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Kawasaki Z750 ABS Service Manual

Other manuals for Z750 ABS: Service Manual

Summary of Z750 ABS

  • Page 1

    Z750 z750 abs motorcycle service manual.

  • Page 3: Quick Reference Guide

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

  • Page 5: Z750

    Z750 z750 abs motorcycle service manual all rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of quality assurance...

  • 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 8: 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 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 generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can l...

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

  • Page 15

    General information 1-7 model identification zr750l7f (europe) left side view zr750l7f (europe) right side view.

  • Page 16

    1-8 general information model identification zr750m7f left side view zr750m7f right side view frame number engine number.

  • Page 17

    General information 1-9 general specifications items zr750l7f, zr750m7f dimensions overall length 2 085 mm (82.09 in.) overall width 805 mm (31.69 in.) overall height 1 100 mm (43.31 in.) wheelbase 1 440 mm (56.69 in.) road clearance 155 mm (6.10 in.) seat height 815 mm (32.09 in.) dry mass: zr750l7...

  • Page 18

    1-10 general information general specifications items zr750l7f, zr750m7f exhaust: open 51° bbdc close 25° atdc duration 256° lubrication system forced lubrication (wet sump) engine oil: type api se, sf or sg api sh, sj or sl with jaso ma viscosity sae 10w-40 capacity 3.8 l (4.0 us qt) drive train pr...

  • Page 19

    General information 1-11 general specifications items zr750l7f, zr750m7f rear suspension: type swingarm (uni-trak) wheel travel 125 mm (4.92 in.) brake type: front dual discs rear single disc electrical equipment battery 12 v 8 ah headlight: type semi-sealed beam bulb 12 v 55 w × 2/55 w (hi/lo) tail...

  • Page 20

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

  • Page 21: Periodic Maintenance

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

  • Page 22

    2-2 periodic maintenance steering play inspection ................................................................................................... 2-43 steering play adjustment.................................................................................................. 2-43 steering stem bea...

  • Page 23

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

  • Page 24

    2-4 periodic maintenance periodic maintenance chart frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) 1 6 12 18 24 30 36 inspection every (0.6) (4) (7.5) (12) (15) (20) (24) see page brake system brake fluid leak (brake hose and pipe) - inspect year • • • • • • • 2-38 brak...

  • Page 25

    Periodic maintenance 2-5 periodic maintenance chart periodic replacement parts frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) 1 12 24 36 48 change/replace item every (0.6) (7.5) (15) (24) (30) see page air cleaner element # • 2-53 fuel hose 4 years • 2-54 coolant 3 year...

  • Page 26

    2-6 periodic maintenance torque and locking agent the following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “remarks” column mean: al: tighten the two clamp bolts alternately two times to ensure...

  • Page 27

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks thermostat bracket bolt 6.9 0.70 61 in·lb thermostat housing ground bolt 6.9 0.70 61 in·lb thermostat housing screws 5.9 0.60 52 in·lb water pipe bolts 11 1.1 97 in·lb l water pump cover bolts 11 1.1 97 in·lb w...

  • Page 28

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks engine lubrication system coolant drain bolt (water pump) 11 1.1 97 in·lb engine oil drain bolt 29 3.0 21 oil filter 17 1.7 13 g, r oil filter holder 78 8.0 58 eo oil filler plug 2.0 0.20 18 in·lb oil jet nozzl...

  • Page 29

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks shift lever bolt 6.9 0.70 61 in·lb shift pedal mounting bolt 34 3.5 25 l shift shaft return spring pin 29 3.0 21 l starter motor clutch bolts 12 1.2 106 in·lb l tie-rod locknuts 6.9 0.70 61 in·lb wheels/tires f...

  • Page 30

    2-10 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks rear shock absorber nut (lower) 34 3.5 25 rear shock absorber nut (upper) 34 3.5 25 swingarm pivot shaft 9.8 1.0 87 in·lb swingarm pivot shaft locknut 98 10.0 72.3 swingarm pivot shaft nut 108 11.0 79.7 tie-ro...

  • Page 31

    Periodic maintenance 2-11 torque and locking agent torque fastener n·m kgf·m ft·lb remarks speed sensor bolt 12 1.2 106 in·lb starter motor mounting bolts 11 1.1 97 in·lb starter relay cable terminal bolts 3.9 0.40 35 in·lb stator coil bolts 12 1.2 106 in·lb l switch housing screws 3.5 0.36 31 in·lb...

  • Page 32

    2-12 periodic maintenance specifications item standard service limit fuel system (dfi) throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 1 100 ±50 r/min (rpm) – – – bypass screws (turn out) 2 1/2 (for reference) – – – throttle body vacuum 35.3 ±1.3 kpa (265 ±10 mmhg) at idle speed ...

  • Page 33

    Periodic maintenance 2-13 specifications item standard service limit final drive drive chain slack 30 ∼ 40 mm (1.2 ∼ 1.6 in.) – – – drive chain wear (20-link length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) standard chain: make enuma – – – type ek520mvxl1 – – – link 112 links – – – bra...

  • Page 34

    2-14 periodic maintenance special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 jack: 57001-1238 oil filter wrench: 57001-1249 vacuum gauge: 57001-1369 throttle sensor setting adapter: 57001-1538 extension tube: 57001-1578 jack attachment: 57001-1608.

  • Page 35

    Periodic maintenance 2-15 periodic maintenance procedures fuel system (dfi) air cleaner element cleaning note ○ in dusty areas, the element should be cleaned more frequently than the recommended interval. ○ after riding through rain or on muddily roads, the ele- ment should be cleaned immediately. W...

  • Page 36

    2-16 periodic maintenance periodic maintenance procedures • loosen the locknuts [a], and turn the lower adjusters [b] until the proper amount of throttle grip free play is ob- tained. • tighten the locknuts against the adjusters securely. If the throttle grip free play can not be adjusted with the l...

  • Page 37

    Periodic maintenance 2-17 periodic maintenance procedures • remove the fuel outlet hose (see fuel hose replace- ment). • connect the following parts temporary. Fuel pump lead connector [a] fuel level sensor lead connector [b] extension tube [c] special tool - extension tube: 57001-1578 • start the e...

  • Page 38

    2-18 periodic maintenance periodic maintenance procedures if any one vacuum measurement is out of the specified range after left (#1, #2) and right (#2, #3) synchronization, adjust the bypass screws [a]. Upside view [b] • adjust the lower vacuum between #1 and #2 to the higher vacuum of #1 and #2. •...

  • Page 39

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

  • Page 40

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

  • Page 41

    Periodic maintenance 2-21 periodic maintenance procedures • check that the outlet hose joints are securely connected. ○ push and pull [a] the hose joint [b] back and forth more than two times, and make sure it is locked and does not come off. Fuel pump side [c] throttle body assy side [d] warning ma...

  • Page 42

    2-22 periodic maintenance periodic maintenance procedures cooling system coolant level inspection note ○ check the level when the engine is cold (room or ambi- ent temperature). • remove the front seat (see front seat removal in the frame chapter). • check the coolant level in the reserve tank [a] w...

  • Page 43

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

  • Page 44

    2-24 periodic maintenance periodic maintenance procedures ○ when positioning #1 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 #4 piston tdc at the end of the compress...

  • Page 45

    Periodic maintenance 2-25 periodic maintenance procedures valve clearance adjustment chart inlet valve 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where th...

  • Page 46

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

  • Page 47

    Periodic maintenance 2-27 periodic maintenance procedures caution be sure to remeasure the clearance after selecting a shim according to the table. If the clearance is out of the specified range, use the additional shim. ○ if there is no valve clearance, use a shim that is a few sizes smaller, and r...

  • Page 48

    2-28 periodic maintenance periodic maintenance procedures • check that there is no play in the inner cables [a] by pulling them lightly. If there is play in the inner cables, adjust them (see ex- haust butterfly valve cable adjustment). Exhaust butterfly valve cable adjustment • slide the dust cover...

  • Page 49

    Periodic maintenance 2-29 periodic maintenance procedures • stretch the open cable (white) [a] first by using the ad- juster [b]. ○ turn the adjuster counterclockwise until it becomes hard to turn. Locknut of white [c] caution to keep the correct exhaust butterfly valve position, adjust the open cab...

  • Page 50

    2-30 periodic maintenance periodic maintenance procedures • turn the ignition switch on and wait until the pulley [a] turns fully clockwise [b]. • turn off the ignition switch when the pulley become fully clockwise position [c] as shown in the figure. ○ the target position is a position in which the...

  • Page 51

    Periodic maintenance 2-31 periodic maintenance procedures • stretch the open cable (white) by using the adjuster [a]. ○ turn the adjuster counterclockwise until it becomes hard to turn. Locknut of white [b] caution do not overstretch. If the adjustment of the exhaust butterfly valve cables are incor...

  • Page 52

    2-32 periodic maintenance periodic maintenance procedures warning to avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment. • turn the adjuster [a] so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) [b] of threads are visible. • slide the dust cover [a] at the clutch cable lower end ...

  • Page 53

    Periodic maintenance 2-33 periodic maintenance procedures wheel/tire damage inspection • remove any imbedded stones [a] or other foreign parti- cles [b] from tread. • visually inspect the tire for cracks and cuts, and replace the tire if necessary. Swelling or high spots indicate inter- nal damage, ...

  • Page 54

    2-34 periodic maintenance periodic maintenance procedures wheel bearing damage inspection • raise the front wheel off the ground with the jack (see front wheel removal in the wheels/tires chapter). • turn the handlebar all the way to the right or left. • inspect the roughness of the front wheel bear...

  • Page 55

    Periodic maintenance 2-35 periodic maintenance procedures • apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the o-rings so that the o-rings will be coated with oil. • wipe off any excess oil. Oil applied areas [a] o-rings [b] drive chain...

  • Page 56

    2-36 periodic maintenance periodic maintenance procedures • insert a new cotter pin [a]. Note ○ when inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [b] up to next alignment. ○ it should be within 30°. ○ loosen once and t...

  • Page 57

    Periodic maintenance 2-37 periodic maintenance procedures drive chain wear inspection • remove the chain cover (see drive chain removal in the final drive chapter). • rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, repla...

  • Page 58

    2-38 periodic maintenance periodic maintenance procedures brake system brake fluid leak (brake hose and pipe) inspection • for abs equipped models; note the following. • remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • apply the brake lever or pedal and inspect the br...

  • Page 59

    Periodic maintenance 2-39 periodic maintenance procedures brake hose and pipe damage and installation condition inspection • for abs equipped models; note the following. • remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • inspect the brake hoses, pipes and fittings for...

  • Page 60

    2-40 periodic maintenance periodic maintenance procedures • follow the procedure below to install the front brake fluid reservoir cap correctly. ○ first, tighten the front brake fluid reservoir cap [b] clock- wise [c] by hand until slight resistance is felt indicating that the cap is seated on the r...

  • Page 61

    Periodic maintenance 2-41 periodic maintenance procedures brake light switch operation inspection • turn on the ignition switch. • the brake light [a] should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm (0.39 in.). If it does not, adjust the brake light swi...

  • Page 62

    2-42 periodic maintenance periodic maintenance procedures • pump the seat down and up [a] 4 or 5 times, and inspect the smooth stroke. If the shock absorber does not smoothly stroke or noise is found, inspect the oil leak (see rear shock absorber oil leak inspection). Front fork oil leak inspection ...

  • Page 63

    Periodic maintenance 2-43 periodic maintenance procedures steering system steering play inspection • raise the front wheel off the ground with the jack. Special tools - jack: 57001-1238 jack attachment: 57001-1608 • with the front wheel pointing straight ahead, alternately tap each end of the handle...

  • Page 64

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

  • Page 65

    Periodic maintenance 2-45 periodic maintenance procedures electrical system spark plug condition inspection • remove the spark plugs (see spark plug replacement), and visually inspect. • clean the spark plug, preferably in a sandblasting device, and then clean off any abrasive particles. The plug ma...

  • Page 66

    2-46 periodic maintenance periodic maintenance procedures lights and switches operation inspection first step • turn on the ignition switch. • the following lights should go on according to below table. City lights [a] go on taillight [b] goes on license plate light [c] goes on meter panel lcd [d] g...

  • Page 67

    Periodic maintenance 2-47 periodic maintenance procedures third step • turn on the turn signal switch [a] (left or right position). • the left or right turn signal lights [b] (front and rear) ac- cording to the switch position should flash. • the turn signal indicator light (led) [c] in the meter un...

  • Page 68

    2-48 periodic maintenance periodic maintenance procedures • set the dimmer switch to high beam position. • the low beam [a] and high beam [b] headlights should go on. • the high beam indicator light (led) [c] should go on. If the high beam headlight and/or high beam indicator light (led) does not go...

  • Page 69

    Periodic maintenance 2-49 periodic maintenance procedures sidestand switch operation inspection • inspect the sidestand switch [a] operation accordance to the following table. Sidestand switch operation sidestand gear position clutch lever engine start engine run up neutral released starts continue ...

  • Page 70

    2-50 periodic maintenance periodic maintenance procedures engine stop switch operation inspection first step • turn on the ignition switch. • set the neutral position. • turn the engine stop switch to stop position [a]. • push the starter button. • the engine does not start. If the engine starts, in...

  • Page 71

    Periodic maintenance 2-51 periodic maintenance procedures cables: lubricate with rust inhibitor. Clutch cable throttle cables • lubricate the cables by seeping the oil between the cable and housing. ○ the cable may be lubricated by using a commercially available pressure cable lubricator with an aer...

  • Page 72

    2-52 periodic maintenance periodic maintenance procedures bolts, nuts and fasteners tightness inspection • check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. Note ○ for the engine fasteners, check the tightness of them wh...

  • Page 73

    Periodic maintenance 2-53 periodic maintenance procedures replacement parts air cleaner element replacement note ○ in dusty areas, the element should be replaced more frequently than the recommended interval. ○ after riding through rain or on muddily roads, the ele- ment should be replaced immediate...

  • Page 74

    2-54 periodic maintenance periodic maintenance procedures • install a new element [a] so that flat side [b] faces forward. • fit the tongue [c] of the air cleaner duct into the slot [d] of the air cleaner housing. • tighten: torque - air cleaner duct screws: 3.8 n·m (0.39 kgf·m, 34 in·lb) fuel hose ...

  • Page 75

    Periodic maintenance 2-55 periodic maintenance procedures • pull the joint lock [a] as shown in the figure. • pull the fuel outlet hose joint [b] out of the delivery pipe. • install a new fuel inlet hose [a] so that the white mark side [b] faces outlet pipe [c] of the fuel tank. Fuel pump [d] bottom...

  • Page 76

    2-56 periodic maintenance periodic maintenance procedures • push and pull [a] the fuel hose joint [b] back and forth more than two times, and make sure it is locked and does not come off. Warning make sure the fuel hose joint is installed correctly on the delivery pipe or the fuel could leak. If it ...

  • Page 77

    Periodic maintenance 2-57 periodic maintenance procedures • remove: right seat cover (see seat cover removal in the frame chapter) hose [a] reserve tank bolts [b] • turn over the reserve tank, remove the cap, and pour the coolant into a suitable container. • install the reserve tank. • tighten: torq...

  • Page 78

    2-58 periodic maintenance periodic maintenance procedures radiator hose and o-ring replacement • drain the coolant (see coolant change). • remove: thermostat housing [a] (see thermostat removal in the cooling system chapter) water pump cover [b] (see water pump removal in the cooling system chapter)...

  • Page 79

    Periodic maintenance 2-59 periodic maintenance procedures recommended engine oil type: api se, sf or sg api sh, sj or sl with jaso ma viscosity: sae 10w-40 capacity: 3.1 l (3.3 us qt) (when filter is not removed) 3.3 l (3.5 us qt) (when filter is removed) 3.8 l (4.0 us qt) (when engine is completely...

  • Page 80

    2-60 periodic maintenance periodic maintenance procedures brake hose and pipe replacement caution brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • remove the brake hose banjo bolts [a]. • when removing the brake hose, take care not...

