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Kawasaki Z750 - 2011 Service Manual

Other manuals for Z750 - 2011: Datasheet, Service Manual
Manual is about: Motorcycle

Summary of Z750 - 2011

  • 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: Z750

    Z750 all rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of quality assurance department/consumer products & mac...

  • Page 6

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

  • Page 7: 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 8

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

  • Page 9: General Information

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

  • Page 10

    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 11

    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 12

    1-4 general information before servicing tightening sequence bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating dia...

  • Page 13

    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 14

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

  • Page 15

    General information 1-7 model identification zr750–j1 left side view: zr750–j1 right side view:.

  • Page 16

    1-8 general information general specifications items zr750–j1 dimensions: overall length 2 080 mm (81.9 in.) overall width 780 mm (30.7 in.) overall height 1 055 mm (41.5 in.) wheelbase 1 425 mm (56.1 in.) road clearance 165 mm (6.5 in.) seat height 815 mm (32.1 in.) dry mass 195 kg (430.0 lb) curb ...

  • Page 17

    General information 1-9 general specifications items zr750–j1 viscosity sae 10w-40 capacity 3.8 l (4.0 us qt) drive train: primary reduction system: type gear reduction ratio 1.714 (84/49) clutch type wet multi disc transmission: type 6-speed, constant mesh, return shift gear ratios: 1st 2.571 (36/1...

  • Page 18

    1-10 general information technical information – air inlet system subthrottle control system the zr750–j1 employs large bore throttle bodies to increase power output. However, sudden changes in throttle opening can cause hesitation and jerky throttle response with a single butterfly valve in a large...

  • Page 19

    General information 1-11 technical information – air inlet system operation the subthrottle control system consists of the subthrottle valve, subthrottle valve actuator with a stepping motor built in it, ecu, and subthrottle sensor. The subthrottle valve is built in the each throttle body. The subth...

  • Page 20

    1-12 general information technical information – new ignition interlock sidestand outline the new ignition interlock sidestand system applied to zr750–j1 models that cannot function if gears are engaged and/or the sidestand is not lifted upward even though clutch lever pulled in, which differs from ...

  • Page 21

    General information 1-13 technical information – tail/brake lights employing led outline this model employs a tail/brake light containing 21 light emitting diodes (led). The led emits luminous beams over a longer life span than those emitted from a traditional electric heated bulb (more than 5 times...

  • Page 22

    1-14 general information technical information – tail/brake lights employing led the emitting color differs according to the materials of semi-conductors. Materials of semi-conductor and emitting color materials of semi-conductor emitting color gaasp, gaalas red gap green gan blue ga: gallium as: ar...

  • Page 23

    General information 1-15 technical information – kawasaki low exhaust emission system since the emission regulations become more severe, kawasaki has adopted a type of simplified kawasaki low exhaust emission system (kleen), which have no catalyst protection sys- tem, according to each regulation of...

  • Page 24

    1-16 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 25: Periodic Maintenance

    Periodic maintenance 2-1 2 periodic maintenance table of contents periodic maintenance chart .............. 2-2 torque and locking agent................. 2-5 specifications .................................... 2-10 special tools ..................................... 2-12 periodic maintenance procedu...

  • Page 26

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

  • Page 27

    Periodic maintenance 2-3 periodic maintenance chart frequency whichever comes first * odometer reading km × 1000 (mile × 1000) 1 6 12 18 24 30 36 see inspection every (0.6) (4) (7.5) (12) (15) (20) (24) page engine stop switch operation year • • • — fuel system (dfi): air cleaner element - clean # •...

  • Page 28

    2-4 periodic maintenance periodic maintenance chart periodic replacement parts: frequency whichever comes first * odometer reading km × 1000 (mile × 1000) 1 12 24 36 48 see change/replace item every (0.6) (7.5) (15) (24) (30) page brake hoses 4 years • 2–36 brake fluid (front and rear) 2 years • • 2...

  • Page 29

    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 liquid gasket. Letters used in the “remarks” column mean: al: tighten the two clamp bolts alternately two times to ensure even ...

  • Page 30

    2-6 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks water pump drain bolt 11 1.1 95 in·lb water pipe bolts 11 1.1 95 in·lb thermostat housing ground bolt 7.0 0.70 61 in·lb thermostat bracket bolt 7.0 0.70 61 in·lb radiator upper bolts 7.0 0.70 61 in·lb radiator ...

  • Page 31

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks engine lubrication: oil filler plug 1.5 0.15 13 in·lb engine oil drain bolt 20 2.0 14 oil filter 31 3.2 23 eo, r holder mounting bolt 76 7.8 56 eo oil pan bolts 11 1.1 95 in·lb oil pipe holder bolts 13 1.3 113 ...

  • Page 32

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks tie-rod locknuts 6.9 0.70 61 in·lb neutral switch 15 1.5 11 wheels/tires: front axle clamp bolt 34 3.5 25 front axle 108 11 80 rear axle nut 108 11 80 final drive: engine sprocket nut 125 13 92 mo engine sprock...

  • Page 33

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks handlebar lower clamp nuts 34 3.5 25 switch housing screws 3.5 0.36 31 in·lb front fork clamp bolts (upper) 20 2.0 14 front fork clamp bolts (lower) 20 2.0 14 al frame: footpeg bracket bolts 34 3.5 25 l side st...

  • Page 34

    2-10 periodic maintenance specifications item standard service limit fuel system: throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 1 100 ±50 r/min (rpm) – – – bypass screws (turn out) 2 ±1/4 (for reference) – – – engine vacuum 29.7 ±1.333 kpa (225 ±10 mmhg) – – – air cleaner eleme...

  • Page 35

    Periodic maintenance 2-11 specifications item standard service limit air pressure: (when cold) front up to 180 kg (397 lb) load: 250 kpa (2.5 kgf/cm², 36 psi) – – – rear up to 180 kg (397 lb) load: 290 kpa (2.9 kgf/cm², 42 psi) – – – final drive: drive chain slack 25 ∼ 35 mm (1.0 ∼ 1.4 in.) – – – dr...

  • Page 36

    2-12 periodic maintenance special tools steering stem nut wrench: 57001–1100 jack: 57001–1238 oil filter wrench: 57001–1249 pilot screw adjuster, c: 57001–1292 hand tester: 57001–1394 spark plug wrench (owner’s tool): 92110–1146.

  • Page 37

    Periodic maintenance 2-13 periodic maintenance procedures fuel system (dfi) fuel hose and connection inspection ○ the fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure in- side the fuel l...

  • Page 38

    2-14 periodic maintenance periodic maintenance procedures throttle control system inspection throttle grip play inspection • check the throttle grip free play [a]. If the free play is incorrect, adjust the throttle cable. Throttle grip free play standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) • check that the ...

  • Page 39

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

  • Page 40

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

  • Page 41

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

  • Page 42

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

  • Page 43

    Periodic maintenance 2-19 periodic maintenance procedures • remove the fuel tank (see fuel system (dfi) chapter). • remove the fuel tank bracket bolts and bracket [a]. • remove: air cleaner duct holder screws [a] • remove the air cleaner duct holder [b] backward. • clean the element by tapping it li...

  • Page 44

    2-20 periodic maintenance periodic maintenance procedures cooling system radiator hose and connection inspection ○ the high pressure inside the radiator hose can cause coolant to leak [a] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deteriorati...

  • Page 45

    Periodic maintenance 2-21 periodic maintenance procedures • when filling the coolant, choose a suitable mixture ratio by referring to the coolant manufacturer’s directions. Caution soft or distilled water must be used with the an- tifreeze in the cooling system. If hard water is used in the system, ...

  • Page 46

    2-22 periodic maintenance periodic maintenance procedures engine top end air suction valve inspection • remove the air suction valve (see engine top end chap- ter). • visually inspect the reeds for cracks, folds, warps, heat damage or other damage. If there is any doubt as to the condition of the re...

  • Page 47

    Periodic maintenance 2-23 periodic maintenance procedures ○ when positioning #4 piston tdc at the end of the compression stroke: inlet valve clearance of #2 and #4 cylinders exhaust valve clearance of #3 and #4 cylinders measuring valve [a] ○ when positioning #1 piston tdc at the end of the compress...

  • Page 48

    2-24 periodic maintenance periodic maintenance procedures • slide the dust cover [a] at the clutch cable lower end out of place. • loosen both adjusting nuts [b] at the clutch cover as far as they will go. • pull the clutch outer cable [c] tight and tighten the adjust- ing nuts against the cover [d]...

  • Page 49

    Periodic maintenance 2-25 periodic maintenance procedures note ○ although 10w-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area. Oil filter change • drain the engine oil (see engine oil change)...

  • Page 50

    2-26 periodic maintenance periodic maintenance procedures tread depth front: standard: 3.4 mm (0.13 in.) service limit: 1 mm (0.04 in.) 1.6 mm (0.06 in.) (at, ch, de) rear: standard: 5.8 mm (0.23 in.) service limit: 2 mm (0.08 in.) (up to 130 km/h (80 mph)) 3 mm (0.12 in.) (over 130 km/h (80 mph)) w...

  • Page 51

    Periodic maintenance 2-27 periodic maintenance procedures final drive 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...

  • Page 52

    2-28 periodic maintenance periodic maintenance procedures • bend the cotter pin [a] over the nut. Warning if the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condi- tion may result. Drive chain wear inspection • remove: chain cover screws [a] chain cov...

  • Page 53

    Periodic maintenance 2-29 periodic maintenance procedures drive chain lubrication • if a special lubricant is not available, a heavy oil such as sae 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. • if the chain appears especially dirty, clea...

  • Page 54

    2-30 periodic maintenance periodic maintenance procedures if it does not, adjust and inspect the brake light switch. • while holding the switch body, turn the adjusting nut [a] to adjust the switch. Caution to avoid damaging the electrical connections in- side the switch, be sure that the switch bod...

  • Page 55

    Periodic maintenance 2-31 periodic maintenance procedures master cylinder inspection (visual inspection) • remove the master cylinders (see brakes chapter). • disassemble the front and rear master cylinders. • check that there are no scratches, rust or pitting on the inner wall [a] of each master cy...

  • Page 56

    2-32 periodic maintenance periodic maintenance procedures brake fluid level inspection • check that the brake fluid level in the front brake reservoir [a] is above the lower level line [b]. Note ○ hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid le...

  • Page 57

    Periodic maintenance 2-33 periodic maintenance procedures • level the brake fluid reservoir. • remove the reservoir cap and diaphragm. • remove the rubber cap from the bleed valve [a] on the caliper. • attach a clear plastic hose [b] to the bleed valve, and run the other end of the hose into a conta...

  • Page 58

    2-34 periodic maintenance periodic maintenance procedures brake line bleeding the brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air ent...

  • Page 59

    Periodic maintenance 2-35 periodic maintenance procedures • bleed the brake line and the caliper: ○ repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [a]. 2. Quickly open and close [b...

  • Page 60

    2-36 periodic maintenance periodic maintenance procedures warning when working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types ...

  • Page 61

    Periodic maintenance 2-37 periodic maintenance procedures suspension front fork oil leak check • visually inspect the front forks [a] for oil leakage, scoring or scratches on the inner surface of the inner tubes. Replace or repair any defective parts, if necessary. Rear shock absorber oil leak check...

  • Page 62

    2-38 periodic maintenance periodic maintenance procedures • bend the claw washer tabs [a]. • remove the steering stem locknut [b] and claw washer [c]. • adjust the steering. Special tool - steering stem nut wrench: 57001–1100 [b] if the steering is too tight, loosen the stem nut [a] a fraction of a ...

