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Kawasaki Z1000 Service Manual

Summary of Z1000

  • Page 1

    Z1000 z1000 abs.

  • 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 information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component par...

  • Page 6

    List of abbreviations a ampere(s) ic integrated circuit abdc after bottom dead center in. Inch(es) abs antilock brake system km/h kilometers per hour ac alternating current l liter(s) ah ampere hour lcd liquid crystal display atdc after top dead center led light emitting diode bbdc before bottom dea...

  • 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 zr1000fe left side view zr1000fe right side view frame number engine number.

  • Page 18: 1-8 General Information

    1-8 general information model identification zr1000ge left side view zr1000ge right side view.

  • Page 19: General Information 1-9

    General information 1-9 general specifications items zr1000fe ∼ ff/ge ∼ gf dimensions overall length 2 045 mm (80.51 in.) overall width 790 mm (31.10 in.) overall height 1 055 mm (41.54 in.) wheelbase 1 435 mm (56.50 in.) road clearance 125 mm (4.92 in.) seat height 815 mm (32.09 in.) curb mass: zr1...

  • Page 20: 1-10 General Information

    1-10 general information general specifications items zr1000fe ∼ ff/ge ∼ gf cylinder numbering method left to right, 1-2-3-4 firing order 1-2-4-3 valve timing: intake: open 25° btdc close 65° abdc duration 270° exhaust: open 58° bbdc close 18° atdc duration 256° lubrication system forced lubrication...

  • Page 21: General Information 1-11

    General information 1-11 general specifications items zr1000fe ∼ ff/ge ∼ gf rear tire: type tubeless size 190/50 zr17 m/c (73w) rim size j17m/c × mt6.00 front suspension: type telescopic fork (upside-down) wheel travel 120 mm (4.72 in.) rear suspension: type swingarm wheel travel 122 mm (4.80 in.) b...

  • Page 22: 1-12 General Information

    1-12 general information unit conversion table prefixes for units: prefix symbol power mega m × 1 000 000 kilo k × 1 000 centi c × 0.01 milli m × 0.001 micro µ × 0.000001 units of mass: kg × 2.205 = lb g × 0.03527 = oz units of volume: l × 0.2642 = gal (us) l × 0.2200 = gal (imp) l × 1.057 = qt (us)...

  • Page 23: Periodic Maintenance 2-1

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

  • Page 24: 2-2 Periodic Maintenance

    2-2 periodic maintenance suspension .......................................................................................................................... 2-54 suspension system .......................................................................................................... 2-54 steeri...

  • Page 25: 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 *a: service at number of years shown o...

  • Page 26: 2-4 Periodic Maintenance

    2-4 periodic maintenance periodic maintenance chart odometer reading (*b) × 1 000 km (× 1 000 mile) items year (*a) 1 (0.6) 6 (3.8) 12 (7.6) 18 (11.4) 24 (15.2) see page wheel bearing damage :1 2-36 final drive drive chain lubrication condition (*c) : every 600 km (400 mile) 2-37 drive chain slack (...

  • Page 27: Periodic Maintenance 2-5

    Periodic maintenance 2-5 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. All of the values are for use with dry solvent - cleaned threads unless otherwise indicated. Letters used ...

  • Page 28: 2-6 Periodic Maintenance

    2-6 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks cylinder head bolts (m10) (final) 54 5.5 40 s, mo cylinder head jacket plugs 19.6 2.00 14.5 l cylinder head bolts (m6) 12 1.2 106 in·lb s throttle body assy holder bolts 12 1.2 106 in·lb l throttle body assy ho...

  • Page 29: Periodic Maintenance 2-7

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks lower engine mounting nut 44 4.5 32 s lower adjusting collar locknut 49 5.0 36 s middle engine mounting nut 44 4.5 32 s middle engine bracket bolts 25 2.5 18 l, s lower adjusting collar 9.8 1.0 87 in·lb s upper...

  • Page 30: 2-8 Periodic Maintenance

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks front brake light switch screw 1.2 0.12 11 in·lb front master cylinder clamp bolts 11 1.1 97 in·lb s brake hose banjo bolts 25 2.5 18 bleed valves 7.8 0.80 69 in·lb front brake pad pins 15 1.5 11 front caliper ...

  • Page 31: Periodic Maintenance 2-9

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks upper fairing screws 1.2 0.12 11 in·lb front fender mounting bolts 3.9 0.40 35 in·lb rear frame bracket bolts 44 4.5 32 front footpeg bracket bolts 25 2.5 18 side stand switch bolt 8.8 0.90 78 in·lb l side stan...

  • Page 32: 2-10 Periodic Maintenance

    2-10 periodic maintenance torque and locking agent the table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cl...

  • Page 33: Periodic Maintenance 2-11

    Periodic maintenance 2-11 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) – – – throttle body vacuum 40.7 ±1.3 kpa (305 ±10 mmhg) at idle speed – – – bypass screws (turn out) 2 1/2 (for reference) ...

  • Page 34: 2-12 Periodic Maintenance

    2-12 periodic maintenance 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 (12.6 in.) standard chain: make enuma – – – type ek525zx – – – link 112 links – – – brakes...

  • Page 35: Periodic Maintenance 2-13

    Periodic maintenance 2-13 special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 jack: 57001-1238 pilot screw adjuster, a: 57001-1239 oil filter wrench: 57001-1249 attachment jack: 57001-1252 vacuum gauge: 57001-1369 throttle sensor setting adapter: 57001-1538 extension ...

  • Page 36: 2-14 Periodic Maintenance

    2-14 periodic maintenance periodic maintenance procedures fuel system (dfi) 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 37: Periodic Maintenance 2-15

    Periodic maintenance 2-15 periodic maintenance procedures idle speed inspection • start the engine and warm it up thoroughly. • with the engine idling, turn the handlebars to both sides [a]. If handlebars movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly ...

  • Page 38: 2-16 Periodic Maintenance

    2-16 periodic maintenance periodic maintenance procedures if the free play is incorrect, adjust the throttle cable as follows. • slide the dust covers. • loosen the locknuts [a] [b]. • screw both throttle cable adjusters [c] [d] to give the throttle grip plenty of play. • turn the decelerator cable ...

  • Page 39: Periodic Maintenance 2-17

    Periodic maintenance 2-17 periodic maintenance procedures • plug the air switching valve hose end [a] and air cleaner housing fitting [b]. • install the air cleaner housing (see air cleaner housing installation in the fuel system (dfi) chapter). • connect the following parts temporarily. Fuel pump l...

  • Page 40: 2-18 Periodic Maintenance

    2-18 periodic maintenance periodic maintenance procedures if any vacuum is not within specifications, adjust the by- pass screws [a]. View from rear [b] special tool - pilot screw adjuster, a [c]: 57001-1239 • adjust the each vacuum (#1 ∼ #4) to the standard value. • open and close the throttle valv...

  • Page 41: 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 42: 2-20 Periodic Maintenance

    2-20 periodic maintenance periodic maintenance procedures • check that the fuel hose is routed according to cable, wire, and hose routing section in the appendix chapter. Replace the hose if it has been sharply bent or kinked. Hose joints [a] fuel hose [b] • check that the fuel hose joints are secur...

  • Page 43: Periodic Maintenance 2-21

    Periodic maintenance 2-21 periodic maintenance procedures • pull the fuel hose joint [a] out of the delivery pipe [b]. Warning fuel is flammable and explosive under certain con- ditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediatel...

  • Page 44: 2-22 Periodic Maintenance

    2-22 periodic maintenance periodic maintenance procedures evaporative emission control system inspection (cal, sea-b1 and th models) • inspect the canister as follows. ○ remove the front seat (see front seat removal in the frame chapter). ○ pull the canister [a] out of the rear fender. ○ slide the c...

  • Page 45: Periodic Maintenance 2-23

    Periodic maintenance 2-23 periodic maintenance procedures cooling system water hose and pipe inspection (coolant leak, damage, installation condition) ○ the high pressure inside the water hose can cause coolant to leak [a] or the hose to burst if the line is not properly maintained. • visually inspe...

  • Page 46: 2-24 Periodic Maintenance

    2-24 periodic maintenance periodic maintenance procedures • remove: lower rear shock absorber nut and bolt [a] (see rear shock absorber removal in the suspension chapter) • remove: coolant reserve tank bolts [a] collars • pull up the coolant reserve tank [a]. • disconnect the radiator overflow hose ...

  • Page 47: Periodic Maintenance 2-25

    Periodic maintenance 2-25 periodic maintenance procedures • fill the radiator up to the filler neck [a] with coolant. Note ○ pour in the coolant slowly so that it can expel the air from the engine and radiator. • check the cooling system for leaks. • tap the water hoses to force any air bubbles caug...

  • Page 48: 2-26 Periodic Maintenance

    2-26 periodic maintenance periodic maintenance procedures water hose and o-ring replacement • drain the coolant (see coolant change). • remove: middle fairing (see middle fairing removal in the frame chapter) oil cooler [a] (see oil cooler removal in the engine lubrication system chapter) thermostat...

  • Page 49: Periodic Maintenance 2-27

    Periodic maintenance 2-27 periodic maintenance procedures engine top end valve clearance inspection note ○ valve clearance must be checked and adjusted when the engine is cold (at room temperature). • remove: cylinder head cover (see cylinder head cover re- moval in the engine top end chapter) crank...

  • Page 50: 2-28 Periodic Maintenance

    2-28 periodic maintenance periodic maintenance procedures ○ when positioning #1 piston tdc at the end of the compression stroke: intake valve clearance of #1 and #3 cylinders exhaust valve clearance of #1 and #2 cylinders measuring valve [a] ○ when positioning #4 piston tdc at the end of the compres...

  • Page 51: Periodic Maintenance 2-29

    Periodic maintenance 2-29 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 52: 2-30 Periodic Maintenance

    2-30 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 53: Periodic Maintenance 2-31

    Periodic maintenance 2-31 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 54: 2-32 Periodic Maintenance

    2-32 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 55: Periodic Maintenance 2-33

    Periodic maintenance 2-33 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 56: 2-34 Periodic Maintenance

    2-34 periodic maintenance periodic maintenance procedures engine lubrication system engine oil change • situate the motorcycle so that it is vertical after warming up the engine. • remove the engine oil drain bolt [a] to drain the oil. ○ the oil in the oil filter can be drained by removing the filte...

  • Page 57: Periodic Maintenance 2-35

    Periodic maintenance 2-35 periodic maintenance procedures oil filter replacement • drain the engine oil (see engine oil change). • remove the oil filter with the oil filter wrench [a]. Special tool - oil filter wrench: 57001-1249 • replace the filter with a new one. • apply grease to the gasket [a] ...

  • Page 58: 2-36 Periodic Maintenance

    2-36 periodic maintenance periodic maintenance procedures tire tread wear inspection as the tire tread wears down, the tire becomes more sus- ceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn). So it is false eco...

  • Page 59: Periodic Maintenance 2-37

    Periodic maintenance 2-37 periodic maintenance procedures • raise the rear wheel off the ground with the stand (see rear wheel removal in the wheels/tires chapter). • inspect the roughness of the rear wheel bearing by push- ing and pulling [a] the wheel. • spin [b] the rear wheel lightly, and check ...

  • Page 60: 2-38 Periodic Maintenance

    2-38 periodic maintenance periodic maintenance procedures drive chain slack inspection note ○ check the slack with the motorcycle setting on its side stand. ○ clean the chain if it is dirty, and lubricate it if it appears dry. • check the wheel alignment (see wheel alignment inspec- tion). • rotate ...

  • Page 61: Periodic Maintenance 2-39

    Periodic maintenance 2-39 periodic maintenance procedures wheel alignment adjustment • remove the right retaining ring [a]. • loosen the axle nut [b]. • loosen the right chain adjuster clamp bolt [c], and turn the right chain adjuster [d] so that the left and right notches on the swingarm may point ...

  • Page 62: 2-40 Periodic Maintenance

    2-40 periodic maintenance periodic maintenance procedures chain guide wear inspection • remove the swingarm (see swingarm removal in the suspension chapter). • visually inspect the chain guide [a]. Replace the chain guide if it shows any signs of abnormal wear or damage. Brakes brake system brake fl...

  • Page 63: Periodic Maintenance 2-41

    Periodic maintenance 2-41 periodic maintenance procedures brake hose and pipe damage and installation condi- tion inspection • for abs equipped models, remove the air cleaner hous- ing (see air cleaner housing removal in the fuel system (dfi) chapter). • inspect the brake hoses, pipe and fittings fo...

  • Page 64: 2-42 Periodic Maintenance

    2-42 periodic maintenance 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 65: Periodic Maintenance 2-43

    Periodic maintenance 2-43 periodic maintenance procedures • change the brake fluid. ○ repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. 1. Open the bleed valve [a]. 2. Apply the brake and hold it [b]. 3. Close the bleed valve [c]. 4. Rel...

  • Page 66: 2-44 Periodic Maintenance

    2-44 periodic maintenance periodic maintenance procedures brake hose and pipe replacement notice brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • remove: upper fairing cover (see upper fairing removal in the frame chapter) brake ho...

  • Page 67: Periodic Maintenance 2-45

    Periodic maintenance 2-45 periodic maintenance procedures this page intentionally left blank..

  • Page 68: 2-46 Periodic Maintenance

    2-46 periodic maintenance periodic maintenance procedures • for abs equipped models; note the following. Note ○ when removing the brake pipes and hoses on the hy- draulic unit, remove them with the flare nut wrench ac- cording to each assembly of the exploded view in the brakes chapter. • remove: up...

  • Page 69: Periodic Maintenance 2-47

    Periodic maintenance 2-47 periodic maintenance procedures.

  • Page 70: 2-48 Periodic Maintenance

    2-48 periodic maintenance periodic maintenance procedures master cylinder rubber parts replacement front master cylinder disassembly • remove the front master cylinder (see front master cylin- der removal in the brakes chapter). • remove: front brake reservoir cap bolts [a] reservoir cap [b] diaphra...

  • Page 71: Periodic Maintenance 2-49

    Periodic maintenance 2-49 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 72: 2-50 Periodic Maintenance

    2-50 periodic maintenance periodic maintenance procedures • hold the pistons nearest the oil passage [a] with the bands [b]. • using compressed air, remove the pistons. ○ cover the caliper opening with a clean heavy cloth [a]. ○ lightly apply compressed air [b] to the oil passage. Warning the piston...

  • Page 73: Periodic Maintenance 2-51

    Periodic maintenance 2-51 periodic maintenance procedures • apply brake fluid to the outside of the pistons, and push them into each cylinder by hand. • install the removed parts (see appropriate chapters). • wipe up any spilled brake fluid on the caliper with wet cloth. Rear caliper disassembly • r...

  • Page 74: 2-52 Periodic Maintenance

    2-52 periodic maintenance periodic maintenance procedures • replace the fluid seal [a] with a new one. ○ apply silicone grease to the fluid seal, and install it into the cylinder by hand. • replace the dust seal [b] with a new one. ○ apply silicone grease to the dust seal, and install it into the cy...

  • Page 75: Periodic Maintenance 2-53

    Periodic maintenance 2-53 periodic maintenance procedures brake light switch operation inspection • turn the ignition switch on. • the brake light (led) [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 lig...

  • Page 76: 2-54 Periodic Maintenance

    2-54 periodic maintenance periodic maintenance procedures suspension suspension system front forks/rear shock absorber operation inspec- tion • 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 fo...

  • Page 77: Periodic Maintenance 2-55

    Periodic maintenance 2-55 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] do not smoothly stroke or noise is found, inspect the fasteners and tie-rod bearings (see rocker arm/tie-rod bearing, sle...

  • Page 78: 2-56 Periodic Maintenance

    2-56 periodic maintenance periodic maintenance procedures • bend the claws [a] of the claw washer straighten. • remove: steering stem locknut [b] claw washer • adjust the steering using the steering stem nut wrench [a]. Special tool - steering stem nut wrench: 57001-1100 if the steering is too tight...

  • Page 79: Periodic Maintenance 2-57

    Periodic maintenance 2-57 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 [a] in the cages, and wipe the upper and lower...

  • Page 80: 2-58 Periodic Maintenance

    2-58 periodic maintenance periodic maintenance procedures electrical system lights and switches operation inspection first step • set the gear position in the neutral position. • turn the ignition switch on. • the following lights should go on according to below table. City light (led) [a] goes on t...

  • Page 81: Periodic Maintenance 2-59

    Periodic maintenance 2-59 periodic maintenance procedures • turn the ignition switch off. • the all lights should go off. ○ for models equipped with an immobilizer system, red warning indicator (led) will blinks. Refer to the immobi- lizer system (equipped models) section in the electrical system ch...

  • Page 82: 2-60 Periodic Maintenance

    2-60 periodic maintenance periodic maintenance procedures fourth step • set the dimmer switch [a] to low beam position. • start the engine. • the low beam headlights should go on. If the low beam headlights do not go on, inspect or replace the following parts. Headlight (led) assembly (see headlight...

  • Page 83: Periodic Maintenance 2-61

    Periodic maintenance 2-61 periodic maintenance procedures headlight beam horizontal adjustment • turn the horizontal adjuster [a] in both headlights in or out until the beam points straight ahead. If the headlight beam points too low or high, adjust the vertical beam. Headlight beam vertical adjustm...

  • Page 84: 2-62 Periodic Maintenance

    2-62 periodic maintenance periodic maintenance procedures if the side stand switch operation does not work, inspect or replace the following parts. Battery (see charging condition inspection in the elec- trical system chapter) main fuse 30 a (see fuse inspection in the electrical system chapter) ign...

  • Page 85: Periodic Maintenance 2-63

    Periodic maintenance 2-63 periodic maintenance procedures spark plug replacement • remove the stick coils (see stick coil removal in the electrical system chapter). • remove the spark plugs using the 16 mm (0.63 in.) plug wrench [a] vertically. • replace the spark plugs with new ones. Standard spark...

  • Page 86: 2-64 Periodic Maintenance

    2-64 periodic maintenance periodic maintenance procedures cables: lubricate with rust inhibitor. Clutch cable throttle cables • lubricate the cables by seeping the oil between the cable and housing. ○ the cable may be lubricated by using a commercially available pressure cable lubricator with an aer...

  • Page 87: Periodic Maintenance 2-65

    Periodic maintenance 2-65 periodic maintenance procedures bolt, nut and fastener to be checked engine: clutch lever pivot bolt locknut engine mounting bolts and nuts exhaust pipe holder nuts muffler body clamp bolts muffler body mounting bolts and nuts premuffler chamber mounting bolt radiator bolts...

  • Page 89: Fuel System (Dfi) 3-1

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

  • Page 90: 3-2 Fuel System (Dfi)

    3-2 fuel system (dfi) vehicle-down sensor installation ...................................................................................... 3-74 vehicle-down sensor input voltage inspection................................................................. 3-74 vehicle-down sensor output voltage ins...