  • Page 81

    Periodic maintenance 2-61 periodic maintenance procedures • for abs equipped models; note the following. • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) rear fender (see flap and rear fender removal in the frame chapter) abs hydraulic unit (see abs hydraulic unit removal...

  • Page 82

    2-62 periodic maintenance periodic maintenance procedures brake fluid change note ○ the procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is the same as for the front brake. • level the brake fluid reservoir. • remove the reservoir cap. • remove the rubber cap ...

  • Page 83

    Periodic maintenance 2-63 periodic maintenance procedures master cylinder rubber parts replacement front master cylinder disassembly • remove the front master cylinder (see front master cylin- der removal in the brakes chapter). • remove the seal cover [a], circlip [b], connector [c] and o-ring [d]....

  • Page 84

    2-64 periodic maintenance periodic maintenance procedures master cylinder assembly • before assembly, clean all parts including the master cylinder with brake fluid or alcohol. Caution except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brak...

  • Page 85

    Periodic maintenance 2-65 periodic maintenance procedures warning to avoid serious injury, never place your fingers or palm in front of the piston. If you apply compressed air into the caliper, the piston may crush your hand or fingers. ○ pull out the pistons by hand. • remove the dust seals [a] and...

  • Page 86

    2-66 periodic maintenance periodic maintenance procedures rear caliper disassembly • remove: rear caliper (see rear caliper removal in the brakes chapter) brake pads (see rear brake pad removal in the brakes chapter) • using compressed air, remove the piston. ○ cover the piston area with a wooden bo...

  • Page 87

    Periodic maintenance 2-67 periodic maintenance procedures • apply brake fluid to the cylinder bore. • replace the fluid seal [a] with a new one. ○ apply silicone grease to the fluid seal, and install it into the cylinder by hand. • replace the dust seal [b] with a new one if it is damaged. • install...

  • Page 89: Fuel System (Dfi)

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

  • Page 90

    3-2 fuel system (dfi) speed sensor input voltage inspection............................................................................ 3-67 speed sensor output voltage inspection ......................................................................... 3-68 vehicle-down sensor (service code 31).......

  • Page 91

    Fuel system (dfi) 3-3 ecu identification ............................................................................................................. 3-106 ecu removal ................................................................................................................... 3-106 ecu insta...

  • Page 92

    3-4 fuel system (dfi) exploded view.

  • Page 93

    Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air cleaner duct screws 3.8 0.39 34 in·lb 2 air cleaner housing mounting bolts 9.8 1.0 87 in·lb 3 air cleaner housing tapping screws 1.2 0.12 11 in·lb 4 air duct clamp bolts 2.0 0.20 18 in·lb 5 bypass screws 0.2 0.02 1...

  • Page 94

    3-6 fuel system (dfi) exploded view.

  • Page 95

    Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 camshaft position sensor bolt 12 1.2 106 in·lb 2 crankshaft sensor bolts 5.9 0.60 52 in·lb 3 oxygen sensor (equipped models) 44.1 4.50 32.5 4 speed sensor bolt 12 1.2 106 in·lb 5 vehicle-down sensor bolts 6.0 0.61 53 i...

  • Page 96

    3-8 fuel system (dfi) exploded view.

  • Page 97

    Fuel system (dfi) 3-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 exhaust butterfly valve actuator bracket bolt 6.9 0.70 61 in·lb 2 exhaust butterfly valve actuator mounting bolts 6.9 0.70 61 in·lb 3 exhaust butterfly valve actuator pulley bolt 5.0 0.51 44 in·lb 4 fuel pump bolts 9.8...

  • Page 98

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

  • Page 99

    Fuel system (dfi) 3-11 dfi system 1. Ecu 2. Crankshaft sensor 3. Camshaft position sensor 4. Main throttle sensor 5. Subthrottle sensor 6. Subthrottle valve actuator 7. Inlet air pressure sensor 8. Atmospheric pressure sensor 9. Water temperature sensor 10. Inlet air temperature sensor 11. Vehicle-d...

  • Page 100

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

  • Page 101

    Fuel system (dfi) 3-13 dfi system part names 1. Fan motor 2. Fuse box 2 3. Radiator fan fuse 15 a 4. Ecu fuse 10 a 5. Ignition fuse 10 a 6. Stick coil #1, #2, #3, #4 7. Air switching valve 8. Subthrottle valve actuator 9. Fuel injector #1, #2, #3, #4 10. Subthrottle sensor 11. Main throttle sensor 1...

  • Page 102

    3-14 fuel system (dfi) dfi system terminal numbers of ecu connectors terminal names 1. Subthrottle valve actuator: bk/bl 2. Subthrottle valve actuator: g 3. Exhasut butterfly valve actuator (+): gy 4. Exhasut butterfly valve actuator (–): g/r 5. Exhasut butterfly valve actuator sensor: r/bk 6. Speed...

  • Page 103

    Fuel system (dfi) 3-15 dfi system 35. Engine stop switch: r 36. Starter lockout switch: r/g 37. Starter button: bk/r 38. Fuel pump relay: br/y 39. Oxygen sensor (equipped models): w/bl 40. Unused 41. Neutral switch: lg 42. Radiator fan relay: p/bl 43. Injector #2: bl/g 44. Injector #1: bl/r 45. Stic...

  • Page 104

    3-16 fuel system (dfi) dfi parts location main throttle sensor [a] subthrottle sensor [b] fuel injectors #1, #2, #3, #4 [c] crankshaft sensor [a] oxygen sensor [b] (equipped models) ignition key (transponder (equipped models)) [a] ignition switch [b] immobilizer antenna [c] (equipped models) immobil...

  • Page 105

    Fuel system (dfi) 3-17 dfi parts location water temperature sensor [a] inlet air pressure sensor [b] inlet air temperature sensor [a] exhaust butterfly valve actuator [a] fuse box 1 (oxygen sensor heater fuse 10 a, (equipped models)) [b] battery 12 v 8 ah [c] atmospheric pressure sensor [d] relay bo...

  • Page 106

    3-18 fuel system (dfi) specifications item standard digital fuel injection system idle speed 1 100 ±50 r/min (rpm) throttle body assy: type four oval type bore 32 mm (1.26 in.) throttle body vacuum 35.3 ±1.3 kpa (265 ±10 mmhg) at idle speed bypass screws (turn out) 2 1/2 (for reference) ecu: make de...

  • Page 107

    Fuel system (dfi) 3-19 specifications item standard output voltage with sensor tilted 60 ∼ 70° or more right or left: dc 0.65 ∼ 1.35 v with sensor arrow mark pointed up: dc 3.55 ∼ 4.45 v subthrottle sensor: input voltage dc 4.75 ∼ 5.25 v output voltage dc 0.48 ∼ 0.52 v at idle throttle opening dc 3....

  • Page 108

    3-20 fuel system (dfi) special tools and sealant oil pressure gauge, 5 kgf/cm²: 57001-125 fork oil level gauge: 57001-1290 vacuum gauge: 57001-1369 hand tester: 57001-1394 throttle sensor setting adapter #1: 57001-1400 peak voltage adapter: 57001-1415 needle adapter set: 57001-1457 throttle sensor s...

  • Page 109

    Fuel system (dfi) 3-21 special tools and sealant fuel pressure gauge adapter: 57001-1593 fuel hose: 57001-1607 speed sensor measuring adapter: 57001-1667 oxygen sensor measuring adapter: 57001-1682 measuring adapter: 57001-1700 kawasaki bond (silicone sealant): 56019-120

  • Page 110

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

  • Page 111

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

  • Page 112

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

  • Page 113

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

  • Page 114

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

  • Page 115

    Fuel system (dfi) 3-27 troubleshooting the dfi system • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. • check the wiring for continuity. ○ use the...

  • Page 116

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

  • Page 117

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

  • Page 118

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

  • Page 119

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

  • Page 120

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

  • Page 121

    Fuel system (dfi) 3-33 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). Inlet air pressure sensor troubl...

  • Page 122

    3-34 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) inlet air temperature sensor trouble inspect (see chapter 3). Other: intermittent any dfi fault and its recovery check that dfi connectors are clean and tight, and examine leads for signs of burning...

  • Page 123

    Fuel system (dfi) 3-35 dfi system troubleshooting guide symptoms or possible causes actions (chapter) water temperature sensor trouble inspect (see chapter 3). Inlet air temperature sensor trouble inspect (see chapter 3). Miscellaneous: subthrottle sensor trouble inspect (see chapter 3). Subthrottle...

  • Page 124

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

  • Page 125

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

  • Page 126

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

  • Page 127

    Fuel system (dfi) 3-39 self-diagnosis self-diagnosis flow chart.

  • Page 128

    3-40 fuel system (dfi) self-diagnosis service code reading ○ the service code(s) is displayed on the lcd by the number of two digits. ○ when there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical or...

  • Page 129

    Fuel system (dfi) 3-41 self-diagnosis service code table service code problems 11 main throttle sensor malfunction, wiring open or short 12 inlet air pressure sensor malfunction, wiring open or short 13 inlet air temperature sensor malfunction, wiring open or short 14 water temperature sensor malfun...

  • Page 130

    3-42 fuel system (dfi) self-diagnosis backups ○ the ecu takes the following measures to prevent engine damage when the dfi, ignition or immo- bilizer system parts have troubles. Service codes parts output signal usable range or criteria backups by ecu 11 main throttle sensor output voltage 0.2 ∼ 4.8...

  • Page 131

    Fuel system (dfi) 3-43 self-diagnosis service codes parts output signal usable range or criteria backups by ecu 33 oxygen sensor (equipped models) the oxygen sensor is active and sensor must send signals (output voltage) continuously to the ecu. If the oxygen sensor is not activated, the ecu stops t...

  • Page 132

    3-44 fuel system (dfi) self-diagnosis service codes parts output signal usable range or criteria backups by ecu 64 air switching valve the air switching valve controls the flow of the secondary air by opening and shutting the solenoid valve. – 67 oxygen sensor heater (equipped models) the oxygen sen...

  • Page 133

    Fuel system (dfi) 3-45 main throttle sensor (service code 11) the main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ecu senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm,...

  • Page 134

    3-46 fuel system (dfi) main throttle sensor (service code 11) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main harness side connectors. ○ disconnect the ecu and sensor connectors. Wiring inspection ecu connector [a] ←→ main throttle sensor connec...

  • Page 135

    Fuel system (dfi) 3-47 main throttle sensor (service code 11) • turn the ignition switch off. • measure the output voltage with the engine stopped, and with the connector joined. • turn the ignition switch on. Output voltage standard: dc 0.985 ∼ 1.015 v at idle throttle opening dc 4.18 ∼ 4.38 v at f...

  • Page 136

    3-48 fuel system (dfi) main throttle sensor (service code 11) main throttle sensor circuit 1. Ecu 2. Main throttle sensor.

  • Page 137

    Fuel system (dfi) 3-49 inlet air pressure sensor (service code 12) inlet air pressure sensor removal caution never drop the inlet air pressure sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove: fuel tank (see fuel tank removal) water temperature sensor connecto...

  • Page 138

    3-50 fuel system (dfi) inlet air pressure sensor (service code 12) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main harness side connectors. ○ disconnect the ecu and sensor connectors. Wiring inspection ecu connector [a] ←→ inlet air pressure sen...

  • Page 139

    Fuel system (dfi) 3-51 inlet air pressure sensor (service code 12) if the wiring is good, check the sensor for various vacuum. • remove the inlet air pressure sensor [a] and disconnect the vacuum hose from the sensor. • connect an auxiliary hose [b] to the inlet air pressure sen- sor. • temporarily ...

  • Page 140

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

  • Page 141

    Fuel system (dfi) 3-53 inlet air pressure sensor (service code 12) inlet air pressure sensor circuit 1. Ecu 2. Inlet air pressure sensor.

  • Page 142

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

  • Page 143

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

  • Page 144

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

  • Page 145

    Fuel system (dfi) 3-57 water temperature sensor (service code 14) water temperature sensor removal/installation caution never drop the water temperature sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove: fuel tank (see fuel tank removal) coolant (drain, see c...

  • Page 146

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

  • Page 147

    Fuel system (dfi) 3-59 atmospheric pressure sensor (service code 15) atmospheric pressure sensor removal caution never drop the atmospheric pressure sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove: left seat cover (see seat cover removal in the frame chapte...

  • Page 148

    3-60 fuel system (dfi) atmospheric pressure sensor (service code 15) if the input voltage is out of the standard, remove the ecu and check the wiring for continuity between main harness side connectors. ○ disconnect the ecu and sensor connectors. Wiring inspection ecu connector [a] ←→ atmospheric pr...

  • Page 149

    Fuel system (dfi) 3-61 atmospheric pressure sensor (service code 15) if the wiring is good, check the sensor for various vacuum. ○ determine the local altitude (elevation). If you know the local altitude, use the chart in this section. If you know the local atmospheric pressure using a barometer, su...

  • Page 150

    3-62 fuel system (dfi) atmospheric pressure sensor (service code 15) atmospheric pressure/altitude relationship.

  • Page 151

    Fuel system (dfi) 3-63 atmospheric pressure sensor (service code 15) atmospheric pressure sensor circuit 1. Ecu 2. Atmospheric pressure sensor.

  • Page 152

    3-64 fuel system (dfi) crankshaft sensor (service code 21) the crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no sig- nals. Crankshaft sensor removal/installation • refer to the crankshaft sensor removal/installation in the electrical system chapter...

  • Page 153

    Fuel system (dfi) 3-65 camshaft position sensor (service code 23) the camshaft position sensor detects the position of the camshaft, and distinguishes the cylinder. The camshaft position sensor has no power source, and when the engine stops, the camshaft position sensor gen- erates no signals. Camsh...

  • Page 154

    3-66 fuel system (dfi) camshaft position sensor (service code 23) camshaft position sensor circuit 1. Ecu 2. Camshaft position sensor.

  • Page 155

    Fuel system (dfi) 3-67 speed sensor (service code 24, 25) speed sensor removal/installation • refer to the speed sensor removal/installation in the electrical system chapter. Speed sensor input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • disconne...

  • Page 156

    3-68 fuel system (dfi) speed sensor (service code 24, 25) speed sensor output voltage inspection • raise the rear wheel off the ground with the stand. • measure the output voltage at the speed sensor in the same way as input voltage inspection, note the following. ○ disconnect the speed sensor conne...

  • Page 157

    Fuel system (dfi) 3-69 speed sensor (service code 24, 25) speed sensor circuit 1. Ecu 2. Speed sensor.

  • Page 158

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

  • Page 159

    Fuel system (dfi) 3-71 vehicle-down sensor (service code 31) vehicle-down sensor input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • disconnect the vehicle-down sensor connector and con- nect the harness adapter [a] between these connectors as show...

  • Page 160

    3-72 fuel system (dfi) vehicle-down sensor (service code 31) vehicle-down sensor output voltage inspection • remove the vehicle-down sensor (see vehicle-down sensor removal). • connect the harness adapter [a] to the vehicle-down sen- sor connectors as shown in the figure. Special tool - measuring ad...

  • Page 161

    Fuel system (dfi) 3-73 vehicle-down sensor (service code 31) if the reading is within the standard, remove the ecu and check the wiring for continuity between main harness side connectors. ○ disconnect the ecu and sensor connectors. Wiring inspection ecu connector [a] ←→ vehicle-down sensor connecto...

  • Page 162

    3-74 fuel system (dfi) subthrottle sensor (service code 32) the subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ecu senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and...

  • Page 163

    Fuel system (dfi) 3-75 subthrottle sensor (service code 32) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main harness side connectors. ○ disconnect the ecu and sensor connectors. Wiring inspection ecu connector [a] ←→ subthrottle sensor connector ...

  • Page 164

    3-76 fuel system (dfi) subthrottle sensor (service code 32) • measure the output voltage with the engine stopped with the connector joined. • turn the ignition switch on. • measure the output voltage when the subthrottle valve is completely closed by turning the lever [a] fully clockwise [b]. Output...

  • Page 165

    Fuel system (dfi) 3-77 subthrottle sensor (service code 32) subthrottle sensor circuit 1. Ecu 2. Subthrottle sensor.