  • Page 63

    Periodic maintenance 2-39 periodic maintenance procedures electrical system spark plug inspection • remove: fuel tank (see fuel system (dfi) chapter) • unscrew the thermostat bracket bolt [a]. • disconnect: water temperature sensor connector [b] left switch housing connector [c] ○ if removing the sp...

  • Page 64

    2-40 periodic maintenance periodic maintenance procedures • clean the spark plug, preferably in a sandblasting device, and then clean off any abrasive particles. The plug may also be cleaned using a high-flash point solvent and a wire brush or other suitable tool. If the spark plug center electrode ...

  • Page 65

    Periodic maintenance 2-41 periodic maintenance procedures general lubrication lubrication • before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • lubricate the points listed below with indicated lubricant. Note ○ whenever the vehicl...

  • Page 66

    2-42 periodic maintenance periodic maintenance procedures nut, bolt, and fastener tightness tightness inspection • check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. Note ○ for the engine fasteners, check the tightness of...

  • Page 67: Fuel System (Dfi)

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

  • Page 68

    3-2 fuel system (dfi) sensor resistance inspection .......................................................................................... 3-50 atmospheric pressure sensor (service code 15).................................................................. 3-51 removal................................

  • Page 69

    Fuel system (dfi) 3-3 3 fuel pump relay removal ............................................................................................... 3-80 fuel pump relay inspection ............................................................................................. 3-80 fuel injectors .............

  • Page 70

    3-4 fuel system (dfi) exploded view.

  • Page 71

    Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 throttle cable plate bolt 6.0 0.60 52 in·lb 2 throttle body assy holder clamp bolts 2.0 0.20 17 in·lb 3 choke link holder screws 2.1 0.21 18 in·lb 4 delivery pipe screws 3.4 0.35 30 in·lb 5 fuel pump bolts 9.8 1.0 87 i...

  • Page 72

    3-6 fuel system (dfi) exploded view.

  • Page 73

    Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 inlet air pressure sensor bolt 12 1.2 104 in·lb 2 water temperature sensor 25 2.5 18 3 vehicle down sensor bolts 2.0 0.20 17 in·lb 4 camshaft position sensor bolt 12 1.2 104 in·lb 5 camshaft position sensor rotor bolt ...

  • Page 74

    3-8 fuel system (dfi) dfi parts location dfi: dfi parts (this chapter) 1. Water temperature sen- sor (dfi) 2. Inlet air pressure sensor (dfi) 3. Injectors (dfi) 4. Fuel pump (dfi) 5. Inlet air temperature sensor (dfi) 6. Sealed battery 7. Junction box 8. Ecu fuse 15 a 9. Ecu (dfi) 10. Stick coils 11...

  • Page 75

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

  • Page 76

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

  • Page 77

    Fuel system (dfi) 3-11 dfi wiring diagram terminal names 1. Power supply to sensors 2. Main throttle sensor signal 3. Subthrottle sensor signal 4. Atmospheric pressure sensor signal 5. Water temperature sensor signal (+) 6. Unused 7. Ignition switch signal 8. Unused 9. Camshaft position sensor signa...

  • Page 78

    3-12 fuel system (dfi) specifications item standard digital fuel injection system idle speed 1 100 ±50 r/min (rpm) throttle assy: type four barrel type bore 34 mm (1.34 in.) ecu (electronic control unit): make denso type digital memory type, with built in ic igniter, sealed with resin usable engine ...

  • Page 79

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

  • Page 80

    3-14 fuel system (dfi) special tools oil pressure gauge: 57001–125 fork oil level gauge: 57001–1290 hand tester: 57001–1394 throttle sensor setting adapter: 57001–1400 fuel pressure gauge adapter: 57001–1417 needle adapter set: 57001–1457 throttle sensor setting adapter: 57001–1538 sensor harness ad...

  • Page 81

    Fuel system (dfi) 3-15 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 82

    3-16 fuel system (dfi) dfi servicing precautions ○ whenever the dfi electrical connections are to be discon- nected, first turn off the ignition sw (switch), and discon- nect the battery (–) terminal. Do not pull the lead, only the connector. Conversely, make sure that all the dfi elec- trical conne...

  • Page 83

    Fuel system (dfi) 3-17 troubleshooting the dfi system outline outline when an abnormality in the system occurs, the fi indica- tor led (light emitting diode) light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ecu (electronic ...

  • Page 84

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

  • Page 85

    Fuel system (dfi) 3-19 troubleshooting the dfi system • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. • check the wiring for continuity. ○ use the...

  • Page 86

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

  • Page 87

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

  • Page 88

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

  • Page 89

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

  • Page 90

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

  • Page 91

    Fuel system (dfi) 3-25 dfi system troubleshooting guide symptoms or possible causes actions (chapter) starting technique faulty when flooded, don’t crank engine with throttle fully opened. No spark or spark weak : ignition and engine stop switches not on turn both switches on . Clutch lever not pull...

  • Page 92

    3-26 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) cylinder, piston worn inspect and replace (see chapter 5). Piston ring bad (worn, weak, broken or sticking) inspect and replace (see chapter 5). Piston ring/groove clearance excessive inspect and re...

  • Page 93

    Fuel system (dfi) 3-27 dfi system troubleshooting guide symptoms or possible causes actions (chapter) inlet air temperature sensor trouble inspect (see chapter 3). Water temperature sensor trouble inspect (see chapter 3). Atmospheric pressure sensor trouble inspect (see chapter 3). Fuel pressure too...

  • Page 94

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

  • Page 95

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

  • Page 96

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

  • Page 97

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

  • Page 98

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

  • Page 99

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

  • Page 100

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

  • Page 101

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

  • Page 102

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

  • Page 103

    Fuel system (dfi) 3-37 self-diagnosis service code table service code table service code fi indicator led light problems 11 main throttle sensor malfunction, wiring open or short 12 inlet air pressure sensor malfunction, wiring open or short 13 inlet air temperature sensor malfunction, wiring open o...

  • Page 104

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

  • Page 105

    Fuel system (dfi) 3-39 self-diagnosis service codes parts output signal usable range or criteria backups by ecu 32 subthrottle sensor subthrottle sensor output voltage 0.15 ∼ 4.85 v if the subthrottle sensor system fails (the signal is out of the usable range, wiring short or open), the actuator loc...

  • Page 106

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

  • Page 107

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

  • Page 108

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

  • Page 109

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

  • Page 110

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

  • Page 111

    Fuel system (dfi) 3-45 inlet air pressure sensor (service code 12) then pv = pl – pg for example, suppose the following data is obtained: pg = 8 cmhg (vacuum gauge reading) pl = 70 cmhg (barometer reading) vv = 3.2 v (digital volt meter reading) then pv = 70 – 8 = 62 cmhg (abs) plot this pv (62 cmhg...

  • Page 112

    3-46 fuel system (dfi) inlet air pressure sensor (service code 12) pv = 55 ∼ 86 cmhg vv: inlet air pressure sensor output volt- age (v) (digital meter reading) id: idling pv: throttle vacuum pressure (absolute) to: throttle full open ps: standard atmospheric pressure (abso- lute) st: standard of sen...

  • Page 113

    Fuel system (dfi) 3-47 inlet air temperature sensor (service code 13) removal/installation caution never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove the fuel tank (see fuel tank removal). • disconnect the connector [a] from the inlet air tempera-...

  • Page 114

    3-48 fuel system (dfi) inlet air temperature sensor (service code 13) sensor resistance inspection • remove the inlet air temperature sensor (see this sec- tion). • suspend the sensor [a] in a container of machine oil so that the heat-sensitive portion is submerged. • suspend a thermometer [b] with ...

  • Page 115

    Fuel system (dfi) 3-49 water temperature sensor (service code 14) removal/installation caution never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove the fuel tank (see fuel tank removal). • drain the coolant (see cooling system chapter). • disconnect...

  • Page 116

    3-50 fuel system (dfi) water temperature sensor (service code 14) a. Ecu d. Water temperature sensor v. Coolant temperature gauge in tachometer sensor resistance inspection • remove the water temperature sensor (see this section). • refer to the electrical system chapter for water temper- ature sens...

  • Page 117

    Fuel system (dfi) 3-51 atmospheric pressure sensor (service code 15) caution never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Note ○ the atmospheric pressure sensor is the same part as the inlet air pressure sensor except that the inlet air pressure sens...

  • Page 118

    3-52 fuel system (dfi) atmospheric pressure sensor (service code 15) output voltage inspection • measure the output voltage at the ecu in the same way as input voltage inspection. Note the following. Digital meter [a] ecu connector [b] atmospheric pressure sensor output voltage connections to ecu me...

  • Page 119

    Fuel system (dfi) 3-53 atmospheric pressure sensor (service code 15) va: atmospheric pressure sensor output voltage (v) st: standard of sensor output voltage (v) h: altitude (m or feet) ur: usable range of sensor output voltage (v) a. Ecu e. Atmospheric pressure sensor.

  • Page 120

    3-54 fuel system (dfi) crankshaft sensor (service code 21) start the engine and switch the diagnosis mode to dealer 1 mode to know all the problem that the dfi system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of ...

  • Page 121

    Fuel system (dfi) 3-55 camshaft position sensor (service code 23) start the engine and switch the diagnosis mode to dealer 1 mode to know all the problem that the dfi system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- t...

  • Page 122

    3-56 fuel system (dfi) speed sensor (service code 24, 25) speed sensor removal/installation • see the switches and sensors section in the electrical system chapter. Speed sensor inspection • see the switches and sensors section in the electrical system chapter. Input voltage inspection note ○ be sur...

  • Page 123

    Fuel system (dfi) 3-57 speed sensor (service code 24, 25) • disconnect the speed sensor connector [a] and connect the harness adapter [b] between the harness connector and speed sensor connector. Engine sprocket cover [c] • connect a digital meter to the harness adapter leads. Special tool - throttl...

  • Page 124

    3-58 fuel system (dfi) vehicle-down sensor (service code 31) removal caution never drop the down-sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove: connection and vehicle-down sensor [a] bolts [b] installation • the up mark [a] of the sensor should face upward....

  • Page 125

    Fuel system (dfi) 3-59 vehicle-down sensor (service code 31) • turn the ignition switch off. • remove the sensor. • connect a digital volt meter [a] to the connector with nee- dle adapter set [b]. Special tool - needle adapter set: 57001–1457 vehicle-down sensor output voltage connections to sensor ...

  • Page 126

    3-60 fuel system (dfi) vehicle-down sensor (service code 31) a. Ecu s. Ecu main relay t. Ignition switch a. Ecu fuse 15 a b. Vehicle-down sensor d. Starter relay f. Sealed battery j. Joint connector b k. Main fuse 30 a.

  • Page 127

    Fuel system (dfi) 3-61 subthrottle sensor (service code 32) subthrottle sensor removal/adjustment caution do not remove or adjust the subthrottle sensor [a] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sens...

  • Page 128

    3-62 fuel system (dfi) subthrottle sensor (service code 32) output voltage inspection • remove the throttle body assy (see throttle body assy removal). • measure the output voltage at the subthrottle sensor in the same way as input voltage inspection. Note the fol- lowing. • disconnect the subthrott...

  • Page 129

    Fuel system (dfi) 3-63 subthrottle sensor (service code 32) resistance inspection • turn the ignition switch off. • disconnect the subthrottle sensor connector. • connect a digital meter [a] to the subthrottle sensor con- nector [b]. • measure the subthrottle sensor resistance. Throttle sensor resis...

  • Page 130

    3-64 fuel system (dfi) stick coils (#1, #2, #3, #4: service code 51, 52, 53, 54) stick coil #1: ignition coil (service code 51) stick coil #2: ignition coil (service code 52) stick coil #3: ignition coil (service code 53) stick coil #4: ignition coil (service code 54) removal/installation caution ne...