  • Page 91: Fuel System (Dfi) 3-3

    Fuel system (dfi) 3-3 ecu removal ................................................................................................................... 3-109 ecu installation ................................................................................................................ 3-110 ecu powe...

  • Page 92: 3-4 Fuel System (Dfi)

    3-4 fuel system (dfi) exploded view.

  • Page 93: Fuel System (Dfi) 3-5

    Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 throttle body assy holder clamp bolts 2.9 0.30 26 in·lb 2 delivery pipe assy mounting screws 3.43 0.35 30 in·lb 3 air cleaner housing assembly screws 1.1 0.11 10 in·lb 4 air cleaner housing plate screws 1.1 0.11 10 in·...

  • Page 94: 3-6 Fuel System (Dfi)

    3-6 fuel system (dfi) exploded view.

  • Page 95: Fuel System (Dfi) 3-7

    Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oxygen sensor (equipped models) 44 4.5 32 2 water temperature sensor 12 1.2 106 in·lb 3 exhaust butterfly valve actuator pulley bolt 5.0 0.51 44 in·lb 4 exhaust butterfly valve actuator mounting screws 1.2 0.12 11 in·l...

  • Page 96: 3-8 Fuel System (Dfi)

    3-8 fuel system (dfi) exploded view.

  • Page 97: 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, s 2. Purge valve 3. Canister 4. Other than cal, sea-b1 and th models 5. Cal, sea-b1 and th models l: apply a non-permanent locking agent. R: replacement parts s: follow the specified...

  • Page 98: 3-10 Fuel System (Dfi)

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

  • Page 99: Fuel System (Dfi) 3-11

    Fuel system (dfi) 3-11 dfi system 1. Ecu 2. Battery 12 v 10 ah 3. Vehicle-down sensor 4. Pressure regulator 5. Fuel pump 6. Fuel filter 7. Intake air temperature sensor 8. Delivery pipe assy 9. Fuel injectors 10. Wheel rotation sensors 11. Exhaust butterfly valve actuator 12. Oxygen sensor (equipped...

  • Page 100: 3-12 Fuel System (Dfi)

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

  • Page 101: Fuel System (Dfi) 3-13

    Fuel system (dfi) 3-13 dfi system part names 1. Ecu 2. Rear wheel rotation sensor 3. Joint connector e 4. Immobilizer (equipped models)/kawasaki diagnostic system connector 5. Exhaust butterfly valve actuator 6. Fuel pump 7. Frame ground 4 8. Frame ground 2 9. Frame ground 1 10. Engine ground 11. Ba...

  • Page 102: 3-14 Fuel System (Dfi)

    3-14 fuel system (dfi) dfi system dfi system wiring diagram (abs equipped models).

  • Page 103: Fuel System (Dfi) 3-15

    Fuel system (dfi) 3-15 dfi system part names 1. Ecu 2. Rear wheel rotation sensor 3. Joint connector e 4. Immobilizer (equipped models)/kawasaki diagnostic system connector 5. Exhaust butterfly valve actuator 6. Fuel pump 7. Abs hydraulic unit 8. Frame ground 5 9. Frame ground 2 10. Frame ground 1 1...

  • Page 104: 3-16 Fuel System (Dfi)

    3-16 fuel system (dfi) dfi system ○ color codes: bk: black bl: blue br: brown ch: chocolate dg: dark green g: green gy: gray lb: light blue lg: light green o: orange p: pink pu: purple r: red v: violet w: white y: yellow.

  • Page 105: Fuel System (Dfi) 3-17

    Fuel system (dfi) 3-17 dfi system this page intentionally left blank..

  • Page 106: 3-18 Fuel System (Dfi)

    3-18 fuel system (dfi) dfi system terminal numbers of ecu connectors terminal names 1. Subthrottle valve actuator: p/bl 2. Exhaust butterfly valve actuator (–): w/r 3. Unused 4. Power supply to sensors: bl 5. Fuel pump relay: br/y 6. Power supply to ecu (from battery): br/w 7. Power supply to ecu (f...

  • Page 107: Fuel System (Dfi) 3-19

    Fuel system (dfi) 3-19 dfi system 32. Power supply to rear wheel rotation sensor (zr1000f): w/g unused (zr1000g) 33. Side stand switch: g/bk 34. Unused 35. Starter button: r/bk 36. Neutral switch: lg 37. Crankshaft sensor (–): y/bk 38. Ground for control system: bk/bl 39. Ground for fuel system: bk/...

  • Page 108: 3-20 Fuel System (Dfi)

    3-20 fuel system (dfi) dfi parts location main throttle sensor [a] subthrottle sensor [b] subthrottle valve actuator [c] intake air pressure sensor #2 [d] stick coils #1, #2, #3, #4 [e] intake air pressure sensor #1 [f] fuel injectors #1, #2, #3, #4 [g] air switching valve [a] water temperature sens...

  • Page 109: Fuel System (Dfi) 3-21

    Fuel system (dfi) 3-21 dfi parts location vehicle-down sensor [a] battery 12 v 10 ah [b] fuse box 1 [c] exhaust butterfly valve actuator [d] main fuse 30 a [a] ecu fuse 15 a [b] ecu [a] relay box [b] (ecu main relay, fuel pump relay, ra- diator fan relay) immobilizer (equipped models)/kawasaki diagn...

  • Page 110: 3-22 Fuel System (Dfi)

    3-22 fuel system (dfi) dfi parts location immobilizer amplifier [a] (equipped models) front wheel rotation sensor [a] (abs equipped mod- els) rear wheel rotation sensor [a] purge valve [a] (cal, sea-b1 and th models).

  • Page 111: Fuel System (Dfi) 3-23

    Fuel system (dfi) 3-23 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 112: 3-24 Fuel System (Dfi)

    3-24 fuel system (dfi) 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 kΩ exhaust butterfly valve actuator ...

  • Page 113: Fuel System (Dfi) 3-25

    Fuel system (dfi) 3-25 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 throttle sensor setting adapter #1: 57001-1400 peak voltage adapter: 57001-1415 needle adapter set: 5700...

  • Page 114: 3-26 Fuel System (Dfi)

    3-26 fuel system (dfi) special tools and sealant fuel hose: 57001-1607 measuring adapter: 57001-1700 liquid gasket, tb1211: 56019-120

  • Page 115: Fuel System (Dfi) 3-27

    Fuel system (dfi) 3-27 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 116: 3-28 Fuel System (Dfi)

    3-28 fuel system (dfi) 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 117: Fuel System (Dfi) 3-29

    Fuel system (dfi) 3-29 troubleshooting the dfi system outline when a problem occurs with dfi system, the yellow en- gine warning indicator (led) [a] goes on to alert the rider. For models equipped with an immobilizer system, the red warning indicator (led) [a] and immobilizer warning indica- tor [b]...

  • Page 118: 3-30 Fuel System (Dfi)

    3-30 fuel system (dfi) 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 119: Fuel System (Dfi) 3-31

    Fuel system (dfi) 3-31 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 120: 3-32 Fuel System (Dfi)

    3-32 fuel system (dfi) troubleshooting the dfi system • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. • check the wiring for continuity. ○ use the...

  • Page 121: Fuel System (Dfi) 3-33

    Fuel system (dfi) 3-33 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 122: 3-34 Fuel System (Dfi)

    3-34 fuel system (dfi) troubleshooting the dfi system sample diagnosis sheet rider name: registration no. (license plate no.): year of initial registration: model: engine no.: frame no.: date problem occurred: mileage: environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ al...

  • Page 123: Fuel System (Dfi) 3-35

    Fuel system (dfi) 3-35 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 124: 3-36 Fuel System (Dfi)

    3-36 fuel system (dfi) dfi system troubleshooting guide note ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in dfi system. ○ the ecu may be involved in t...

  • Page 125: Fuel System (Dfi) 3-37

    Fuel system (dfi) 3-37 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 126: 3-38 Fuel System (Dfi)

    3-38 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) subthrottle sensor trouble inspect (see chapter 3). Subthrottle valve actuator trouble inspect (see chapter 3). Intake air pressure sensor #1 trouble inspect (see chapter 3). Intake air pressure sen...

  • Page 127: Fuel System (Dfi) 3-39

    Fuel system (dfi) 3-39 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 128: 3-40 Fuel System (Dfi)

    3-40 fuel system (dfi) 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). Throttle...

  • Page 129: Fuel System (Dfi) 3-41

    Fuel system (dfi) 3-41 self-diagnosis self-diagnosis outline the self-diagnosis system is monitoring the following mechanisms. Dfi system and ignition system immobilizer system (equipped models) the following indicators (led) are used for warning indi- cators of below table. Led color warning indica...

  • Page 130: 3-42 Fuel System (Dfi)

    3-42 fuel system (dfi) self-diagnosis self-diagnosis procedures note ○ use a fully charged battery when conducting self-diagnosis. Otherwise, the warning indicator (led) and indicator do not light or blink. • turn the ignition switch on. ○ when a problem occurs with dfi system and ignition sys- tem,...

  • Page 131: Fuel System (Dfi) 3-43

    Fuel system (dfi) 3-43 self-diagnosis • any of the following procedures ends self-diagnosis. ○ when the service code is displayed on the lcd, push the upper button for more than two seconds. The display will return to the previous display. ○ when the ignition switch is turned off. Self-diagnosis flo...

  • Page 132: 3-44 Fuel System (Dfi)

    3-44 fuel system (dfi) self-diagnosis 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 service code in the numerical ...

  • Page 133: Fuel System (Dfi) 3-45

    Fuel system (dfi) 3-45 self-diagnosis service code system problems 35 immobilizer immobilizer amplifier malfunction (equipped models) 36 immobilizer blank key detection (equipped models) 39 fi ecu communication error 51 fi stick coil #1 malfunction, wiring open or short 52 fi stick coil #2 malfuncti...

  • Page 134: 3-46 Fuel System (Dfi)

    3-46 fuel system (dfi) self-diagnosis service codes parts or function output signal usable range or criteria backups by ecu 21 crankshaft sensor crankshaft sensor must send 22 signals to the ecu at the 1 cranking. If the crankshaft sensor fails, the engine stops by itself. 24 rear wheel rotation sen...

  • Page 135: Fuel System (Dfi) 3-47

    Fuel system (dfi) 3-47 self-diagnosis service codes parts or function output signal usable range or criteria backups by ecu 52 stick coil #2* the ecu sends signals (output voltage) continuously to the stick coil. If the stick coil #2 primary winding has failures (no signal, wiring short or open), th...

  • Page 136: 3-48 Fuel System (Dfi)

    3-48 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 137: Fuel System (Dfi) 3-49

    Fuel system (dfi) 3-49 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 continuity inspection ecu connector [a] ←→ main throttle sensor ...

  • Page 138: 3-50 Fuel System (Dfi)

    3-50 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 139: Fuel System (Dfi) 3-51

    Fuel system (dfi) 3-51 main throttle sensor (service code 11) main throttle sensor circuit 1. Main throttle sensor 2. Subthrottle sensor 3. Ecu.

  • Page 140: 3-52 Fuel System (Dfi)

    3-52 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) •...

  • Page 141: Fuel System (Dfi) 3-53

    Fuel system (dfi) 3-53 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 142: 3-54 Fuel System (Dfi)

    3-54 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 143: Fuel System (Dfi) 3-55

    Fuel system (dfi) 3-55 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 144: 3-56 Fuel System (Dfi)

    3-56 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 145: Fuel System (Dfi) 3-57

    Fuel system (dfi) 3-57 intake air pressure sensor #1 (service code 12) intake air pressure sensor #1 circuit 1. Intake air pressure sensor #2 2. Intake air pressure sensor #1 3. Ecu.

  • Page 146: 3-58 Fuel System (Dfi)

    3-58 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 147: Fuel System (Dfi) 3-59

    Fuel system (dfi) 3-59 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 148: 3-60 Fuel System (Dfi)

    3-60 fuel system (dfi) intake air temperature sensor (service code 13) intake air temperature sensor circuit 1. Intake air temperature sensor 2. Ecu.

  • Page 149: Fuel System (Dfi) 3-61

    Fuel system (dfi) 3-61 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 150: 3-62 Fuel System (Dfi)

    3-62 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 continuity inspection ecu connector [a] ←→ sub harne...

  • Page 151: Fuel System (Dfi) 3-63

    Fuel system (dfi) 3-63 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: air cleaner housing (see air cleaner housing removal) •...

  • Page 152: 3-64 Fuel System (Dfi)

    3-64 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 153: Fuel System (Dfi) 3-65

    Fuel system (dfi) 3-65 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 154: 3-66 Fuel System (Dfi)

    3-66 fuel system (dfi) intake air pressure sensor #2 (service code 16) intake air pressure sensor #2 circuit 1. Intake air pressure sensor #2 2. Intake air pressure sensor #1 3. Ecu.

  • Page 155: Fuel System (Dfi) 3-67

    Fuel system (dfi) 3-67 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 156: 3-68 Fuel System (Dfi)

    3-68 fuel system (dfi) rear wheel rotation sensor signal (service code 24, 25) rear wheel rotation sensor signal inspection ○ the rear wheel rotation sensor sends the signal to the ecu through the abs hydraulic unit (abs equipped mod- els). For other than abs equipped models, the signal is sent dire...

  • Page 157: Fuel System (Dfi) 3-69

    Fuel system (dfi) 3-69 rear wheel rotation sensor signal (service code 24, 25) if the wiring is good, check the ecu for its ground and power supply (see ecu power supply inspection in the fuel system (dfi) chapter). If the ground and power supply are good, replace the ecu (see ecu removal/installati...

  • Page 158: 3-70 Fuel System (Dfi)

    3-70 fuel system (dfi) rear wheel rotation sensor signal (service code 24, 25) wheel rotation sensor circuit (other than abs equipped models) 1. Ecu 2. Rear wheel rotation sensor.

  • Page 159: Fuel System (Dfi) 3-71

    Fuel system (dfi) 3-71 front wheel rotation sensor signal (service code 27, abs equipped models) front wheel rotation sensor signal inspection ○ the front wheel rotation sensor sends the signal to the ecu through the abs hydraulic unit. ○ the service code 27 is detected with the ecu. • inspect the w...

  • Page 160: 3-72 Fuel System (Dfi)

    3-72 fuel system (dfi) front wheel rotation sensor signal (service code 27, abs equipped models) wheel rotation sensor circuit 1. Front wheel rotation sensor 2. Rear wheel rotation sensor 3. Ecu 4. Abs hydraulic unit.

  • Page 161: Fuel System (Dfi) 3-73

    Fuel system (dfi) 3-73 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 162: 3-74 Fuel System (Dfi)

    3-74 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 163: Fuel System (Dfi) 3-75

    Fuel system (dfi) 3-75 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 connectors. Wiring continuity inspection ecu connector [a] ←→ vehicle-down sensor co...

  • Page 164: 3-76 Fuel System (Dfi)

    3-76 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 165: Fuel System (Dfi) 3-77

    Fuel system (dfi) 3-77 vehicle-down sensor (service code 31) vehicle-down sensor circuit 1. Vehicle-down sensor 2. Ecu.

  • Page 166: 3-78 Fuel System (Dfi)

    3-78 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 167: Fuel System (Dfi) 3-79

    Fuel system (dfi) 3-79 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 continuity inspection ecu connector [a] ←→ subthrottle sensor conn...

  • Page 168: 3-80 Fuel System (Dfi)

    3-80 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 valves [a] are fully opened by hand. Output voltage standard: dc 1.08 ∼ 1.12 v ...

  • Page 169: Fuel System (Dfi) 3-81

    Fuel system (dfi) 3-81 subthrottle sensor (service code 32) subthrottle sensor resistance inspection • turn the ignition switch off. • disconnect the subthrottle sensor connector. • connect the setting adapter [a] to the sensor connector only. Special tool - throttle sensor setting adapter: 57001 -1...

  • Page 170: 3-82 Fuel System (Dfi)

    3-82 fuel system (dfi) oxygen sensor - not activated (service code 33, equipped models) oxygen sensor removal/installation • refer to the oxygen sensor removal/installation (equipped models) in the electrical system chapter. Oxygen sensor inspection • turn the ignition switch off. • open the clamp [...

  • Page 171: Fuel System (Dfi) 3-83

    Fuel system (dfi) 3-83 oxygen sensor - not activated (service code 33, equipped models) • install the suitable plugs [a] on the fitting of the air suction valve covers, and shut off the secondary air. • remove the fuel hose (see fuel hose replacement in the periodic maintenance chapter). • connect t...

  • Page 172: 3-84 Fuel System (Dfi)

    3-84 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 173: Fuel System (Dfi) 3-85

    Fuel system (dfi) 3-85 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 174: 3-86 Fuel System (Dfi)

    3-86 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 is original po- sition (see exhaust butterfly valve cable installation in the engine top end chapter). ...

  • Page 175: Fuel System (Dfi) 3-87

    Fuel system (dfi) 3-87 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] (see exhaust butterfly valve actuat...

  • Page 176: 3-88 Fuel System (Dfi)

    3-88 fuel system (dfi) immobilizer amplifier (service code 35, equipped models) antenna resistance inspection • turn the ignition switch off. • remove the left middle fairing (see middle fairing re- moval in the frame chapter). • slide the dust cover [a]. • disconnect the antenna lead connector [b]....

  • Page 177: Fuel System (Dfi) 3-89

    Fuel system (dfi) 3-89 blank key detection (service code 36, equipped models) • this code appears in the following conditions. ○ the transponder [a] in the ignition key is malfunction. ○ when the spare key of unregistration is used. ○ when the ignition key is registered in the registered ecu. • ther...

  • Page 178: 3-90 Fuel System (Dfi)

    3-90 fuel system (dfi) 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 179: Fuel System (Dfi) 3-91

    Fuel system (dfi) 3-91 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 180: 3-92 Fuel System (Dfi)

    3-92 fuel system (dfi) 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 stick coil circuit). If the wiring is good, check the ecu for its ground and power supply (see ecu power s...

  • Page 181: Fuel System (Dfi) 3-93

    Fuel system (dfi) 3-93 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 182: 3-94 Fuel System (Dfi)

    3-94 fuel system (dfi) 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 183: Fuel System (Dfi) 3-95

    Fuel system (dfi) 3-95 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 measuring adapter [a] between the...

  • Page 184: 3-96 Fuel System (Dfi)

    3-96 fuel system (dfi) subthrottle valve actuator (service code 62) subthrottle valve actuator circuit 1. Subthrottle valve actuator 2. Ecu.

  • Page 185: Fuel System (Dfi) 3-97

    Fuel system (dfi) 3-97 exhaust butterfly valve actuator (service code 63) exhaust butterfly valve actuator removal • refer to the exhaust butterfly valve actuator removal in the engine top end chapter. Exhaust butterfly valve actuator installation • refer to the exhaust butterfly valve actuator inst...