  • Page 166

    3-78 fuel system (dfi) oxygen sensor - not activated (service code 33 (equipped models)) oxygen sensor removal/installation • refer to the oxygen sensor removal/installation in the electrical system chapter. Oxygen sensor inspection • warm up the engine thoroughly until the radiator fan starts. • tu...

  • Page 167

    Fuel system (dfi) 3-79 oxygen sensor - not activated (service code 33 (equipped models)) • remove the connector [a] from the clamp [b]. • separate the hoses [a] from the air suction valve covers. • pull the air switching valve [a] and hoses out to the left side of the motorcycle. ○ do not disconnect...

  • Page 168

    3-80 fuel system (dfi) oxygen sensor - not activated (service code 33 (equipped models)) • start the engine, and let it idle. • measure the output voltage with the connector joined. Output voltage (with plugs) standard: dc 0.7 v or more • next, remove the plugs from the fittings [a] with idling. • m...

  • Page 169

    Fuel system (dfi) 3-81 oxygen sensor - not activated (service code 33 (equipped models)) oxygen sensor circuit 1. Ecu 2. Meter ground 3. Oxygen sensor 4. Water-proof joint c 5. Fuse box 1 6. Oxygen sensor heater fuse 10 a 7. Ignition switch 8. Main fuse 30 a 9. Battery 12 v 8 ah.

  • Page 170

    3-82 fuel system (dfi) exhaust butterfly valve actuator sensor (service code 34) exhaust butterfly valve actuator sensor removal/installation the exhaust butterfly valve actuator sensor is built in the exhaust butterfly valve actuator. So, the sensor itself can not be removed. Remove the exhaust but...

  • Page 171

    Fuel system (dfi) 3-83 exhaust butterfly valve actuator sensor (service code 34) exhaust butterfly valve actuator sensor output voltage inspection note ○ before this inspection, confirm the pulley [a] is original position (see exhaust butterfly valve actuator installa- tion). • disconnect: 2 pins co...

  • Page 172

    3-84 fuel system (dfi) exhaust butterfly valve actuator sensor (service code 34) exhaust butterfly valve actuator sensor resistance inspection • turn the ignition switch off. • disconnect the exhaust butterfly valve actuator sensor connector (3 pins connector) [a]. • connect a digital meter [b] to t...

  • Page 173

    Fuel system (dfi) 3-85 immobilizer amplifier (service code 35 (equipped models)) antenna resistance inspection • turn the ignition switch off. • remove the fuel tank (see fuel tank removal). • disconnect the antenna lead connector [a]. • measure the antenna resistance. Antenna resistance connections...

  • Page 174

    3-86 fuel system (dfi) blank key detection (service code 36 (equipped models)) • this code appears in the following conditions. ○ the transponder [a] in the master and/or user key is mal- function. ○ when the spare key of unregistration is used. ○ when the master key is registered in the registered ...

  • Page 175

    Fuel system (dfi) 3-87 ecu communication error (service code 39) ecu communication line inspection ○ when the data is not sent from the ecu to the meter unit for more than about 10 seconds, the service code 39 is displayed. ○ the service code 39 is detected with meter unit. • remove the ecu and mete...

  • Page 176

    3-88 fuel system (dfi) stick coils #1, #2, #3, #4 (service code 51, 52, 53, 54) stick coil #1: service code 51 stick coil #2: service code 52 stick coil #3: service code 53 stick coil #4: service code 54 stick coil removal/installation • refer to the stick coil removal/installation in the electri- c...

  • Page 177

    Fuel system (dfi) 3-89 stick coils #1, #2, #3, #4 (service code 51, 52, 53, 54) • turn the ignition switch off. If the input voltage is out of the standard, check the wiring for continuity (see wiring diagram in this section). If the wiring is good, check the ecu for its ground and power supply (see...

  • Page 178

    3-90 fuel system (dfi) radiator fan relay (service code 56) radiator fan relay removal/installation ○ the radiator fan relay is built in the relay box [a]. • refer to the relay box removal in the electrical system chapter. Radiator fan relay inspection • refer to the relay circuit inspection in the ...

  • Page 179

    Fuel system (dfi) 3-91 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 throttle body assy, especially on a hard surface. Such a sh...

  • Page 180

    3-92 fuel system (dfi) subthrottle valve actuator (service code 62) subthrottle valve actuator input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • disconnect the subthrottle valve actuator connector and connect the harness adapter [a] between these...

  • Page 181

    Fuel system (dfi) 3-93 subthrottle valve actuator (service code 62) subthrottle valve actuator circuit 1. Ecu 2. Subthrottle valve actuator.

  • Page 182

    3-94 fuel system (dfi) exhaust butterfly valve actuator (service code 63) exhaust butterfly valve actuator removal caution never drop the exhaust butterfly valve actuator, es- pecially on a hard surface. Such a shock to the ac- tuator can damage it. • slide the dust covers [a]. • loosen the locknuts...

  • Page 183

    Fuel system (dfi) 3-95 exhaust butterfly valve actuator (service code 63) exhaust butterfly valve actuator installation • install the pulley [a] on the actuator as shown in the figure. • tighten the pulley bolt [b] while holding the pulley with the suitable tool [c]. Torque - exhaust butterfly valve...

  • Page 184

    3-96 fuel system (dfi) exhaust butterfly valve actuator (service code 63) • install the bracket [a] on the actuator [b]. Washer [c] nut [d] bolt [e] • tighten: torque - exhaust butterfly valve actuator bracket bolt: 6.9 n·m (0.70 kgf·m, 61 in·lb) • install the actuator and bracket on the frame [f]. ...

  • Page 185

    Fuel system (dfi) 3-97 exhaust butterfly valve actuator (service code 63) if the reading is in specification, remove the ecu and check the wiring for continuity between main harness side connectors. ○ disconnect the ecu and actuator connectors. Wiring inspection ecu connector [a] ←→ exhaust butterfl...

  • Page 186

    3-98 fuel system (dfi) air switching valve (service code 64) air switching valve removal/installation • refer to the air switching valve removal/installation in the engine top end chapter. Air switching valve inspection • refer to the air switching valve unit test in the electrical system chapter. I...

  • Page 187

    Fuel system (dfi) 3-99 oxygen sensor heater (service code 67 (equipped models)) oxygen sensor heater removal/installation the oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see oxygen sensor removal (equipped mod- els) in the...

  • Page 188

    3-100 fuel system (dfi) oxygen sensor heater (service code 67 (equipped models)) oxygen sensor heater power source voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • disconnect the oxygen sensor lead connector and con- nect the harness adapter [a] betwe...

  • Page 189

    Fuel system (dfi) 3-101 oxygen sensor heater (service code 67 (equipped models)) oxygen sensor circuit 1. Ecu 2. Meter ground 3. Oxygen sensor 4. Water-proof joint c 5. Fuse box 1 6. Oxygen sensor heater fuse 10 a 7. Ignition switch 8. Main fuse 30 a 9. Battery 12 v 8 ah.

  • Page 190

    3-102 fuel system (dfi) oxygen sensor - incorrect output voltage (service code 94 (equipped models)) oxygen sensor removal/installation • refer to the oxygen sensor removal/installation (equipped models) in the electrical system chapter. Oxygen sensor inspection • warm up the engine thoroughly until...

  • Page 191

    Fuel system (dfi) 3-103 oxygen sensor - incorrect output voltage (service code 94 (equipped models)) • remove the connector [a] from the clamp [b]. • separate the hoses [a] from the air suction valve covers. • pull the air switching valve [a] and hoses out to the left side of the motorcycle. ○ do no...

  • Page 192

    3-104 fuel system (dfi) oxygen sensor - incorrect output voltage (service code 94 (equipped models)) • start the engine, and let it idle. • measure the output voltage with the connector joined. Output voltage (with plugs) standard: dc 0.7 v or more • next, remove the plugs from the fittings [a] with...

  • Page 193

    Fuel system (dfi) 3-105 warning indicator light (led) light (led) inspection ○ the warning indicator light (led) [a] is used for the fi in- dicator, immobilizer indicator (immobilizer equipped mod- els) and oil pressure warning indicator. ○ in this model, the warning indicator light (led) (fi/immo- ...

  • Page 194

    3-106 fuel system (dfi) ecu ecu identification ○ most countries have their own regulations, so each ecu has different characteristic. So, do not confuse ecu with each other and use only the ecu for your model. Other- wise, the motorcycle cannot clear the regulation. Ecu identification part number [a...

  • Page 195

    Fuel system (dfi) 3-107 ecu ecu installation • install: ecu [a] (in rubber protector [b]) ecu connectors [c] (connect) • insert the slits of the rubber protector to the projections [a] of the bracket. Ecu power supply inspection • remove the relay box (see relay box removal in the electrical system ...

  • Page 196

    3-108 fuel system (dfi) ecu if the wiring is good, check the power source voltage of the ecu. Note ○ be sure the battery is fully charged. • connect the ecu connectors. • connect a digital meter [a] to the connector [b] with the needle adapter set. Special tool - needle adapter set: 57001-1457 ecu p...

  • Page 197

    Fuel system (dfi) 3-109 ecu ecu power source circuit 1. Ecu 2. Frame ground 3. Water-proof joint c 4. Fuse box 2 5. Ecu fuse 10 a 6. Water-proof joint b 7. Ignition switch 8. Relay box 9. Ecu main relay 10. Main fuse 30 a 11. Battery 12 v 8 ah.

  • Page 198

    3-110 fuel system (dfi) dfi power source ecu fuse removal • refer to the 10 a ecu fuse removal in the electrical system chapter. Ecu fuse installation if a fuse fails during operation, inspect the dfi system to determine the cause, and then replace it with a new fuse of proper amperage. • refer to t...

  • Page 199

    Fuel system (dfi) 3-111 fuel line fuel pressure inspection note ○ be sure the battery is fully charged. • remove: fuel tank (see fuel tank removal) fuel outlet hose (see fuel hose replacement in the periodic maintenance chapter) ○ be sure to place a piece of cloth around the fuel outlet pipe of the ...

  • Page 200

    3-112 fuel system (dfi) fuel line note ○ the gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. • turn the ignition switch off. If the fuel pressure is much higher than specified, replace the fuel pump because the fuel pressure regulator in the fuel...

  • Page 201

    Fuel system (dfi) 3-113 fuel line • connect the prepared fuel hose [a] to the fuel outlet pipe. • secure the fuel hose with a clamp. • insert the fuel hose into the measuring cylinder [b]. Warning wipe off spilled out fuel immediately. Be sure to hold the measuring cylinder vertical. • close the fue...

  • Page 202

    3-114 fuel system (dfi) fuel pump fuel pump removal warning gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignit...

  • Page 203

    Fuel system (dfi) 3-115 fuel pump fuel pump installation • remove dirt or dust from the fuel pump [a] by lightly ap- plying compressed air. • replace the fuel pump gasket with a new one. • check that the fuel pump terminal [a] and band [b] are in place. Front [c] • apply a non-permanent locking agen...

  • Page 204

    3-116 fuel system (dfi) fuel pump fuel pump operating voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the right side cover (see side cover removal in the frame chapter). • disconnect the fuel pump lead connector and connect the harness adapter...

  • Page 205

    Fuel system (dfi) 3-117 fuel pump pressure regulator removal ○ the pressure regulator [a] is built into the fuel pump [b] and can not be removed. Pump screen, fuel filter cleaning ○ the pump screen [a] and fuel filter [b] are built into the pump and can not be cleaned or checked. If the pump screen ...

  • Page 206

    3-118 fuel system (dfi) fuel pump fuel pump circuit 1. Ecu 2. Frame ground 3. Fuel pump 4. Water-proof joint b 5. Engine stop switch 6. Fuse box 2 7. Ecu fuse 10a 8. Ignition fuse 10 a 9. Relay box 10. Fuel pump relay 11. Ecu main relay 12. Ignition switch 13. Main fuse 30 a 14. Battery 12 v 8 ah.

  • Page 207

    Fuel system (dfi) 3-119 fuel injectors fuel injector removal/installation • refer to the throttle body assy disassembly/assembly. Fuel injector audible inspection note ○ be sure the battery is fully charged. • start the engine, and let it idle. • apply the tip of a screwdriver [a] to the fuel inject...

  • Page 208

    3-120 fuel system (dfi) fuel injectors fuel injector power source voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • disconnect the injector connector and connect the har- ness adapter [a] between these connectors as shown in the figure. Main harness [b...

  • Page 209

    Fuel system (dfi) 3-121 fuel injectors fuel injector output voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the ecu (see ecu removal). ○ do not disconnect the ecu connector. • connect a digital meter [a] to the connector [b] with the needle ad...

  • Page 210

    3-122 fuel system (dfi) fuel injectors if the reading is out of the specification, remove the ecu and check the wiring for continuity between main harness side connector. ○ disconnect the ecu and injector connector. Wiring inspection ecu connector [a] ←→ fuel injector connector [b] for fuel injector...

  • Page 211

    Fuel system (dfi) 3-123 fuel injectors ○ watch the gauge for at least 6 seconds. If the pressure holds steady, the fuel line is good. If the pressure drops at once or if bubbles are found in the area, the fuel line is leaking. Replace the delivery pipe assy, injectors and related parts. ○ repeat the...

  • Page 212

    3-124 fuel system (dfi) throttle grip and cables free play inspection • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Free play adjustment • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Cable installation • install th...

  • Page 213

    Fuel system (dfi) 3-125 throttle body assy idle speed inspection/adjustment • refer to the idle speed inspection/adjustment in the pe- riodic maintenance chapter. Synchronization inspection/adjustment • refer to the engine vacuum synchronization inspection in the periodic maintenance chapter. Thrott...

  • Page 214

    3-126 fuel system (dfi) throttle body assy • disconnect: main throttle sensor connector [a] subthrottle sensor connector [b] • open the clamp [c]. • for models equipped with an abs, remove the bolt [a] and bracket [b]. • remove: air cleaner duct (see air cleaner element replacement in the periodic m...

  • Page 215

    Fuel system (dfi) 3-127 throttle body assy • remove the left frame cover (see frame cover removal in the frame chapter). • open the clamp [a] and pull the alternator lead connector [b] downward. • loosen the air duct clamp bolts [a]. • move [b] the air cleaner housing [c] backward, and pull out the ...

  • Page 216

    3-128 fuel system (dfi) throttle body assy • remove the bolt [a] and the throttle cable plate [b] from the throttle body assy. • remove the throttle cable lower ends [a] from the throttle pulley. Throttle body assy installation • turn the lever [a] fully clockwise, and close the subthrottle valves [...

  • Page 217

    Fuel system (dfi) 3-129 throttle body assy • install the air duct clamp bolts in the direction as shown. Bolt heads [a] • fit the projections [b] of the holder into the holes in the clamps. • install the air ducts to the throttle body assy. ○ apply a small amount of 2-stroke oil to the throttle body...

  • Page 218

    3-130 fuel system (dfi) throttle body assy caution do not remove, disassemble or adjust the main throttle sensor, subthrottle sensor, subthrottle valve actuator, throttle link mechanism and throttle body assy, because they are adjust or set surely at the manufacturer. Adjustment of these parts could...

  • Page 219

    Fuel system (dfi) 3-131 throttle body assy • replace the dust seals [a] with new ones. • apply engine oil to the new dust seals. • install the injectors along with the delivery pipe assy to the throttle body. • tighten: torque - delivery pipe assy mounting screws: 3.4 n·m (0.35 kgf·m, 30 in·lb) • co...

  • Page 220

    3-132 fuel system (dfi) air cleaner air cleaner element removal/installation • refer to the air cleaner element replacement in the pe- riodic maintenance chapter. Air cleaner element inspection • remove the air cleaner element (see air cleaner element replacement in the periodic maintenance chapter)...

  • Page 221

    Fuel system (dfi) 3-133 fuel tank fuel tank removal warning gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignit...

  • Page 222

    3-134 fuel system (dfi) fuel tank • disconnect: fuel pump lead connector [a] fuel level sensor lead connector [b] • be sure to place a piece of cloth [a] around the fuel outlet hose joint [b]. • push the joint lock claws [c]. • pull the joint lock [a] as shown in the figure. • pull [b] the fuel outl...