  • Page 131

    Fuel system (dfi) 3-65 stick coils (#1, #2, #3, #4: service code 51, 52, 53, 54) a. Ecu m. Stick coils n. Engine stop switch t. Ignition switch x. Ignition fuse 10 a y. Junction box d. Starter relay e. Joint connector c f. Sealed battery k. Main fuse 30 a.

  • Page 132

    3-66 fuel system (dfi) subthrottle valve actuator (service code 62) subthrottle valve actuator removal caution do not remove the subthrottle valve actuator [a] since it has been adjusted and set with precision at the factory. Never drop the actuator , especially on a hard sur- face. Such a shock to ...

  • Page 133

    Fuel system (dfi) 3-67 subthrottle valve actuator (service code 62) input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the throttle body assy (see throttle body assy removal). • connect the peak voltage adapter [a] and a digital meter [b] t...

  • Page 134

    3-68 fuel system (dfi) fi indicator led light inspection flow chart.

  • Page 135

    Fuel system (dfi) 3-69 fi indicator led light led light inspection • remove the meter unit (see electrical system chapter). • using two auxiliary leads, supply battery power to the fi indicator led light [a]. 12 v battery [b] fi indicator led light check connector: meter connector [c] (disconnected)...

  • Page 136

    3-70 fuel system (dfi) ecu caution never drop the ecu, especially on a hard surface. Such a shock to the ecu can damage it. Ecu removal • remove: seats (see frame chapter) junction box [a] • take the ecu [a] out along with the harness. • disconnect the ecu lead connectors [b]. Ecu installation • con...

  • Page 137

    Fuel system (dfi) 3-71 ecu • with the ecu connectors [a] connected, check the fol- lowing ground lead for continuity with the ignition switch off, using a tester and needle adapter set. Ecu grounding inspection 26, 50, or 51 (bk/y) terminal ←→ battery (–) terminal: 0 Ω engine ground ←→ battery (–) t...

  • Page 138

    3-72 fuel system (dfi) ecu ecu power source circuit a. Ecu s. Ecu main relay t. Ignition switch a. Ecu fuse 15 a d. Starter relay e. Joint connector c f. Sealed battery j. Joint connector b k. Main fuse 30 a.

  • Page 139

    Fuel system (dfi) 3-73 dfi power source ecu fuse removal • refer to the electrical system chapter for the ecu fuse removal. Ecu fuse installation if a fuse fails during operation, inspect the dfi system to determine the cause, and then replace it with a new fuse of proper amperage. • refer to the el...

  • Page 140

    3-74 fuel system (dfi) fuel line fuel pressure inspection note ○ this inspection can determine which trouble the dfi system has, mechanical or electrical trouble. ○ it is preferable to measure the fuel pressure while run- ning the motorcycle just when trouble occurred in order to know symptom well. ...

  • Page 141

    Fuel system (dfi) 3-75 fuel line • start the engine, and let it idle. • measure the fuel pressure with the engine idling. Fuel pressure (idling) standard: 310 kpa (3.2 kgf/cm², 46 psi) note ○ the gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. If...

  • Page 142

    3-76 fuel system (dfi) fuel line • open the fuel tank cap [a] to lower the pressure in the tank. • be sure to place a piece of cloth around the fuel pump outlet hose. • remove the fuel pump outlet hose [a] from the fuel pump [b] and the delivery pipe [c] (see fuel pump removal). Front [d] warning be...

  • Page 143

    Fuel system (dfi) 3-77 fuel pump fuel pump removal caution never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. Warning gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from an...

  • Page 144

    3-78 fuel system (dfi) fuel pump • replace the fuel pump gasket [a] with a new one. • check that the fuel pump (–) terminal [a] and band [b] are in place. Front [c] • apply a non-permanent locking agent to the threads of the fuel pump bolts. • tighten the fuel pump bolts to a snug fit, following the...

  • Page 145

    Fuel system (dfi) 3-79 fuel pump • connect the hand tester (25 v dc) to the fuel pump con- nector [a] with needle adapter set. Special tools - hand tester: 57001–1394 needle adapter set: 57001–1457 ○ measure the operating voltage with the engine stopped, and with the connector joined. • turn the ign...

  • Page 146

    3-80 fuel system (dfi) fuel pump fuel pump relay removal caution never drop the relay, especially on a hard surface. Such a shock to the relay can damage it. • remove the seat cover (see frame chapter). • remove the fuel pump relay [a] from the tongue of the storage compartment. • disconnect the con...

  • Page 147

    Fuel system (dfi) 3-81 fuel injectors removal/installation • refer to the throttle body assy disassembly/assembly. Audible inspection • start the engine. • apply the tip of a screwdriver [a] to the injector [c]. Put the grip end onto your ear, and listen whether the injector is clicking or not. ○ a ...

  • Page 148

    3-82 fuel system (dfi) fuel injectors output voltage inspection • turn the ignition switch off. • remove the ecu (see ecu section). • connect a digital voltmeter [a] to the ecu connector [b] with the needle adapter set [c]. Special tool - needle adapter set: 57001-1457 injector output voltage connec...

  • Page 149

    Fuel system (dfi) 3-83 fuel injectors injector signal test • prepare two test light sets with male terminals as shown. Rating of bulb [a]: 12 v × 3 ∼ 3.4 w terminal width [b]: 1.8 mm (0.071 in.) terminal thickness [c]: 0.8 mm (0.031 in.) caution do not use larger terminals than specified above. A la...

  • Page 150

    3-84 fuel system (dfi) fuel injectors injector resistance inspection • remove the fuel tank (see fuel tank removal). • disconnect the connector from the injector [a] (see throt- tle body assy disassembly/assembly). • measure the injector resistance with the hand tester [b]. Special tool - hand teste...

  • Page 151

    Fuel system (dfi) 3-85 fuel injectors • check the injector fuel line for leakage as follows: ○ connect a commercially available vacuum/pressure pump [a] to the nipple of the delivery pipe [b] with a high-pressure fuel hose [c] (both ends connected with the clamps [d]) as shown. Torque - fuel hose cl...

  • Page 152

    3-86 fuel system (dfi) fuel injectors a. Ecu k. Fuel injectors n. Engine stop switch t. Ignition switch x. Ignition fuse 10 a y. Junction box z. Fuel pump relay (for fuel pump an injectors) d. Starter relay e. Joint connector c f. Sealed battery j. Joint connector b k. Main fuse 30 a.

  • Page 153

    Fuel system (dfi) 3-87 throttle grip and cables throttle grip play inspection/adjustment • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Choke lever operation ○ do not use the choke lever except when the engine has a starting difficulty like in cold weather (...

  • Page 154

    3-88 fuel system (dfi) throttle body assy idle speed inspection • refer to the idle speed inspection in the periodic main- tenance chapter. Engine vacuum synchronization inspection/ adjustment • refer to the engine vacuum synchronization inspection in the periodic maintenance chapter. High altitude ...

  • Page 155

    Fuel system (dfi) 3-89 throttle body assy • loosen: throttle assy holder clamp bolts [a] air cleaner duct clamp bolts [b] • remove: right and left side covers (see frame chapter) coolant reserve tank (see cooling system in the peri- odic maintenance chapter) crankcase breather hose right and left ai...

  • Page 156

    3-90 fuel system (dfi) throttle body assy • remove the bolt [a] and the throttle cable plate [b] from the throttle body front side. • remove the throttle cable lower ends from the throttle pulley. • remove: choke cable upper end (from choke lever) choke cable lower end [a] • after removing the throt...

  • Page 157

    Fuel system (dfi) 3-91 throttle body assy • apply a thin coating of grease to the throttle cable upper ends. • install the upper ends of the throttle cables in the grip. • fit the projection [a] of the right switch housing into the hole [b] of the handlebar. • turn the throttle grip and make sure th...

  • Page 158

    3-92 fuel system (dfi) throttle body assy caution never drop the injector, especially on a hard sur- face. Such a shock to the injector can damage it. • pull out the injectors along with the delivery pipe [a]. If necessary, remove the injectors from the delivery pipe. Replace the o-rigs of the indic...

  • Page 159

    Fuel system (dfi) 3-93 air cleaner element removal/installation • refer to the air cleaner element cleaning in the periodic maintenance chapter. Air cleaner oil draining a drain hose is connected to the bottom of the air cleaner to drain water or oil accumulated in the cleaner part. • visually check...

  • Page 160

    3-94 fuel system (dfi) fuel tank fuel tank removal warning gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the igniti...

  • Page 161

    Fuel system (dfi) 3-95 fuel tank • be sure to place a piece of cloth [a] around the fuel hose pump outlet joint [b]. • while pinching the hose joint locks [c] with fingers, pull the joint out along the delivery pipe. Warning be prepared for fuel spillage; any spilled fuel must be completely wiped up...

  • Page 162

    3-96 fuel system (dfi) fuel tank • insert the pump outlet hose joint [a] straight onto the de- livery pipe [b] until the hose joint clicks [c]. Front [d] • push and pull [a] the hose joint [b] back and forth more than two times and make sure it is locked and doesn’t come off. When the hose joint is ...

  • Page 163: Cooling System

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

  • Page 164

    4-2 cooling system exploded view.

  • Page 165

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 radiator hose clamp screws 2.0 0.20 17 in·lb 2 radiator fan bolts 8.3 0.85 74 in·lb 3 water pump impeller bolt 9.8 1.0 87 in·lb 4 water pump cover bolts 11 1.1 95 in·lb 5 water pump drain bolt 11 1.1 95 in·lb 6 water pipe...

  • Page 166

    4-4 cooling system coolant flow chart.

  • Page 167

    Cooling system 4-5 coolant flow chart 1. Drain bolt 2. Water pump 3. Cylinder jacket 4. Cylinder head jacket 5. Thermostat housing 6. Radiator cap 7. Radiator 8. Oil filter 9. Reserve tank 10. Reserve tank hose 11. Reserve tank overflow hose 12. Radiator fan 13. Water temperature sensor 14. Radiator...

  • Page 168

    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 169

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

  • Page 170

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

  • Page 171

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

  • Page 172

    4-10 cooling system water pump water pump removal • refer to the oil pump removal in the engine lubrication system chapter. Water pump installation • refer to the oil pump installation in the engine lubrica- tion system chapter. Water pump inspection • check the drainage outlet passage [a] at the bo...

  • Page 173

    Cooling system 4-11 water pump • take the oil seal [a] out of the housing [b] with a hook [c]. Water pump housing assembly caution 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 174

    4-12 cooling system radiator radiator and radiator fan removal warning the radiator fan is connected directly to the bat- tery. The radiator fan may start even if the ignition switch is off. Never touch the radiator fan until the radiator fan connector is dis- connected. Touching the fan before the ...

  • Page 175

    Cooling system 4-13 radiator radiator and radiator fan installation • installation is the reverse of removal. • install the radiator bracket collars [a] as shown. Rubber damper [b] 30 ∼ 40° [c] radiator [d] bracket [e] • tighten: torque - radiator lower bolts [f]: 7.0 n·m (0.70 kgf·m, 61 in·lb) radi...

  • Page 176

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

  • Page 177

    Cooling system 4-15 thermostat thermostat removal • drain the coolant (see cooling system in the periodic maintenance chapter). • remove: fuel tank (see fuel system (dfi) chapter) thermostat bracket bolt [a] ground lead [b] water temperature sensor connector [c] three water hoses [d] • remove the th...

  • Page 178

    4-16 cooling system thermostat • to check valve opening temperature, suspend the ther- mostat [a] in a container of water and raise the tempera- ture of the water. ○ the thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [b] in...

  • Page 179

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

  • Page 180

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

  • Page 181: Engine Top End

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

  • Page 182

    5-2 engine top end exploded view.