  • Page 186: 3-98 Fuel System (Dfi)

    3-98 fuel system (dfi) 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 187: Fuel System (Dfi) 3-99

    Fuel system (dfi) 3-99 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 188: 3-100 Fuel System (Dfi)

    3-100 fuel system (dfi) 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 189: Fuel System (Dfi) 3-101

    Fuel system (dfi) 3-101 oxygen sensor heater (service code 67, equipped models) oxygen sensor heater power source voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • disconnect the oxygen sensor lead connector and con- nect the measuring adapter [a] betw...

  • Page 190: 3-102 Fuel System (Dfi)

    3-102 fuel system (dfi) oxygen sensor heater (service code 67, equipped models) oxygen sensor circuit 1. Ignition switch 2. Fuse box 1 3. Ignition fuse 15 a 4. Oxygen sensor 5. Ecu 6. Joint connector e 7. Frame ground 5 8. Engine ground 9. Battery 12 v 10 ah 10. Starter relay 11. Main fuse 30 a 12. ...

  • Page 191: Fuel System (Dfi) 3-103

    Fuel system (dfi) 3-103 oxygen sensor - incorrect output voltage (service code 94, equipped models) oxygen sensor removal/installation • refer to the oxygen sensor removal/installation (equipped models) in the electrical system chapter. Oxygen sensor inspection • turn the ignition switch off. • open...

  • Page 192: 3-104 Fuel System (Dfi)

    3-104 fuel system (dfi) oxygen sensor - incorrect output voltage (service code 94, equipped models) • install the suitable plugs [a] on the fitting of the air suction valve covers, and shut off the secondary air. • remove the fuel hose (see fuel hose replacement in the periodic maintenance chapter)....

  • Page 193: Fuel System (Dfi) 3-105

    Fuel system (dfi) 3-105 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 194: 3-106 Fuel System (Dfi)

    3-106 fuel system (dfi) purge valve (service code 3a) (cal, sea-b1 and th models) purge valve removal/installation • remove: battery case (see battery case removal in the frame chapter) • disconnect the purge valve lead connector [a]. • remove the nut [b]. • remove the purge valve [c] from the brack...

  • Page 195: Fuel System (Dfi) 3-107

    Fuel system (dfi) 3-107 purge valve (service code 3a) (cal, sea-b1 and th models) • disconnect the 12 v battery. • blow the air to the intake air duct [a] again, and make sure that the air does not flow from the outlet air duct [b]. If the purge valve dose not operate as described, replace it with a...

  • Page 196: 3-108 Fuel System (Dfi)

    3-108 fuel system (dfi) warning indicator light (led) yellow engine warning/red warning indicator (led) inspection yellow engine warning indicator (led) [a] red warning indicator (led) [b] ○ in this model, the above mentioned warning indicators (led) go on or blink by the data sent from the ecu. • r...

  • Page 197: Fuel System (Dfi) 3-109

    Fuel system (dfi) 3-109 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 part number [a...

  • Page 198: 3-110 Fuel System (Dfi)

    3-110 fuel system (dfi) ecu • lift up the ecu [a] with rubber protector [b] to clear the projections. • remove the relay box [c] from the rubber protector. • disconnect the ecu connectors [d]. • remove: ecu (with rubber protector) ecu installation • connect the ecu connectors [a]. • install: ecu [b]...

  • Page 199: Fuel System (Dfi) 3-111

    Fuel system (dfi) 3-111 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 connectors. • connect a digital meter [a] to the connector (black) [b] with the needle adapter set. Special tool - needle adapter set: 57001-14...

  • Page 200: 3-112 Fuel System (Dfi)

    3-112 fuel system (dfi) ecu ecu power source circuit 1. Ignition switch 2. Fuse box 1 3. Ignition fuse 15 a 4. Joint connector c 5. Joint connector d 6. Ecu 7. Joint connector e 8. Frame ground 5 9. Frame ground 2 10. Engine ground 11. Battery 12 v 10 ah 12. Starter relay 13. Main fuse 30 a 14. Ecu ...

  • Page 201: Fuel System (Dfi) 3-113

    Fuel system (dfi) 3-113 dfi power source ecu fuse removal • refer to the 30 a main/15 a ecu fuse removal in the electrical system 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. • ...

  • Page 202: 3-114 Fuel System (Dfi)

    3-114 fuel system (dfi) fuel line fuel pressure inspection note ○ be sure the battery is fully charged. • remove: seat cover (see seat cover removal in the frame chapter) fuel tank bolts [a] fuel hose (see fuel hose replacement in the periodic maintenance chapter) ○ be sure to place a piece of cloth...

  • Page 203: Fuel System (Dfi) 3-115

    Fuel system (dfi) 3-115 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 204: 3-116 Fuel System (Dfi)

    3-116 fuel system (dfi) 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 205: Fuel System (Dfi) 3-117

    Fuel system (dfi) 3-117 fuel pump fuel pump removal warning gasoline is extremely flammable and can be explo- sive under certain conditions, creating the potential for serious burns. Make sure the area is well venti- lated and free from any source of flame or sparks; this includes any appliance with...

  • Page 206: 3-118 Fuel System (Dfi)

    3-118 fuel system (dfi) 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. Note ○ be careful not to bend the fuel level sensor arm. • check that the fuel pump terminal [a] and band [b] are...

  • Page 207: Fuel System (Dfi) 3-119

    Fuel system (dfi) 3-119 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 measuring adapter [a]...

  • Page 208: 3-120 Fuel System (Dfi)

    3-120 fuel system (dfi) fuel pump pressure regulator removal ○ the pressure regulator [a] is built into the fuel pump [b] and can not be removed. Pump screen, fuel filter cleaning ○ the pump screen [a] and fuel filter [b] are built into the fuel pump and can not be cleaned or checked. If the pump sc...

  • Page 209: Fuel System (Dfi) 3-121

    Fuel system (dfi) 3-121 fuel pump fuel pump circuit 1. Ignition switch 2. Engine stop switch 3. Fuse box 1 4. Ignition fuse 15 a 5. Joint connector d 6. Ecu 7. Fuel pump 8. Frame ground 2 9. Engine ground 10. Battery 12 v 10 ah 11. Starter relay 12. Main fuse 30 a 13. Ecu fuse 15 a 14. Relay box 15....

  • Page 210: 3-122 Fuel System (Dfi)

    3-122 fuel system (dfi) 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 standard tip screwdriver [a] to the fuel in...

  • Page 211: Fuel System (Dfi) 3-123

    Fuel system (dfi) 3-123 fuel injectors fuel injector power source voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the throttle body assy with the connectors in- stalled (see throttle body assy removal). • disconnect the injector connector and ...

  • Page 212: 3-124 Fuel System (Dfi)

    3-124 fuel system (dfi) 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 a digital meter [a] to the connector [b] with the needle ad...

  • Page 213: Fuel System (Dfi) 3-125

    Fuel system (dfi) 3-125 fuel injectors if the reading is out of the specification, remove the ecu and check the wiring for continuity between main harness connectors. ○ disconnect the ecu and injector connector. Wiring continuity inspection ecu connector (gray) [a] ←→ fuel injector connector [b] for...

  • Page 214: 3-126 Fuel System (Dfi)

    3-126 fuel system (dfi) fuel injectors • check the fuel injector fuel line for leakage as follows. ○ connect a commercially available vacuum/pressure pump [a] to the nipple of the delivery pipe [b] with the fuel hose [c] (both ends with the clamps [d]) as shown. Rear side view [e] ○ apply soap and w...

  • Page 215: Fuel System (Dfi) 3-127

    Fuel system (dfi) 3-127 fuel injectors fuel injector circuit 1. Ignition switch 2. Engine stop switch 3. Fuse box 1 4. Ignition fuse 15 a 5. Joint connector d 6. Fuel injector #1 7. Fuel injector #2 8. Fuel injector #3 9. Fuel injector #4 10. Ecu 11. Frame ground 2 12. Engine ground 13. Battery 12 v...

  • Page 216: 3-128 Fuel System (Dfi)

    3-128 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 217: Fuel System (Dfi) 3-129

    Fuel system (dfi) 3-129 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 218: 3-130 Fuel System (Dfi)

    3-130 fuel system (dfi) throttle body assy • remove: bolts [a] throttle pulley cover [b] • remove: throttle cable holder clamp [a] throttle cable lower ends [b] • loosen the throttle body assy holder clamp bolts [a]. Special tool - carburetor drain plug wrench, hex 3: 57001-1269 • remove the throttl...

  • Page 219: Fuel System (Dfi) 3-131

    Fuel system (dfi) 3-131 throttle body assy throttle body assy installation • be sure to position the throttle body assy holder clamp in original position (see throttle body assy holder installa- tion in the engine top end chapter). • connect the fuel injector connectors [a]. • install the throttle b...

  • Page 220: 3-132 Fuel System (Dfi)

    3-132 fuel system (dfi) throttle body assy throttle body assy disassembly 1. Throttle body assy 2. Subthrottle valve actuator 3. Main throttle sensor 4. Subthrottle sensor 5. Fuel injectors 6. Delivery pipe assy 7. Intake air pressure sensor #1 8. Intake air pressure sensor #2 notice do not remove, ...

  • Page 221: Fuel System (Dfi) 3-133

    Fuel system (dfi) 3-133 throttle body assy • remove 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 fuel injector especially on a hard surface. Such a shoc...

  • Page 222: 3-134 Fuel System (Dfi)

    3-134 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 223: Fuel System (Dfi) 3-135

    Fuel system (dfi) 3-135 air cleaner • loosen the air cleaner housing clamp bolt [a] on both sides. • lift up the air cleaner housing, and disconnect the air switching valve hose [a]. • after removing the air cleaner housing, cover the clean cloth on the throttle body assy. Air cleaner housing instal...

  • Page 224: 3-136 Fuel System (Dfi)

    3-136 fuel system (dfi) fuel tank fuel tank removal warning gasoline is extremely flammable and can be explo- sive under certain conditions, creating the potential for serious burns. Make sure the area is well venti- lated and free from any source of flame or sparks; this includes any appliance with...

  • Page 225: Fuel System (Dfi) 3-137

    Fuel system (dfi) 3-137 fuel tank • draw the fuel out from the fuel tank with a commercially available pump [a]. ○ use a soft plastic hose [b] as a pump intake hose in order to insert the hose smoothly. ○ put the hose through the fill opening [c] into the tank and draw the fuel out. Warning spilled ...

  • Page 226: 3-138 Fuel System (Dfi)

    3-138 fuel system (dfi) fuel tank • pull [a] the fuel hose joint [b] out of the outlet pipe. Warning fuel is flammable and explosive under certain con- ditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is d...

  • Page 227: Fuel System (Dfi) 3-139

    Fuel system (dfi) 3-139 fuel tank • remove the vinyl bag on the pipe and fuel hose joint. • check the joint lock for deformation and wear. If the joint lock is deformed, replace the fuel hose with a new one. • check that there are no flaws, burrs, and adhesion of foreign materials on the pipe [a]. •...

  • Page 228: 3-140 Fuel System (Dfi)

    3-140 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 229: Fuel System (Dfi) 3-141

    Fuel system (dfi) 3-141 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 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 water hose clamp screws 3.0 0.31 27 in·lb 2 fitting bolt 8.8 0.90 78 in·lb l 3 thermostat housing bolts 5.9 0.60 52 in·lb l 4 water pipe bolts 12 1.2 106 in·lb l 5 water pump impeller bolt 9.8 1.0 87 in·lb 6 water pump co...

  • Page 234: 4-4 Cooling System

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

  • 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 37.5: 57001-1660

  • Page 238: 4-8 Cooling System

    4-8 cooling system coolant coolant deterioration inspection • visually inspect the coolant in the reserve tank [a]. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the coolin...

  • 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: left lower fairing (see lower fairing removal in the frame chapter) engine sprocket cover (...

  • 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] • replace the washer with a new one, and install it. • 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 [...

  • Page 242: 4-12 Cooling System

    4-12 cooling system water pump water pump inspection • check the drainage outlet passage [a] at the bottom of the water pump housing for coolant leaks. • if a coolant leak or ooze is found, start the engine and check if the coolant leaks continuously. ○ when coolant does not continuously leak, it is...

  • 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 • drain: coolant (see coolant change in the periodic mainte- nance chapter) • remove: air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter) bolts [a] • disconnect the connectors [b], and remove the horn [...

  • Page 245: Cooling System 4-15

    Cooling system 4-15 radiator • move the radiator rightward [a] to clear the frame projec- tion [b]. • remove: radiator [c] notice do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling effi- ciency. • remove: radiator fan mounting bolts [a] radiator fan [b]...

  • Page 246: 4-16 Cooling System

    4-16 cooling system radiator • fit the slits [a] of the heat insulation rubber plate to the up- per mounting brackets [b] and fan bracket [c] as shown. • run the radiator fan motor lead [d] into the slit. • insert the upper right mounting bracket [a] to the frame projection [b]. • run the radiator f...

  • Page 247: Cooling System 4-17

    Cooling system 4-17 radiator • install the cap [a] on a cooling system pressure tester [b]. Note ○ wet the cap sealing surfaces with water or coolant to prevent pressure leaks. • watching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gauge ne...

  • Page 248: 4-18 Cooling System

    4-18 cooling system thermostat thermostat removal • drain: coolant (see coolant change in the periodic mainte- nance chapter) • remove: engine sprocket cover (see engine sprocket removal in the final drive chapter) harness holder clamp [a] • loosen the water hose clamp screw [b]. • disconnect the wa...

  • 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. • apply a non-permanent locking agent...

  • Page 250: 4-20 Cooling System

    4-20 cooling system thermostat • to check valve opening temperature, suspend the ther- mostat [a] in a container of water and raise the tempera- ture of the water. ○ the thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [b] in...

  • Page 251: Cooling System 4-21

    Cooling system 4-21 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 252: 4-22 Cooling System

    4-22 cooling system 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 .................................... 5-8 special tools and sealants ............... 5-10 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 spark plugs 13 1.3 115 in·lb 3 cylinder head cover bolts 10 1.0 89 in·lb s 4 camshaft cap bolts 12 1.2 106 in·lb s 5 upper camshaft chain guide bolts 12 1.2 106 in·lb s c...

  • 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 pipe cover bracket bolts 10 1.0 89 in·lb 2 exhaust buttery valve actuator pulley bolt 5.0 0.51 44 in·lb 3 exhaust battery valve actuator mounting screws 1.2 0.12 11 in·lb 4 muffler body mounting bolts 34 3.5 25 5 ...

  • Page 258: 5-6 Engine Top End

    5-6 engine top end exhaust system identification exhaust pipe mark position [a] left muffler body mark position [a].

  • Page 259: Engine Top End 5-7

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

  • Page 260: 5-8 Engine Top End

    5-8 engine top end 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 34.443 ∼ 34.557 mm (1.3560 ∼ 1.3605 in.) 34.34 mm (1.352 in.) camshaft journal, camshaft cap clearance 0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in...

  • Page 261: Engine Top End 5-9

    Engine top end 5-9 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 262: 5-10 Engine Top End

    5-10 engine top end special tools and sealants 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 se...

  • Page 263: Engine Top End 5-11

    Engine top end 5-11 special tools and sealants 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 adap...

  • Page 264: 5-12 Engine Top End

    5-12 engine top end special tools and sealants liquid gasket, tb1216b: 92104-1064.

  • Page 265: Engine Top End 5-13

    Engine top end 5-13 clean air system air suction valve removal • remove: air switching valve (see air switching valve removal) bolts [a] • disconnect the connectors [b], and remove the horn [c]. • slide the dust cover [a]. • disconnect the radiator fan motor lead connector [b]. • remove: radiator lo...

  • Page 266: 5-14 Engine Top End

    5-14 engine top end clean air system • move the radiator rightward [a] to clear the frame projec- tion [b], and remove it. • disconnect the stick coil connectors. • turn up the heat insulation rubber plate. • install the radiator temporarily to prevent damage the ra- diator core. • remove the connec...

  • Page 267: Engine Top End 5-15

    Engine top end 5-15 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 268: 5-16 Engine Top End

    5-16 engine top end clean air system clean air system hose inspection • be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the air cleaner housing, air switching valve and air suction valve covers. If they are not, correct them. Replace them ...

  • Page 269: Engine Top End 5-17

    Engine top end 5-17 cylinder head cover cylinder head cover removal • remove: air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter) stick coils (see stick coil removal in the electrical sys- tem chapter) air suction valves (see air suction valve removal) bracket bolt...

  • Page 270: 5-18 Engine Top End

    5-18 engine top end cylinder head cover • replace the head cover gasket with a new one. • using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. • apply liquid gasket [a] to the cylinder head cover [b] as shown. Sealant...

  • Page 271: Engine Top End 5-19

    Engine top end 5-19 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 272: 5-20 Engine Top End

    5-20 engine top end 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) • using a wrench on the timing rotor bolt [a], turn the crank- shaft clockwise un...

  • Page 273: Engine Top End 5-21

    Engine top end 5-21 camshaft, camshaft chain camshaft installation • be sure to install the following parts. Plug hole gaskets [a] dowel pins [b] note ○ the exhaust camshaft has a 8943 ex mark [a] and the intake camshaft has a 8943 in mark [b]. Be careful not to mix up these shafts. • install the ca...

  • Page 274: 5-22 Engine Top End

    5-22 engine top end camshaft, camshaft chain • pull the tension side (exhaust side) [a] of the chain taut to install the chain. • engage the camshaft chain with the sprockets so that tim- ing marks on the sprockets are positioned as shown. ○ the timing marks must be aligned with the cylinder head up...

  • 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. Identification no. 1...

  • Page 276: 5-24 Engine Top End

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

  • Page 277: Engine Top End 5-25

    Engine top end 5-25 camshaft, camshaft chain cam wear inspection • remove the camshafts (see camshaft removal). • measure the height [a] of each cam with a micrometer. If the cams are worn down past the service limit, replace the camshaft. Cam height standard: exhaust 33.743 ∼ 33.857 mm (1.3285 ∼ 1....

  • 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: spark plugs (see spark plug replacement in the peri- odic maintenance chapter) • attach the compression gauge [a] and adapte...

  • Page 279: Engine Top End 5-27

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

  • Page 280: 5-28 Engine Top End

    5-28 engine top end cylinder head • remove the m6 cylinder head bolts [a]. • loosen the m10 cylinder head bolts as shown sequence [1 ∼ 10], and remove them with washers and spring wash- ers. • remove the cylinder head. Cylinder head installation note ○ the camshaft cap is machined with the cylinder ...

  • 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] • 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) [f]: 12 n·m (1.2 kgf·m, 106 in·lb...