  • Page 223

    Fuel system (dfi) 3-135 fuel tank fuel tank installation • note the above warning (see fuel tank removal). • run the hoses correctly (see cable, wire, and hose rout- ing in the appendix chapter). • check that the dampers [a] are in place on the frame and the fuel tank. If the dampers are damaged or ...

  • Page 224

    3-136 fuel system (dfi) fuel tank fuel tank inspection • visually inspect the gasket [a] on the tank cap for any damage. Replace the gasket if it is damaged. • check to see if the water drain pipe [b] in the tank are not clogged. Check the tank cap breather also. If they are clogged, remove the tank...

  • Page 225: Cooling System

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

  • Page 226

    4-2 cooling system exploded view.

  • Page 227

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 coolant drain bolt (cylinder) 9.8 1.0 87 in·lb 2 coolant drain bolt (water pump) 11 1.1 97 in·lb 3 radiator bracket mounting bolt 6.9 0.70 61 in·lb 4 radiator lower bolt 6.9 0.70 61 in·lb 5 radiator upper bolts 6.9 0.70 6...

  • Page 228

    4-4 cooling system coolant flow chart.

  • Page 229

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

  • Page 230

    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 231

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

  • Page 232

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

  • Page 233

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

  • Page 234

    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 235

    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 236

    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 motor lead con- nector is disconnected. Touching the fan ...

  • Page 237

    Cooling system 4-13 radiator radiator and radiator fan installation • installation is the reverse of removal. • run the radiator fan motor lead correctly (see cable, wire, and hose routing section in the appendix chapter). • install the radiator bracket collars [a] as shown in the fig- ure. Rubber d...

  • Page 238

    4-14 cooling system radiator caution when cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage: keep the steam gun [a] away more than 0.5 m (1.6 ft) [b] from the radiator core. Hold the steam gun perpendicular [c] (not oblique [d]) to the core surface. Run...

  • Page 239

    Cooling system 4-15 thermostat thermostat removal • remove: coolant (drain, see coolant change in the periodic maintenance chapter) fuel tank (see fuel tank removal in the fuel system (dfi) chapter) right center fairing (see center fairing removal in the frame chapter) radiator hose clamp screw [a] ...

  • Page 240

    4-16 cooling system thermostat thermostat inspection • remove the thermostat (see thermostat removal), and inspect the thermostat valve [a] at room temperature. If the valve is open, replace the thermostat with a new one. • to check valve opening temperature, suspend the ther- mostat [a] in a contai...

  • Page 241

    Cooling system 4-17 hose and pipes hose installation • install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • run the hoses (see cable, wire, and hose routing sec- tion in the appendix chapter). • install the clamp [a] as nea...

  • Page 242

    4-18 cooling system water temperature sensor caution the water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it. Water temperature sensor removal/installation • refer to the water temperature sensor removal/instal- lat...

  • Page 243: Engine Top End

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

  • Page 244

    5-2 engine top end exploded view.

  • Page 245

    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 camshaft cap bolts (l = 45 mm) 12 1.2 106 in·lb s 3 camshaft cap bolts (l = 40 mm) 12 1.2 106 in·lb s 4 camshaft chain tensioner cap bolt 20 2.0 15 5 camshaft chain tension...

  • Page 246

    5-4 engine top end exploded view.

  • Page 247

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 exhaust butterfly valve actuator bracket bolt 6.9 0.70 61 in·lb 2 exhaust butterfly valve actuator mounting bolts 6.9 0.70 61 in·lb 3 exhaust butterfly valve actuator pulley bolt 5.0 0.51 44 in·lb 4 exhaust butterfly valv...

  • Page 248

    5-6 engine top end exhaust system exhaust system full: full power h: honeycomb type catalyst manifold mark position [a] muffler body mark position [b] honeycomb type catalyst position [c].

  • Page 249

    Engine top end 5-7 exhaust system manifold with hole [d] for oxygen sensor. Oxygen sensor [e].

  • Page 250

    5-8 engine top end specifications item standard service limit camshafts cam height: exhaust 35.743 ∼ 35.857 mm (1.4072 ∼ 1.4117 in.) 35.64 mm (1.403 in.) inlet 35.943 ∼ 36.057 mm (1.4151 ∼ 1.4196 in.) 35.84 mm (1.411 in.) camshaft journal, camshaft cap clearance 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in....

  • Page 251

    Engine top end 5-9 specifications item standard service limit cylinder, pistons cylinder inside diameter 68.400 ∼ 68.412 mm (2.6929 ∼ 2.6934 in.) 68.50 mm (2.6969 in.) piston diameter 68.345 ∼ 68.360 mm (2.6907 ∼ 2.6913 in.) 68.20 mm (2.6850 in.) piston/cylinder clearance 0.040 ∼ 0.067 mm (0.0016 ∼ ...

  • Page 252

    5-10 engine top end special tools and sealant compression gauge, 20 kgf/cm²: 57001-221 valve spring compressor assembly: 57001-241 piston pin puller assembly: 57001-910 valve seat cutter, 45° - 24.5: 57001-1113 valve seat cutter, 32° - 25: 57001-1118 valve seat cutter, 32° - 30: 57001-1120 valve sea...

  • Page 253

    Engine top end 5-11 special tools and sealant valve guide arbor, 4: 57001-1273 valve guide reamer, 4: 57001-1274 valve seat cutter holder, 4: 57001-1275 compression gauge adapter, m10 × 1.0: 57001-1317 valve seat cutter, 60° - 25: 57001-1328 compression gauge adapter, m10 × 1.0: 57001-1601 l-shape h...

  • Page 254

    5-12 engine top end clean air system air suction valve removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) connector [a] (from clamp [b]) air suction valve cover bolts [c] and bracket [d] air suction valve covers [e] air suction valves air suction valve installation ...

  • Page 255

    Engine top end 5-13 clean air system air switching valve removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) thermostat housing (see thermostat removal in the cooling system chapter) connector [a] (disconnect) • separate the hoses [b] from the air suction valve cover...

  • Page 256

    5-14 engine top end cylinder head cover cylinder head cover removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) air switching valve (see air switching valve removal) stick coils (see stick coil removal in the electrical sys- tem chapter) air suction valve covers (see...

  • Page 257

    Engine top end 5-15 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 258

    5-16 engine top end camshaft, camshaft chain camshaft removal • remove: cylinder head cover (see cylinder head cover re- moval) crankshaft sensor cover (see crankshaft sensor re- moval in the electrical system chapter) • position the crankshaft at #1, 4 piston tdc. Tdc mark [a] for #1, 4 pistons tim...

  • Page 259

    Engine top end 5-17 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 in ...

  • Page 260

    5-18 engine top end 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 261

    Engine top end 5-19 cylinder head cylinder compression measurement note ○ use the battery which is fully charged. • warm up the engine thoroughly. • stop the engine. • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) stick coils (see stick coil removal in the electrical sys...

  • Page 262

    5-20 engine top end cylinder head cylinder head removal • remove: coolant (drain, see coolant change in the periodic maintenance chapter) cylinder head cover (see cylinder head cover re- moval) camshafts (see camshaft removal) throttle body assy (see throttle body assy removal in the fuel system (df...

  • Page 263

    Engine top end 5-21 cylinder head • install: front camshaft chain guide [a] rear camshaft chain guide [b] new o-rings [c] collar [d] ○ apply grease to the new o-ring. • tighten: torque - front camshaft chain guide bolt (upper) [e]: 25 n·m (2.5 kgf·m, 18 ft·lb) front camshaft chain guide bolt (lower)...

  • Page 264

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

  • Page 265

    Engine top end 5-23 valves valve guide installation • apply engine oil to the valve guide outer surface before installation. • heat the area around the valve guide hole to about 120 ∼ 150°c (248 ∼ 302°f). Caution do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the ...

  • Page 266

    5-24 engine top end valves valve seat inspection • remove the valve (see valve removal). • check the valve seating surface [a] between the valve [b] and valve seat [c]. ○ measure the outside diameter [d] of the seating pattern on the valve seat. If the outside diameter is too large or too small, rep...

  • Page 267

    Engine top end 5-25 valves seat cutter operation care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. 3. Do not fai...

  • Page 268

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

  • Page 269

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

  • Page 270

    5-28 engine top end valves.

  • Page 271

    Engine top end 5-29 cylinder, pistons cylinder removal • remove: cylinder head (see cylinder head removal) subframe [a] (see engine removal in the engine re- moval/installation chapter) • remove: water hose clamp screw (loosen) [a] water hose [b] cylinder [c] cylinder installation note ○ if a new cy...

  • Page 272

    5-30 engine top end cylinder, pistons piston removal • remove the cylinder (see cylinder removal). • place a clean cloth under the pistons and remove the pis- ton pin snap ring [a] from the outside of each piston. • remove the piston pins. Special tool - piston pin puller assembly [a]: 57001-910 • r...

  • Page 273

    Engine top end 5-31 cylinder, pistons • do not mix up the top and second ring. • install the top ring [a] so that the “1t” mark [b] faces up. • install the second ring [c] so that the “2t” mark [d] faces up. ○ apply molybdenum disulfide oil solution to the piston rings. Note ○ if a new piston is use...

  • Page 274

    5-32 engine top end 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 275

    Engine top end 5-33 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 276

    5-34 engine top end throttle body holder throttle body holder installation • apply grease to the o-rings [a]. • be sure to install the o-rings. • install the clamps [b] as shown and so that its hole fit on the projection [c] of the holder. • tighten: torque - throttle body assy holder bolts [d]: 13 ...

  • Page 277

    Engine top end 5-35 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 • slide the dust covers [a]. • loosen the locknuts [b], and turn the adjusters [c] to give the cable plenty of play. • remove: c...

  • Page 278

    5-36 engine top end muffler muffler body installation • replace the muffler body gasket [a] with a new one. • install the muffler body gasket until it is bottomed so that the inside chamfer side faces rear [b]. • install the muffler body clamp bolt [c] as shown in the figure. Downside [d] inside [e]...

  • Page 279

    Engine top end 5-37 muffler • install the exhaust butterfly valve cables, and adjust them (see exhaust butterfly valve cable installation). • thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts and nut. • install the removed parts (see appropriate chapters). ○ wh...

  • Page 280

    5-38 engine top end muffler • loosen the clamp bolt [a]. • remove: exhaust pipe manifold holder nuts [a] exhaust pipe [b] exhaust pipe installation • replace the exhaust pipe gaskets [a] and muffler body gasket [b] with new ones and install them. • install the muffler body gasket until it is bottome...

  • Page 281

    Engine top end 5-39 muffler exhaust butterfly valve cable removal • slide the dust covers [a]. • loosen the locknuts [b], and turn the adjusters [c] to give the cable plenty of play. • remove: left side cover (see side cover removal in the frame chapter) clamp [a] exhaust butterfly valve cable upper...

  • Page 282

    5-40 engine top end muffler exhaust butterfly valve cable installation • confirm whether pulley [a] is an angle shown in the figure. 41.7° ±7° [b] ○ this position is original position of the pulley. Note ○ correct the position electrically after confirming use is discontinued and there is no damage ...

  • Page 283

    Engine top end 5-41 muffler • stretch the open cable (white) [a] first by using the ad- juster [b]. ○ turn the adjuster counterclockwise until it becomes hard to turn. Locknut of white [c] caution to keep the correct exhaust butterfly valve position, adjust the open cable first. Do not overstretch. ...

  • Page 284

    5-42 engine top end muffler • turn the ignition switch on and wait until the pulley [a] turns fully clockwise [b]. • turn off the ignition switch when the pulley become fully clockwise position [c] as shown in the figure. ○ the target position is a position in which the upper end [d] of the open cab...

  • Page 285

    Engine top end 5-43 muffler • stretch the open cable (white) by using the adjuster [a]. ○ turn the adjuster counterclockwise until it becomes hard to turn. Locknut of white [b] caution do not overstretch. If the adjustment of the exhaust butterfly valve cables are incorrect, the exhaust but- terfly ...

  • Page 287: Clutch

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

  • Page 288

    6-2 clutch exploded view.

  • Page 289

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 clutch cover mounting bolts 11 1.1 97 in·lb 2 clutch hub nut 135 13.8 99.6 r 3 clutch lever clamp bolts 7.8 0.80 69 in·lb s 4 clutch spring bolts 8.8 0.90 78 in·lb 5 oil filler plug 2.0 0.20 18 in·lb cl: apply cable lubricant. Eo...

  • Page 290

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

  • Page 291

    Clutch 6-5 special tool and sealant clutch holder: 57001-1243 kawasaki bond (silicone sealant): 92104-0004.

  • Page 292

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

  • Page 293

    Clutch 6-7 clutch cover clutch cover removal • remove: engine oil (drain, see engine oil change 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 in the figure, and remove the clutch cover [b]. About ...

  • Page 294

    6-8 clutch clutch cover • fit the spring [a] as shown in the figure. Viewed from rear [b] release shaft [c] clutch cover [d] clutch cover disassembly • remove: oil seal [a] needle bearings [b] oil level gauge clutch cover assembly • replace the needle bearings and oil seal with new ones. Note ○ inst...

  • Page 295

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

  • Page 296

    6-10 clutch clutch ○ install the spacer [a] so that the tapered side [b] faces inward. ○ install the washer [a] so that the “outside” mark [b] 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 to...

  • Page 297

    Clutch 6-11 clutch • align the mark [a] of the clutch spring plate [b] with the groove [c] of the clutch hub. • install the clutch spring plate, springs and spring holders, and tighten the clutch spring bolts. Torque - clutch spring bolts: 8.8 n·m (0.90 kgf·m, 78 in·lb) • install the clutch cover (s...

  • Page 298

    6-12 clutch clutch clutch plate, wear, damage inspection • visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. • measure the thickness of each friction plate [a] at several points. If any plates show signs of damage, or if they have worn ...

  • Page 299: Engine Lubrication System

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

  • Page 300

    7-2 engine lubrication system exploded view.

  • Page 301

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 coolant drain bolt (water pump) 11 1.1 97 in·lb 2 engine oil drain bolt 29 3.0 21 3 oil filter 17 1.7 13 g, r 4 oil filter holder 78 8.0 58 eo 5 oil filler plug 2.0 0.20 18 in·lb 6 oil jet nozzle bolts 6.9 0.70...

  • Page 302

    7-4 engine lubrication system engine oil flow chart.

  • Page 303

    Engine lubrication system 7-5 specifications item standard engine oil type api se, sf or sg api sh, sj or sl 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 b...

  • Page 304

    7-6 engine lubrication system special tools and sealant outside circlip pliers: 57001-144 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 305

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

  • Page 306

    7-8 engine lubrication system oil pan oil pan removal • remove: engine oil (drain, see engine oil change in the periodic maintenance chapter) exhaust pipe (see exhaust pipe removal in the engine top end chapter) oil pan bolts [a] and clamps oil pan [b] and gasket [c] • remove the oil pipe [a], oil p...

  • Page 307

    Engine lubrication system 7-9 oil pressure relief valve oil pressure relief valve removal • refer to the oil pan removal. Oil pressure relief valve installation • refer to the oil pan installation. Oil pressure relief valve inspection • check to see if the valve [a] slides smoothly when push- ing it...

  • Page 308

    7-10 engine lubrication system oil pump oil pump removal • remove: coolant (drain, see coolant change in the periodic maintenance chapter) engine oil (drain, see engine oil change in the periodic maintenance chapter) water pipe bolts [a] water pipes [b] • remove: water pump cover bolts [a] clamp [b]...

  • Page 309

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

  • Page 310

    7-12 engine lubrication system 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, pt3/8: 57001 -1233 • start the engine and w...

  • Page 311

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

  • Page 313: Engine Removal/installation

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

  • Page 314

    8-2 engine removal/installation exploded view.

  • Page 315

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 adjusting collar lock bolt 34 3.5 25 s 2 adjusting collar locknut 49 5.0 36 s 3 engine ground cable terminal bolt 9.8 1.0 87 in·lb 4 front engine mounting bolts 44 4.5 32 s 5 lower engine mounting nut 44 4.5 ...