  • Page 183

    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 2 cylinder head cover bolts 9.8 1.0 87 in·lb s 3 camshaft cap bolts 12 1.2 104 in·lb s 4 camshaft chain guide bolts 12 1.2 104 in·lb s 5 cylinder head bolts (m10 new bolts) 5...

  • Page 184

    5-4 engine top end exploded view.

  • Page 185

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 coolant drain plug (cylinder) 9.8 1.0 87 in·lb 2 exhaust pipe manifold holder nuts 17 1.7 12 3 muffler body clamp bolt 17 1.7 12 4 muffler body mounting bolt 30 3.0 22 5 crankshaft sensor cover bolts 11 1.1 95 in·lb 6. "1...

  • Page 186

    5-6 engine top end specifications item standard service limit clean air system: vacuum switch valve closing open → close – – – pressure 41 ∼ 49 kpa (310 ∼ 370 mmhg, 6.0 ∼ 7.1 psi) camshafts: cam height: exhaust 36.146 ∼ 36.254 mm (1.4231 ∼ 1.4273 in.) 36.05 mm (1.419 in.) inlet 36.746 ∼ 36.854 mm (1...

  • Page 187

    Engine top end 5-7 specifications item standard service limit valve spring free length: exhaust 40.7 mm (1.602 in.) 38.9 mm (1.531 in.) inlet 40.7 mm (1.602 in.) 38.9 mm (1.531 in.) cylinder, pistons: cylinder inside diameter: 68.400 ∼ 68.412 mm (2.6929 ∼ 2.6934 in.) 68.50 mm (2.6969 in.) piston dia...

  • Page 188

    5-8 engine top end special tools and sealant compression gauge: 57001–221 valve spring compressor assembly: 57001–241 piston pin puller assembly: 57001–910 valve seat cutter, 45° - 24: 57001–1113 valve seat cutter, 45° - 27.5: 57001–1114 valve seat cutter, 32° - 25: 57001–1118 valve seat cutter, 32°...

  • Page 189

    Engine top end 5-9 special tools and sealant valve guide reamer, 4: 57001–1274 valve seat cutter holder, 4: 57001–1275 fork oil level gauge: 57001–1290 compression gauge adapter, m10 × 1.0: 57001–1317 valve seat cutter, 60° - 25: 57001–1328 valve seat cutter, 60° - 27: 57001–1409 spark plug wrench (...

  • Page 190

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

  • Page 191

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

  • Page 192

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

  • Page 193

    Engine top end 5-13 cylinder head cover • tighten the cover bolts following the specified tightening sequence. Torque - cylinder head cover bolts [b]: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install the removed parts (see appropriate chapters)..

  • Page 194

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

  • Page 195

    Engine top end 5-15 camshaft, camshaft chain camshaft removal • remove: cylinder head cover (see cylinder head cover re- moval) pickup coil cover • position the crankshaft at #1, 4 piston tdc. Tdc mark [a] for #1, 4 pistons timing mark (crankcase halves mating surface) [b] • remove: camshaft chain t...

  • Page 196

    5-16 engine top end camshaft, camshaft chain • position the crankshaft at #1, 4 piston tdc. • pull the tension side (exhaust side) [a] of the chain taut to install the chain. • engage the camshaft chain with the camshaft sprockets so that the timing marks on the sprockets are positioned as shown. ○ ...

  • Page 197

    Engine top end 5-17 camshaft, camshaft chain if any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer. Camshaft journal diameter standard: 23.950 ∼ 23.972 mm (0.9429 ∼ 0.9438 in.) service limit: 23.92 mm (0.942 in.) if the camshaft journal diameter ...

  • Page 198

    5-18 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: seats (see frame chapter) fuel tank (see fuel system (dfi) chapter) stick coils spark plugs owner’s tool - spark plug wrench...

  • Page 199

    Engine top end 5-19 cylinder head cylinder head removal • drain the coolant (see cooling system chapter). • remove: exhaust pipes (see exhaust pipe removal) coolant drain bolt [a] (cylinder) • remove: cylinder head cover (see cylinder head cover re- moval) camshaft position sensor (see electrical sy...

  • Page 200

    5-20 engine top end cylinder head • install: front camshaft chain guide [a] o-ring [b] collar [c] • tighten: torque - front camshaft chain guide bolt (upper) [d]: 25 n·m (2.5 kgf·m, 18 ft·lb) front camshaft chain guide bolt (lower) [e]: 12 n·m (1.2 kgf·m, 104 in·lb) • install the removed parts (see ...

  • Page 201

    Engine top end 5-21 valves valve clearance inspection • refer to the engine top end in the periodic maintenance chapter. Valve removal • remove the cylinder head (see cylinder head removal). • remove the valve lifter and shim. ○ mark and record the valve lifter and shim locations so they can be inst...

  • Page 202

    5-22 engine top end valves valve guide installation • apply oil to the valve guide outer surface before installa- tion. • heat the area around the valve guide hole to about 120 ∼ 150°c (248 ∼ 302°f). • drive the valve guide in from the top of the head using the valve guide arbor. The flange stops th...

  • Page 203

    Engine top end 5-23 valves valve seat inspection • remove the valve (see valve removal). • check the valve seating surface [a] between the valve [b] and valve seat [c]. ○ measure the outside diameter [d] of the seating pattern on the valve seat. If the outside diameter is too large or too small, rep...

  • Page 204

    5-24 engine top end valves seat cutter operation care: 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. 3. Do not fa...

  • Page 205

    Engine top end 5-25 valves • measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range. Widened width [a] of engagement by machining with 45° cutter ...

  • Page 206

    5-26 engine top end valves if the seat width is too wide, make the 60° [a] grind de- scribed below. If the seat width is within the specified range, lap the valve to the seat as described below. • grind the seat at a 60° angle until the seat width is within the specified range. ○ to make the 60° gri...

  • Page 207

    Engine top end 5-27 valves.

  • Page 208

    5-28 engine top end cylinder, pistons cylinder removal • remove: cylinder head (see cylinder head removal) water hose [a] • remove the cylinder [b]. Cylinder installation note ○ if a new cylinder is used, use new piston ring. • install the dowel pins [a] and new cylinder gasket [b]. • apply engine o...

  • Page 209

    Engine top end 5-29 cylinder, pistons • remove the piston pins. Special tool - piston pin puller assembly: 57001–910 [a] • remove the pistons. • carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [a] to remove it. • remove the 3-piece oil ring with y...

  • Page 210

    5-30 engine top end cylinder, pistons note ○ if a new piston is used, use new piston ring. • install the piston with its marking hollow facing forward. • fit a new piston pin snap ring into the side of the piston so that the ring opening [a] does not coincide with the slit [b] of the piston pin hole...

  • Page 211

    Engine top end 5-31 cylinder, pistons piston ring, piston ring groove wear • check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. • with the piston rings in their grooves, make ...

  • Page 212

    5-32 engine top end cylinder, pistons piston ring end gap • place the piston ring [a] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. • measure the gap [b] between the ends of the ring with a thickn...

  • Page 213

    Engine top end 5-33 throttle body holder throttle body holder installation • be sure to install the o-rings [a]. • install the clamps [b] as shown and so that its hole fit on the projection [c] of the holder. • tighten: torque - throttle body holder bolts [d]: 13 n·m (1.3 kgf·m, 113 in·lb) throttle ...

  • Page 214

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

  • Page 215

    Engine top end 5-35 muffler ○ install the muffler body clamp bolt as shown. Upper side [h] outside [i] • thoroughly warm up the engine, wait until the engine cools down, and retighten all the bolts and nuts..

  • Page 217: Clutch

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

  • Page 218

    6-2 clutch exploded view.

  • Page 219

    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 cover mounting bolts 11 1.1 95 in·lb 3 oil filler plug 1.5 0.15 13 in·lb 4 clutch spring bolts 8.8 0.90 78 in·lb 5 clutch hub nut 135 14 100 r cl: apply cable lubricant. Eo: a...

  • Page 220

    6-4 clutch specifications item standard service limit clutch lever free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – clutch: clutch plate assembly 37.7 ∼ 38.3 mm (1.48 ∼ 1.51 in.) – – – friction plate thickness 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) 2.4 mm (0.094 in.) friction and steel plate warp 0.2 mm (0.00...

  • Page 221

    Clutch 6-5 special tool and sealant clutch holder: 57001–1243 kawasaki bond (silicone sealant): 56019–120

  • Page 222

    6-6 clutch clutch lever and cable clutch lever free play inspection • refer to the clutch in the periodic maintenance chapter. Clutch lever free play adjustment • refer to the clutch in the periodic maintenance chapter. Cable removal • slide the dust cover [a] at the clutch cable lower end out of pl...

  • Page 223

    Clutch 6-7 clutch lever and cable clutch lever adjustment the adjuster has 5 positions so that the clutch lever posi- tion 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 holder. ○ the distance f...

  • Page 224

    6-8 clutch clutch cover clutch cover removal • remove: engine oil (drain, see engine lubrication system in the periodic maintenance chapter) clutch cable lower end [a] clutch cover mounting bolts [b] • turn the release lever [a] toward the rear as shown, and remove the clutch cover [b]. About 90° [c...

  • Page 225

    Clutch 6-9 clutch cover • fit the spring [a] as shown. Viewed from rear [b] release shaft [c] clutch cover [d] clutch cover disassembly • remove: oil seal [a] needle bearings • remove: circlip [a] oil level gauge [b] clutch cover assembly • replace the needle bearings and oil seal with new ones. Not...

  • Page 226

    6-10 clutch clutch clutch removal • remove: engine oil (drain, see engine lubrication system in the periodic maintenance chapter) clutch cover (see clutch cover removal) clutch spring bolts [a] clutch springs clutch spring plate [b] (with thrust bearing and pusher [c], spring and washer) • remove: f...

  • Page 227

    Clutch 6-11 clutch ○ install the spacer [a] so that the tapered side [b] faces inward. ○ install the washer [a] so that the outside mark faces outward. ○ replace the clutch hub nut with a new one. ○ holding the clutch hub, tighten the clutch hub nut. Special tool - clutch holder: 57001–1243 torque -...

  • Page 228

    6-12 clutch clutch • apply molybdenum disulfide grease to the pusher ends [a] and install the bearing [b], pusher [c], spring [d] and washer [e] in the clutch spring plate [f]. ○ apply engine oil to the needle bearing. • install the clutch spring plate, springs and spring holders, and tighten the cl...

  • Page 229

    Clutch 6-13 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 231: Engine Lubrication System

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

  • Page 232

    7-2 engine lubrication system exploded view.

  • Page 233

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oil filler plug 1.5 0.15 13 in·lb 2 engine oil drain bolt 20 2.0 14 3 oil filter 31 3.2 23 eo, r 4 holder mounting bolt 76 7.8 56 eo 5 oil pan bolts 11 1.1 95 in·lb 6 oil pipe holder bolts 13 1.3 113 in·lb l 7 ...

  • Page 234

    7-4 engine lubrication system engine oil flow chart.

  • Page 235

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

  • Page 236

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

  • Page 237

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

  • Page 238

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

  • Page 239

    Engine lubrication system 7-9 oil pan oil pan removal • remove: engine oil (drain, see engine lubrication system in the periodic maintenance chapter) exhaust pipe assy and muffler body (see engine top end chapter) oil pan bolts [a] oil pan [b] oil pan installation • clean the oil screen [a]. • insta...

  • Page 240

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

  • Page 241

    Engine lubrication system 7-11 oil pump oil pump removal • drain: coolant (see cooling system in the periodic mainte- nance chapter) engine oil (see engine lubrication system in the peri- odic maintenance chapter) • remove: water pipe bolts [a] water pipes [b] • remove: water pump cover bolts [a] cl...