  • 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-to-guide clearance measurement (wobble method) if a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. • insert a new valve [a] into the guide [b] and set a dial g...

  • Page 285: Engine Top End 5-33

    Engine top end 5-33 valves valve seat repair • repair the valve seat with the valve seat cutters [a]. Special tools - valve seat cutter holder bar [b]: 57001 -1128 valve seat cutter holder, 4.5 [c]: 57001 -1330 [for exhaust valve seat] valve seat cutter, 45° - 27.5: 57001-1114 valve seat cutter, 32°...

  • Page 286: 5-34 Engine Top End

    5-34 engine top end valves operating procedures • clean the seat area carefully. • coat the seat with machinist’s dye. • fit a 45° cutter into the holder and slide it into the valve guide. • press down lightly on the handle and turn it right or left. Grind the seating surface only until it is smooth...

  • Page 287: Engine Top End 5-35

    Engine top end 5-35 valves if the outside diameter [a] of the seating surface is too large, make the 32° [b] grind described below. If the outside diameter of the seating surface is within the specified range, measure the seat width as described be- low. • grind the seat at a 32° angle until the sea...

  • Page 288: 5-36 Engine Top End

    5-36 engine top end valves • lap the valve to the valve seat, once the seat width and outside diameter are within the ranges specified above. ○ put a little coarse grinding compound on the face of the valve in a number of places around the valve head. ○ spin the valve against the seat until the grin...

  • Page 289: Engine Top End 5-37

    Engine top end 5-37 valves.

  • Page 290: 5-38 Engine Top End

    5-38 engine top end cylinder, pistons cylinder removal • remove: cylinder head (see cylinder head removal) engine bracket (see engine removal in the engine re- moval/installation chapter) radiator bracket bolt [a] radiator bracket [b] • loosen the water hose clamp screw [a]. • disconnect the water h...

  • Page 291: Engine Top End 5-39

    Engine top end 5-39 cylinder, pistons • the piston ring openings must be positioned as shown. 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] lower oil ring ste...

  • Page 292: 5-40 Engine Top End

    5-40 engine top end cylinder, pistons • carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [a] to remove it. • remove the 3-piece oil ring with your thumbs in the same manner. Piston installation note ○ if a new piston is used, use new piston ring. •...

  • Page 293: Engine Top End 5-41

    Engine top end 5-41 cylinder, pistons cylinder wear inspection • since there is a difference in cylinder wear in different di- rections, take a side-to-side and a front-to-back measure- ment at each of the two locations (total of four measure- ments) as shown. If any of the cylinder inside diameter ...

  • Page 294: 5-42 Engine Top End

    5-42 engine top end 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 295: Engine Top End 5-43

    Engine top end 5-43 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] throttle body assy holder bolts [b] throttle body assy holders [c] throttle body assy holder installation • replac...

  • Page 296: 5-44 Engine Top End

    5-44 engine top end 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 297: Engine Top End 5-45

    Engine top end 5-45 muffler • loosen the locknuts [a]. • remove the cable lower ends [b]. • remove the bolts [a] and collars. • clear the hook [b], and remove the exhaust pipe cover [c]. • loosen the muffler body clamp bolt [a]. • remove: right muffler body mounting bolt [b], washer and nut right mu...

  • Page 298: 5-46 Engine Top End

    5-46 engine top end muffler muffler body installation • replace the muffler body gaskets [a] with new ones. • install the muffler body gaskets until it is bottomed so that the inside chamfer side faces rear [b]. • install the muffler body clamps [c] so that the projection [d] fits into the clamp sli...

  • Page 299: Engine Top End 5-47

    Engine top end 5-47 muffler • after installation, make sure that the clearance [a] of both side mufflers are 12 mm (0.47 in.) or more. Muffler body [b] swingarm [c] • install the exhaust pipe cover, and tighten its bolts to- gether with the collars. ○ insert the hook [a] into the grommet [b]. • thor...

  • Page 300: 5-48 Engine Top End

    5-48 engine top end muffler • when installing the muffler covers, note the following. • install the pads [a] to the muffler covers as shown. • install the dampers [b], collars [c] and pads [d] as shown. ○ align the center line of the pad aligns with the edge [e] of the bracket. ○ align the side [f] ...

  • Page 301: Engine Top End 5-49

    Engine top end 5-49 muffler exhaust pipe removal • remove: muffler bodies (see muffler body removal) oxygen sensor (equipped models) (see oxygen sen- sor removal (equipped models) in the electrical system chapter) • support the premuffler chamber with the suitable stand [a]. • remove the premuffler ...

  • Page 302: 5-50 Engine Top End

    5-50 engine top end muffler • slide the dust covers [a] off the adjusters [b]. • loosen the locknuts [c], and turn the adjusters to give the cable plenty of play. • remove: bolts [a] exhaust butterfly valve pulley cover [b] • loosen the locknuts [a]. • remove the cable lower ends [b]. • remove: bolt...

  • Page 303: Engine Top End 5-51

    Engine top end 5-51 muffler exhaust butterfly valve cable installation • before installing the exhaust butterfly valve cables, con- firm that the exhaust valve actuator pulley [a] is in the original position as shown. ○ the pulley edge [b] and housing screw [c] are on the same line. This position is...

  • Page 304: 5-52 Engine Top End

    5-52 engine top end muffler • after adjusting the cables, turn the ignition switch on and make sure that the pulley turns clockwise, then counter- clockwise and then returns slightly clockwise as shown. Note ○ the stop position [a] of the pulley is changed by the cables tension and the closed positi...

  • Page 305: Engine Top End 5-53

    Engine top end 5-53 muffler • when replacing the pulley, note the following. • remove the pulley bolt while holding the pulley [a] with the suitable tool [b]. Notice if the pulley bolt is removed without holding, the actuator damage will occur. • remove the pulley from the actuator. Exhaust butterfl...

  • Page 306: 5-54 Engine Top End

    5-54 engine top end muffler exhaust butterfly valve actuator adjustment pulley position electrically adjustment • turn the ignition switch off. • disconnect the exhaust butterfly valve actuator connec- tors. • connect the exhaust butterfly valve actuator connector (2 pins) to the battery to turn the...

  • Page 307: Clutch 6-1

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

  • Page 308: 6-2 Clutch

    6-2 clutch exploded view.

  • Page 309: Clutch 6-3

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 clutch lever clamp bolts 7.8 0.80 69 in·lb s 2 clutch spring bolts 8.8 0.90 78 in·lb 3 clutch hub nut 135 13.8 100 r 4 clutch cover bolts 9.8 1.0 87 in·lb 5 oil filler plug 2.0 0.20 18 in·lb cl: apply cable lubricant. Eo: apply e...

  • Page 310: 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 311: Clutch 6-5

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

  • Page 312: 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 • remove: upper f...

  • Page 313: Clutch 6-7

    Clutch 6-7 clutch lever and cable clutch lever installation warning if the starter lockout switch pin has been damaged the starter lockout system will not work properly. This allows the motorcycle to be started in gear with the clutch lever released (clutch engaged), creat- ing sudden forward moveme...

  • Page 314: 6-8 Clutch

    6-8 clutch clutch cover clutch cover removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: right lower fairing (see lower fairing removal in the frame chapter) clutch cable lower end (see clutch cable removal) clutch cover bolts [a] bracket [b] • tur...

  • Page 315: Clutch 6-9

    Clutch 6-9 clutch cover release shaft installation • apply grease to the oil seal lips on the upper ridge of the clutch cover. • apply engine oil to the needle bearings in the hole of the clutch cover. • apply molybdenum disulfide grease to the pusher-holding portion [a] on the release shaft. • inst...

  • Page 316: 6-10 Clutch

    6-10 clutch clutch cover clutch cover assembly • replace the needle bearings and oil seal with new ones. Note ○ install the needle bearings so that the manufacture’s mark face out. • apply soap and water solution to the oil seal. • install the needle bearings [a] and oil seal [b] position as shown. ...

  • Page 317: Clutch 6-11

    Clutch 6-11 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]) friction plates and steel plates spring and spring seat note ○ the two plates at both ends are different fro...

  • Page 318: 6-12 Clutch

    6-12 clutch 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 washer • insta...

  • Page 319: Clutch 6-13

    Clutch 6-13 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 ends two f...

  • Page 320: 6-14 Clutch

    6-14 clutch 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. ○ assemble: clutch hub [b] spring seat [c] spring [d] friction plates [e] steel plates [f] clutch sp...

  • Page 321: Clutch 6-15

    Clutch 6-15 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 323: Engine Lubrication System

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

  • Page 324

    7-2 engine lubrication system exploded view.

  • Page 325

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oil cooler bolts 12 1.2 106 in·lb l 2 oil filler plug 2.0 0.20 18 in·lb 3 oil passage plugs 20 2.0 15 l 4 oil passage plug 9.8 1.0 87 in·lb 5 oil pressure switch 15 1.5 11 ss 6 oil pressure switch terminal bolt...

  • Page 326

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

  • Page 327

    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 qt) (when filter is not removed) 3.8 l (4.0 us qt) (when filter is removed) 4.0 l (4.2 us qt) (when engine is completely dry) leve...

  • Page 328

    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 329

    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 330

    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 331

    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 332

    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 333

    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-permanent locking agent to the threads of the oil pressure relief valve, and tig...

  • Page 334

    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 335

    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 fits into the hole [d] of the oil pump cover. • install the ...

  • Page 336

    7-14 engine lubrication system oil cooler oil cooler removal • drain: coolant (see coolant change in the periodic mainte- nance chapter) engine oil (see engine oil change in the periodic main- tenance chapter) • loosen the water hose clamp screws [a]. • disconnect the water hoses [b]. • remove: oil ...

  • Page 337

    Engine lubrication system 7-15 oil pressure measurement oil pressure measurement • remove: right lower fairing (see lower fairing removal in the frame chapter) oil passage plug [a] • attach the adapter [a] and gauge [b] to the plug hole. Special tools - oil pressure gauge, 10 kgf/cm²: 57001-164 oil ...

  • Page 338

    7-16 engine lubrication system oil pressure switch oil pressure switch removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove the left lower fairing (see lower fairing removal in the frame chapter). • slide the switch cover. • remove: switch terminal b...

  • Page 339

    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. • install: oil pipe oil pan (see oil pan installation).

  • Page 341: Engine Removal/installation

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

  • Page 342

    8-2 engine removal/installation exploded view.

  • Page 343

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper engine bracket bolts 44 4.5 32 s 2 lower engine bracket bolts 59 6.0 44 s 3 upper adjusting collar 5.0 0.51 44 in·lb 2t, s 4 upper adjusting collar locknut 49 5.0 36 s 5 upper engine mounting bolt (l = ...

  • Page 344

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

  • Page 345

    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 346

    8-6 engine removal/installation engine removal/installation • slide the clamp [a]. • disconnect the air bleeder hose [b]. • remove the heat insulation rubber plate. • loosen the water hose clamp screw [a]. • disconnect: water hose [b] water temperature sensor connector [c] • disconnect: stick coil c...

  • Page 347

    Engine removal/installation 8-7 engine removal/installation • remove the drive chain [a] from the output shaft [b]. • remove: clamp [a] upper engine bracket bolts [b] middle fairing bracket [c] lower engine bracket bolt [d] and washer engine bracket [e] • free the clutch cable [a] from the guide and...

  • Page 348

    8-8 engine removal/installation engine removal/installation • remove: upper engine mounting bolt [a] (both sides) middle engine mounting nut [b] and bolt lower engine mounting nut [c] • using the nut wrench [a], loosen the upper adjusting collar locknut [b]. Special tool - engine mount nut wrench: 5...

  • Page 349

    Engine removal/installation 8-9 engine removal/installation this page intentionally left blank..

  • Page 350

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

  • Page 351

    Engine removal/installation 8-11 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). • adjust: throttle cables (see throttle control system inspection in t...

  • Page 353: 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 354: 9-2 Crankshaft/transmission

    9-2 crankshaft/transmission exploded view.

  • Page 355: 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 connecting rod big end nuts see the text ← ← mo 4 breather side plate bolt 5.9 0.60 52 in·lb l 5 breather plate bolts 9.8...

  • Page 356: 9-4 Crankshaft/transmission

    9-4 crankshaft/transmission exploded view.

  • Page 357: 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 shift drum bearing holder bolts 12 1.2 106 in·lb l 3 shift drum cam holder bolt 12 1.2 106 in·lb l 4 shift shaft return spring pin 39 4.0 29 l 5 shift pedal mounting...

  • Page 358: 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 359: 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 360: 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 361: 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 362

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

  • Page 363

    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 364

    9-12 crankshaft/transmission crankcase splitting • install: crankshaft (see crankshaft installation) connecting rods (see connecting rod installation) balancer (see balancer installation) transmission shafts (see transmission shaft installa- tion) dowel pins [a] shift drum (see shift drum and fork i...

  • Page 365

    Crankshaft/transmission 9-13 crankcase splitting • fit the lower crankcase to the upper crankcase. Note ○ make the application finish within 20 minutes when the liquid gasket to the mating surface of the lower crankcase half is applied. ○ moreover fit the case and tighten the bolts just after applic...

  • Page 366

    9-14 crankshaft/transmission crankcase splitting • tighten the upper crankcase bolts using the following steps. ○ tighten the m8 bolts [a]. Torque - crankcase bolts (m8): 27 n·m (2.8 kgf·m, 20 ft·lb) ○ replace the washer [b] with a new one. ○ tighten the m7 bolts. L = 85 mm (3.35 in.) [c] l = 50 mm ...

  • Page 367

    Crankshaft/transmission 9-15 crankshaft and connecting rods crankshaft removal • split the crankcase (see crankcase splitting). • remove: connecting rods (see connecting rod removal) balancer (see balancer removal) crankshaft [a] crankshaft installation notice if the crankshaft, bearing inserts, or ...

  • Page 368

    9-16 crankshaft/transmission 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 369

    Crankshaft/transmission 9-17 crankshaft and connecting rods • 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 clamping force without exceeding it unnecessarily, allow...

  • Page 370

    9-18 crankshaft/transmission 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 371

    Crankshaft/transmission 9-19 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 372

    9-20 crankshaft/transmission crankshaft and connecting rods connecting rod bend inspection • remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap. • select an arbor [a] of the same diameter as the connect- ing rod big end, and insert the arbor through the c...

  • Page 373

    Crankshaft/transmission 9-21 crankshaft and connecting rods connecting rod big end bearing insert/crankpin wear inspection • remove the connecting rod big end (see connecting rod removal). • cut strips of plastigage (press gauge) to crankpin width. Place a strip on the crankpin parallel to the crank...

  • Page 374

    9-22 crankshaft/transmission 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 375

    Crankshaft/transmission 9-23 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 376

    9-24 crankshaft/transmission crankshaft and connecting rods crankshaft main journal diameter standard: 34.984 ∼ 35.000 mm (1.3773 ∼ 1.3780 in.) service limit: 34.96 mm (1.376 in.) if any journal has worn past the service limit, replace the crankshaft with a new one. If the measured journal diameters...

  • Page 377

    Crankshaft/transmission 9-25 crankshaft and connecting rods bearing insert* crankcase main bearing inside diameter marking crankshaft main journal diameter marking size color part number journal nos. 92139-0034 2, 4 ○ 1 brown 92139-0219 1, 3, 5 none 1 92139-0033 2, 4 ○ none black 92139-0218 1, 3, 5 ...

  • Page 378

    9-26 crankshaft/transmission balancer balancer removal • split the crankcase (see crankcase splitting). • remove: oil seal [a] balancer [b] balancer installation • check that the rubber dampers [a] are in place as shown. • apply molybdenum disulfide oil solution to the damper contact portions of the...

  • Page 379

    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. • install the balancer shaft clamp lever [b]. • apply a non-permanent locking ...

  • Page 380

    9-28 crankshaft/transmission starter motor clutch starter motor clutch removal/installation • refer to the starter motor clutch disassembly/assembly. Starter motor clutch inspection • remove: alternator cover (see alternator cover removal in the electrical system chapter) starter idle gear and shaft...

  • Page 381

    Crankshaft/transmission 9-29 external shift mechanism shift pedal removal • remove: shift lever bolt [a] shift lever [b] if the tie-rod is removed from the shift pedal and shift lever, note the following. ○ the following portions have left-hand threads. Locknut [c] of shift lever side ball joint [d]...

  • Page 382

    9-30 crankshaft/transmission external shift mechanism external shift mechanism removal • remove: shift lever (see shift pedal removal) clutch (see clutch removal in the clutch chapter) circlip [a] washer [b] special tool - outside circlip pliers: 57001-144 • remove: shift shaft assembly [a] • remove...

  • Page 383

    Crankshaft/transmission 9-31 external shift mechanism • apply grease to the lips of the oil seal [a]. • install the shift shaft [a] so that the return spring pin [b] fits between the spring [c]. • install the washer [a]. • replace the circlip [b] with a new one, and install it. Special tool - outsid...

  • Page 384

    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 385

    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. • apply molybdenum disulfide o...

  • Page 386

    9-34 crankshaft/transmission transmission • remove the ball bearing [a] from each shafts. Special tools - bearing puller [b]: 57001-135 bearing puller adapter [c]: 57001-317 • discard the bearing. Transmission shaft assembly • install the new ball bearing [a] on the each shaft, using the bearing dri...

  • Page 387

    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 388

    9-36 crankshaft/transmission transmission.

  • Page 389

    Crankshaft/transmission 9-37 transmission 1. Output shaft 2. Collar 3. Ball bearings 4. Bushing 5. 2nd gear (39 t) 6. Washer ( 34 × 28.1) 7. Circlips ( 33 × 25.9) 8. Top gear (31 t) 9. Toothed washer ( 34) 10. 4th gear (25 t) 11. Bushings 12. Toothed washer ( 40.5) 13. Toothed washer ( 37) 14. 3rd g...

  • Page 390

    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) shift drum bearing holder bolts [a] shift drum bearing hol...

  • Page 391

    Crankshaft/transmission 9-39 transmission shift fork bending inspection • visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [a] shift fork/gear groove wear inspectio...

  • Page 392

    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 393: Wheels/tires 10-1

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

  • Page 394: 10-2 Wheels/tires

    10-2 wheels/tires exploded view.

  • Page 395: Wheels/tires 10-3

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front axle clamp bolts 20 2.0 15 al 2 front axle 108 11.0 79.7 3 rear axle nut 98 10.0 72 al: tighten the two clamp bolts alternately two times to ensure even tightening torque. Hg: apply high-temperature grease. R: replac...

  • Page 396: 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 0.3 mm (0.01 in.) or less tir 1.0 mm (0.04 in.) axle runout/100 mm (3.94 in.): front tir 0.03 mm (0.0012 in.) or less tir 0.2 mm (0.008 in.) rea...