  • Page 316

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

  • Page 317

    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 318

    8-6 engine removal/installation engine removal/installation • disconnect: stick coil harness connector [a] camshaft position sensor lead connector (see camshaft position sensor removal in the electrical system chapter) • disconnect: starter motor cable (see starter motor removal in the electrical sy...

  • Page 319

    Engine removal/installation 8-7 engine removal/installation • using the nut wrench [a], loosen the locknut [b]. Special tool - engine mount nut wrench: 57001-1450 • using the hexagon wrench, turn the adjusting collar [a] counterclockwise to make the gap between the engine and adjusting collar. • rem...

  • Page 320

    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, install the rear en...

  • Page 321

    Engine removal/installation 8-9 engine removal/installation • run the leads, cables and hoses correctly (see cable, wire, and hose routing section in the appendix chapter). • install the removed parts (see appropriate chapters). Torque - engine ground cable terminal bolt: 9.8 n·m (1.0 kgf·m, 87 in·l...

  • Page 323: Crankshaft/transmission

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

  • Page 324

    9-2 crankshaft/transmission exploded view.

  • Page 325

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 breather plate bolts (m6) 9.8 1.0 87 in·lb l 2 breather plate bolts (m5) 5.9 0.60 52 in·lb l 3 connecting rod big end nuts see the text ← ← mo 4 crankcase bolts (m9) 42 4.3 31 mo, s 5 crankcase bolts (m8) 27 2.8 ...

  • Page 326

    9-4 crankshaft/transmission exploded view.

  • Page 327

    Crankshaft/transmission 9-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front footpeg bracket bolts 25 2.5 18 2 gear positioning lever bolt 12 1.2 106 in·lb 3 neutral switch 15 1.5 11 4 shift drum cam holder bolt 12 1.2 106 in·lb l 5 shift lever bolt 6.9 0.70 61 in·lb 6 shift pedal m...

  • Page 328

    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 (0.0051 ∼ 0.0150 in.) 0.58 mm (...

  • Page 329

    Crankshaft/transmission 9-7 specifications item standard service limit crankshaft main bearing insert/journal clearance 0.020 ∼ 0.044 mm (0.0008 ∼ 0.0017 in.) 0.07 mm (0.0028 in.) crankshaft main journal diameter: 32.984 ∼ 33.000 mm (1.2986 ∼ 1.2992 in.) 32.96 mm (1.2976 in.) marking none 32.984 ∼ 3...

  • Page 330

    9-8 crankshaft/transmission special tools and sealant bearing puller: 57001-135 outside circlip pliers: 57001-144 bearing puller adapter: 57001-317 kawasaki bond (liquid gasket - black) : 92104-1062.

  • Page 331

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

  • Page 332

    9-10 crankshaft/transmission crankcase splitting • apply liquid gasket to the breather plate mating surface [a] 1 mm (0.04 in.) or more thick, and then install the breather plate. 22 mm (0.87 in.) [b] sealant - three bond: tb1207b note ○ make the application finish within 7 minutes when the liquid g...

  • Page 333

    Crankshaft/transmission 9-11 crankcase splitting • apply grease to the o-rings [a]. • install the oil jet nozzles [b]. • apply a non-permanent locking agent to the threads of oil jet nozzle bolts [c]. • tighten: torque - oil jet nozzle bolts: 6.9 n·m (0.70 kgf·m, 61 in·lb) • install: crankshaft (see...

  • Page 334

    9-12 crankshaft/transmission crankcase splitting • the m9 bolts (l = 95 mm, 3.74 in.) [a] has a copper plated washer [b], replace it with a new one. • apply molybdenum disulfide oil solution to the seating sur- face [c] on the lower crankcase for the m9 bolts (l = 95 mm, 3.74 in.). • tighten the low...

  • Page 335

    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 336

    9-14 crankshaft/transmission crankshaft and connecting rods • apply molybdenum disulfide oil solution [a] to the inner surfaces of upper and lower bearing inserts. • do not apply any grease or oil to the cap inside and cap insert outside [b]. • install the inserts so that their nails [c] are on the ...

  • Page 337

    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 338

    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 339

    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 340

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

  • Page 341

    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 342

    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 343

    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 (s...

  • Page 344

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

  • Page 345

    Crankshaft/transmission 9-23 transmission shift pedal removal • align the mark [a] on the shift shaft with the slit [b] on the shift lever. • remove: shift lever bolt [c] shift lever • remove: front footpeg bracket bolts [a] front footpeg bracket [b] • remove: bolt [a] front footpeg [b] shift pedal ...

  • Page 346

    9-24 crankshaft/transmission transmission • install the front footpeg bracket [a]. • tighten: torque - front footpeg bracket bolts [b]: 25 n·m (2.5 kgf·m, 18 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·...

  • Page 347

    Crankshaft/transmission 9-25 transmission • remove: oil pump drive gear (see oil pump drive gear removal in the engine lubrication system chapter) gear positioning lever bolt [a] gear positioning lever [b] collar and spring external shift mechanism installation • install the gear positioning lever [...

  • Page 348

    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 349

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

  • Page 350

    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 351

    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, 29 mm (1.14 in.) 10. Circlip 11. Bushing 12. Bushing 13. Needle bearing 14. Needle bearing 15. Be...

  • Page 352

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

  • Page 353

    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 355: Wheels/tires

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

  • Page 356

    10-2 wheels/tires exploded view.

  • Page 357

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front axle 108 11.0 79.7 2 front axle clamp bolt 20 2.0 15 3 rear axle nut 108 11.0 79.7 4. Caliper bracket (abs equipped models) g: apply grease. Hg: apply high-temperature grease. R: replacement parts wl: apply soap and ...

  • Page 358

    10-4 wheels/tires specifications item standard service limit wheels (rims) rim runout: axial tir 0.5 mm (0.02 in.) or less tir 1.0 mm (0.04 in.) radial tir 0.8 mm (0.03 in.) or less tir 1.0 mm (0.04 in.) axle runout/100 mm (3.94 in.) tir 0.03 mm (0.0012 in.) or less tir 0.2 mm (0.008 in.) wheel bala...

  • Page 359

    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 jack attachment: 57001-1608.

  • Page 360

    10-6 wheels/tires wheels (rims) front wheel removal • remove: front caliper mounting bolts [a] (both sides) front calipers [b] (both sides) • remove: front fender (see front fender removal in the frame chapter) front axle clamp bolt [a] (loosen) front axle [b] • raise the front wheel off the ground....

  • Page 361

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

  • Page 362

    10-8 wheels/tires wheels (rims) • remove: cotter pin [a] axle nut [b] washer [c] axle [d] (from right side) • remove the rear wheel rotation sensor from the caliper bracket (see rear wheel rotation sensor removal in the brakes chapter) (abs equipped models). • remove the drive chain [a] from the rea...

  • Page 363

    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 drive chain slack inspection in the perio...

  • Page 364

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

  • Page 365

    Wheels/tires 10-11 wheels (rims) balance inspection • remove the front and rear wheels (see front/rear wheel removal). • support the wheel so that it can be spun freely. • spin the wheel lightly, and mark [a] the wheel at the top when the wheel stops. ○ repeat this procedure several times. If the wh...

  • Page 366

    10-12 wheels/tires wheels (rims) balance weight part number weight 41075-0007 10 g (0.35 oz.) 41075-0008 20 g (0.71 oz.) 41075-0009 30 g (1.06 oz.) note ○ balance weights are available from kawasaki dealers in 10, 20, and 30 grams (0.35, 0.71, and 1.06 oz.) sizes. An imbalance of less than 10 grams ...

  • Page 367

    Wheels/tires 10-13 tires air pressure inspection/adjustment • refer to the air pressure inspection in the periodic main- tenance chapter. Tire inspection • refer to the wheel/tire damage inspection in the peri- odic maintenance chapter. Tire removal • remove: wheels (see front/rear wheel removal) va...

  • Page 368

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

  • Page 369

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

  • Page 370

    10-16 wheels/tires hub bearing hub bearing removal • remove the wheels (see front/rear wheel removal), and take out the following. Collars [a] coupling [b] (out of rear hub) grease seals [c] front wheel [d] rear wheel [e] • use the bearing remover to remove the hub bearings [a]. Caution do not lay t...

  • Page 371

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

  • Page 373: Final Drive

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

  • Page 374

    11-2 final drive exploded view.

  • Page 375

    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 cover plate bolts 9.8 1.0 87 in·lb 3 engine sprocket nut 125 12.7 92.2 mo 4 rear axle nut 108 11.0 79.7 5 rear sprocket nuts 59 6.0 44 g: apply grease. Hg: appl...

  • Page 376

    11-4 final drive specifications item standard service limit drive chain drive chain slack 30 ∼ 40 mm (1.2 ∼ 1.6 in.) – – – drive chain wear (20-link length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) standard chain: make enuma – – – type ek520mvxl1 – – – link 112 links – – – sprockets re...

  • Page 377

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

  • Page 378

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

  • Page 379

    Final drive 11-7 drive chain caution for safety, if the drive chain shall be replaced, re- place it using a recommended tool. Recommended tool - type: ek joint tool #50 brand: enuma body [a] handlebar [b] cutting and riveting pin [c] for cutting [d] for riveting [e] plate holder (a) [f] plate holder...

  • Page 380

    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. • install the link pl...

  • Page 381

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

  • Page 382

    11-10 final drive sprocket, coupling engine sprocket removal • remove: engine sprocket cover bolts [a] engine sprocket cover [b] • flatten out the bended washer [a]. • remove the engine sprocket nut [b] and washer. Note ○ when loosening the engine sprocket nut, hold the rear brake on. • raise the re...

  • Page 383

    Final drive 11-11 sprocket, coupling • install the engine sprocket cover [a]. • install the clamp [b] as shown in the figure, and tighten the cover bolts [c]. Torque - engine sprocket cover bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • adjust the drive chain slack after installing the engine sprocket (see ...

  • Page 384

    11-12 final drive sprocket, coupling • grease the following. Wheel flange portion [a] o-ring [b] • install the collar [c]. Coupling bearing removal • remove: coupling grease seal circlip [a] special tool - inside circlip pliers: 57001-143 • remove the bearing [a] by tapping from the wheel side. Spec...

  • Page 385

    Final drive 11-13 sprocket, coupling coupling bearing inspection since the coupling bearing is made to extremely close tolerances, the clearance can not normally be measured. Note ○ it is not necessary to remove the coupling bearing for inspection. If the bearing is removed, it will need to be repla...

  • Page 386

    11-14 final drive sprocket, coupling rear sprocket warp inspection • raise the rear wheel off the ground with the stand so that it will turn freely. • set a dial gauge [a] against the rear sprocket [b] near the teeth as shown in the figure, and rotate [c] the rear wheel to measure the sprocket runou...

  • Page 387: Brakes

    Brakes 12-1 12 brakes table of contents exploded view........................................................................................................................ 12-4 specifications .............................................................................................................

  • Page 388

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

  • Page 389

    Brakes 12-3 dummy page.

  • Page 390

    12-4 brakes exploded view.

  • Page 391

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bleed valves 7.8 0.80 69 in·lb 2 brake hose banjo bolts 25 2.5 18 3 brake lever pivot bolt 1.0 0.10 9 in·lb si 4 brake lever pivot bolt locknut 5.9 0.60 52 in·lb 5 front brake disc mounting bolts 27 2.8 20 l 6 front brake light ...

  • Page 392

    12-6 brakes exploded view.

  • Page 393

    Brakes 12-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bleed valve 7.8 0.80 69 in·lb 2 brake hose banjo bolts 25 2.5 18 3 brake pedal bolt 34 3.5 25 l 4 rear brake disc mounting bolts 27 2.8 20 l 5 rear brake pad pin 17.2 1.8 13 6 rear brake pad pin plug 2.5 0.25 25 in·lb 7 rear cal...

  • Page 394

    12-8 brakes exploded view abs equipped models.

  • Page 395

    Brakes 12-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bleed valves 7.8 0.80 69 in·lb 2 brake hose banjo bolts 25 2.5 18 3 brake lever pivot bolt 1.0 0.10 9 in·lb si 4 brake lever pivot bolt locknut 5.9 0.60 52 in·lb 5 brake pipe joint nuts 18 1.8 13 6 front brake disc mounting bolt...

  • Page 396

    12-10 brakes exploded view abs equipped models.

  • Page 397

    Brakes 12-11 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bleed valve 7.8 0.80 69 in·lb 2 brake hose banjo bolts 25 2.5 18 3 brake pedal bolt 34 3.5 25 l 4 brake pipe joint nuts 18 1.8 13 5 rear brake disc mounting bolts 27 2.8 20 l 6 rear brake pad pin 17.2 1.8 13 7 rear brake pad pi...

  • Page 398

    12-12 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 45 mm (1.77 in.) below footpeg top – – – brake pads lining...

  • Page 399

    Brakes 12-13 special tools inside circlip pliers: 57001-143 jack: 57001-1238 hand tester: 57001-1394 jack attachment: 57001-1608.

  • Page 400

    12-14 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 hol...

  • Page 401

    Brakes 12-15 brake lever, brake pedal • remove: cotter pin [a] joint pin [b] rear brake light switch spring [c] return spring [d] brake pedal bolt [e] brake pedal [f] brake pedal installation • apply grease to the footpeg pivot shaft [a]. • install: bushing [b] brake pedal [c] • apply a non-permanen...

  • Page 402

    12-16 brakes calipers front caliper removal • loosen the banjo bolt [a] at the brake hose lower end, and tighten it loosely. • unscrew the caliper mounting bolts [b], and detach the caliper [c] from the disc. • unscrew the banjo bolt and remove the brake hoses [d] from the caliper (see brake hose re...

  • Page 403

    Brakes 12-17 calipers • fit the rear brake pads [a] to the guide [b]. • apply silicone grease to the rear caliper pin bolt. • tighten: torque - caliper mounting bolts: front: 25 n·m (2.5 kgf·m, 18 ft·lb) rear: 22 n·m (2.2 kgf·m, 16 ft·lb) rear caliper pin bolt: 27 n·m (2.8 kgf·m, 20 ft·lb) brake hos...

  • Page 404

    12-18 brakes calipers caliper fluid seal damage the fluid seal (piston seal) [a] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- perature of ...

  • Page 405

    Brakes 12-19 calipers caliper piston and cylinder damage • visually inspect the pistons [a] and cylinder surfaces [b]. Replace the caliper if the cylinder and piston are badly scores or rusty. Front caliper holder shaft wear the caliper body must slide smoothly on the caliper holder shaft [a]. If th...

  • Page 406

    12-20 brakes brake pads front brake pad removal • unscrew the pad pin plug [a]. • loosen the pad pin [a]. • unscrew the bolts [b]. • remove the caliper with the hose installed. • remove: pad pin [a] brake pads [b] front brake pad installation • push the caliper pistons in by hand as far as they will...

  • Page 407

    Brakes 12-21 brake pads rear brake pad removal • unscrew the pad pin plug [a]. • loosen the pad pin [a]. • unscrew the bolts [b]. • remove the caliper with the hose installed. • remove: pad pin [a] brake pads [b] rear brake pad installation • push the caliper piston in by hand as far as they will go...

  • Page 408

    12-22 brakes brake pads brake pad wear inspection • refer to the brake pad wear inspection in the periodic maintenance chapter..

  • Page 409

    Brakes 12-23 master cylinder front master cylinder removal • remove the banjo bolt [a] to disconnect the brake hose from the master cylinder (see brake hose removal/in- stallation). • unscrew the clamp bolts [b], and take off the master cylin- der [c] as an assembly with the reservoir, brake lever, ...

  • Page 410

    12-24 brakes master cylinder rear master cylinder installation • replace the cotter pin with a new one. • replace the washers that are on each side of hose fitting with new ones. • tighten: torque - rear master cylinder mounting bolts: 25 n·m (2.5 kgf·m, 18 ft·lb) brake hose banjo bolts: 25 n·m (2.5...

  • Page 411

    Brakes 12-25 brake disc brake disc removal • remove the wheels (see front/rear wheel removal in the wheels/tires chapter). • unscrew the mounting bolts, and take off the disc. ○ remove the sensor rotor (abs equipped models). • remove the gaskets. Brake disc installation • replace the gaskets with ne...