  • Page 242

    7-12 engine lubrication system oil pump • install: pins [a] water pump body [b] • install: impeller [a], washer and bolt [b] • tighten: torque - water pump impeller bolt: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install: pins [c] water pump cover and bolts torque - water pump cover bolts: 11 n·m (1.1 kgf·m, ...

  • Page 243

    Engine lubrication system 7-13 oil pressure measurement oil pressure measurement • remove the oil passage plug, and attach the adapter [a] and gauge [b] to the plug hole. Special tools - oil pressure gauge, 10 kgf/cm²: 57001–164 oil pressure gauge adapter, pt 3/8: 57001–1233 • start the engine and w...

  • Page 244

    7-14 engine lubrication system oil pressure switch oil pressure switch removal • remove: engine oil (drain, see engine lubrication system in the periodic maintenance chapter) switch cover [a] switch terminal [b] oil pressure switch [c] oil pressure switch installation • apply silicone sealant to the...

  • Page 245: Engine Removal/installation

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

  • Page 246

    8-2 engine removal/installation exploded view.

  • Page 247

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 adjusting collar locknut 49 5.0 36 s 2 upper engine mounting bolts 44 4.5 33 s 3 rear engine bracket bolts 25 2.5 18 s 4 front engine bracket bolts 44 4.5 33 s 5 middle engine mounting nut 44 4.5 33 s 6 lower...

  • Page 248

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

  • Page 249

    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 be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It could c...

  • Page 250

    8-6 engine removal/installation engine removal/installation • remove: camshaft position sensor connector [a] injector harness connector [b] • remove the vacuum switch valve hose from the air cleaner housing. • remove: breather hose end [a] engine ground cable terminal bolt [b] • support the engine w...

  • Page 251

    Engine removal/installation 8-7 engine removal/installation • remove the middle and lower engine mounting nuts [a] and bolts. • remove: rear engine bracket bolts [b] rear engine bracket [c] • using the nut wrench [a], loosen the locknut [b]. Special tool - engine mount nut wrench: 57001–1450 • using...

  • Page 252

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

  • Page 253

    Engine removal/installation 8-9 engine removal/installation ○ tenth, temporarily install: front engine bracket [c] right upper engine mounting bolt [a] front engine bracket bolts [b] ○ eleventh, tighten the right upper engine mounting bolt. ○ lastly, tighten the front engine bracket bolts. Torque - ...

  • Page 255: Crankshaft/transmission

    Crankshaft/transmission 9-1 9 crankshaft/transmission table of contents exploded view................................... 9-2 specifications .................................... 9-6 special tools and sealant ................. 9-9 crankcase splitting............................ 9-10 crankcase splittin...

  • Page 256

    9-2 crankshaft/transmission exploded view.

  • Page 257

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 breather plate bolts 9.8 1.0 87 in·lb l 2 crankcase bolts (m9, l = 81 mm) 42 4.3 31 mo, s 3 crankcase bolts (m9, l = 95 mm) 42 4.3 31 mo, s 4 crankcase bolts (m8) 27 2.8 20 s 5 crankcase bolts (m7) 20 2.0 14 s 6 ...

  • Page 258

    9-4 crankshaft/transmission exploded view.

  • Page 259

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

  • Page 260

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

  • Page 261

    Crankshaft/transmission 9-7 specifications item standard service limit crankshaft side clearance 0.05 ∼ 0.20 mm 0.40 mm (0.0020 ∼ 0.0079 in.) (0.0157 in.) crankshaft runout tir 0.02 mm (0.0008 in.) or less tir 0.05 mm (0.0020 in.) crankshaft main bearing insert/journal clearance 0.020 ∼ 0.044 mm 0.0...

  • Page 262

    9-8 crankshaft/transmission specifications item standard service limit shift fork guide pin diameter 6.9 ∼ 7.0 mm 6.8 mm (0.272 ∼ 0.276 in.) (0.268 in.) shift drum groove width 7.05 ∼ 7.20 mm 7.3 mm (0.278 ∼ 0.283 in.) (0.287 in.).

  • Page 263

    Crankshaft/transmission 9-9 special tools and sealant bearing puller: 57001–135 bearing puller adapter: 57001–317 kawasaki bond (silicone sealant): 56019–120 kawasaki bond (silicone sealant): 92104–1066.

  • Page 264

    9-10 crankshaft/transmission crankcase splitting crankcase splitting • remove the engine (see engine removal/installation chapter). • set the engine on a clean surface and hold the engine steady while parts are being removed. • remove: crankshaft sensor (see electrical system chapter) clutch (see cl...

  • Page 265

    Crankshaft/transmission 9-11 crankcase splitting • apply liquid gasket to the breather plate mating surface [a] 1 to 1.5 mm (0.04 to 0.06 in.) thick, and then install the breather plate. Sealant - three bond: 1207b • apply a non-permanent locking agent to the threads and tighten the bolts [a]. Torqu...

  • Page 266

    9-12 crankshaft/transmission crankcase splitting • apply liquid gasket [a] to the mating surface of the lower crankcase half. Sealant - kawasaki bond (silicone sealant): 92104–1066 caution do not apply liquid gasket around the crankshaft main bearing inserts, and oil passage holes. • fit the lower c...

  • Page 267

    Crankshaft/transmission 9-13 crankshaft and connecting rods crankshaft removal • split the crankcase (see crankcase splitting). • remove the crankshaft [a]. Crankshaft installation caution if the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing insert...

  • Page 268

    9-14 crankshaft/transmission crankshaft and connecting rods • apply molybdenum disulfide grease [a] to the outer sur- face of the upper insert and the inner surface of the con- necting rod big end. • apply molybdenum disulfide oil [b] to the inner surfaces of upper and lower bearing inserts. ○ the m...

  • Page 269

    Crankshaft/transmission 9-15 crankshaft and connecting rods (1) bolt length measurement method • be sure to clean the bolts, nuts, and connecting rods thoroughly with a high-flash point solvent, because the new connecting rods, bolts, and nuts are treated with an anti-rust solution. Warning clean th...

  • Page 270

    9-16 crankshaft/transmission crankshaft and connecting rods (2) rotation angle method if you don’t have a point micrometer, you may tighten the nuts using the “rotation angle method”. • be sure to clean the bolts and nuts thoroughly with a high -flash point solvent, because the new bolts and nuts ar...

  • Page 271

    Crankshaft/transmission 9-17 crankshaft and connecting rods connecting rod bend • remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap. • select an arbor [a] of the same diameter as the connect- ing rod big end, and insert the arbor through the connect- ing...

  • Page 272

    9-18 crankshaft/transmission crankshaft and connecting rods connecting rod big end bearing insert/crankpin wear • measure the bearing insert/crankpin [b] clearance with plastigage [a]. • tighten the big end nuts to the specified torque (see con- necting rod installation). Note ○ do not move the conn...

  • Page 273

    Crankshaft/transmission 9-19 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 274

    9-20 crankshaft/transmission crankshaft and connecting rods crankshaft runout • 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.) crankshaft main be...

  • Page 275

    Crankshaft/transmission 9-21 crankshaft and connecting rods • measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. Crankcase main bearing inside diameter marks : " " or no mark. • tighten the crankcase bolts to the specified torque (se...

  • Page 276

    9-22 crankshaft/transmission starter motor clutch starter motor clutch removal/installation • refer to the alternator rotor removal and installation in the electrical system chapter. Starter motor clutch inspection • remove: alternator cover (see electrical system chapter) starter idle gear • turn t...

  • Page 277

    Crankshaft/transmission 9-23 transmission shift pedal removal • mark [a] the position of the shift lever [b] on the shift shaft so that it can be installed later in the same position. • remove: shift lever bolt [c] shift lever • remove: footpeg bracket bolts [a] footpeg bracket [b] • remove the bolt...

  • Page 278

    9-24 crankshaft/transmission transmission • install the footpeg bracket [a]. • tighten: torque - footpeg bracket bolts [b]: 34 n·m (3.5 kgf·m, 25 ft·lb) • install the shift lever [a], aligning the mark (previously marked). • tighten: torque - shift lever bolt: 6.9 n·m (0.70 kgf·m, 61 in·lb) • instal...

  • Page 279

    Crankshaft/transmission 9-25 transmission • remove: gear positioning lever bolt [a] gear positioning lever [b], collar and spring external shift mechanism installation • install the gear positioning lever [a] as shown. Spring [b] collar [c] bolt [d] • tighten: torque - gear positioning lever bolt: 1...

  • Page 280

    9-26 crankshaft/transmission transmission transmission shaft removal • split the crankcase (see crankcase splitting). • remove the drive shaft [a] and output shaft [b]. Transmission shaft installation • check to see that the set pins [a] and set rings [b] are in place. • install the drive shaft and ...

  • Page 281

    Crankshaft/transmission 9-27 transmission • remove the ball bearing [a] from each shafts. Special tools - bearing puller: 57001–135 [b] bearing puller adapter: 57001–317 [c] • discard the bearing. Transmission shaft assembly • apply engine oil to the bushings, ball bearings and shafts. • install the...

  • Page 282

    9-28 crankshaft/transmission transmission note ○ when the toothed washers [28] [29] are assembled onto the output shaft, note the following. ○ when the tangs [a] of the toothed washer [29] shall be assembled, they should be installed into the notch [b] of the toothed washer [28] (see page 9–29). • f...

  • Page 283

    Crankshaft/transmission 9-29 transmission 1. 1st gear 2. 2nd gear 3. 3rd gear 4. 4th gear 5. 5th gear 6. 6th (top) gear 7. Toothed washer, 31 mm (1.22 in.) 8. Thrust washer, 30 mm (1.18 in.) 9. Circlip 10. Circlip 11. Bushing 12. Bushing 13. Needle bearing 14. Needle bearing 15. Bearing outer race 1...

  • Page 284

    9-30 crankshaft/transmission transmission shift drum and fork removal • remove: lower crankcase half (see crankcase splitting) transmission shafts external shift mechanism (see external shift mecha- nism removal) bolt [a] and screw [b] shift drum bearing holder [c] • pull out the shift rods [d], and...

  • Page 285

    Crankshaft/transmission 9-31 transmission shift fork bending • visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [a] shift fork/gear groove wear • measure the thickn...

  • Page 287: Wheels/tires

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

  • Page 288

    10-2 wheels/tires exploded view.

  • Page 289

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front axle clamp bolt 34 3.5 25 2 front axle 108 11 80 3 rear axle nut 108 11 80 g: apply grease. R: replacement parts wl: apply soap and water solution or rubber lubricant..

  • Page 290

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

  • Page 291

    Wheels/tires 10-5 special tools bearing driver set: 57001–1129 jack: 57001–1238 bearing remover head, 20 × 22: 57001–1293 bearing remover shaft, 13: 57001–1377.

  • Page 292

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

  • Page 293

    Wheels/tires 10-7 wheels (rims) • tighten the front axle. Torque - front axle: 108 n·m (11 kgf·m, 80 ft·lb) • before tightening the clamp bolt on the right front fork leg, pump the front fork up and down 4 or 5 times to allow the right front fork leg to seat on the front axle. Note ○ put a block in ...

  • Page 294

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

  • Page 295

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

  • Page 296

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

  • Page 297

    Wheels/tires 10-11 wheels (rims) caution when removing the balance weight, do not touch the brake disc. The disc could be damaged. Do not tap the screwdrivers. The rim could be dam- aged. Balance weight installation • check if the weight portion has any play on the clip. If it does, discard it. Warn...

  • Page 298

    10-12 wheels/tires tires air pressure inspection • refer to the air pressure inspection in the periodic main- tenance chapter. Tire inspection • refer to the tire wear inspection in the periodic mainte- nance chapter. Tire removal • remove: wheel (see front wheel removal, rear wheel re- moval) disc(...