  • Page 397: Wheels/tires 10-5

    Wheels/tires 10-5 special tools 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 398: 10-6 Wheels/tires

    10-6 wheels/tires wheels (rims) front wheel removal • for the abs equipped models, remove the bolt [a] and front wheel rotation sensor [b]. • remove: front caliper mounting bolts [c] (both sides) front caliper [d] (both sides) • loosen: front axle clamp bolts [a] front axle [b] • remove: lower fairi...

  • Page 399: Wheels/tires 10-7

    Wheels/tires 10-7 wheels (rims) • apply high-temperature grease to the grease seal lips. • fit the collar [a] on the both sides of the hub. ○ the collars are identical. • insert the front axle from the right side. • tighten: torque - front axle: 108 n·m (11.0 kgf·m, 79.7 ft·lb) • before tightening t...

  • Page 400: 10-8 Wheels/tires

    10-8 wheels/tires wheels (rims) • loosen the torque link nuts [a] lightly to turn the chain adjuster easily. • remove: bolt [a] clamp [b] rear wheel rotation sensor [c] rear caliper mounting bolts [d] rear caliper [e] • loosen the chain adjuster clamp bolt [a] on both sides. • turn the chain adjuste...

  • Page 401: Wheels/tires 10-9

    Wheels/tires 10-9 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] ( 41 × 28) • engage the drive chain with the rear sprocket. • insert the rear axle fr...

  • Page 402: 10-10 Wheels/tires

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

  • Page 403: Wheels/tires 10-11

    Wheels/tires 10-11 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 404: 10-12 Wheels/tires

    10-12 wheels/tires 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 405: Wheels/tires 10-13

    Wheels/tires 10-13 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 406: 10-14 Wheels/tires

    10-14 wheels/tires 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 407: Wheels/tires 10-15

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

  • Page 408: 10-16 Wheels/tires

    10-16 wheels/tires 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] • use the bearing remover to remove the hub bearings [a]. Notice do not lay the wheel on the ground with the ...

  • Page 409: Wheels/tires 10-17

    Wheels/tires 10-17 hub bearing • replace the grease seals with new ones. • press in the grease seals [a] so that the seal surface is flush [b] with the end of the hole. ○ apply high-temperature grease to the grease seal lips. Special tool - bearing driver set [c]: 57001-1129 • install the removed pa...

  • Page 411: Final Drive 11-1

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

  • Page 412: 11-2 Final Drive

    11-2 final drive exploded view.

  • Page 413: Final Drive 11-3

    Final drive 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 chain guide bolts 9.8 1.0 87 in·lb l 2 engine sprocket outer cover screws 0.70 0.07 6.2 in·lb 3 engine sprocket nut 125 12.7 92.2 mo 4 rear sprocket nuts 59 6.0 44 r, s 5 chain adjuster clamp bolts 64 6.5 47 hg: apply high-...

  • Page 414: 11-4 Final Drive

    11-4 final drive specifications item standard service limit drive chain 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 (12.6 in.) standard chain: make enuma – – – type ek525zx – – – link 112 links – – – link pin outsid...

  • Page 415: Final Drive 11-5

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

  • Page 416: 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 417: Final Drive 11-7

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

  • Page 418: 11-8 Final Drive

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

  • Page 419: Final Drive 11-9

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

  • Page 420: 11-10 Final Drive

    11-10 final drive sprocket, coupling engine sprocket removal • remove: engine sprocket cover bolts [a] engine sprocket cover [b] • 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 the re...

  • Page 421: Final Drive 11-11

    Final drive 11-11 sprocket, coupling • install: dowel pins [a] • install: engine sprocket cover [a] • tighten the engine sprocket cover bolts. ○ first tighten the two bolts [b] at the dowel pin positions. Engine sprocket cover disassembly • remove: engine sprocket cover (see engine sprocket removal)...

  • Page 422: 11-12 Final Drive

    11-12 final drive sprocket, coupling rear sprocket removal • remove the rear wheel (see rear wheel removal in the wheels/tires chapter). Notice do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch...

  • Page 423: Final Drive 11-13

    Final drive 11-13 sprocket, coupling • install: collar [a] coupling [b] coupling bearing removal • remove: coupling grease seal circlip [a] special tool - inside circlip pliers: 57001-143 • remove the bearing [a] by tapping from the wheel side. Special tool - bearing driver set [b]: 57001-1129 coupl...

  • Page 424: 11-14 Final Drive

    11-14 final drive sprocket, coupling coupling bearing inspection since the coupling bearing is made to extremely close tolerances, the clearance can not normally be measured. Note ○ it is not necessary to remove the coupling bearing for inspection. If the bearing is removed, it will need to be repla...

  • Page 425: Final Drive 11-15

    Final drive 11-15 sprocket, coupling rear sprocket warp inspection • raise the rear wheel off the ground with the stand so that it will turn freely. • set a dial gauge [a] against the rear sprocket [b] near the teeth as shown, and rotate [c] the rear wheel to measure the sprocket runout (warp). The ...

  • Page 427: Brakes 12-1

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

  • Page 428: 12-2 Brakes

    12-2 brakes parts location ................................................................................................................... 12-29 abs servicing precautions ............................................................................................... 12-33 abs troubleshooting out...

  • Page 429: Brakes 12-3

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

  • Page 430: 12-4 Brakes

    12-4 brakes exploded view.

  • Page 431: Brakes 12-5

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front brake reservoir cap bolts 1.5 0.15 13 in·lb 2 front brake reservoir inner bolt 1.2 0.12 11 in·lb l 3 front brake reservoir bolt 7.8 0.80 69 in·lb l 4 brake lever pivot bolt 1.0 0.10 8.9 in·lb si 5 front master cylinder ble...

  • Page 432: 12-6 Brakes

    12-6 brakes exploded view.

  • Page 433: Brakes 12-7

    Brakes 12-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake hose banjo bolts 25 2.5 18 2 rear master cylinder mounting bolts 25 2.5 18 3 brake pedal bolt 8.8 0.90 78 in·lb l 4 rear master cylinder push rod locknut 17 1.7 13 5 rear wheel rotation sensor bolt 25 2.5 18 6 bleed valve ...

  • Page 434: 12-8 Brakes

    12-8 brakes exploded view abs equipped models.

  • Page 435: 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 wheel rotation sensor bolt 25 2.5 18 4. Abs hydraulic unit r: replacement parts note ○ when disassembling the brake hose and pipe, disassemble them by th...

  • Page 436: 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 437: Brakes 12-11

    Brakes 12-11 special tools jack: 57001-1238 attachment jack: 57001-1252 needle adapter set: 57001-1457 jack attachment: 57001-1608.

  • Page 438: 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. ○ ...

  • Page 439: 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] and washer brake pedal [f] brake pedal installation • apply grease to the footpeg pivot shaft [a]. • install: washer [b] brake pedal [c] washer [d] •...

  • Page 440: 12-14 Brakes

    12-14 brakes calipers front caliper removal • remove (abs equipped models): bolt [a] front wheel rotation sensor [b] • loosen the banjo bolt [c] at the brake hose lower end, and tighten it loosely. • remove the caliper mounting bolts [d], and detach the caliper [e] from the disc. • remove the banjo ...

  • Page 441: Brakes 12-15

    Brakes 12-15 calipers front caliper assembly • refer to the caliper rubber parts replacement in the pe- riodic maintenance chapter. Rear caliper disassembly • refer to the caliper rubber parts replacement in the pe- riodic maintenance chapter. Rear caliper assembly • refer to the caliper rubber part...

  • Page 442: 12-16 Brakes

    12-16 brakes calipers rear caliper dust boot and friction boot damage inspection • check that the dust boot [a] and friction boot [b] are not cracked, worn, swollen, or otherwise damaged. If they show any damage, replace it. Caliper piston and cylinder damage inspection • visually inspect the piston...

  • Page 443: Brakes 12-17

    Brakes 12-17 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 brake pads front brake pad installation • check that the pad spring [a] is in place on the caliper. • push the caliper pistons...

  • Page 444: 12-18 Brakes

    12-18 brakes brake pads rear brake pad installation • check that the pad spring [a], guide [b] and insulator [c] are in place on the caliper and holder. • push the caliper piston in by hand as far as it will go. • install the brake pad [a] on the piston side first, then install the other pad on the ...

  • Page 445: Brakes 12-19

    Brakes 12-19 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. • unscrew the clamp bolts [b], and take off the master cylin- der [c] as ...

  • Page 446: 12-20 Brakes

    12-20 brakes master cylinder • remove: cotter pin [a] joint pin [b] • slide the clamp [c]. • disconnect the reservoir hose lower end, and drain the brake fluid into a container. Rear master cylinder installation • replace the cotter pin [a] with a new one. • insert the cotter pin and bend the pin en...

  • Page 447: Brakes 12-21

    Brakes 12-21 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 448: 12-22 Brakes

    12-22 brakes brake disc brake disc removal • remove the wheels (see front/rear wheel removal in the wheels/tires chapter). • remove the brake disc mounting bolts [a], and take off the disc [b]. • remove the wheel rotation sensor rotor [c] (front, abs equipped models). Brake disc installation • repla...

  • Page 449: Brakes 12-23

    Brakes 12-23 brake disc brake disc warp inspection • raise the front/rear wheel off the ground. Special tools - jack: 57001-1238 attachment jack: 57001-1252 jack attachment: 57001-1608 ○ for front disc inspection, turn the handlebars fully to one side. • set up a dial gauge against the disc [a] as s...

  • Page 450: 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 451: 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 452: 12-26 Brakes

    12-26 brakes brake fluid • bleed the brake line and the caliper. ○ repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [a]. 2. Quickly open and close [b] the bleed valve while hold- ing...

  • Page 453: Brakes 12-27

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

  • Page 454: 12-28 Brakes

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

  • Page 455: 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] note ○ the rear wheel rotation sensor and rotor are standard parts of this motorcycle. Rear wheel rotation sensor [a] rear wheel rotation sensor rotor [b] yellow...

  • Page 456: 12-30 Brakes

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

  • Page 457: Brakes 12-31

    Brakes 12-31 anti-lock brake system (equipped models) abs system wiring diagram 1. Ecu 2. Rear wheel rotation sensor 3. Rear brake light switch 4. Abs hydraulic unit 5. Abs self-diagnosis terminal 6. Abs kawasaki diagnosis system connector 7. Frame ground 4 8. Frame ground 1 9. Engine ground 10. Bat...

  • Page 458: 12-32 Brakes

    12-32 brakes anti-lock brake system (equipped models) abs hydraulic unit terminal names 1. Ground: bk/bl 2. Unused 3. Front wheel rotation sensor signal input: bk/w 4. Power supply: br/w 5. Abs kawasaki diagnosis system terminal: p 6. Front and rear brake light switch signal: bl/r 7. Abs self-diagno...

  • Page 459: 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 460: 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 461: Brakes 12-35

    Brakes 12-35 anti-lock brake system (equipped models) ○ the yellow abs indicator (led) may come on if the en- gine is run with the motorcycle on its stand and the trans- mission in gear. If the indicator comes on, just turn the ignition switch off, then clear service code 42, which indi- cates a “fa...

  • Page 462: 12-36 Brakes

    12-36 brakes anti-lock brake system (equipped models) even when the abs is operating normally, the yellow abs indicator (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 indic...

  • Page 463: Brakes 12-37

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

  • Page 464: 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 465: Brakes 12-39

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

  • Page 466: 12-40 Brakes

    12-40 brakes anti-lock brake system (equipped models) pre-diagnosis inspection 2 self-diagnosis outline when the yellow abs indicator light (led) has blinked or goes on, the abs hydraulic unit memorizes and stores the service code (19 codes including “normal code”) for the service person to troubles...

  • Page 467: Brakes 12-41

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

  • Page 468: 12-42 Brakes

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

  • Page 469: Brakes 12-43

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

  • Page 470: 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 yellow abs indicator light (led) as shown below. ○ read 10th digit and unit digit as the yellow abs indicator light (led) blinks. ○ when there are a n...

  • Page 471: Brakes 12-45

    Brakes 12-45 anti-lock brake system (equipped models) service code table service code yellow abs indicator light (led) problems light state 12 start code (not fault) after starts, turn off 13 rear inlet solenoid valve trouble (shorted or open, stuck valve) on 14 rear outlet solenoid valve trouble (s...

  • Page 472: 12-46 Brakes

    12-46 brakes anti-lock brake system (equipped models) service code yellow abs indicator light (led) problems light state 84 output fluid pressure sensor (front brake) trouble (offset abnormal) on 89 power supply voltage for fluid pressure sensor abnormal (voltage abnormal, wiring shorted or open) on.

  • Page 473: Brakes 12-47

    Brakes 12-47 anti-lock brake system (equipped models) yellow abs indicator (led) inspection ○ in this model, the yellow abs indicator (led) [a] goes on or blinks by the control of the abs hydraulic unit. • turn the ignition switch on. If the yellow abs indicator (led) lights, it is normal. If the ye...

  • Page 474: 12-48 Brakes

    12-48 brakes anti-lock brake system (equipped models) if the fuse is good, check the wiring continuity between the positive (+) terminal [a] of the battery and r/bk lead terminal [b] in the abs hydraulic unit lead connector [c]. If there is not the continuity in the lead, replace or repair the main ...

  • Page 475: Brakes 12-49

    Brakes 12-49 anti-lock brake system (equipped models) abs motor relay inspection (service code 35) • remove: front seat (see front seat removal in the frame chap- ter) • check the abs motor relay fuse (25 a) [a] (see fuse inspection in the electrical system chapter). If the fuse is good, check the w...

  • Page 476: 12-50 Brakes

    12-50 brakes 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 yellow abs indicator (led) [a] lights, the abs hy- draulic unit has trouble. Replace the abs hydrau...

  • Page 477: Brakes 12-51

    Brakes 12-51 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 478: 12-52 Brakes

    12-52 brakes 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 yellow abs indicator (led) [a] lights, the abs hy- draulic unit has trouble. Replace the abs hydrau...

  • Page 479: Brakes 12-53

    Brakes 12-53 anti-lock brake system (equipped models) output fluid pressure sensor (front brake) wiring inspection (service code 83) • perform the pre-diagnosis inspection 1 and 2 (see in- quiries to rider). If the yellow abs indicator (led) [a] lights, the abs hy- draulic unit has trouble. Replace ...

  • Page 480: 12-54 Brakes

    12-54 brakes anti-lock brake system (equipped models) • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) battery case (see battery case removal in the frame chapter) • clean the abs hydraulic unit. Notice clean all fittings on the abs hydraulic unit and the rear master cyli...

  • Page 481: Brakes 12-55

    Brakes 12-55 anti-lock brake system (equipped models) • remove: bolts [a] bracket [b] • pull up the abs hydraulic unit [a]. • remove: bolts [b] abs hydraulic unit notice the abs hydraulic unit has been adjusted and set with precision at the factory. Do not try to disas- semble and repair the abs hyd...

  • Page 482: 12-56 Brakes

    12-56 brakes 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 483: Brakes 12-57

    Brakes 12-57 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 484: 12-58 Brakes

    12-58 brakes 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 485: Brakes 12-59

    Brakes 12-59 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 486: 12-60 Brakes

    12-60 brakes anti-lock brake system (equipped models) fuse inspection • remove the fuses (see abs solenoid valve relay fuse (15 a)/abs motor relay fuse (25 a) removal). • refer to the fuse inspection in the electrical system chapter..

  • Page 487: Suspension 13-1

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

  • Page 488: 13-2 Suspension

    13-2 suspension exploded view.

  • Page 489: Suspension 13-3

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper front fork clamp bolts 20 2.0 15 2 lower front fork clamp bolts 23 2.3 17 al 3 front fork top plugs 35 3.6 26 4 piston rod guide case 90 9.2 66 5 front axle clamp bolts 20 2.0 15 al al: tighten the two clamp bolts alte...

  • Page 490: 13-4 Suspension

    13-4 suspension exploded view.

  • Page 491: Suspension 13-5

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper rear shock absorber bolt 34 3.5 25 2 swingarm pivot shaft nut 108 11.0 79.7 3 swingarm pivot shaft 20 2.0 15 4 swingarm pivot adjusting collar locknut 98 10.0 72 5 tie-rod nuts 34 3.5 25 r 6 lower rear shock absorber n...

  • Page 492: 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 1/2 turns out from the fully clockwise position (usable range: 0 ←→ 5 1/2 turns out) compression damper setting ...

  • Page 493: 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 hook wrench t=3.2 r37: 57001-1539 swingarm pivot nut wrench: 57001-1597 jack att...

  • Page 494: 13-8 Suspension

    13-8 suspension special tools needle bearing driver, 28: 57001-1610 top plug wrench (45 mm): 57001-1741 rod guide case wrench, 33 mm: 57001-1744 fork oil seal driver weight, 26 ∼ 46: 57001-1795 fork oil seal driver attachment, 36 ∼ 46: 57001-1798.

  • Page 495: Suspension 13-9

    Suspension 13-9 front fork rebound damping force adjustment • to adjust the rebound damping force, turn the rebound damping force adjuster [a]. ○ the standard adjuster setting is the 2 1/2 turns out from the fully clockwise position. ○ the damping force can be left soft for average riding. But it sh...

  • Page 496: 13-10 Suspension

    13-10 suspension front fork spring preload adjustment • to adjust the spring preload, turn the spring preload ad- juster [a]. ○ the standard adjuster setting is the 6 1/4 turns in from the fully counterclockwise position. ○ the spring preload can be left soft for average riding. But it should be adj...

  • Page 497: Suspension 13-11

    Suspension 13-11 front fork note ○ tighten the front fork top plug before tightening the han- dlebar clamp bolt and upper front fork clamp bolt. ○ the torque of front fork top plug is specified to 35 n·m (3.6 kgf·m, 26 ft·lb) however, when you use the top plug wrench (special tool: 57001-1741) [a], ...

  • Page 498: 13-12 Suspension

    13-12 suspension front fork front fork oil change right front fork • remove the front fork (see front fork removal (each fork leg)). • hold the inner tube lower end in a vise. • using the wrench [a], unscrew the top plug [b] out of the outer tube. Special tool - top plug wrench (45 mm): 57001-1741 •...

  • Page 499: Suspension 13-13

    Suspension 13-13 front fork • remove: piston rod assy [a] collar [b] fork spring [c] • drain the fork oil into a suitable container [a]. ○ pump the inner tube up and down at least 10 times to expel the oil from the fork. • install: fork spring [a] • install the collar [b] so that the large diameter ...

  • Page 500: 13-14 Suspension

    13-14 suspension front fork • hold the inner tube bottom by a vise. • using the rod guide case wrench [a], tighten the piston rod guide case to the inner tube. Special tool - rod guide case wrench, 33 mm: 57001 -1744 torque - piston rod guide case: 90 n·m (9.2 kgf·m, 66 ft·lb) note ○ the tightening ...