  • Page 412

    12-26 brakes brake fluid brake fluid level inspection • refer to the brake fluid level inspection in the periodic maintenance chapter. Brake fluid change • refer to the brake fluid change in the periodic mainte- nance chapter. Brake line bleeding the brake fluid has a very low compression coefficien...

  • Page 413

    Brakes 12-27 brake fluid • bleed the brake line and the caliper. ○ repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [a]. 2. Quickly open and close [b] the bleed valve while hold- ing...

  • Page 414

    12-28 brakes brake fluid warning when working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types and brands of fluid for use in th...

  • Page 415

    Brakes 12-29 brake hose brake hose and pipe removal/installation • refer to the brake hose and pipe replacement in the periodic maintenance chapter. Brake hose and pipe inspection • refer to the brake hose and pipe damage and instal- lation condition inspection in the periodic maintenance chapter..

  • Page 416

    12-30 brakes anti-lock brake system (equipped models) parts location 1. Front wheel rotation sensor 2. Front wheel rotation sensor rotor 3. Rear wheel rotation sensor 4. Rear wheel rotation sensor rotor 5. Abs indicator light (led) 6. Abs hydraulic unit 7. Abs fuse box 8. Abs kawasaki self-diagnosis...

  • Page 417

    Brakes 12-31 anti-lock brake system (equipped models) abs system wiring diagram 1. Abs self-diagnosis terminal 2. Rear wheel rotation sensor 3. Front wheel rotation sensor 4. Abs kawasaki self-diagnosis system con- nector 5. Abs hydraulic unit 6. Fuse box 1 7. Ignition switch 8. Abs ecu fuse 10 a 9....

  • Page 418

    12-32 brakes anti-lock brake system (equipped models) terminal names 1. Unused 2. Power supply to rear wheel rotation sensor 3. Front wheel rotation sensor signal 4. Front and rear brake light switch 5. Unused 6. Unused 7. Unused 8. Power supply to abs solenoid valve relay 9. Power supply to abs mot...

  • Page 419

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

  • Page 420

    12-34 brakes anti-lock brake system (equipped models) ○ the abs indicator light (led) [a] may light if the tire pres- sure is incorrect, a non-recommended tire is installed, or the wheel is deformed. If the indicator light lights, remedy the problem and clear the service code. Warning use of non-rec...

  • Page 421

    Brakes 12-35 anti-lock brake system (equipped models) abs troubleshooting outline when an abnormality in the system occurs, the abs in- dicator light (led) lights up to alert the rider. In addition, the nature of the fault is stored in the memory of the abs hydraulic unit and when in the self-diagno...

  • Page 422

    12-36 brakes anti-lock brake system (equipped models) • visually inspect the wiring for signs of burning or fraying. 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, clean it caref...

  • Page 423

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

  • Page 424

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

  • Page 425

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

  • Page 426

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

  • Page 427

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

  • Page 428

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

  • Page 429

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

  • Page 430

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

  • Page 431

    Brakes 12-45 anti-lock brake system (equipped models) service code table service code abs indicator light (led) problems light state 13 rear inlet solenoid valve trouble (shorted or open, stuck valve (on)) on 14 rear outlet solenoid valve trouble (shorted or open, stuck valve (on)) on 17 front inlet...

  • Page 432

    12-46 brakes anti-lock brake system (equipped models) abs indicator light (led) inspection • turn the ignition switch on. If the abs indicator light (led) [a] lights, it is normal. If the abs indicator light (led) does not light, go to step “abs indicator light (led) is unlit (when the ignition swit...

  • Page 433

    Brakes 12-47 anti-lock brake system (equipped models) • do the 3rd step test. ○ disconnect the abs hydraulic unit connector. ○ check for continuity between the black/white lead termi- nal of the main harness side connector [a] and black/white lead terminal of the main harness side connector [b]. If ...

  • Page 434

    12-48 brakes anti-lock brake system (equipped models) • do the 2nd step test. ○ disconnect the abs hydraulic unit connector [a]. ○ check for continuity between the light green and black/yellow lead terminals of the abs hydraulic unit connector. If there is the continuity in the lead, replace the abs...

  • Page 435

    Brakes 12-49 anti-lock brake system (equipped models) front, rear wheel rotation difference abnormal (service code 25) • do the 1st step test. ○ check the following and correct the faulty part. Incorrect the tire pressure. Tires not recommended for the motorcycle were installed (incorrect tire size)...

  • Page 436

    12-50 brakes anti-lock brake system (equipped models) • do the 4th step test. ○ check the battery terminal voltage between the red lead terminal of the fuse box [a] and ground. Special tool - hand tester: 57001-1394 battery terminal voltage standard: battery voltage if the battery terminal voltage i...

  • Page 437

    Brakes 12-51 anti-lock brake system (equipped models) • do the 2nd step test. ○ check that there is iron or other magnetic deposits be- tween the sensor [a] and sensor rotor [b], and the sensor rotor slots for obstructions. ○ check the installation condition of the sensor for loose- ness. ○ check th...

  • Page 438

    12-52 brakes anti-lock brake system (equipped models) • do the 3rd step test. ○ recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the abs indicator light (led) [a] lit, faulty ecu in the abs hydraulic unit. Re...

  • Page 439

    Brakes 12-53 anti-lock brake system (equipped models) rear wheel rotation sensor wiring inspection (service code 45) • do the 1st step test. ○ disconnect the abs hydraulic unit connector and rear wheel rotation sensor connector. ○ short the black and brown/black lead terminals of the main harness si...

  • Page 440

    12-54 brakes anti-lock brake system (equipped models) • do the 2nd step test. ○ connect the ignition switch connector and abs hydraulic unit connector. ○ check the battery terminal voltage, connect the hand tester to the brown terminal of ignition switch connector [a] and ground. Special tool - hand...

  • Page 441

    Brakes 12-55 anti-lock brake system (equipped models) • do the 2nd step test. ○ connect the ignition switch connector and abs hydraulic unit connector. ○ check the battery terminal voltage, connect the hand tester to the brown terminal of ignition switch connector [a] and ground. Special tool - hand...

  • Page 442

    12-56 brakes anti-lock brake system (equipped models) • remove: seats (see rear/front seat removal in the frame chap- ter) rear fender (see flap and rear fender removal in the frame chapter) • clean the abs hydraulic unit. Caution clean all fittings on the abs hydraulic unit and the rear master cyli...

  • Page 443

    Brakes 12-57 anti-lock brake system (equipped models) caution the abs hydraulic unit [a] has been adjusted and set with precision at the factory. Do not try to dis- assemble and repair the abs hydraulic unit. Abs hydraulic unit installation • install the abs hydraulic unit to the bracket. Caution br...

  • Page 444

    12-58 brakes anti-lock brake system (equipped models) • visually inspect the connector terminals [a]. Replace the abs hydraulic unit or main harness if either of the terminals are cracked, bent, or otherwise damaged. If the abs hydraulic unit connector is clogged with mud or dust, blow it off with c...

  • Page 445

    Brakes 12-59 anti-lock brake system (equipped models) rear wheel rotation sensor removal caution the wheel rotation sensor should be handled care- fully, never struck sharply, as with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made. Be careful not...

  • Page 446

    12-60 brakes anti-lock brake system (equipped models) wheel rotation sensor inspection • remove the front wheel rotation sensor [a] from the front fork. • remove the rear wheel rotation sensor [b] from the caliper bracket. • visually inspect the wheel rotation sensors. Replace the wheel rotation sen...

  • Page 447

    Brakes 12-61 anti-lock brake system (equipped models) wheel rotation sensor rotor inspection • remove: wheels (see front/rear wheel removal in the wheels/tires chapter) brake disc mounting bolts [a] sensor rotor [b] front wheel [c] rear wheel [d] • visually inspect the wheel rotation sensor rotor. I...

  • Page 448

    12-62 brakes anti-lock brake system (equipped models) fuse installation • if a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage (see fuse installation in the electrical system chapter). Fuse inspection • remov...

  • Page 449: Suspension

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

  • Page 450

    13-2 suspension exploded view.

  • Page 451

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front axle clamp bolt 20 2.0 15 2 front fork bottom allen bolts 40 4.1 30 l 3 front fork top plugs 23 2.3 17 4 lower front fork clamp bolts 21 2.1 15 al 5 piston rod nuts 15 1.5 11 6 upper front fork clamp bolts 20 2.0 15 7....

  • Page 452

    13-4 suspension exploded view.

  • Page 453

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear shock absorber nut (lower) 34 3.5 25 2 rear shock absorber nut (upper) 34 3.5 25 3 swingarm pivot shaft 9.8 1.0 87 in·lb 4 swingarm pivot shaft locknut 98 10.0 72.3 5 swingarm pivot shaft nut 108 11.0 79.7 6 tie-rod nut...

  • Page 454

    13-6 suspension specifications item standard front fork (per one unit) fork inner tube diameter 41 mm (1.6 in.) air pressure atmospheric pressure (non-adjustable) rebound damper setting (only right fork leg) 7th click from the 1st click of the fully clockwise position (usable range: 0 ←→ 11 clicks) ...

  • Page 455

    Suspension 13-7 special tools inside circlip pliers: 57001-143 oil seal & bearing remover: 57001-1058 bearing driver set: 57001-1129 jack: 57001-1238 fork oil seal driver, 41: 57001-1288 fork oil level gauge: 57001-1290 bearing remover head, 20 × 22: 57001-1293 fork piston rod puller, m10 × 1.0: 570...

  • Page 456

    13-8 suspension special tools fork cylinder holder, hex 24: 57001-1537 hook wrench r=35 57001-1580 swingarm pivot nut wrench: 57001-1597 jack attachment: 57001-1608 needle bearing driver, 17/ 18: 57001-1609 needle bearing driver, 28: 57001-1610 spacer, 18: 57001-1636 spacer 28: 57001-1663 fork sprin...

  • Page 457

    Suspension 13-9 front fork rebound damping force adjustment • to adjust the rebound damping force, turn the rebound damping adjuster [a] until you feel a click. ○ the standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 7th click from th...

  • Page 458

    13-10 suspension front fork front fork removal (each fork leg) • remove: upper fairing (see upper fairing removal in the frame chapter) front wheel (see front wheel removal in the wheels/tires chapter) front fender (see front fender removal in the frame chapter) loosen the upper front fork clamp bol...

  • Page 459

    Suspension 13-11 front fork • install the fork spring compressor as shown in the figure. Note ○ set the fork spring compressor so that the end of the handle [a] passes the upper side hole on the spacer [b] by screwing the handle in the holder [c] to the bottom. Special tool - fork spring compressor:...

  • Page 460

    13-12 suspension front fork • drain the fork oil into a suitable container. ○ pump the piston rod [a] up and down at least ten times to expel the oil from the fork. Special tool - fork piston rod puller, m10 × 1.0 [b]: 57001 -1298 • hold the fork tube upright, press the outer tube [a] and the piston...

  • Page 461

    Suspension 13-13 front fork oil level (fully compressed, without spring) standard: right fork leg: 106 ±2 mm (4.17 ±0.08 in.) (from the top of the outer tube) left fork leg: 100 ±2 mm (3.94 ±0.08 in.) (from the top of the outer tube) note ○ fork oil level may also be measured using the fork oil leve...

  • Page 462

    13-14 suspension front fork • screw the fork piston rod puller onto the end of the piston rod. Special tool - fork piston rod puller, m10 × 1.0: 57001 -1298 • pull the puller up above the outer tube top. • install the fork spring [a] with the smaller end [b] facing upward. • install: spacer [a] wash...

  • Page 463

    Suspension 13-15 front fork • check the o-ring [a] on the top plug and replace it with a new one if damaged. ○ apply grease to the new o-ring. • holding the spring preload adjuster [b] with a wrench [c], tighten the piston rod nut [d] against the top plug. Torque - piston rod nuts: 15 n·m (1.5 kgf·m...

  • Page 464

    13-16 suspension front fork front fork assembly • replace the following parts with a new one. Oil seal bottom allen bolt gasket • insert the cylinder unit into the inner tube. • stop the cylinder from turning by using the fork cylinder holder. Special tool - fork cylinder holder, hex 24: 57001-1537 ...

  • Page 465

    Suspension 13-17 front fork inner tube, outer tube inspection • visually inspect the inner tube [a], and repair any dam- age. • nicks or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage. If the damage is not repairable, replace ...

  • Page 466

    13-18 suspension rear shock absorber rebound damping force adjustment • to adjust the rebound damping force, turn the lower damping adjuster [a] to the desired position, until you feel a click. ○ the standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no acce...

  • Page 467

    Suspension 13-19 rear shock absorber rear shock absorber removal • raise the rear wheel off the ground with the jack. Special tools - jack: 57001-1238 jack attachment: 57001-1608 • squeeze the brake lever slowly and hold it with a band [a]. Warning be sure to hold the front brake when removing the s...

  • Page 468

    13-20 suspension swingarm swingarm removal • remove: frame covers (see frame cover removal in the frame chapter) chain cover (see drive chain removal in the final drive chapter) rear wheel (see rear wheel removal in the wheels/tires chapter) • remove: screw [a] clamps [b] [c] • raise the rear wheel ...

  • Page 469

    Suspension 13-21 swingarm • unscrew the swingarm pivot shaft nut [a] and the swingarm pivot shaft [b]. • pull out the pivot shaft and remove the 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...

  • Page 470

    13-22 suspension swingarm swingarm bearing removal • remove: swingarm (see swingarm removal) collar [a] oil seals [b] sleeve [c] circlip [d] (right side) special tool - inside circlip pliers: 57001-143 • remove the ball bearing and needle bearings. Special tool - oil seal & bearing remover [a]: 5700...

  • Page 471

    Suspension 13-23 swingarm • install the needle bearings [a], ball bearing [b] and oil seals [c] position as shown in the figure. Circlip [d] 23.5 mm (0.93 in.) [e] 17 mm (0.67 in.) [f] 6 mm (0.24 in.) [g] swingarm bearing, sleeve inspection caution do not remove the bearings for inspection. Re- mova...

  • Page 472

    13-24 suspension swingarm swingarm bearing lubrication note ○ since the bearings are packed with grease and sealed, lubrication is not required. Chain guide inspection • refer to the chain guide wear inspection in the periodic maintenance chapter..

  • Page 473

    Suspension 13-25 tie-rod, rocker arm tie-rod removal • squeeze the brake lever slowly and hold it with a band [a]. • raise the rear wheel off the ground with the jack. Special tools - jack: 57001-1238 jack attachment: 57001-1608 • remove: upper tie-rod nut and bolt [a] lower tie-rod nut and bolt [b]...

  • Page 474

    13-26 suspension tie-rod, rocker arm tie-rod and rocker arm bearing removal • remove: tie-rods (see tie-rod removal) rocker arm (see rocker arm removal) sleeves [a] oil seals [b] swingarm [c] (see swingarm removal) • remove the needle bearings [d], using the bearing re- mover head and bearing remove...

  • Page 475

    Suspension 13-27 tie-rod, rocker arm note ○ install the needle bearings so that the marked side faces in. Needle bearings [a] oil seals [b] front [c] right side [d] left side [e] rear shock absorber [f] tie-rods [g] rocker arm [h] 7.5 mm (0.30 in.) [i] 5.0 mm (0.20 in.) [j] 5.5 mm (0.22 in.) [k] roc...

  • Page 477: Steering

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

  • Page 478

    14-2 steering exploded view.

  • Page 479

    Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 handlebar holder bolts 25 2.5 18 s 2 handlebar lower clamp nuts 34 3.5 25 3 lower front fork clamp bolts 21 2.1 15 al 4 steering stem head bolt 108 11.0 79.7 5 steering stem nut 27 2.8 20 6 switch housing screws 3.5 0.36 31 in...

  • Page 480

    14-4 steering special tools head pipe outer race press shaft: 57001-1075 steering stem nut wrench: 57001-1100 bearing driver set: 57001-1129 steering stem bearing driver, 42.5: 57001-1344 steering stem bearing driver adapter, 41.5: 57001-1345 head pipe outer race driver, 55: 57001-1446.