  • Page 299

    Wheels/tires 10-13 tires • install a new valve in the rim. ○ remove the valve cap, lubricate the stem seal with a soap and water solution or rubber lubricant, and pull [b] the valve stem [a] through the rim from the inside out until it snaps into place. Caution do not use engine oil or petroleum dis...

  • Page 300

    10-14 wheels/tires tires • check to see that the rim lines [a] on both sides of the tire sidewalls are parallel with the rim flanges. If the rim flanges and tire sidewall rim lines are not parallel, remove the valve core. • lubricate the rim flanges and tire beads. • install the valve core and infla...

  • Page 301

    Wheels/tires 10-15 hub bearing hub bearing removal • remove the wheel, and take out the following. Collars coupling (out of rear hub) grease seals circlip • use the bearing remover to remove the hub bearings [a]. Caution do not lay the wheel on the ground with the disc facing down. This can damage o...

  • Page 303: Final Drive

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

  • Page 304

    11-2 final drive exploded view.

  • Page 305

    Final drive 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine sprocket cover bolts 9.8 1.0 87 in·lb 2 engine sprocket nut 125 13 92 mo 3 rear sprocket nuts 59 6.0 43 4 speed sensor cover bolts 6.9 0.70 61 in·lb l 5 speed sensor bolt 6.9 0.70 61 in·lb l 6 rear axle nut 108 11 80...

  • Page 306

    11-4 final drive specifications item standard service limit drive chain: chain slack 25 ∼ 35 mm (1.0 ∼ 1.4 in.) – – – 20-link length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) standard chain make enuma – – – type ek520mvxl – – – link 112 links – – – sprockets: rear sprocket warp 0.4 mm (...

  • Page 307

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

  • Page 308

    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. Drive chain wear inspection • refer to the drive ch...

  • Page 309

    Final drive 11-7 drive chain drive chain replacement • remove: chain cover (see drive chain removal) engine sprocket cover (see engine sprocket removal) ek joint tool #50 body [a] handlebar [b] cutting & riveting pin [c] for cutting [d] for riveting [e] plate holder (a) [f] plate holder (b) [g] gaug...

  • Page 310

    11-8 final drive drive chain • replace the link pin, link plate and grease seals. • apply grease to the link pins [a] and grease seals [b] [c]. • engage the drive chain on the engine and rear sprockets. • insert the link pins in the drive chain ends. • install the grease seals [c]. • install the lin...

  • Page 311

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

  • Page 312

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

  • Page 313

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

  • Page 314

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

  • Page 315

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

  • Page 317: Brakes

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

  • Page 318

    12-2 brakes exploded view.

  • Page 319

    Brakes 12-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front caliper mounting bolts 34 3.5 25 2 brake hose banjo bolts 25 2.5 18 3 bleed valve 7.8 0.80 69 in·lb 4 brake lever pivot bolt 1.0 0.10 9 in·lb si 5 brake lever pivot bolt locknut 5.9 0.60 52 in·lb 6 front brake disc mountin...

  • Page 320

    12-4 brakes exploded view.

  • Page 321

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

  • Page 322

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

  • Page 323

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

  • Page 324

    12-8 brakes brake lever, brake pedal brake lever position adjustment the brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator’s hand. • push the lever forward and turn the adjuster [a] to align the number with the arrow mark [b] on the lever hold...

  • Page 325

    Brakes 12-9 calipers front caliper removal • loosen the banjo bolt [a] at the brake hose lower end, and tighten it loosely. • unscrew the caliper mounting bolts [b], and detach the caliper [c] from the disc. • unscrew the banjo bolt and remove the brake hoses [d] from the caliper (see brake hose rem...

  • Page 326

    12-10 brakes calipers front caliper disassembly • remove: front caliper (see caliper removal) brake pads and springs (see brake pad removal) • using compressed air, remove the pistons. ○ cover the piston area with a clean, thick cloth [a]. ○ blow compressed air [b] into the hole for the banjo bolt t...

  • Page 327

    Brakes 12-11 calipers • replace the fluid seals [a] with new ones. ○ apply brake fluid to the fluid seals, and install them into the cylinders by hand. • replace the dust seals [b] with new ones if they are dam- aged. ○ apply brake fluid to the dust seals, and install them into the cylinders by hand...

  • Page 328

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

  • Page 329

    Brakes 12-13 calipers caliper piston and cylinder damage • visually inspect the piston [e] and cylinder surfaces. Replace the caliper if the cylinder and piston are badly scores or rusty. Fluid seal [a] dust seal [b] rubber boot [c] front caliper [j] rear caliper [k] caliper holder shaft wear the ca...

  • Page 330

    12-14 brakes brake pads front brake pad removal • remove the caliper from the disc. • draw out the holder shaft pin [a], and take off the holder shaft [b]. • remove the pad [c] on the piston side. • push the holder [d] towards the piston, and remove the pad of the other side [e] from the holder shaf...

  • Page 331

    Brakes 12-15 master cylinder front master cylinder removal • disconnect the front brake light switch connectors [a]. • remove the banjo bolt [b] to disconnect the brake hose from the master cylinder [c] (see brake hose removal/in- stallation). • unscrew the clamp bolts [a], and take off the master c...

  • Page 332

    12-16 brakes master cylinder rear master cylinder removal • unscrew the brake hose banjo bolt [a] on the master cylin- der (see brake hose removal/installation). • pull off the reservoir hose lower end [b], and drain the brake fluid into a container. • loosen the master cylinder mounting bolts [c] l...

  • Page 333

    Brakes 12-17 master cylinder rear master cylinder disassembly note ○ do not remove the push rod clevis for master cylinder disassembly since removal requires brake position ad- justment. • remove the rear master cylinder (see rear master cylin- der removal). • slide the dust cover on the push rod ou...

  • Page 334

    12-18 brakes brake disc brake disc removal • remove the wheel (see wheels/tires chapter). • unscrew the mounting bolts, and take off the disc. Brake disc installation • install the brake disc on the wheel so that the marked side [a] faces out. • apply a non-permanent locking agent to the threads of ...

  • Page 335

    Brakes 12-19 brake fluid brake fluid level inspection • refer to the brakes in the periodic maintenance chapter. Brake fluid change • refer to the brakes in the periodic maintenance chapter. Brake line bleeding • refer to the brakes in the periodic maintenance chapter..

  • Page 336

    12-20 brakes brake hose brake hose removal/installation caution brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wiped up immediately with wet cloth. • when removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts....

  • Page 337: Suspension

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

  • Page 338

    13-2 suspension exploded view.

  • Page 339

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fork clamp bolts (upper) 20 2.0 14 2 front fork clamp bolts (lower) 20 2.0 14 al 3 front fork top plugs 25 2.5 18 4 front fork bottom allen bolts 30 3.1 22 l 5 front axle clamp bolt 34 3.5 25 6. Right fork leg 7. Left ...

  • Page 340

    13-4 suspension exploded view.

  • Page 341

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear shock absorber nuts (upper and lower) 34 3.5 25 2 swingarm pivot shaft nut 108 11 80 3 swingarm pivot shaft locknut 98 10 72 4 rocker arm nut 34 3.5 25 5 tie-rod bolts 59 6.0 43.

  • Page 342

    13-6 suspension specifications item standard front fork (per one unit): fork inner tube outside diameter 41 mm (1.61 in.) air pressure atmospheric pressure (non-adjustable) fork spring setting non-adjustable damper setting non-adjustable fork oil viscosity kayaba khl34-g10 fork oil capacity 452 ±4 m...

  • Page 343

    Suspension 13-7 special tools fork cylinder holder handle: 57001–183 fork cylinder holder adapter: 57001–1057 oil seal & bearing remover: 57001–1058 bearing driver set: 57001–1129 jack: 57001–1238 fork oil seal driver: 57001–1288 fork oil level gauge: 57001–1290 hook wrench: 57001–1539 swingarm pivo...

  • Page 344

    13-8 suspension front fork front fork removal • remove: front wheel (see tires/wheels chapter) front fender (see frame chapter) fairing (see frame chapter) loosen the handlebar bolt, upper fork clamp bolt and fork top plug before-hand if the fork leg is to be disassembled. Note ○ loosen the top plug...

  • Page 345

    Suspension 13-9 front fork • hold the outer tube vertically in a vise and compress the fork completely. • wait until the oil level stabilizes. • use the fork oil level gauge [a] to measure the distance between the top of the inner tube to the oil level. Special tool - fork oil level gauge: 57001–129...

  • Page 346

    13-10 suspension front fork • remove the cylinder unit [a], washer, and the spring [b] from the inner tube. • remove the following from the top of the outer tube: dust seal [a] retaining ring [b] • separate the inner tube [a] from the outer tube [b]. Note ○ from the compressed state, firmly pull dow...

  • Page 347

    Suspension 13-11 front fork front fork assembly • check the top plug o-ring and replace it with a new one. • replace the following parts with new ones: retaining ring [a] dust seal [b] oil seal [c] inner guide bushing [d] outer guide bushing [e] fork bottom allen bolt gasket [f] • install the guide ...

  • Page 348

    13-12 suspension front fork inner tube/outer tube inspection • visually inspect the inner tube [a] and repair any nicks or rust by using an oil stone. If the damage is not repairable, replace the inner tube. Since damage to the inner tube damages the oil seal slip, replace the oil seal whenever the ...

  • Page 349

    Suspension 13-13 rear shock absorber rebound damping force adjustment • turn the damper adjuster [a] to adjust the rebound damp- ing. ○ align the numbered mark [b] of the adjuster. ○ the standard adjuster setting for average-build rider of 68 kg (150 ib) with no passenger and no accessories is posit...

  • Page 350

    13-14 suspension rear shock absorber • remove: lower shock absorber nut [a] lower shock absorber bolt [b] • remove: upper shock absorber nut [a] upper shock absorber bolt [b] • remove the shock absorber [a] from upside. Rear shock absorber installation • tighten: torque - rear shock absorber nuts: 3...

  • Page 351

    Suspension 13-15 swingarm swingarm removal • raise the rear wheel off the ground with jack. Special tool - jack: 57001–1238 • remove: chain cover (see final drive chapter) mud guard (see frame chapter) brake hose clamp [a] rear wheel (see wheels/tires chapter) lower shock absorber nut and bolt [a] u...

  • Page 352

    13-16 suspension swingarm swingarm installation ○ place the collar [a] on the stopper [b] inside the frame [c]. • insert the pivot shaft into the frame from the right side. • tighten the pivot shaft so that the clearance [d] between the collar and the frame come to zero mm. • tighten: torque - swing...

  • Page 353

    Suspension 13-17 swingarm swingarm bearing installation • install the needle bearings so that the manufacturer’s marks face in. • install the ball bearing so that the manufacturer’s marks faces out. Special tool - bearing driver set: 57001–1129 [a] swingarm bearing, sleeve inspection caution do not ...

  • Page 354

    13-18 suspension tie-rod, rocker arm tie-rod removal • remove the side stand (see frame chapter). • using the jack, raise the rear wheel off the ground. Special tool - jack: 57001–1238 • squeeze the brake lever slowly and hold it with a band [a]. • remove: lower rear shock absorber bolt and nut [a] ...

  • Page 355

    Suspension 13-19 tie-rod, rocker arm rocker arm/tie-rod bearing, sleeve inspection • visually inspect the rocker arm/tie-rod sleeves and needle bearings. • the rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abras...

  • Page 357: Steering

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

  • Page 358

    14-2 steering exploded view.

  • Page 359

    Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 steering stem nut 27 2.8 20 2 steering stem head bolt 108 11 80 3 front fork clamp bolts (upper) 20 2.0 14 4 front fork clamp bolts (lower) 20 2.0 14 al 5 handlebar clamp bolts 25 2.5 18 s 6 handlebar lower clamp nuts 34 3.5 2...