  • Page 501: Suspension 13-15

    Suspension 13-15 front fork • replace the o-ring [a] with a new one. • apply grease to the new o-ring. • install the top plug [b] to the piston rod. • holding the top plug with a wrench [c], tighten the piston rod nut against the top plug. Special tool - top plug wrench (45 mm): 57001-1741 • pour th...

  • Page 502: 13-16 Suspension

    13-16 suspension front fork left front fork • remove the front fork (see front fork removal (each fork leg)). • turn the spring preload adjuster fully counterclockwise for removing the piston rod assy easily. • hold the inner tube lower end in a vise. • using the wrench [a], unscrew the top plug [b]...

  • Page 503: Suspension 13-17

    Suspension 13-17 front fork • remove: piston rod [a] collar [b] fork spring [c] • drain the fork oil into a suitable container [a]. ○ pump the inner tube up and down at least 10 times to expel the oil from the fork. • install: fork spring [a] • install the collar [b] so that the large diameter side ...

  • Page 504: 13-18 Suspension

    13-18 suspension front fork • insert the piston rod into the inner tube. • hold the inner tube bottom by a vise. • using rod guide case wrench [a], tighten the piston rod guide case to the inner tube. Special tool - rod guide case wrench, 33 mm: 57001 -1744 torque - piston rod guide case: 90 n·m (9....

  • Page 505: Suspension 13-19

    Suspension 13-19 front fork • replace the o-ring [a] with a new one. • apply grease to the new o-ring. • install the top plug [b] to the piston rod. • holding the top plug with the wrench [c], tighten the piston rod nut against the top plug. Special tool - top plug wrench (45 mm): 57001-1741 • pour ...

  • Page 506: 13-20 Suspension

    13-20 suspension front fork front fork disassembly • remove the front fork (see front fork removal (each fork leg)). • drain the fork oil (see front fork oil change). • remove the dust seal [a] from the outer tube. • remove the circlip [b]. Special tool - inside circlip pliers: 57001-143 • separate ...

  • Page 507: Suspension 13-21

    Suspension 13-21 front fork • insert the inner tube to the outer tube. • after installing the washer, install the oil seal [a] by using the fork oil seal driver [b]. Special tools - fork oil seal driver, 41: 57001-1288 or fork oil seal driver weight, 26 ∼ 46: 57001-1795 fork oil seal driver attachme...

  • Page 508: 13-22 Suspension

    13-22 suspension front fork spring tension inspection • since a spring becomes shorter as it weakens, check its free length [a] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the r...

  • Page 509: Suspension 13-23

    Suspension 13-23 rear shock absorber rebound damping force adjustment • to adjust the rebound damping force, turn the rebound damping force adjuster [a] to the desired position. ○ the standard adjuster setting is the 3/4 turns out from the fully clockwise position. Rebound damping force adjustment a...

  • Page 510: 13-24 Suspension

    13-24 suspension rear shock absorber • 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 attached the frame. Special tool - hook wrench t=3.2 r37: 57001-1539 if the spring action feels too s...

  • Page 511: Suspension 13-25

    Suspension 13-25 rear shock absorber • remove: lower rear shock absorber nut and bolt [a] upper rear shock absorber bolt [b] • remove the rear shock absorber [c] rearward. Rear shock absorber installation • replace the rear shock absorber nuts with new ones. • install the rear shock absorber so that...

  • Page 512: 13-26 Suspension

    13-26 suspension 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, using a suitable tool. Rear shock absorber bearing installation • replace the needle bearing [a] and gre...

  • Page 513: Suspension 13-27

    Suspension 13-27 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 mud guard removal in the frame chapter) chain cover (see drive chain replacement in the final...

  • Page 514: 13-28 Suspension

    13-28 suspension 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 515: Suspension 13-29

    Suspension 13-29 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 516: 13-30 Suspension

    13-30 suspension 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 517: Suspension 13-31

    Suspension 13-31 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 518: 13-32 Suspension

    13-32 suspension tie-rod, rocker arm • raise the rear wheel off the ground with the jack (see rear shock absorber removal). Special tools - jack: 57001-1238 jack attachment: 57001-1608 warning when raising the rear wheel off the ground with the jack and removing part(s) from the motorcycle, be sure ...

  • Page 519: Suspension 13-33

    Suspension 13-33 tie-rod, rocker arm tie-rod and rocker arm bearing removal • remove: tie-rod (see tie-rod removal) rocker arms (see rocker arm removal) swingarm [a] (see swingarm removal) sleeves [b] grease seals [c] • remove the needle bearings [d], using a suitable tool. Tie-rod and rocker arm be...

  • Page 520: 13-34 Suspension

    13-34 suspension tie-rod, rocker arm 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 bearings [b]. • the rollers in a needle bearing normally wear very litt...

  • Page 521: Steering 14-1

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

  • Page 522: 14-2 Steering

    14-2 steering exploded view.

  • Page 523: 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 s 2 right switch housing bolts 3.5 0.36 31 in·lb 3 throttle case bolts 3.5 0.36 31 in·lb 4 left switch housing bolts 3.5 0.36 31 in·lb 5 steering stem head bolt 108 11.0 79.7 6 upper front fork...

  • Page 524: 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 525: 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 526: 14-6 Steering

    14-6 steering steering stem stem, stem bearing removal • remove: front wheel (see front wheel removal in the wheels/tires chapter) front fender (see front fender removal in the frame chapter) upper fairing (see upper fairing removal in the frame chapter) handlebars (see handlebar removal) clamp [a] ...

  • Page 527: Steering 14-7

    Steering 14-7 steering stem • pushing up the stem base, and remove the steering stem nut [a]. Special tool - steering stem nut wrench [b]: 57001-1100 • remove: steering stem stem cap [c] upper ball bearing inner race and ball bearing • to remove the ball bearing outer races [a] pressed into the head...

  • Page 528: 14-8 Steering

    14-8 steering steering stem • apply grease to the lower ball bearing [a], and install it onto the steering stem. ○ the lower and upper ball bearings are identical. • apply grease to the upper ball bearing [b] and inner race [c]. • install the lower ball bearing to the steering stem. • install the st...

  • Page 529: Steering 14-9

    Steering 14-9 steering stem note ○ tighten the upper front fork clamp bolts first, next the stem head bolt, last the lower front fork clamp bolts. ○ tighten the two lower front fork clamp bolts alternately two times to ensure even tightening torque. Torque - upper front fork clamp bolts: 20 n·m (2.0...

  • Page 530: 14-10 Steering

    14-10 steering handlebar handlebar removal • remove: rear view mirror [a] (see rear view mirror removal in the frame chapter) clutch lever clamp bolts [b] clutch lever assembly [c] left switch housing [d] handlebar weight [e] left handlebar grip [f] • remove: rear view mirror [a] (see rear view mirr...

  • Page 531: Steering 14-11

    Steering 14-11 handlebar • install the handlebar holder [a]. • tighten the front holder bolts [b] first, and then tighten the rear holder bolts [c]. There will be a gap [d] at the rear part of the holder after tightening. Torque - handlebar holder bolt: 25 n·m (2.5 kgf·m, 18 ft·lb) • using a high fl...

  • Page 533: Frame 15-1

    Frame 15-1 15 frame table of contents exploded view................................... 15-2 seats ................................................. 15-8 front seat removal ..................... 15-8 front seat installation .................. 15-8 rear seat removal...................... 15-8 rear sea...

  • Page 534: 15-2 Frame

    15-2 frame exploded view.

  • Page 535: Frame 15-3

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear view mirror locknut (upper) 18 1.8 13 lh 2 rear view mirror nut (lower) 30 3.1 22 3 middle fairing screws 1.2 0.12 11 in·lb 4 upper fairing screws 1.2 0.12 11 in·lb 5 front fender mounting bolts 3.9 0.40 35 in·lb 6. Us, ca, ...

  • Page 536: 15-4 Frame

    15-4 frame exploded view.

  • Page 537: Frame 15-5

    Frame 15-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear frame bracket bolts 44 4.5 32 2 front footpeg bracket bolts 25 2.5 18 3 side stand switch bolt 8.8 0.90 78 in·lb l 4 side stand bracket bolts 49 5.0 36 l 5 side stand bolt 29 3.0 21 s 6 side stand nut 44 4.5 32 r, s 7 rear f...

  • Page 538: 15-6 Frame

    15-6 frame exploded view.

  • Page 539: Frame 15-7

    Frame 15-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear frame bolts 25 2.5 18 l 2 rear frame end cover screws 1.2 0.12 11 in·lb 3 flap screws 1.2 0.12 11 in·lb 4. Au model 5. Us, ca, and cal models l: apply a non-permanent locking agent..

  • Page 540: 15-8 Frame

    15-8 frame seats front seat removal • insert the ignition switch key [a] into the seat lock. • pull up the rear part of the front seat [b] while turning the key clockwise, and remove it backward. Front seat installation • insert the front seat tabs [a] under the fuel tank bracket [b]. • insert the s...

  • Page 541: Frame 15-9

    Frame 15-9 fairings upper fairing removal warning the cooling fins [a] at the rear of headlight become hot during normal operation and can cause serious burns. To prevent burns, never touch the cooling fins at the rear of headlight while the engine is run- ning or shortly after it has been stopped. ...

  • Page 542: 15-10 Frame

    15-10 frame fairings upper fairing installation • installation is the reverse of removal. • insert the projections [a] into the holes [b]. • hold the turn signal light leads with the clamps [c]. • insert the hooks [a] into the slots [b]. • insert the projection [c] into the hole [d]. Upper fairing d...

  • Page 543: Frame 15-11

    Frame 15-11 fairings upper fairing assembly • assembly is the reverse of disassembly. Torque - upper fairing screws: 1.2 n·m (0.12 kgf·m, 11 in·lb) headlight (led) assembly mounting screws: 1.2 n·m (0.12 kgf·m, 11 in·lb) headlight control unit bracket screws: 1.2 n·m (0.12 kgf·m, 11 in·lb) fuel tank...

  • Page 544: 15-12 Frame

    15-12 frame fairings middle fairing removal • remove: fuel tank cover (see fuel tank cover removal) bolt [a] (l = 16 mm) and washer bolt [b] (l = 10 mm) and washer bolt [c] (l = 20 mm) and washer • remove the bolts [a]. • pull the middle fairing [b] outward to clear the projection [c] and the hook f...

  • Page 545: Frame 15-13

    Frame 15-13 fairings middle fairing disassembly • remove: middle fairing (see middle fairing removal) quick rivet [a] middle fairing screws [b] • clear the projections [c], and remove the cover [d]. • remove: middle fairing screws [a] middle fairing screws [b] and washers cover [c] brackets [d] • se...

  • Page 546: 15-14 Frame

    15-14 frame fairings ignition switch cover removal • remove: fuel tank cover (see fuel tank cover removal) bolts [a] and washers • remove the bolts [a] while pulling the middle fairing [b] outward. • remove the ignition switch cover [c]. Ignition switch cover installation • installation is the rever...

  • Page 547: Frame 15-15

    Frame 15-15 side covers side cover removal • remove: middle fairing (see middle fairing removal) bolts [a] and washers bolt [b] and collar (only on left side cover) • pull the side cover [c] outward to clear the projection [d] and the hooks [e], and remove the side cover. Side cover installation • i...

  • Page 548: 15-16 Frame

    15-16 frame seat covers seat cover removal • remove: seats (see front/rear seat removal) side covers (see side cover removal) bolt [a] and washer • pull the seat cover [b] outward to clear the projection [c]. • clear the hook [a] with the standard tip screwdriver [b]. ○ push the sear cover from its ...

  • Page 549: Frame 15-17

    Frame 15-17 seat covers • insert the hooks [a] into the slots [b]. • insert the projection [a] into the hole [b]. • be sure to insert the hooks [a]..

  • Page 550: 15-18 Frame

    15-18 frame fenders front fender removal • clear the brake hose from the clamps [a]. • for abs equipped models, clear the front wheel rotation sensor lead from the clamp [b]. • remove: bolts [c] and washers front fender [d] front fender installation • install the front fender. • tighten: torque - fr...

  • Page 551: Frame 15-19

    Frame 15-19 fenders • open the clamp [a]. • remove: bolts [b] guide [c] • remove: connector bracket screws [a] connector bracket [b] flap screws [c] flap [d] rear fender [e] flap and rear fender installation • installation is the reverse of removal. Torque - rear frame end cover screws: 1.2 n·m (0.1...

  • Page 552: 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 warped,...

  • Page 553: Frame 15-21

    Frame 15-21 frame • remove: rear footpeg bracket bolts [a] (both sides) rear frame bracket bolts [b] (both sides) rear frame brackets [c] rear frame bracket installation • tighten: torque - rear frame bracket bolts: 44 n·m (4.5 kgf·m, 32 ft·lb) rear footpeg bracket bolts: 25 n·m (2.5 kgf·m, 18 ft·lb...

  • Page 554: 15-22 Frame

    15-22 frame battery case battery case removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) battery (see battery removal in the electrical system chapter) bolts [a] fuel tank bracket [b] • remove: rivet [a] clamp [b] • disconnect: vehicle-down sensor lead connector [a]...

  • Page 555: Frame 15-23

    Frame 15-23 guard mud guard removal • remove: mud guard mounting bolts [a] • remove: right front footpeg bracket bolts [a] • remove: quick rivets [a] mud guard mounting bolt [b] bracket [c] mud guard [d] mud guard installation • installation is the reverse of removal. • apply a non-permanent locking...

  • Page 556: 15-24 Frame

    15-24 frame side stand side stand removal • raise the rear wheel off the ground with a stand. • remove: side stand switch bolt [a] side stand switch [b] • remove: spring [a] side stand nut [b] side stand bolt [c] collar side stand [d] side stand installation • apply grease to the sliding area [a] of...

  • Page 557: Frame 15-25

    Frame 15-25 rear view mirrors rear view mirror removal • remove: bolt [a] cover [b] • loosen the rear view mirror locknut (upper) [a], and re- move the rear view mirror stay [b] from the rear view mir- ror nut (lower) [c]. ○ the rear view mirror locknut (upper) and rear view mirror stay are left-han...

  • Page 559: Electrical System 16-1

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

  • Page 560: 16-2 Electrical System

    16-2 electrical system starter motor removal...................................................................................................... 16-53 starter motor installation................................................................................................... 16-53 starter motor d...

  • Page 561: Electrical System 16-3

    Electrical system 16-3 fuse installation................................................................................................................ 16-113 fuse inspection................................................................................................................. 16-113.

  • Page 562: 16-4 Electrical System

    16-4 electrical system exploded view.

  • Page 563: Electrical System 16-5

    Electrical system 16-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 meter cover bolts 0.40 0.04 3.5 in·lb 2 city light mounting screws 1.2 0.12 11 in·lb 3 headlight (led) assembly mounting screws 1.2 0.12 11 in·lb 4 headlight control unit bracket screws 1.2 0.12 11 in·lb 5 turn signal...

  • Page 564: 16-6 Electrical System

    16-6 electrical system exploded view.

  • Page 565: Electrical System 16-7

    Electrical system 16-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 left switch housing bolts 3.5 0.36 31 in·ib 2 right switch housing bolts 3.5 0.36 31 in·lb 3 front brake light switch screw 1.2 0.12 11 in·lb 4 side stand switch bolt 8.8 0.90 78 in·lb l 5 oil pressure switch 15 1.5 1...

  • Page 566: 16-8 Electrical System

    16-8 electrical system exploded view.

  • Page 567: Electrical System 16-9

    Electrical system 16-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 spark plugs 13 1.3 115 in·lb 2 water temperature sensor 12 1.2 106 in·lb 3 fuel pump bolts 9.8 1.0 87 in·lb l, s 4 engine ground cable terminal bolt 9.8 1.0 87 in·lb 5 oxygen sensor (equipped models) 44 4.5 32 6. Wvta...

  • Page 568: 16-10 Electrical System

    16-10 electrical system specifications item standard battery type sealed battery model name yt12a-bs capacity 12 v 10 ah (10 hr) voltage 12.8 v or more gross weight 3.5 kg (7.7 lb) electrolyte volume 0.47 l (29 cu in.) charging system type three-phase ac alternator output voltage 51 v or more at 4 0...

  • Page 569: Electrical System 16-11

    Electrical system 16-11 special tools and sealant 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 × 1.5/m35 × 1.5: 57001-...

  • Page 570: 16-12 Electrical System

    16-12 electrical system special tools and sealant key registration adapter: 57001-1746 rotor holder: 57001-1757 liquid gasket, tb1211f: 92104-0004.

  • Page 571: Electrical System 16-13

    Electrical system 16-13 parts location timing rotor [a] crankshaft sensor [b] oxygen sensor (equipped models) [c] horn [a] regulator/rectifier [b] relay box [a] ecu [b] turn signal relay [c] rear brake light switch [a] immobilizer amplifier (immobilizer equipped models) [a].

  • Page 572: 16-14 Electrical System

    16-14 electrical system parts location water temperature sensor [a] alternator [b] radiator fan motor [c] stater motor [d] neutral switch [a] oil pressure switch [b] side stand switch [c] battery 12 v 10 ah [a] starter relay [b] fuse box 1 [c] fuse box 2 [d] air switching valve [a] stick coils [b] s...

  • Page 573: Electrical System 16-15

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

  • Page 574: 16-16 Electrical System

    16-16 electrical system wiring diagram (sea-b1 model).

  • Page 575: Electrical System 16-17

    Electrical system 16-17 wiring diagram (sea-b1 model).

  • Page 576: 16-18 Electrical System

    16-18 electrical system wiring diagram (other than sea-b1 model).

  • Page 577: Electrical System 16-19

    Electrical system 16-19 wiring diagram (other than sea-b1 model).

  • Page 578: 16-20 Electrical System

    16-20 electrical system wiring diagram (abs equipped models: us, ca and cal models).

  • Page 579: Electrical System 16-21

    Electrical system 16-21 wiring diagram (abs equipped models: us, ca and cal models).

  • Page 580: 16-22 Electrical System

    16-22 electrical system wiring diagram (abs equipped models: sea-b1 and th models).

  • Page 581: Electrical System 16-23

    Electrical system 16-23 wiring diagram (abs equipped models: sea-b1 and th models).

  • Page 582: 16-24 Electrical System

    16-24 electrical system wiring diagram (abs equipped models: other than us, ca, cal, sea-b1 and th models).

  • Page 583: Electrical System 16-25

    Electrical system 16-25 wiring diagram (abs equipped models: other than us, ca, cal, sea-b1 and th models).

