of the brake hose (from rear brake reserve tank to rear master cylinder). 2. Viewed from a 3. Fit the projection of the brake hose end to the stopper as shown, and tighten...

  • Page 734: 17-60 Appendix

    17-60 appendix cable, wire, and hose routing cal, sea-b1 and th models.

  • Page 735: Appendix 17-61

    Appendix 17-61 cable, wire, and hose routing 1. Stick the damper on the front center of the canister as shown in the direction. 2. Blue hose (between separator and canister) 3. Green hose (between canister and fitting for air switching valve) 4. Run the blue hose and green hose to the upside of the ...

  • Page 736: 17-62 Appendix

    17-62 appendix cable, wire, and hose routing cal, sea-b1 and th models.

  • Page 737: Appendix 17-63

    Appendix 17-63 cable, wire, and hose routing 1. Run the green hose to the inside of the sidestand switch lead and speed sensor lead, under the frame ground leads, and to the outside of the battery negative (–) lead. 2. Green hose (between canister and fitting for air switching valve) 3. Speed sensor...

  • Page 738: 17-64 Appendix

    17-64 appendix cable, wire, and hose routing cal, sea-b1 and th models.

  • Page 739: Appendix 17-65

    Appendix 17-65 cable, wire, and hose routing 1. Air switching valve 2. Hoses 3. Fitting 4. Install the green hose as shown in the direction. 5. Run the white hose to the front side of the vacuum hose. 6. Vacuum hose 7. Front.

  • Page 740: 17-66 Appendix

    17-66 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 741: Appendix 17-67

    Appendix 17-67 troubleshooting guide throttle body assy holder loose 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 excessiv...

  • Page 742: 17-68 Appendix

    17-68 appendix troubleshooting guide air cleaner duct loose air cleaner poorly sealed, or missing air cleaner clogged compression high: carbon built up in combustion chamber engine load faulty: clutch slipping engine oil level too high engine oil viscosity too high drive train trouble brake dragging...

  • Page 743: Appendix 17-69

    Appendix 17-69 troubleshooting guide piston ring groove worn piston seizure, damage cylinder head gasket leaking exhaust pipe leaking at cylinder head con- nection crankshaft runout excessive engine mount loose crankshaft bearing worn primary gear worn or chipped camshaft chain tensioner trouble cam...

  • Page 744: 17-70 Appendix

    17-70 appendix troubleshooting guide shock absorption unsatisfactory: (too hard) front fork oil excessive front fork oil viscosity too high rear shock absorber adjustment too hard tire air pressure too high front fork bent (too soft) tire air pressure too low front fork oil insufficient and/or leaki...

  • Page 745: Model Application

    Model application year model beginning frame no. 2010 zr1000da jkazrcd1 □ aa000001 jkazrt00dda000001 2010 zr1000ea jkazrce1 □ aa000001 jkazrt00dea000001 2011 zr1000db jkazrcd1 □ ba015001 jkazrt00dda015001 2011 zr1000eb jkazrce1 □ ba003001 jkazrt00dea015001 2012 zr1000dc jkazrcd1 □ ca025001 jkazrt00d...