  • Page 360

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

  • Page 361

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

  • Page 362

    14-6 steering steering stem stem, stem bearing removal • remove: inner cover (see frame chapter) fairing and bracket (see frame chapter) front wheel (see wheels/tires chapter) handlebar (see handlebar removal) steering stem head bolt plug steering stem head bolt [a] and washer front fork clamp bolts...

  • Page 363

    Steering 14-7 steering stem stem, stem bearing installation • replace the bearing outer races with new ones. • apply grease to the outer races, and drive them into the head pipe at the same time. Special tool - bearing driver set: 57001–1129 [a] • replace the bearing inner races and oil seal with ne...

  • Page 364

    14-8 steering steering stem • install the claw washer [a] so that its bent side [b] faces upward, and engage the bent claws with the grooves of stem locknut [c]. • hand tighten the stem locknut until it touches the claw washer. • tighten the stem locknut clockwise until the claws are aligned with th...

  • Page 365

    Steering 14-9 handlebar handlebar removal • remove: handlebar holder plugs clutch lever assembly [a] left handlebar switch housing [b] front brake master cylinder [c] right handlebar switch housing [d] handlebar holder bolts [e] • remove the handlebar holder [f] and then pull out the handlebar. • re...

  • Page 367: Frame

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

  • Page 368

    15-2 frame exploded view.

  • Page 369

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 footpeg bracket bolts 34 3.5 25 l 2 side stand bracket bolts 49 5.0 36 3 side stand bolt 44 4.5 33 4 side stand switch bolt 8.8 0.90 78 in·lb g: apply grease. L: apply a non-permanent locking agent..

  • Page 370

    15-4 frame exploded view.

  • Page 371

    Frame 15-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fender bracket bolts 8.8 0.90 78 in·lb l 2 front fender bolts 3.9 0.40 35 in·lb.

  • Page 372

    15-6 frame exploded view.

  • Page 373

    Frame 15-7 seats rear seat removal • insert the ignition switch key into the seat lock [a], turning the key clockwise, pulling up on the rear of the seat [b], and pulling the seat backward. Rear seat installation • slip the rear seat hooks [a] into the hollow-cubic bracket [b] on the frame. • insert...

  • Page 374

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

  • Page 375

    Frame 15-9 fairings inner cover removal • remove: inner cover screws [a] and washers inner cover [b] inner cover installation • fit the projection [a] on the inner cover [b] into the hole [c] in the fairing. • install the washers and inner cover screws. Fairing removal • remove: fairing mounting bol...

  • Page 376

    15-10 frame seat covers seat cover removal • remove: seats screws [a] • push the central pin, and then remove the quick rivets [a]. • pull the front portions [a] of the seat cover outside [b], and then remove the seat cover backward. Seat cover installation • installation is reverse of removal. • pu...

  • Page 377

    Frame 15-11 mud guard mud guard removal • remove: chain cover (see final drive chapter) bolt [a] clamp [b] • lift up the mud guard [a], and then pull it out backward. Mud guard installation • put the projections [a] into the grommets [b]..

  • Page 378

    15-12 frame fenders front fender removal • remove: front wheel (see wheels/tires chapter) brake hose clamps front reflector bolts [a] bolts [b] (both side) • remove the front fender [c]. Front fender installation • apply a non-permanent locking agent to the threads of the bracket bolts. • tighten: t...

  • Page 379

    Frame 15-13 fenders • remove: quick rivets [a] rear fender rear [b] rear fender rear installation • put the projection [a] into the hole [b]. • put the projections [a] into the holes [b]. • installation is reverse of removal..

  • Page 380

    15-14 frame frame cover frame cover removal • remove: bolts [a] frame cover [b] (both side).

  • Page 381

    Frame 15-15 battery case battery case removal • remove: seats seat cover rear fender assy side covers battery reserver tank screws • pull out the battery case [a] backward. Battery case installation • put the battery case attachments [a] at the projections [b] on the frame..

  • Page 382

    15-16 frame side stand side stand removal • raise the rear wheel off the ground with the stand. • remove: side stand switch bolt [a] side stand switch [b] spring [c] side stand nut [d] side stand bolt [e] side stand [f] side stand installation • apply grease to the sliding area [b] of the side stand...

  • Page 383

    Frame 15-17 rear view mirrors rear view mirrors removal • loosen the lower hexagonal area [a] for tightening to re- move the rear view mirror from the holder. Caution do not force to tighten and/or loosen the upper hexagonal area (adapter) [b] with a pair of span- ners. Disassembly of this area is n...

  • Page 384

    15-18 frame frame frame inspection • visually inspect the frame for cracks, dents, bending, or warp. ○ if there is any damage to the frame, replace it. Warning a repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it..

  • Page 385: Electrical System

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

  • Page 386

    16-2 electrical system spark plug installation ...................................................................................................... 16-44 spark plug inspection ....................................................................................................... 16-44 spark plug g...

  • Page 387

    Electrical system 16-3 parts location 1. Starter lockout switch 2. Camshaft position sen- sor 3. Radiator fan switch 4. Starter motor 5. Alternator 6. Speed sensor 7. Neutral switch 8. Side stand switch 9. Water temperature sen- sor 10. Battery 11. Junction box 12. Front brake light switch 13. Stick...

  • Page 388

    16-4 electrical system exploded view.

  • Page 389

    Electrical system 16-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 meter mounting screws 1.2 0.12 10 in·lb 2 tail/brake light mounting screws 1.2 0.12 10 in·lb 3 license plate light mounting screws 1.2 0.12 10 in·lb 4 front brake light switch screw 1.0 0.10 9 in·lb 5 starter locknut ...

  • Page 390

    16-6 electrical system exploded view.

  • Page 391

    Electrical system 16-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 water temperature sensor 25 2.5 18 ss 2 spark plugs 13 1.3 113 in·lb 3 alternator lead holding plate bolt 11 1.1 95 in·lb l 4 starter motor mounting bolts 11 1.1 95 in·lb 5 stator coil bolts 11 1.1 95 in·lb 6 alternat...

  • Page 392

    16-8 electrical system exploded view.

  • Page 393

    Electrical system 16-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 regulator/rectifier bolts 6.9 0.70 61 in·lb 2 fuel level sensor bolts 6.9 0.70 61 in·lb 3 side stand switch bolt 8.8 0.90 78 in·lb l 4 neutral switch 15 1.5 11 5 speed sensor bolt 6.9 0.70 61 in·lb l 6 speed sensor co...

  • Page 394

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

  • Page 395

    Electrical system 16-11 special tools and sealant rotor puller, m16/m18/m20/m22 × 1.5 : 57001–1216 flywheel & pulley holder : 57001–1343 hand tester : 57001–1394 flywheel puller, m38 × 1.5 : 57001–1405 lead wire-peak voltage adapter : 57001–1449 needle adapter : 57001–1457 harness adapter : 57001–15...

  • Page 396

    16-12 electrical system wiring diagram (canada).

  • Page 397

    Electrical system 16-13 wiring diagram (canada).

  • Page 398

    16-14 electrical system wiring diagram (australia).

  • Page 399

    Electrical system 16-15 wiring diagram (australia).

  • Page 400

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

  • Page 401

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

  • Page 402

    16-18 electrical system wiring diagram (malaysia).

  • Page 403

    Electrical system 16-19 wiring diagram (malaysia).

  • Page 404

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

  • Page 405

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

  • Page 406

    16-22 electrical system electrical wiring wiring inspection • visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clea...

  • Page 407

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

  • Page 408

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

  • Page 409

    Electrical system 16-25 battery • fit the seal cap [a] tightly into the filler ports until the seal caps are at the same level as the top of the battery. Note ○ do not hammer. Press down evenly with both hands. Caution once you installed the seal caps after filling the bat- tery, never remove it, no...

  • Page 410

    16-26 electrical system battery precautions 1) no need of topping–up no topping–up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seat cap to add water is very dangerous. Never do that. 2) refreshing charge if an engine will not start, a horn sounds wea...

  • Page 411

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

  • Page 412

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

  • Page 413

    Electrical system 16-29 charging system alternator cover removal • remove: left frame cover (see frame chapter) clamp (open) [a] alternator lead connector [b] • place a suitable container under the alternator cover [a], and remove the cover bolts [b]. • pull the alternator cover outside. Alternator ...

  • Page 414

    16-30 electrical system 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: 11 n·m (1.1 kgf·m, 95 in·lb) • secure the alternator lead with a holding plate, and tighten the bolt. ○ apply a...

  • Page 415

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

  • Page 416

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

  • Page 417

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

  • Page 418

    16-34 electrical system charging system • do the 1st step regulator circuit test: ○ connect the test light and the 12 v battery to the regula- tor/rectifier as shown. ○ check bk1, bk2, and bk3 terminal respectively. If the test light turns on, the regulator/rectifier is defective. Replace it. If the...

  • Page 419

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

  • Page 420

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

  • Page 421

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

  • Page 422

    16-38 electrical system ignition system crankshaft sensor installation • route the crankshaft sensor lead correctly (see cable, wire, and hose routing in appendix chapter). • tighten: torque - crankshaft sensor bolts: 5.9 n·m (0.60 kgf·m, 52 in·lb) • apply silicone sealant [a] to the crankshaft sens...

  • Page 423

    Electrical system 16-39 ignition system crankshaft sensor inspection • remove: right frame cover (see frame chapter) crankshaft sensor lead connector [a] • set the hand tester to the × 100 Ω range and connect (+) lead to the yellow/black lead and (–) lead to the black lead in the connector. Special ...

  • Page 424

    16-40 electrical system ignition system timing rotor removal • remove the crankshaft sensor cover (see crankshaft sensor removal) • remove the timing rotor [a]. ○ holding the timing rotor with the flywheel & pulley holder [b] and remove the bolt [c]. Special tool - flywheel & pulley holder : 57001–1...

  • Page 425

    Electrical system 16-41 ignition system camshaft position sensor inspection • remove: fuel tank (see fuel system (dfi) chapter) camshaft position sensor lead connector [a] (discon- nect) • set the hand tester to the × 10 Ω range and connect it to the yellow and black leads in the connector. Special ...

  • Page 426

    16-42 electrical system ignition system stick coil (ignition coil together with spark plug cap) removal • remove the fuel tank (see fuel system (dfi) chapter). • remove the thermostat bracket bolt [a]. • disconnect: water temperature sensor connector [b] left switch housing connector [c] ○ if removi...

  • Page 427

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

  • Page 428

    16-44 electrical system ignition system warning to avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • turn the ignition switch and the engine stop switch on. • pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measur...

  • Page 429

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

  • Page 430

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

  • Page 431

    Electrical system 16-47 ignition system.

  • Page 432

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

  • Page 433

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

  • Page 434

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

  • Page 435

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

  • Page 436

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

  • Page 437

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

  • Page 438

    16-54 electrical system lighting system this models adopt the daylight system and have a head- light relay in the junction box. In these models, the head- light does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is ...

  • Page 439

    Electrical system 16-55 lighting system • fit the projection [a] of the bulb in the hollow [b] of the headlight. • install the hook [c]. • fit the dust cover [a] with the arrow mark upward onto the bulb [b] firmly as shown. Good [c] bad [d] arrow mark [e] • after installation, adjust the headlight a...

  • Page 440

    16-56 electrical system lighting system city light bulb replacement (european model) • remove the fairing (see frame chapter). • pull out the socket [a] together with the bulb. • pull the bulb [a] out of the socket. Caution do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do no...