  • Page 584: 16-26 Electrical System

    16-26 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 585: Electrical System 16-27

    Electrical system 16-27 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 586: 16-28 Electrical System

    16-28 electrical system battery battery removal • turn the ignition switch off. • 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 587: Electrical System 16-29

    Electrical system 16-29 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 588: 16-30 Electrical System

    16-30 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 589: Electrical System 16-31

    Electrical system 16-31 battery initial charge • newly activated sealed batteries require an initial charge. Standard charge: 1.2 a × 5 ∼ 10 hours if using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers: battery mate...

  • Page 590: 16-32 Electrical System

    16-32 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 591: Electrical System 16-33

    Electrical system 16-33 battery terminal voltage: 11.5 ∼ less than 12.8 v standard charge: 1.2 a × 5 ∼ 10 h (see following chart) quick charge: 5 a × 1 h 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 char...

  • Page 592: 16-34 Electrical System

    16-34 electrical system charging system alternator cover removal • drain: engine oil (see engine oil change in the periodic main- tenance chapter) • remove: air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter) left lower fairing (see lower fairing removal in the fra...

  • Page 593: Electrical System 16-35

    Electrical system 16-35 charging system stator coil installation • apply a non-permanent locking agent to the threads of the stator coil bolts and tighten them. Torque - stator coil bolts: 12 n·m (1.2 kgf·m, 106 in·lb) • secure the alternator lead with a holding plate. • apply a non-permanent lockin...

  • Page 594: 16-36 Electrical System

    16-36 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 595: Electrical System 16-37

    Electrical system 16-37 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 596: 16-38 Electrical System

    16-38 electrical system charging system • apply a thin coat of molybdenum disulfide grease to the shaft [a], and install it and starter idle gear [b]. • install the alternator cover (see alternator cover installa- tion). Charging voltage inspection • check the battery condition (see charging conditi...

  • Page 597: Electrical System 16-39

    Electrical system 16-39 charging system • to check the alternator output voltage, do the following procedures. ○ turn the ignition switch off. ○ remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). ○ disconnect the alternator lead connector [a]. ○ connect a tester as shown ...

  • Page 598: 16-40 Electrical System

    16-40 electrical system charging system regulator/rectifier removal • remove: left middle fairing (see middle fairing removal in the frame chapter) • disconnect the connector [a]. • remove: bolts [b] regulator/rectifier [c] with bracket • remove: bolts and nuts [a] regulator/rectifier [b] regulator/...

  • Page 599: Electrical System 16-41

    Electrical system 16-41 charging system.

  • Page 600: 16-42 Electrical System

    16-42 electrical system charging system charging system circuit 1. Ignition switch 2. Load 3. Frame ground 1 4. Engine ground 5. Battery 12 v 10 ah 6. Starter relay 7. Main fuse 30 a 8. Regulator/rectifier 9. Alternator.

  • Page 601: Electrical System 16-43

    Electrical system 16-43 ignition system warning the ignition system produces extremely high volt- age. Do not touch the spark plug, stick coil or stick coil lead while the engine is running, or you could receive a severe electrical shock. Notice do not disconnect the battery cables or any other elec...

  • Page 602: 16-44 Electrical System

    16-44 electrical system ignition system • remove: crankshaft sensor cover bolts [a] crankshaft sensor cover [b] • remove: crankshaft sensor bolts [a] crankshaft sensor [b] crankshaft sensor installation • tighten: torque - crankshaft sensor bolts: 5.9 n·m (0.60 kgf·m, 52 in·lb) • using a high flash-...

  • Page 603: Electrical System 16-45

    Electrical system 16-45 ignition system • install: crankshaft sensor cover [a] • tighten the crankshaft sensor cover bolts [b] while push- ing the crankshaft sensor cover rearward. Torque - crankshaft sensor cover bolts: 12 n·m (1.2 kgf·m, 106 in·lb) • run the crankshaft sensor lead and clutch cable...

  • Page 604: 16-46 Electrical System

    16-46 electrical system ignition system crankshaft sensor peak voltage inspection note ○ be sure the battery is fully charged. ○ using the peak voltage adapter [a] is more reliable way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements. • disc...

  • Page 605: Electrical System 16-47

    Electrical system 16-47 ignition system stick coil removal notice never drop the stick coils, especially on a hard sur- face. Such a shock to the stick coils can damage it. • remove: air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter) • disconnect the stick coil co...

  • Page 606: 16-48 Electrical System

    16-48 electrical system ignition system • remove the stick coils (see stick coil removal), but do not remove the spark plugs. • measure the primary peak voltage as follows. ○ install the new spark plug [a] into each stick coil [b], and ground them onto the engine. ○ connect the peak voltage adapter ...

  • Page 607: Electrical System 16-49

    Electrical system 16-49 ignition system spark plug condition inspection • remove the spark plugs (see spark plug replacement in the periodic maintenance chapter). • visually inspect the spark plugs. If the spark plug center electrode [a] and/or side elec- trode [b] are corroded or damaged, or if the...

  • Page 608: 16-50 Electrical System

    16-50 electrical system ignition system 3rd check • inspect the engine for its secure stop after the following operations are completed. • run the engine to the following conditions. Condition: transmission gear → 1st position clutch lever → release side stand → up • set the side stand on the ground...

  • Page 609: Electrical System 16-51

    Electrical system 16-51 ignition system.

  • Page 610: 16-52 Electrical System

    16-52 electrical system ignition system ignition system circuit 1. Engine stop switch 2. Spark plugs 3. Stick coils 4. Vehicle-down sensor 5. Crankshaft sensor 6. Main throttle sensor 7. Subthrottle sensor 8. Water temperature sensor 9. Neutral switch 10. Side stand switch 11. Ecu 12. Joint connecto...

  • Page 611: Electrical System 16-53

    Electrical system 16-53 electric starter system starter motor removal • remove the throttle body assy (see throttle body assy removal in the fuel system (dfi) chapter) • slide out the rubber cap [a]. • remove: starter motor cable terminal bolt [b] starter motor mounting bolts [c] starter motor [d] s...

  • Page 612: 16-54 Electrical System

    16-54 electrical system electric starter system • remove: left-hand end cover [a] right-hand end cover [b] armature [c] yoke [d] starter motor assembly • apply a thin coat of grease to the oil seal [a]. • install: toothed washer [b] washer [c] • press the springs holding the brush leads with suitabl...

  • Page 613: Electrical System 16-55

    Electrical system 16-55 electric starter system • align the hollow mark [a] on the left-hand end cover and the hollow mark [b] on the yoke. Brush inspection • measure the length [a] of each brush. If any is worn down to the service limit, replace the right -hand end cover assembly. Starter motor bru...

  • Page 614: 16-56 Electrical System

    16-56 electrical system electric starter system note ○ even if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with a tester. If all other starter motor and starter motor circuit components check good, but the starter motor still does not ...

  • Page 615: Electrical System 16-57

    Electrical system 16-57 electric starter system • connect a tester [a] and 12 v battery [b] to the starter relay [c] as shown. If the relay does not work as specified, the relay is defec- tive. Replace the relay. Testing relay criteria: when battery is connected → 0 Ω when battery is disconnected → ...

  • Page 616: 16-58 Electrical System

    16-58 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 617: Electrical System 16-59

    Electrical system 16-59 lighting system input voltage inspection • connect the measuring adapter [a] to the headlight con- trol unit lead connector [b]. Special tool - measuring adapter: 57001-1700 • inspect the input voltage as shown. Input voltage (1) connection to adapter (left headlight): digita...

  • Page 618: 16-60 Electrical System

    16-60 electrical system lighting system • remove: city light mounting screws [a] bracket [b] city light (led) [c] city light (led) installation • installation is the reverse of removal. • check that the pad [a] is in place on the city light (led) [b]. ○ do not install the pad on the mark [c]. ○ fit ...

  • Page 619: Electrical System 16-61

    Electrical system 16-61 lighting system • remove: bolts [a] clamp [b] • remove the tail/brake light (led) [c] rearward. Tail/brake light (led) installation • installation is the reverse of removal. • check that the pads [a] are in place on the tail/brake light (led) [b] ○ fit the pad to the corner l...

  • Page 620: 16-62 Electrical System

    16-62 electrical system lighting system headlight/tail light circuit 1. Ignition switch 2. Fuse box 1 3. Headlight relay fuse 15 a 4. Brake light/horn fuse 7.5 a 5. Fuse box 2 6. Headlight fuse (low left) 7.5 a 7. Headlight fuse (low right) 7.5 a 8. Joint connector e 9. Tail/brake light (led) 10. Li...

  • Page 621: Electrical System 16-63

    Electrical system 16-63 lighting system turn signal light bulb replacement • remove: turn signal light lens screw [a] turn signal light lens [b] • push and turn the bulb [a] counterclockwise and remove it. • insert the new bulb [a] by aligning its pins [b] with the grooves [c] in the socket, and tur...

  • Page 622: 16-64 Electrical System

    16-64 electrical system lighting system • connect one 12 v battery and turn signal lights as indi- cated, and count how many times the lights blink for one minute. Turn signal relay [a] turn signal lights [b] 12 v battery [c] if the lights do not blink as specified, replace the turn sig- nal relay. ...

  • Page 623: Electrical System 16-65

    Electrical system 16-65 lighting system turn signal light circuit 1. Ignition switch (other than us, ca and cal models) 2. Ignition switch (us, ca and cal models) 3. Fuse box 2 4. Turn signal relay fuse 7.5 a 5. Joint connector e 6. Rear right turn signal light 12 v 10 w 7. Rear left turn signal lig...

  • Page 624: 16-66 Electrical System

    16-66 electrical system 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). • co...

  • Page 625: Electrical System 16-67

    Electrical system 16-67 air switching valve air switching valve circuit 1. Ignition switch 2. Fuse box 1 3. Ignition fuse 15 a 4. Air switching valve 5. Ecu 6. Joint connector e 7. Frame ground 5 8. Frame ground 2 9. Engine ground 10. Battery 12 v 10 ah 11. Starter relay 12. Main fuse 30 a 13. Ecu f...

  • Page 626: 16-68 Electrical System

    16-68 electrical system radiator fan system fan motor inspection • remove the air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter). • slide the dust cover [a]. • disconnect the connector [b]. • using an auxiliary leads, supply battery power to the fan motor. If the ...

  • Page 627: Electrical System 16-69

    Electrical system 16-69 meter, gauge, indicator unit meter unit removal • remove: meter cover bolts [a] and washers meter cover [b] • remove: bolts [a] and washers collars city light (led) [b] • slide the dust cover [a], and disconnect the meter con- nector. • remove: meter mounting bolts [b] and wa...

  • Page 628: 16-70 Electrical System

    16-70 electrical system meter, gauge, indicator unit meter unit disassembly • remove: meter unit (see meter unit removal) pads [a] screws [b] lower meter cover [c] • separate the meter assembly [a] and upper meter cover [b]. Meter operation inspection check 1: meter unit switching inspection display...

  • Page 629: Electrical System 16-71

    Electrical system 16-71 meter, gauge, indicator unit clock setting • set the clock mode [a] by pushing the upper button [b]. • push the lower button [c] for more than two seconds. ○ the clock setting menu (hour and minute) should blink. • push the lower button. ○ the hour display [a] starts blinking...

  • Page 630: 16-72 Electrical System

    16-72 electrical system meter, gauge, indicator unit meter system inspection check 2-1: tachometer brightness sensor inspection note ○ this meter unit has the automatically tachometer bright- ness function by the sensor in addition to the manual brightness setting. • push the upper and lower buttons...

  • Page 631: Electrical System 16-73

    Electrical system 16-73 meter, gauge, indicator unit meter unit inspection • remove the meter unit [a] (see meter unit removal). [1] ecu communication line [2] fuel level sensor [3] green left turn signal indicator (led) (+) [4] yellow abs indicator (led) (–) [equipped models] [5] unused [6] ignitio...

  • Page 632: 16-74 Electrical System

    16-74 electrical system meter, gauge, indicator unit ○ about 5 seconds after, the all fuel level gauge segments and fuel level warning indicator start blinking [a]. If the fuel level gauge does not blink, replace the meter unit. Note ○ this meter unit has a failure detection function (for open or sh...

  • Page 633: Electrical System 16-75

    Electrical system 16-75 meter, gauge, indicator unit • check the following items. ○ the number 39 [a] in the display appears and yellow en- gine warning indicator (led) [b] goes on. • push the upper button for more than 2 seconds. • check the following items. ○ the display returns odo mode from numb...

  • Page 634: 16-76 Electrical System

    16-76 electrical system meter, gauge, indicator unit • push the upper [a] and lower [b] buttons more than 2 seconds, within 20 seconds after the terminal [6] discon- nected. • check that the red warning indicator (led) [c] goes on 1 second, and then the indicator starts blinking (immobilizer warning...

  • Page 635: Electrical System 16-77

    Electrical system 16-77 meter, gauge, indicator unit check 3-6: green right turn signal indicator (led) in- spection • connect the leads in the same circuit as check 3-1. • connect the terminal [13] to the battery (+) terminal. • check that the green right turn signal indicator (led) [a] goes on. If...

  • Page 636: 16-78 Electrical System

    16-78 electrical system meter, gauge, indicator unit • check that the yellow abs indicator (led) [a] goes off. If the indicator (led) does not go off, replace the meter unit. Check 3-9: red warning indicator (led) inspection (oil pressure warning) • connect the leads in the same circuit as check 3-1...

  • Page 637: Electrical System 16-79

    Electrical system 16-79 meter, gauge, indicator unit • check that the number of segments on the fuel level gauge [a] matches the resistance value of the variable rheostat. ○ when the terminal [2] is connected, 1 segment in the fuel level gauge should appear about every 15 seconds. Variable rheostat ...

  • Page 638: 16-80 Electrical System

    16-80 electrical system meter, gauge, indicator unit check 3-13: trip a/b meter check • check the trip meter with the speedometer in the same way. If value indicated in the trip meter is not added, replace the meter unit. Note ○ the integrated value of the odometer cannot be reset. • check that when...

  • Page 639: Electrical System 16-81

    Electrical system 16-81 meter, gauge, indicator unit fuel level sensor line self-diagnosis mode inspection note ○ usually when the open or short of the fuel level sensor circuit is detected, it becomes the fuel level sensor line self-diagnosis mode. ○ the all segments of the fuel level gauge and fue...

  • Page 640: 16-82 Electrical System

    16-82 electrical system meter, gauge, indicator unit meter circuit (zr1000f) 1. Ignition switch 2. Water temperature sensor 3. Neutral switch 4. Oil pressure switch 5. Ecu 6. Rear wheel rotation sensor 7. Fuel level sensor 8. Frame ground 2 9. Frame ground 1 10. Engine ground 11. Battery 12 v 10 ah ...

  • Page 641: Electrical System 16-83

    Electrical system 16-83 meter, gauge, indicator unit meter circuit (zr1000g) 1. Ignition switch 2. Water temperature sensor 3. Neutral switch 4. Oil pressure switch 5. Ecu 6. Rear wheel rotation sensor 7. Fuel level sensor 8. Abs hydraulic unit 9. Frame ground 2 10. Frame ground 1 11. Engine ground ...

  • Page 642: 16-84 Electrical System

    16-84 electrical system immobilizer system (equipped models) 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. If the code does not match, ign...

  • Page 643: Electrical System 16-85

    Electrical system 16-85 immobilizer system (equipped models) • insert the registered ignition key to the ignition switch and turn it to “on.” verified ○ the red warning indicator (led) and immobilizer warning indicator [a] blink to display the registration mode (go to the next step). Not verified ○ ...

  • Page 644: 16-86 Electrical System

    16-86 electrical system immobilizer system (equipped models) ○ if there is any problem in the registration, the red warning indicator (led) and immobilizer warning indicator [a] blink to display the collation error. Immobilizer amplifier failure when registered ignition key is inserted. Ignition key...

  • Page 645: Electrical System 16-87

    Electrical system 16-87 immobilizer system (equipped models) • turn the ignition key 1 to “off” and remove the ignition key 1. ○ the red warning indicator (led) and immobilizer warning indicator [a] blink to display the registration mode. Note ○ turn to “off” the ignition switch and wait for the per...

  • Page 646: 16-88 Electrical System

    16-88 electrical system immobilizer system (equipped models) • the ignition key 2 is registered in the ecu. ○ the red warning indicator (led) and immobilizer warning indicator [a] blink 4 times and stops for 1 second and then repeats this cycle. ○ this procedure has registered the 2 ignition keys. •...

  • Page 647: Electrical System 16-89

    Electrical system 16-89 immobilizer system (equipped models) spare ignition key registration flow chart.

  • Page 648: 16-90 Electrical System

    16-90 electrical system immobilizer system (equipped models) 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]. • remove: ignition swi...

  • Page 649: Electrical System 16-91

    Electrical system 16-91 immobilizer system (equipped models) ○ the red warning indicator (led) and immobilizer warning indicator [a] blink 1 time and stops for 1 second and re- peats this cycle. Not verified ○ the red warning indicator (led) and immobilizer warning indicator [a] blink to display the...

  • Page 650: 16-92 Electrical System

    16-92 electrical system immobilizer system (equipped models) • disconnect the immobilizer antenna lead connector, then connect the antenna lead connector of the new ignition switch. • insert the ignition key 1 [a] again into the new ignition switch and turn it to “on.” note ○ insert the next key and...

  • Page 651: Electrical System 16-93

    Electrical system 16-93 immobilizer system (equipped models) • the ignition key 1 is successfully registered in the ecu. ○ the red warning indicator (led) and immobilizer warning indicator [a] blink 2 times and stops for 1 second and then repeats this cycle to indicate successful registering of igni...

  • Page 652: 16-94 Electrical System

    16-94 electrical system immobilizer system (equipped models) ignition key collation error • the ignition key 2 is successfully registered in the ecu. ○ the red warning indicator (led) and immobilizer warning indicator [a] blink 3 times and stops for 1 second and then repeat this cycle to indicate su...

  • Page 653: Electrical System 16-95

    Electrical system 16-95 immobilizer system (equipped models) • replace the ecu [a] (see ecu removal/installation in the fuel system (dfi) chapter). • insert the current registered ignition key into the ignition switch and turn it to “on.” ○ if there is any problem in the registration, the red warnin...

  • Page 654: 16-96 Electrical System

    16-96 electrical system immobilizer system (equipped models) • turn to “off” the registered ignition key and remove it. ○ the red warning indicator (led) and immobilizer warning indicator [a] blink to display the registration mode. Note ○ insert next key and turn it to “on” within 15 seconds af- ter...

  • Page 655: Electrical System 16-97

    Electrical system 16-97 immobilizer system (equipped models) • the other remaining ignition key is registered in the ecu. ○ the red warning indicator (led) and immobilizer warning indicator [a] blink 2 times and stops for 1 second and then repeats this cycle to indicate successful registration of ig...

  • Page 656: 16-98 Electrical System

    16-98 electrical system immobilizer system (equipped models) ○ if there is any problem in the registration, the red warning indicator (led) and immobilizer warning indicator [a] blink to display the collation error. Immobilizer amplifier failure ignition key collation error • the first ignition key ...