  • Page 481

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

  • Page 482

    14-6 steering steering stem stem, stem bearing removal • remove: inner cover (see inner cover removal in the frame chapter) upper fairing (see upper fairing removal in the frame chapter) upper fairing bracket (see upper fairing bracket re- moval in the frame chapter) front wheel (see front wheel rem...

  • Page 483

    Steering 14-7 steering stem • remove the lower ball bearing inner race (with its oil seal) [a] which is pressed onto the steering stem with a suitable commercially available chisel [b]. Stem, stem bearing installation • replace the bearing outer races with new ones. • drive them into the head pipe a...

  • Page 484

    14-8 steering steering stem • settle the bearings in place as follows. ○ tighten the steering stem nut with 55 n·m (5.6 kgf·m, 41 ft·lb) of torque first, and loosen it a fraction of a turn until it turns lightly. Afterward tighten it again with specified torque using a steering stem nut wrench [a]. ...

  • Page 485

    Steering 14-9 steering stem steering stem warp • whenever the steering stem is removed, or if the steering can not be adjusted for smooth action, check the steering stem for straightness. If the steering stem [a] is bent, replace the steering stem. Stem cap deterioration, damage replace the stem cap...

  • Page 486

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

  • Page 487

    Steering 14-11 handlebar • align the punch mark [a] on the handlebar and the corner edge [b] on the lower clamp. • tighten the front holder bolts first, and then the rear holder bolts. There will be a gap [a] at the rear part of the holder after tightening. Torque - handlebar holder bolts: 25 n·m (2...

  • Page 489: Frame

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

  • Page 490

    15-2 frame exploded view.

  • Page 491

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fender bolts 3.9 0.40 35 in·lb 2. Reflector (au model) 3. 2 ∼ 3 mm (0.08 ∼ 0.12 in.) l: apply a non-permanent locking agent..

  • Page 492

    15-4 frame exploded view.

  • Page 493

    Frame 15-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front footpeg bracket bolts 25 2.5 18 2 rear footpeg bracket bolts 25 2.5 18 3 sidestand bolt 44 4.5 32 4 sidestand switch bolt 8.8 0.90 78 in·lb l 5. With guard on the side cover: frame no.; ∼ without guard on the side cover: fr...

  • Page 494

    15-6 frame exploded view.

  • Page 495

    Frame 15-7 seats rear seat removal • insert the ignition switch key [a] into the seat lock, turning the key clockwise, pulling the front part of the seat [b] up, and pull the seat forward. Rear seat installation • insert the rear seat hook [a] into the bracket [b] of the frame. • insert the seat hoo...

  • Page 496

    15-8 frame fairings center fairing removal • remove: bolts [a] center fairing [b] • remove: inner fairing (see inner fairing removal) bracket center fairing installation • installation is the reverse of removal. Upper fairing removal • remove: inner cover (see inner cover removal) bolts [a] (both si...

  • Page 497

    Frame 15-9 fairings upper fairing installation • connect: city light lead connectors headlight lead connectors • fit the projections [a] on the upper fairing bracket into the holes [b] of the headlight. • tighten the bolts. Inner cover removal • push the central pin, and then remove the quick rivets...

  • Page 498

    15-10 frame side covers sub side cover removal • remove the bolt [a]. • pull the sub side cover [b] to clear the stoppers [c]. Sub side cover installation • insert the projections [a] into the holes [b]. • tighten the bolt. Side cover removal • remove: sub side cover (see sub side cover removal) bol...

  • Page 499

    Frame 15-11 seat covers seat cover removal • remove: seats (see rear/front seat removal) side covers (see side cover removal) rivet screws [a] • remove the bolts [a]. • pull the front seat cover [b] to clear the stoppers [c]. • pull the left and right seat covers [d] to clear the stoppers [e]. • rem...

  • Page 500

    15-12 frame seat covers • remove: rivets [a] bolts [b] brackets [c] flap [d] (with turn signal and license plate lights) bolts and seat lock bracket lower seat cover seat cover installation • installation is the reverse of removal. • put the projections [a] into the holes [b] of the center seat cove...

  • Page 501

    Frame 15-13 fenders front fender removal • remove: brake hose clamps [a] (both sides) bolts [b] with washers (both sides) front fender [c] front fender installation • install the front fender to the front fork. • tighten: torque - front fender bolts: 3.9 n·m (0.40 kgf·m, 35 in·lb) • install the brak...

  • Page 502

    15-14 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 503

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

  • Page 504

    15-16 frame frame cover frame cover removal • remove: sub side covers (see sub side cover removal) bolts [a] • pull out the frame cover [b], and clear the stopper [c]. Frame cover installation • insert the projection [a] into the hole [b]. • tighten the bolts..

  • Page 505

    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 507: Electrical System

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

  • Page 508

    16-2 electrical system starter motor disassembly................................................................................................ 16-51 starter motor assembly .................................................................................................... 16-51 brush inspection .....

  • Page 509

    Electrical system 16-3 exploded view dummy page.

  • Page 510

    16-4 electrical system exploded view.

  • Page 511

    Electrical system 16-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front brake light switch screw 1.2 0.12 11 in·lb 2 license plate light cover mounting screws 0.9 0.09 8 in·lb 3 license plate light mounting screws 1.2 0.12 11 in·lb 4 meter mounting screws 1.2 0.12 11 in·lb 5 oxygen ...

  • Page 512

    16-6 electrical system exploded view.

  • Page 513

    Electrical system 16-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 alternator cover bolts 11 1.1 97 in·lb 2 alternator lead holding plate bolt 12 1.2 106 in·lb l 3 alternator rotor bolt 155 15.8 114 s 4 camshaft position sensor bolt 12 1.2 106 in·lb 5 crankshaft sensor bolts 5.9 0.60...

  • Page 514

    16-8 electrical system exploded view.

  • Page 515

    Electrical system 16-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine ground cable terminal bolt 9.8 1.0 87 in·lb 2 fuel level sensor bolts 6.9 0.70 61 in·lb l 3 neutral switch 15 1.5 11 4 regulator/rectifier bolts 6.9 0.70 61 in·lb 5 regulator/rectifier bracket bolts 6.9 0.70 61...

  • Page 516

    16-10 electrical system specifications item standard battery type sealed battery model name ytx9-bs capacity 12 v 8 ah voltage 12.8 v or more charging system type three-phase ac alternator output voltage 39 v or more at 4 000 r/min (rpm) stator coil resistance 0.18 ∼ 0.28 Ω at 20°c (68°f) charging v...

  • Page 517

    Electrical system 16-11 special tools and sealant hand tester: 57001-1394 flywheel puller assembly, m38 × 1.5/m35 × 1.5: 57001-1405 peak voltage adapter: 57001-1415 lead wire - peak voltage adapter: 57001-1449 key registration unit: 57001-1582 grip: 57001-1591 flywheel & pulley holder: 57001-1605 st...

  • Page 518

    16-12 electrical system special tools and sealant kawasaki bond (silicone sealant): 92104-0004.

  • Page 519

    Electrical system 16-13 parts location dummy page.

  • Page 520

    16-14 electrical system parts location.

  • Page 521

    Electrical system 16-15 parts location 1. Immobilizer amplifier (immobilizer equipped models) 2. Starter lockout switch 3. Frame ground 4. Stick coils 5. Spark plugs 6. Starter motor 7. Speed sensor 8. Fuse box 1 9. Starter relay 10. Battery 12 v 8 ah 11. Turn signal relay 12. Fuse box 2 13. Vehicle...

  • Page 522

    16-16 electrical system wiring diagram.

  • Page 523

    Electrical system 16-17 wiring diagram.

  • Page 524

    16-18 electrical system wiring diagram (abs equipped models).

  • Page 525

    Electrical system 16-19 wiring diagram (abs equipped models).

  • Page 526

    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 cable connections. This will burn out the diodes on the electrical parts. ○ always check battery con...

  • Page 527

    Electrical system 16-21 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 528

    16-22 electrical system battery battery removal • turn off the ignition switch. • remove: seats (see rear/front seat removal in the frame chap- ter) front seat cover (see seat cover removal in the frame chapter) bolts [a] and front seat bracket [b] • push the stopper [a] and pull up the fuse box fro...

  • Page 529

    Electrical system 16-23 battery • slide in the fuse box [a] into the front seat bracket [b] until the stopper [c] fits in the bracket. • run the seat lock cable [a] under the front seat bracket [b] and then install the bracket. ○ tighten the left side bolts [c] of the front seat bracket first. • con...

  • Page 530

    16-24 electrical system battery • remove the electrolyte container from the vinyl bag. • detach the strip of caps [a] from the container and set aside, these will be used later to seal the battery. Note ○ do not pierce or otherwise open the sealed cells [b] of the electrolyte container. Do not attem...

  • Page 531

    Electrical system 16-25 battery initial charge • place the strip [a] of caps loosely over the filler ports. • newly activated sealed batteries require an initial charge. Standard charge: 0.9 a × 5 ∼ 10 hours if using a recommended battery charger, follow the charger’s instructions for newly activate...

  • Page 532

    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 seal cap to add water is very dangerous. Never do that. 2) refreshing charge. If an engine will not start, a horn sounds we...

  • Page 533

    Electrical system 16-27 battery if the reading is 12.8 v or more, no refresh charge is re- quired, however, if the read is below the specified, refresh charge is required. Battery terminal voltage standard: 12.8 v or more terminal voltage (v) [a] battery charge rate (%) [b] good [c] refresh charge i...

  • Page 534

    16-28 electrical system charging system alternator cover removal • remove: left frame cover (see frame cover removal in the frame chapter) engine sprocket cover (see engine sprocket removal in the final drive chapter) coolant (drain, see coolant change in the periodic maintenance chapter) • support ...

  • Page 535

    Electrical system 16-29 charging system • place a suitable container under the alternator cover [a]. • remove: alternator cover bolts [b] alternator cover alternator cover installation • apply silicone sealant to the alternator lead grommet and crankcase halves mating surface [a] on the front and re...

  • Page 536

    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: 12 n·m (1.2 kgf·m, 106 in·lb) • secure the alternator lead with a holding plate. • apply a non-permanent lockin...

  • Page 537

    Electrical system 16-31 charging system alternator rotor installation • using a cleaning fluid, clean off any oil or dirt on the fol- lowing portions and dry them with a clean cloth. Crankshaft tapered portion [a] alternator rotor tapered portion [b] • apply a thin coat of molybdenum disulfide greas...

  • Page 538

    16-32 electrical system charging system • install the washer and alternator rotor bolt [a]. Note ○ confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque. • install the rotor bolt and tighten it with 70 n·m (7.0 kgf·m, 52 ft·lb) of torque. Special tools ...

  • Page 539

    Electrical system 16-33 charging system • to check the alternator output voltage, do the following procedures. ○ turn off the ignition switch. ○ remove the left frame cover (see frame cover removal in the frame chapter). ○ disconnect the alternator lead connector [a]. ○ connect the hand tester as sh...

  • Page 540

    16-34 electrical system charging system regulator/rectifier inspection • remove: bolts [a] and bracket [b] regulator/rectifier assembly [c] • remove: connector [a] (disconnect) regulator/rectifier [b] rectifier circuit check • check conductivity of the following pair of terminals. Rectifier circuit ...

  • Page 541

    Electrical system 16-35 charging system • do the 1st step regulator circuit test. ○ connect the test light and the 12 v battery to the regula- tor/rectifier as shown in the figure. ○ check the bk1, bk2 and bk3 terminal respectively. If the test light turns on, the regulator/rectifier is defective. R...

  • Page 542

    16-36 electrical system charging system charging voltage inspection • check the battery condition (see charging condition in- spection). • warm up the engine to obtain actual alternator operating conditions. • take out the battery from the rear fender with the cables connected (see battery removal)....

  • Page 543

    Electrical system 16-37 charging system charging system circuit 1. Ignition switch 2. Alternator 3. Regulator/rectifier 4. Battery 12 v 8 ah 5. Main fuse 30 a 6. Load.

  • Page 544

    16-38 electrical system 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 545

    Electrical system 16-39 ignition system • remove: rubber boot (slide out) [a] oil pressure switch lead terminal [b] crankshaft sensor cover bolts [c] with clamps crankshaft sensor cover [d] • remove: crankshaft sensor bolts [a] crankshaft sensor [b] crankshaft sensor installation • run the crankshaf...

  • Page 546

    16-40 electrical system ignition system • replace the o-ring in the crankshaft sensor cover [a] with a new one. • install: crankshaft sensor cover clamps [b] • tighten: torque - crankshaft sensor cover bolts: 11 n·m (1.1 kgf·m, 97 in·lb) crankshaft sensor inspection • remove: right frame cover (see ...

  • Page 547

    Electrical system 16-41 ignition system crankshaft sensor peak voltage inspection note ○ be sure the battery is fully charged. • remove: right frame cover (see frame cover removal in the frame chapter) crankshaft sensor lead connector [a] (see crankshaft sensor removal) • set the hand tester [b] to ...

  • Page 548

    16-42 electrical system ignition system camshaft position sensor removal caution never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) radiator (see radiator and radiator fan removal...

  • Page 549

    Electrical system 16-43 ignition system camshaft position sensor inspection • disconnect the camshaft position sensor lead connector [a] (see camshaft position sensor removal). • set the hand tester to the × 10 Ω range and connect it to the yellow and white/yellow leads in the connector. Special too...

  • Page 550

    16-44 electrical system ignition system stick coil removal caution never drop the stick coils, especially on a hard sur- face. Such a shock to the stick coils can damage it. • remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • disconnect the stick coil connector and pul...

  • Page 551

    Electrical system 16-45 ignition system stick coil inspection • remove the stick coils (see stick coil removal). • measure the primary winding resistance [a] as follows. ○ connect the hand tester between the coil terminals. ○ set the tester to the × 1 Ω range, and read the tester. • measure the seco...

  • Page 552

    16-46 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 553

    Electrical system 16-47 ignition system 2nd check • start the engine to the following conditions. Condition: transmission gear → 1st position clutch lever → pulled in sidestand → up ○ turn the ignition switch on and push the starter button. ○ then the starter motor should turn when the starter sys- ...

  • Page 554

    16-48 electrical system ignition system.

  • Page 555

    Electrical system 16-49 ignition system ignition system circuit 1. Engine stop switch 2. Stick coils 3. Spark plugs 4. Oxygen sensor (equipped models) 5. Vehicle-down sensor 6. Subthrottle sensor 7. Main throttle sensor 8. Speed sensor 9. Camshaft position sensor 10. Crankshaft sensor 11. Ecu 12. Ig...

  • Page 556

    16-50 electrical system electric starter system starter motor removal caution do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • remove the water pipe (see alternator cover removal). • slide back the rubber cap [a]. • remove the starter motor cable termin...

  • Page 557

    Electrical system 16-51 electric starter system starter motor disassembly • remove the starter motor (see starter motor removal). • take off the starter motor through bolts [a] and remove the both end covers [b] and pull the armature out of the yoke [c]. ○ the brush plate [a] and brushes come off wi...

  • Page 558

    16-52 electrical system electric starter system • install the shims [a] on the armature shaft. • install the armature [a] among the brushes [b]. • align the line marks [a] of the end cover with the square mark [b] on the yoke. • align the line marks [a] of the yoke with the through bolt hole [b] in ...

  • Page 559

    Electrical system 16-53 electric starter system commutator cleaning and inspection • smooth the commutator surface [a] if necessary with fine emery cloth [b], and clean out the grooves. • measure the diameter [a] of the commutator [b]. If the commutator diameter is less than the service limit, repla...

  • Page 560

    16-54 electrical system electric starter system brush plate and terminal bolt inspection • using the highest hand tester range, measure the resis- tance as shown in the figure. Terminal bolt and brush plate [a] terminal bolt and right-hand end cover [b] special tool - hand tester: 57001-1394 if ther...

  • Page 561

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

  • Page 562

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

  • Page 563

    Electrical system 16-57 lighting system • replace the headlight bulb. • fit the projection [a] of the bulb in the hollow [b] of the headlight. • install the hook [a]. • fit the dust cover [a] onto the bulb [b] firmly as shown in the figure. Good [c] bad [d] • after installation, adjust the headlight...