  • Page 441

    Electrical system 16-57 lighting system headlight/tail light circuit (ca, as) headlight/tail light circuit (other than ca, as) as: australia ca: canada 1. Ignition switch 2. Meter ground 3. Alternator 4. Headlight diodes 5. Taillight fuse 10 a 6. Headlight fuse 10 a 7. Junction box 8. High beam indi...

  • Page 442

    16-58 electrical system lighting system turn signal light circuit ca: canada model my: malaysia model 1. Joint connector d 2. Meter unit 3. Right turn signal indica- tor light (led) 4. Left turn signal indicator light (led) 5. Front right turn signal light 6. Front left turn signal light 7. Joint co...

  • Page 443

    Electrical system 16-59 lighting system • push and turn the bulb [a] counterclockwise and remove it. • insert the new bulb [a] by aligning its upper and lower pins [b] with the upper and lower grooves [c] in the socket, and turn the bulb clockwise. ○ turn the bulb about 15°. For the canadian model: ...

  • Page 444

    16-60 electrical system lighting system • insert the new bulb [a] by aligning its upper and lower pins [b] with the upper and lower grooves [c] in the socket, and turn the bulb clockwise. Turn signal relay inspection • remove: seats (see frame chapter) upper seat cover (see frame chapter) turn signa...

  • Page 445

    Electrical system 16-61 lighting system • unscrew the bolts [a]. • unscrew the mounting screws [a]. • remove the tail/brake light (led) [b]. ○ pull out the mount portion [c]. Tail/brake light (led) installation • tighten the tail/brake light mounting screws. Torque - tail/brake light mounting screws...

  • Page 446

    16-62 electrical system radiator fan system fan system circuit inspection • disconnect the lead connector [a] from the radiator fan switch. • using an auxiliary wire [a], connect the radiator fan switch leads. If the fan rotates, inspect the fan switch. If the fan does not rotate, inspect the follow...

  • Page 447

    Electrical system 16-63 radiator fan system radiator fan circuit 1. Radiator fan 2. Radiator fan switch 3. Joint connector a 4. Joint connector d 5. Meter ground 6. Frame ground 7. Joint connector b 8. Junction box 9. Fan fuse 15 a 10. Main fuse 30 a 11. Battery 12 v 8 ah.

  • Page 448

    16-64 electrical system meter, gauge, indicator unit meter unit removal • remove: fairing (see frame chapter) • slide the dust cover [a] and remove the wiring connector [b]. • remove the meter unit by taking off the mounting screws [c] with the washers. Caution place the meter or gauge so that the f...

  • Page 449

    Electrical system 16-65 meter, gauge, indicator unit electronic combination meter unit inspection • remove the meter unit [a]. [1] ignition [10] battery (+) [2] fuel reserve switch [11] oil pressure warning [3] unused indicator light (led) [4] fuel level sensor ground (–) [5] neutral indicator light...

  • Page 450

    16-66 electrical system meter, gauge, indicator unit mode and reset button operation check: • connect the 12 v battery and terminals in the same man- ner as specified in the "liquid crystal display (lcd) seg- ments check". • check that the display change to the odo, trip, and clock displays each tim...

  • Page 451

    Electrical system 16-67 meter, gauge, indicator unit • in the hour setting mode, press the reset button to effect the minute setting mode. ○ the minute display flashes on the display. • press the mode button to set the minute. • in the minute setting mode, press the reset button to return to the hou...

  • Page 452

    16-68 electrical system meter, gauge, indicator unit • if the oscillator is not available, the speedometer can be checked as follows. ○ install the meter unit. ○ raise the rear wheel off the ground, using the jack. ○ turn on the ignition switch. ○ rotate the rear wheel by hand. ○ check that the spee...

  • Page 453

    Electrical system 16-69 meter, gauge, indicator unit water temperature meter check: • connect the 12 v battery and terminals in the same man- ner as specified in the "liquid crystal display (lcd) seg- ments check". • connect the variable rheostat [a] to the terminal [8] as shown. • check that the nu...

  • Page 454

    16-70 electrical system meter, gauge, indicator unit fuel level gauge inspection: • connect the 12 v battery and terminals in the same man- ner as specified in the “liquid crystal display (lcd) seg- ments check”. • connect a variable rheostat [a] to terminal [4] and [9] as shown. • check that the nu...

  • Page 455

    Electrical system 16-71 meter, gauge, indicator unit • if the oscillator is not available, the tachometer can be checked as follows. ○ connect the 12 v battery and terminals in the same man- ner as specified in the "liquid crystal display (lcd) seg- ments check". ○ using an auxiliary wire, quick ope...

  • Page 456

    16-72 electrical system meter, gauge, indicator unit right and left turn signal indicator light (led): for right turn signal indicator light (led) battery positive (+) terminal to terminal [13] for left turn signal indicator light (led) battery positive (+) terminal to terminal [14] high beam indica...

  • Page 457

    Electrical system 16-73 meter, gauge, indicator unit meter circuit 1. Right turn signal indica- tor light (led) 2. High beam indicator light (led) 3. Neutral indicator light (led) 4. Oil pressure warning in- dicator light (led) 5. Fi indicator light (led) 6. Odometer/trip meter/ clock/fuel indicator...

  • Page 458

    16-74 electrical system switches and sensors brake light timing inspection • refer to the brakes in the periodic maintenance chapter. Brake light timing adjustment • refer to the brakes in the periodic maintenance chapter. Switch inspection • using a hand tester, check to see that only the con- nect...

  • Page 459

    Electrical system 16-75 switches and sensors • remove the fan switch [a]. • suspend the switch [a] in a container of coolant so that the temperature–sensing projection and threaded portion are submerged. • suspend an accurate thermometer [b] in the coolant so that the sensitive portions are located ...

  • Page 460

    16-76 electrical system switches and sensors • suspend the sensor [a] in a container of coolant so that the temperature-sensing projection [e] and threaded por- tion [e] are submerged. • suspend an accurate thermometer [b] in the coolant. Note ○ the sensor and thermometer must not touch the con- tai...

  • Page 461

    Electrical system 16-77 switches and sensors • remove: bolts [a] speed sensor cover • remove: bolt [a] • take out the speed sensor [b]. • connect the speed sensor connector [a] with the battery [b], 10 kΩ resistor [c] and hand tester [d] as shown. • set the tester to the dc 25 v range. Special tool ...

  • Page 462

    16-78 electrical system switches and sensors fuel level sensor inspection • remove: fuel tank (see fuel system (dfi) chapter) • open the clamps [a]. • remove: bolts [b] fuel level sensor [c] • check that the float moves up and down smoothly without binding. It should go down under its own weight. If...

  • Page 463

    Electrical system 16-79 switches and sensors • connect the test light [a] (12 v 3.4 w bulb a socket with leads) and the 12 v battery [b] to the fuel level sensor connector [c]. Connections: battery (+) → 12 v 3.4 w bulb (one side) 12 v 3.4 w bulb (other side) → blue lead terminal battery (–) → bk/y ...

  • Page 464

    16-80 electrical system junction box the junction box [a] has fuses [b], relays, and diodes. The relays and diodes can not be removed. Junction box fuse circuit inspection • remove the seats (see frame chapter). • remove the junction box [a]. • pull off the connectors [a] from the junction box [b]. ...

  • Page 465

    Electrical system 16-81 junction box starter circuit/headlight relay inspection • remove the junction box (see junction box fuse circuit inspection). • check conductivity of the following numbered terminals by connecting the hand tester and one 12 v battery to the junction box as shown. ○ refer to t...

  • Page 466

    16-82 electrical system junction box diode circuit inspection • remove the junction box. • check conductivity of the following pairs of terminals. Diode circuit inspection tester connection 13-8, 13-9, 12-11, 12-14, 15-14, 16-14 the resistance should be low in one direction and more than ten times a...

  • Page 467

    Electrical system 16-83 fuse 30 a main fuse removal • remove: right side cover (see frame chapter) 30 a main fuse connector [a] • pull out the main fuse [b] from the starter relay with needle nose pliers. Junction box fuse removal • remove the seats (see frame chapter). • unlock the hook to lift up ...

  • Page 468

    16-84 electrical system fuse fuse inspection • remove the fuse (see fuse removal). • inspect the fuse element. If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check th...

  • Page 469: Appendix

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

  • Page 470

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

  • Page 471

    Appendix 17-3 cable, wire, and hose routing 1. Fixes by the left side clamp of the tank. 2. Run the tank drain hose under the bracket for the side cover. 3. Air cleaner drain hose 4. Cooling reserve tank hose (run the hose inside the under ring.) 5. Fuel tank drain hose 6. Fixes by the swingarm clam...

  • Page 472

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

  • Page 473

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

  • Page 474

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

  • Page 475

    Appendix 17-7 cable, wire, and hose routing 1. Run the main harness through lower and right side of the thermostat. 2. Frame ground (with thermostat bracket) 3. Ignition switch connector 4. Meter ground 5. Engine harness 6. Water temperature sensor 7. Inlet air pressure sensor 8. Clamp 9. To pickup ...

  • Page 476

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

  • Page 477

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

  • Page 478

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

  • Page 479

    Appendix 17-11 cable, wire, and hose routing 1. Clamp the position of branch harness and front right turn signal light lead. 2. Run the meter harness into the hole of cover. 3. Meter 4. Set the cover to cover all of the connector. 5. Clamp the right and left switch housing lead and front left turn s...

  • Page 480

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

  • Page 481

    Appendix 17-13 cable, wire, and hose routing 1. Clamp 2. Brake hose 3. Run the brake hose through the inside of the reservoir hose. 4. Tight the bolt to the specified torque with the stopper (for turning prevention) applied. 5. Seat lock 6. Seat lock cable.

  • Page 482

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

  • Page 483

    Appendix 17-15 cable, wire, and hose routing 1. Cam sensor lead (run the lead between the convex area of cap center and bolt head to secure the coupler.) 2. Fan switch horn lead 3. Cap 4. Clutch cable (run the cable through forward the water hose.) 5. Air suction valve 6. Water hose (thermostat – ra...

  • Page 484

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

  • Page 485

    Appendix 17-17 cable, wire, and hose routing 1. Bend the bracket as shown to secure the lead. 2. Bend the bracket. 3. Install the lead upward. 4. Pickup coil and oil pressure switch (run the cable through inner side from the starter lead.) 5. Install the exterior of the lead with staking area facing...

  • Page 486

    17-18 appendix troubleshooting guide note ○ refer to the fuel system chapter for most of dfi trouble shooting guide. ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common di...

  • Page 487

    Appendix 17-19 troubleshooting guide air cleaner duct loose compression low: spark plug loose cylinder head not sufficiently tightened down no valve clearance cylinder, piston worn piston ring bad (worn, weak, broken, or sticking) piston ring/groove clearance excessive cylinder head warped cylinder ...

  • Page 488

    17-20 appendix troubleshooting guide engine load faulty: clutch slipping engine oil level too high engine oil viscosity too high drive train trouble brake dragging lubrication inadequate: engine oil level too low engine oil poor quality or incorrect gauge incorrect: water temperature gauge broken wa...

  • Page 489

    Appendix 17-21 troubleshooting guide engine mount loose crankshaft bearing worn primary gear worn or chipped camshaft chain tensioner trouble camshaft chain, sprocket, guide worn air suction valve damaged vacuum switch valve damaged alternator rotor loose catalytic converter melt down due to muffler...

  • Page 490

    17-22 appendix troubleshooting guide rear shock adjustment too soft front fork, rear shock absorber spring weak rear shock absorber oil leaking brake doesn’t hold: air in the brake line pad or disc worn brake fluid leakage disc warped contaminated pad brake fluid deteriorated primary or secondary cu...

  • Page 491

    Model application year model beginning frame no. 2004 zr750–j1 jkazrdj1 □ 4a000001 zr750j–000001 jkazr750jja000001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1323-01 printed in japan.