  • Page 657: Electrical System 16-99

    Electrical system 16-99 immobilizer system (equipped models) ○ if there is any problem in the registration, the red warning indicator (led) and immobilizer warning indicator [a] blink to display the collation error. Immobilizer amplifier failure when registered ignition key is inserted ignition key ...

  • Page 658: 16-100 Electrical System

    16-100 electrical system immobilizer system (equipped models) note ○ turn the ignition switch to “on” with the registered igni- tion key. ○ check that the engine can be started using all regis- tered ignition keys..

  • Page 659: Electrical System 16-101

    Electrical system 16-101 immobilizer system (equipped models) all keys initial registration flow chart.

  • Page 660: 16-102 Electrical System

    16-102 electrical system immobilizer system (equipped models) immobilizer system parts replacement ignition switch replacement • remove: air cleaner housing (see air cleaner housing removal in the fuel system (dfi) chapter) ignition switch cover (see ignition switch cover re- moval in the frame chap...

  • Page 661: Electrical System 16-103

    Electrical system 16-103 immobilizer system (equipped models) • replace the ignition switch [a] with a new one. • install: pad [b] brackets [c] trim [d] dampers [e] washers [f] bolts [g] • hold the ignition switch leads with the clamp [h], and in- stall the clamp to the bracket. • check that the pad...

  • Page 662: 16-104 Electrical System

    16-104 electrical system immobilizer system (equipped models) • remove the immobilizer amplifier [a] from the bracket. • disconnect the connector [b]. • installation is the reverse of removal. Ecu replacement notice never drop the ecu especially on a hard surface. Such a shock to the ecu can damage ...

  • Page 663: Electrical System 16-105

    Electrical system 16-105 immobilizer system (equipped models) • check that the pads [a] and trims [b] are in place on the upper [c] and lower [d] guards. • connect the connectors to the ecu. • install the connector guard to the ecu connector. • install the lower and upper guards to the ecu. Notice d...

  • Page 664: 16-106 Electrical System

    16-106 electrical system immobilizer system (equipped models) immobilizer system circuit 1. Ignition switch 2. Ecu 3. Immobilizer/kawasaki diagnostic system connector 4. Frame ground 2 5. Frame ground 1 6. Engine ground 7. Battery 12 v 10 ah 8. Starter relay 9. Main fuse 30 a 10. Meter unit 11. Fuse...

  • Page 665: Electrical System 16-107

    Electrical system 16-107 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 666: 16-108 Electrical System

    16-108 electrical system 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 667: Electrical System 16-109

    Electrical system 16-109 switches and sensors 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 sensing part [b] and filter holes [c] of the sensor to prevent oil contact. Oil co...

  • Page 668: 16-110 Electrical System

    16-110 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 frame cover (see tail/brake light (le...

  • Page 669: Electrical System 16-111

    Electrical system 16-111 relay box relay circuit inspection (with the battery connected) battery connection (+) (–) tester connection tester reading (Ω) headlight relay 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...

  • Page 670: 16-112 Electrical System

    16-112 electrical system relay box relay box internal circuit a: headlight circuit relay b: ecu main relay c: fuel pump relay d: starter circuit relay e: fan relay.

  • Page 671: Electrical System 16-113

    Electrical system 16-113 fuse 30 a main/15 a ecu fuse removal • remove: starter relay cover (see starter relay inspection) • pull out the fuses [a] from the starter relay with needle nose pliers. Fuse box fuse removal • remove: front seat (see front seat removal in the frame chap- ter) • unlock the ...

  • Page 673: Appendix 17-1

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

  • Page 674: 17-2 Appendix

    17-2 appendix cable, wire, and hose routing 1. Right switch housing lead 2. Throttle cables 3. Front brake hose 4. Clamp (hold the meter lead and city light lead.) 5. Left switch housing lead 6. Clutch cable 7. Clamps (hold the headlight leads.) 8. Headlight lead connectors 9. Headlight control unit...

  • Page 675: Appendix 17-3

    Appendix 17-3 cable, wire, and hose routing 1. Run the right switch housing lead in back of the front brake hose and throttle cables. Run the throttle cables in front of the front brake hose. 2. Harness cover (hold the right switch housing lead, throttle cables and front brake hose.) 3. Run the righ...

  • Page 676: 17-4 Appendix

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

  • Page 677: Appendix 17-5

    Appendix 17-5 cable, wire, and hose routing 1. Clamp (hold the horn lead.) 2. Clamp (hold the clutch cable and right switch housing lead. Run the right switch housing lead to inside of the clutch cable.) 3. Run the headlight control unit lead to the left side of the connector. 4. Run the main harnes...

  • Page 678: 17-6 Appendix

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

  • Page 679: Appendix 17-7

    Appendix 17-7 cable, wire, and hose routing 1. Headlight control unit 2. Left switch housing lead 3. Throttle cables 4. Main harness 5. Regulator/rectifier 6. Run the throttle cables to the inside of the immobilizer antenna lead (equipped models), left switch housing lead and ignition switch lead. 7...

  • Page 680: 17-8 Appendix

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

  • Page 681: Appendix 17-9

    Appendix 17-9 cable, wire, and hose routing 1. Run the clutch cable in back of the front brake hose. 2. Clamp (hold the clutch cable and right switch housing lead. Run the right switch housing lead to inside of the clutch cable.) 3. Clamp (hold the horn lead.) 4. Run the right switch housing lead to...

  • Page 682: 17-10 Appendix

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

  • Page 683: Appendix 17-11

    Appendix 17-11 cable, wire, and hose routing 1. Run the main harness under the air switching valve. 2. Run the radiator fan motor lead under the frame. 3. Clamp (hold the main harness (for throttle sensors) at the white tape.) 4. Viewed from a 5. Run the right switch housing lead under the frame. Ru...

  • Page 684: 17-12 Appendix

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

  • Page 685: Appendix 17-13

    Appendix 17-13 cable, wire, and hose routing 1. Frame ground terminal (the angle of ground lead is as shown.) 2. Alternator lead 3. Rear wheel rotation sensor lead 4. Crankshaft sensor lead 5. Run the alternator lead under the rear wheel rotation sensor lead and crankshaft sensor lead. 6. Clamp (hol...

  • Page 686: 17-14 Appendix

    17-14 appendix cable, wire, and hose routing 1. Clamp (hold the immobilizer antenna lead (equipped models) and ignition switch lead.) 2. Radiator fan motor lead 3. Run the right switch housing lead and clutch cable under the frame, and run them to the outside of the radiator mounting portion. Run th...

  • Page 687: Appendix 17-15

    Appendix 17-15 cable, wire, and hose routing 1. Alternator lead connector (install it to the connector bracket.) 2. Crankshaft sensor lead connector (install it to the connector bracket.) 3. Connector bracket (install it to the air cleaner housing.) 4. Rear wheel rotation sensor lead connector (inst...

  • Page 688: 17-16 Appendix

    17-16 appendix cable, wire, and hose routing 1. Fuel pump lead 2. Main harness 3. Install the clamp to the battery case as shown. 4. Clamp (hold the main harness. Install it to the rear frame bracket as shown.) 5. Front 6. Install the fuel pump lead connector to the bracket. 7. Install the clamps to...

  • Page 689: Appendix 17-17

    Appendix 17-17 cable, wire, and hose routing 1. Install the clamp to the left side of the projection as shown. 2. Projection of frame 3. Install the clamp to the frame as shown. 4. Run the immobilizer antenna lead (equipped models) and ignition switch lead above the frame. 5. Run the main harness, l...

  • Page 690: 17-18 Appendix

    17-18 appendix cable, wire, and hose routing 1. Battery negative (–) cable 2. Fuel tank breather hose (other than cal, sea-b1 and th models) 3. Run the battery negative (–) cable between the fuel tank breather hose (other than cal, sea-b1 and th models) and main harness. 4. Fuel tank drain hose 5. R...

  • Page 691: Appendix 17-19

    Appendix 17-19 cable, wire, and hose routing 1. Install the clamp to the frame as shown. 2. Battery positive (+) cable 3. Starter motor cable 4. Battery positive (+) lead connector 5. Run the battery positive (+) lead under the starter motor cable. 6. Fuel tank breather hose (other than cal, sea-b1 ...

  • Page 692: 17-20 Appendix

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

  • Page 693: Appendix 17-21

    Appendix 17-21 cable, wire, and hose routing 1. Clamp (hold the alternator lead, side stand switch lead, engine subharness and fuel tank drain hose. Face the open side of the clamp to the inside.) 2. Clamp (hold the alternator lead and side stand switch lead. Install it to the frame as shown.) 3. Ru...

  • Page 694: 17-22 Appendix

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

  • Page 695: Appendix 17-23

    Appendix 17-23 cable, wire, and hose routing 1. Immobilizer amplifier (equipped models) 2. Clamp (equipped models: hold the immobilizer amplifier lead (equipped models), oxygen sen- sor lead (equipped models), crankshaft sensor lead, rear wheel rotation sensor lead and rear brake light switch lead. ...

  • Page 696: 17-24 Appendix

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

  • Page 697: Appendix 17-25

    Appendix 17-25 cable, wire, and hose routing 1. Breather hose (cal, sea-b1 and th models) 2. Fuel pump lead 3. Main harness 4. Run the exhaust butterfly valve cables to the outside of the purge hose and breather hose (cal, sea-b1 and th models). 5. Run the exhaust butterfly valve cables under the ma...

  • Page 698: 17-26 Appendix

    17-26 appendix cable, wire, and hose routing 1. Clamp (hold the rear wheel rotation sensor lead.) 2. Clamp (hold the grommet of the rear wheel rotation sensor lead.) 3. Clamps (hold the rear wheel rotation sensor lead and rear brake hose.) 4. Run the rear wheel rotation sensor lead to the inside of ...

  • Page 699: Appendix 17-27

    Appendix 17-27 cable, wire, and hose routing 1. Relay box 2. Ecu 3. Turn signal relay 4. Install the clamp to the rear frame bracket as shown. 5. Abs self-diagnosis terminal (abs equipped models) 6. Abs kawasaki diagnosis system connector (abs equipped models) 7. Immobilizer (equipped models)/kawasa...

  • Page 700: 17-28 Appendix

    17-28 appendix cable, wire, and hose routing 1. Install the clamp to the rear frame bracket as shown. 2. Fuel pump lead 3. Rear right turn signal light lead connector (install it to the bracket.) 4. Rear left turn signal light lead connector (install it to the bracket.) 5. License plate light lead c...

  • Page 701: Appendix 17-29

    Appendix 17-29 cable, wire, and hose routing 1. Run the rear turn signal light leads, license plate light lead and tail/brake light lead into this hole. 2. Take care not to pinch the leads by the tool kit. 3. Clamp (hold the rear turn signal light leads, license plate light lead and tail/brake light...

  • Page 702: 17-30 Appendix

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

  • Page 703: Appendix 17-31

    Appendix 17-31 cable, wire, and hose routing 1. Rivet 2. Run the fuel tank breather hose (other than cal, sea-b1 and th models) and battery negative (–) cable into the hole of the heat insulation rubber plate. 3. Run the fuel tank drain hose into the hole of the heat insulation rubber plate. 4. Run ...

  • Page 704: 17-32 Appendix

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

  • Page 705: Appendix 17-33

    Appendix 17-33 cable, wire, and hose routing 1. Front heat insulation rubber plate 2. Stick coil connectors 3. Throttle body assy holder #3 and #4 4. Breather hose 5. Fuel hose 6. Rear heart insulation rubber plate (install the rear heat insulation rubber plate to the throttle body assy holder #2 an...

  • Page 706: 17-34 Appendix

    17-34 appendix cable, wire, and hose routing 1. Water temperature sensor lead 2. Subharness 3. Clamp (hold the neutral switch/oil pressure switch lead. Attach the clamp to the upside of the water pipe branch. 4. Run the neutral switch/oil pressure switch lead to the rear side of the water pipe branc...

  • Page 707: Appendix 17-35

    Appendix 17-35 cable, wire, and hose routing 1. Install the clamps as shown. 2. Water hoses 3. Air bleeder hose 4. Radiator overflow hose 5. Reserve tank overflow hose 6. Coolant reserve tank.

  • Page 708: 17-36 Appendix

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

  • Page 709: Appendix 17-37

    Appendix 17-37 cable, wire, and hose routing 1. Water hoses 2. Install the clamps as shown. 3. Install the water hose so that the white paint mark faces upward. 4. Install the water hose so that the white paint mark faces outward. 5. Align the white paint mark of the water hose with the projection o...

  • Page 710: 17-38 Appendix

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

  • Page 711: Appendix 17-39

    Appendix 17-39 cable, wire, and hose routing 1. Run the fuel tank drain hose to the outside of the fuel hose, side stand switch lead and alternator lead. Run it to the inside of the engine subharness and fuel tank breather hose (other than cal, sea-b1 and th models). 2. Run the fuel tank breather ho...

  • Page 712: 17-40 Appendix

    17-40 appendix cable, wire, and hose routing 1. Take care not to pinch the fuel tank drain hose between the fuel tank and air cleaner housing. 2. Run the fuel tank drain hose along the shape of the upper air cleaner housing. 3. Run the fuel tank drain hose between the brake hoses (abs equipped model...

  • Page 713: Appendix 17-41

    Appendix 17-41 cable, wire, and hose routing 1. Starter motor cable 2. Battery negative (–) cable 3. Fuel tank breather hose (other than cal, sea-b1 and th models) 4. Run the fuel tank breather hose (other than cal, sea-b1 and th models) above the starter motor cable, battery negative (–) cable and ...

  • Page 714: 17-42 Appendix

    17-42 appendix cable, wire, and hose routing 1. Radiator overflow hose 2. Run the reserve tank overflow hose in front of the middle engine bracket. 3. Run the reserve tank overflow hose to the inside of the oxygen sensor lead (equipped models) and crankshaft sensor lead. 4. Reserve tank overflow hos...

  • Page 715: Appendix 17-43

    Appendix 17-43 cable, wire, and hose routing 1. Fuel tank breather hose (other than cal, sea-b1 and th models) 2. Starter motor cable 3. Fuel hose 4. Fuel tank drain hose 5. Clamp (hold the engine subharness, side stand switch lead, fuel tank drain hose and alternator lead.) 6. Battery negative (–) ...

  • Page 716: 17-44 Appendix

    17-44 appendix cable, wire, and hose routing 1. Front brake hose 2. Clamp (hold the front brake hose.) 3. Clamps (hold the front brake hose.) 4. Viewed from a.

  • Page 717: Appendix 17-45

    Appendix 17-45 cable, wire, and hose routing 1. Rear wheel rotation sensor 2. Run the rear wheel rotation sensor lead through the clamp. 3. Clamp (hold the rear wheel rotation sensor lead.) 4. Rear wheel rotation sensor lead 5. Clamp (hold the rear brake hose.) 6. Clamps (hold the rear brake hose an...

  • Page 718: 17-46 Appendix

    17-46 appendix cable, wire, and hose routing abs equipped models.

  • Page 719: Appendix 17-47

    Appendix 17-47 cable, wire, and hose routing 1. About 90° 2. About 50° 3. Clamps (hold the brake pipes.) 4. Clamp (hold the front brake hose.) 5. Front wheel rotation sensor lead connector 6. Clamp (hold the front wheel rotation sensor lead.) 7. Clamps (hold the front brake hose and front wheel rota...

  • Page 720: 17-48 Appendix

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

  • Page 721: Appendix 17-49

    Appendix 17-49 cable, wire, and hose routing 1. Rear wheel rotation sensor 2. Run the rear wheel rotation sensor lead through the clamp. 3. Rear brake hose 4. Clamp (hold the rear wheel rotation sensor lead.) 5. Clamp (hold the rear brake hose.) 6. Clamp (hold the rear brake hose.) 7. Clamps (hold t...

  • Page 722: 17-50 Appendix

    17-50 appendix cable, wire, and hose routing cal, sea-b1 and th models.

  • Page 723: Appendix 17-51

    Appendix 17-51 cable, wire, and hose routing 1. Run the purge hose above the engine subharness. 2. Run the purge hose above the stick coil #3 lead. 3. Run the purge hose between the air switching valve hose and stick coil #4 lead. 4. Run the purge hose above the radiator overflow hose. 5. Run the pu...

  • Page 724: 17-52 Appendix

    17-52 appendix cable, wire, and hose routing cal, sea-b1 and th models.

  • Page 725: Appendix 17-53

    Appendix 17-53 cable, wire, and hose routing 1. Run the purge hose between the brake hoses (abs equipped models) and frame ground lead. 2. Clamp (hold the breather hose and purge hose. Place it to the hose joint of the breather hose.) 3. Run the purge hose above the fuel pump lead and main harness. ...

  • Page 726: 17-54 Appendix

    17-54 appendix cable, wire, and hose routing cal, sea-b1 and th models 1. Run the purge hose to the inside of the brake hoses (abs equipped models). 2. Run the purge hose above the radiator overflow hose. 3. Run the purge hose above the radiator overflow hose. Run it to the outside of the main harne...

  • Page 727: Appendix 17-55

    Appendix 17-55 cable, wire, and hose routing cal, sea-b1 and th models 1. Run the purge hose and breather hose between the battery case and rear frame bracket. 2. Purge hose 3. Breather hose 4. Canister 5. Run the breather hose under the fuel pump lead and main harness. Run the purge hose above the ...

  • Page 728: 17-56 Appendix

    17-56 appendix cable, wire, and hose routing cal, sea-b1 and th models 1. Canister 2. Breather hose 3. Clamp (hold the breather hose and purge hose. Place it to the hose joint of the breather hose.) 4. Run the purge hose and breather hose to the inside of the exhaust butterfly valve cables. 5. Purge...

  • Page 729: Appendix 17-57

    Appendix 17-57 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 730: 17-58 Appendix

    17-58 appendix troubleshooting guide fuel line clogged throttle body assy holder loose air cleaner housing holder 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 ri...

  • Page 731: Appendix 17-59

    Appendix 17-59 troubleshooting guide air cleaner housing holder 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 brak...

  • Page 732: 17-60 Appendix

    17-60 appendix 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 733: Appendix 17-61

    Appendix 17-61 troubleshooting guide right and left front fork oil level uneven 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 l...

  • Page 734: Model Application

    Part no.99924-1478-02 model application year model beginning frame no. 2014 zr1000fe jkazrcf1 □ ea000001 jkazrt00ffa000001 2014 zr1000ge jkazrcg1 □ ea000001 jkazrt00fga000001 2015 zr1000ff jkazrcf1 □ fa010001 jkazrt00ffa010001 2015 zr1000gf jkazrcg1 □ fa005001 jkazrt00fga010001 □ :this digit in the ...