  • Page 564

    16-58 electrical system lighting system • install the bracket [a]; noting the letters “l” [b] and “r” [c]. City light bulb replacement • remove the upper fairing (see upper fairing removal in the frame chapter). • turn the socket [a] counterclockwise and remove it with the bulb. • pull out the bulb ...

  • Page 565

    Electrical system 16-59 lighting system tail/brake light (led) removal • remove: center seat cover (see seat cover removal in the frame chapter) tail/brake light mounting screws [a] tail/brake light (led) [b] tail/brake light (led) installation • installation is the reverse of removal. • tighten the...

  • Page 566

    16-60 electrical system lighting system headlight/tail light circuit 1. Fuse box 2 2. Headlight fuse 10 a 3. Taillight fuse 10 a 4. Fuse box 1 5. Alternator 6. Water-proof joint a 7. Water-proof joint b 8. Meter ground 9. Frame ground 10. Ignition switch 11. Meter unit 12. High beam indicator light ...

  • Page 567

    Electrical system 16-61 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°. Turn signal relay inspec...

  • Page 568

    16-62 electrical system lighting system turn signal light circuit 1. Fuse box 2 2. Turn signal relay fuse 10 a 3. Water-proof joint a 4. Water-proof joint b 5. Meter ground 6. Frame ground 7. Ignition switch 8. Meter unit 9. Right turn signal indicator light (led) 10. Left turn signal indicator ligh...

  • Page 569

    Electrical system 16-63 air switching valve air switching valve operation test • refer to the air suction system damage inspection in the periodic maintenance chapter. Air switching valve unit test • remove the air switching valve (see air switching valve removal in the engine top end chapter). • se...

  • Page 570

    16-64 electrical system air switching valve air switching valve circuit 1. Engine stop switch 2. Air switching valve 3. Water-proof joint b 4. Frame ground 5. Water-proof joint c 6. Ecu 7. Ignition switch 8. Fuse box 2 9. Ecu fuse 10 a 10. Ignition fuse 10 a 11. Relay box 12. Ecu main relay 13. Fuel...

  • Page 571

    Electrical system 16-65 radiator fan system fan motor inspection • remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • disconnect the connector [a]. • using an auxiliary leads, supply battery power to the fan motor. If the fan does not rotate, the fan motor is defective ...

  • Page 572

    16-66 electrical system meter, gauge, indicator unit meter unit removal/installation • remove: upper fairing (see upper fairing removal in the frame chapter) • slide the dust cover [a] and disconnect the connector. • remove the meter unit by taking off the mounting screws [b] with the washers and tw...

  • Page 573

    Electrical system 16-67 meter, gauge, indicator unit electronic combination meter unit inspection • remove the meter unit [a]. [1] left turn signal indicator light (led) (+) [2] unused [3] unused [4] unused [5] unused [6] unused [7] water temperature sensor [8] high beam indicator light (led) [9] ri...

  • Page 574

    16-68 electrical system meter, gauge, indicator unit • connect the terminal [15] to the battery (+) terminal. • check the following items. ○ the tachometer needle momentarily points their last read- ings and back to the minimum position. ○ the following lcd (liquid crystal display) will display the ...

  • Page 575

    Electrical system 16-69 meter, gauge, indicator unit • disconnect the terminal [15]. ○ all the lcd segments and led warning lights disappear. If the meter unit does not work, replace the meter assem- bly. Check 2: meter communication line (service code 39) check • connect the leads in the same circu...

  • Page 576

    16-70 electrical system meter, gauge, indicator unit check 3: mode button operation check • connect the leads in the same circuit as check 1. • by pushing the mode button [a] each time, check that the display [b] changes as follows. If the display function does not work, replace the meter assembly. ...

  • Page 577

    Electrical system 16-71 meter, gauge, indicator unit check 5: clock setting check • connect the leads in the same circuit as check 1. • set the odo mode [a] by pushing the mode button [b]. • push the rest button [c] for more than two seconds. ○ the clock setting menu (hour and minute) [d] should fla...

  • Page 578

    16-72 electrical system meter, gauge, indicator unit check 6: immobilizer flashing mode inspection (equipped models) • connect the leads in the same circuit as check 1. • disconnect the terminal [15]. • check that the warning light (led) [a] starts flashing (im- mobilizer warning light flashing mode...

  • Page 579

    Electrical system 16-73 meter, gauge, indicator unit check 7: left turn signal indicator light (led) inspec- tion • connect the leads in the same circuit as check 1. • connect the terminal [1] to the battery (+) terminal. • check that the left turn signal indicator light (led) [a] goes on. If the in...

  • Page 580

    16-74 electrical system meter, gauge, indicator unit • check that the right turn signal indicator light (led) [a] goes on. If the indicator light (led) does not go on, replace the meter assembly. Check 10: neutral indicator light (led) inspection • connect the leads in the same circuit as check 1. •...

  • Page 581

    Electrical system 16-75 meter, gauge, indicator unit check 12: oil pressure warning indicator light (led) inspection • connect the leads in the same circuit as check 1. • connect the terminal [20] to the battery (–) terminal. • check that the oil symbol [a] and oil pressure warning indicator light (...

  • Page 582

    16-76 electrical system meter, gauge, indicator unit • check that the display of the water temperature meter [a] indicates approximately 50 °c (122 °f). If the water temperature meter does not indicate temper- ature, replace the meter assembly. Check 14: fuel gauge inspection • connect the leads in ...

  • Page 583

    Electrical system 16-77 meter, gauge, indicator unit check 16: odometer inspection • connect the leads in the same circuit as check 15. • set the odo mode [a] by pushing the mode button [b]. • raise the input frequency of the oscillator to see the result of this inspection. ○ example: indicates the ...

  • Page 584

    16-78 electrical system meter, gauge, indicator unit • disconnect the terminal [15]. • check that the tachometer needle [a] back to the mini- mum (0) position. If the meter unit does not work, replace the meter assem- bly. Fuel level sensor line self-diagnosis mode inspection note ○ usually when the...

  • Page 585

    Electrical system 16-79 meter, gauge, indicator unit meter circuit 1. Water temperature sensor 2. Neutral switch 3. Fuel level sensor 4. Meter ground 5. Water-proof joint c 6. Speed sensor 7. Oil pressure switch 8. Crankshaft sensor 9. Immobilizer amplifier (equipped models) 10. Ecu 11. Meter unit 1...

  • Page 586

    16-80 electrical system immobilizer system (equipped models) this motorcycle is equipped with an immobilizer system to protect the motorcycle from theft. This system provides a theft proof device by means of matching a code between the inbuilt key transpon- der and ecu (electronic control unit). If ...

  • Page 587

    Electrical system 16-81 immobilizer system (equipped models) • insert the master key to the ignition switch and turn it on. Verified ○ the warning indicator light (led) [a] blinks to display the registration mode (go to the next step). Not verified ○ the warning indicator light (led) [a] blinks to d...

  • Page 588

    16-82 electrical system immobilizer system (equipped models) ○ if there is any problem in the registration, the warning indicator light (led) [a] blinks to display the collation error. Immobilizer amplifier failure when registered user key is inserted. User key collation error • the user key 1 is su...

  • Page 589

    Electrical system 16-83 immobilizer system (equipped models) • insert the user key 2 to the ignition switch and turn it on. ○ if there is any problem in the registration, the warning indicator light (led) [a] blinks to display the collation error. Immobilizer amplifier failure when registered user k...

  • Page 590

    16-84 electrical system immobilizer system (equipped models) • warning indicator light (led) [a] goes off. • remove the key registration unit and connect the immo- bilizer kawasaki diagnostic system connector. Note ○ turn the ignition switch on with the registered user key. ○ check that the engine c...

  • Page 591

    Electrical system 16-85 immobilizer system (equipped models) spare user key registration flow chart.

  • Page 592

    16-86 electrical system immobilizer system (equipped models) case 2: when the ignition switch is faulty and to be replaced. • prepare a new ignition switch [a] and two new user keys [b]. ○ these parts are available as a set. Prepare the current master key [c]. • remove: ignition switch and immobiliz...

  • Page 593

    Electrical system 16-87 immobilizer system (equipped models) verified ○ the warning indicator light (led) [a] blinks to display the ecu is in the registration mode (go to the next step). Not verified ○ the warning indicator light (led) [a] blinks to display the collation error. Immobilizer amplifier...

  • Page 594

    16-88 electrical system immobilizer system (equipped models) ○ if there is any problem in the registration, the warning indicator light (led) [a] blinks to display the collation error. Immobilizer amplifier failure when registered user key is inserted. User key collation error • the user key 1 is su...

  • Page 595

    Electrical system 16-89 immobilizer system (equipped models) ○ if there is any problem in the registration, the warning indicator light (led) [a] blinks to display the collation error. Immobilizer amplifier failure when registered user key is inserted. User key collation error • the user key 2 is su...

  • Page 596

    16-90 electrical system immobilizer system (equipped models) • remove the key registration unit and connect the immo- bilizer/kawasaki diagnostic system connector. Note ○ turn the ignition switch on with the registered user key. ○ check that the engine can be started using all regis- tered user keys...

  • Page 597

    Electrical system 16-91 immobilizer system (equipped models) • the master key is registered in the ecu. ○ the warning indicator light (led) [a] blinks 1 time and stops for 1 second and the repeats this cycle to indicate successful registration of the master key. • turn off the master key and remove ...

  • Page 598

    16-92 electrical system immobilizer system (equipped models) user key collation error • the user key 1 is registered in the ecu. ○ the warning indicator light (led) [a] blinks 2 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key. • turn off and r...

  • Page 599

    Electrical system 16-93 immobilizer system (equipped models) when registered user key is inserted. User key collation error • the user key 2 is registered in the ecu. ○ the warning indicator light (led) [a] blinks 3 times and stops for 1 second and then repeats this cycle to indicate successful regi...

  • Page 600

    16-94 electrical system immobilizer system (equipped models) • prepare a new ecu [a], new master key [b] and current user keys [c]. Note ○ the key registration unit is not required. ○ the key registration process is same as the ecu re- placement. Case 5: when replacing the antenna. • prepare a new a...

  • Page 601

    Electrical system 16-95 immobilizer system (equipped models) all keys initial registration flow chart.

  • Page 602

    16-96 electrical system immobilizer system (equipped models) immobilizer system parts replacement immobilizer antenna replacement • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) • disconnect the lead connectors [a]. • remove: handlebar (see handlebar removal in the steer...

  • Page 603

    Electrical system 16-97 immobilizer system (equipped models) • remove: connector [a] (disconnect) bolt [b] and holder [c] immobilizer amplifier [d] • when the holder [a] installing, contact the projection [b] to bracket [c]. Ecu (electronic control unit) replacement (for immo- bilizer models) cautio...

  • Page 604

    16-98 electrical system immobilizer system (equipped models) • using a small chisel [a] or other suitable tool, remove the screws. • remove the upper guard [a] and lower guard [b]. • disconnect the connectors [a]. • remove the ecu [b]. • connect the connectors to the ecu. • install the lower and upp...

  • Page 605

    Electrical system 16-99 immobilizer system (equipped models) immobilizer relational parts replacement chart failed or lost part master key (red) user key (black) ignition switch an- tenna ampli- fier ecu master key (red) • user key (black) • ○ ignition switch • an- tenna • ampli- fier • * ecu ○ • * ...

  • Page 606

    16-100 electrical system immobilizer system (equipped models) immobilizer system circuit 1. Fuse box 2 2. Ignition fuse 10 a 3. Ecu fuse 10 a 4. Frame ground 5. Meter ground 6. Immobilizer antenna 7. Immobilizer amplifier 8. Ecu 9. Ignition switch 10. Meter unit 11. Oil pressure/fi/immobilizer warni...

  • Page 607

    Electrical system 16-101 switches and sensors brake light timing inspection • refer to the brake light switch operation inspection in the periodic maintenance chapter. Brake light timing adjustment • refer to the brake light switch operation inspection in the periodic maintenance chapter. Switch ins...

  • Page 608

    16-102 electrical system switches and sensors water temperature sensor inspection • remove the water temperature sensor (see water tem- perature sensor removal/installation in the fuel system (dfi) chapter). • suspend the sensor [a] in a container of coolant so that the threaded portion is submerged...

  • Page 609

    Electrical system 16-103 switches and sensors speed sensor installation • apply grease to the o-ring [a] on the speed sensor [b]. • tighten: torque - speed sensor bolt: 12 n·m (1.2 kgf·m, 106 in·lb) • install the removed parts (see appropriate chapters). Speed sensor inspection • refer to the speed ...

  • Page 610

    16-104 electrical system switches and sensors oxygen sensor installation (equipped models) caution never drop the oxygen sensor [a], especially on a hard surface. Such a shock to the unit can damage it. Do not touch the sensing part [b] and filter holes [c] of the sensor to prevent oil contact. Oil ...

  • Page 611

    Electrical system 16-105 switches and sensors • install a new gasket [a] on the fuel level sensor as shown in the figure. Hollows [b] front [c] • apply a non-permanent locking agent to the threads of the fuel level sensor bolts and tighten them. Torque - fuel level sensor bolts: 6.9 n·m (0.70 kgf·m,...

  • Page 612

    16-106 electrical system relay box the relay box [a] has relays and diodes. The relays and diodes can not be removed. Relay box removal caution never drop the relay box, especially on a hard sur- face. Such a shock to the relay box can damage it. • remove: left seat cover (see seat cover removal in ...

  • Page 613

    Electrical system 16-107 relay box relay circuit inspection (with the battery connected) battery connection (+) (–) tester connection tester reading (Ω) 2-11 1-3 0 ecu main relay 4-5 7-6 0 fuel pump relay 9-10 7-8 0 fan relay 18-19 17-20 0 battery connection (+) (–) tester connection dc 25 v range (...

  • Page 614

    16-108 electrical system relay box relay box internal circuit a: headlight relay b: ecu main relay c: fuel pump relay d: starter circuit relay e: fan relay.

  • Page 615

    Electrical system 16-109 fuse 30 a main fuse removal • remove: rear seat bracket (see relay box removal) 30 a main fuse connector [a] (disconnect) • pull out the main fuse [a] from the starter relay with a needle nose pliers. Fuse box fuse removal • remove the seats (see rear/front seat removal in t...

  • Page 616

    16-110 electrical system fuse 10 a ecu fuse removal • remove the rear seat (see rear seat removal in the frame chapter) • unlock the hook to lift up the lid [a]. • pull out the ecu fuse [b] from the fuse box 2. Fuse installation • if a fuse fails during operation, inspect the electrical sys- tem to ...

  • Page 617: Appendix

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

  • Page 618

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

  • Page 619

    Appendix 17-3 cable, wire, and hose routing 1. Viewed a 2. Viewed b 3. After installing the heat insulation rubber plate, run the radiator fan motor lead under the rivet of the left side. 4. Run the reserve tank hose and main harness into the clamp. 5. Reserve tank overflow hose (from reserve tank t...

  • Page 620

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

  • Page 621

    Appendix 17-5 cable, wire, and hose routing 1. Viewed a 2. Radiator hose (from thermostat housing to radiator) 3. Align the white paint of the radiator hose (from thermostat housing to radiator) with projection of the thermostat housing. 4. Align the white paint of the water hose (from cylinder head...

  • Page 622

    17-6 appendix cable, wire, and hose routing 1. White paint 2. Air switching valve hose (from air switching valve to air cleaner housing) 3. Inlet air temperature sensor 4. Clamp 5. Clamp 6. Main harness (main throttle and subthrottle sensor leads) 7. Viewed a (bend the clamp as shown in the figure. ...

  • Page 623

    Appendix 17-7 cable, wire, and hose routing 1. Hold the fuel tank drain hose with the left side clamp of the fuel tank. 2. Run the fuel tank drain hose between the air cleaner housing and frame. 3. Air cleaner drain hose 4. Fuel tank drain hose 5. Reserve tank overflow hose (run the reserve tank ove...

  • Page 624

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

  • Page 625

    Appendix 17-9 cable, wire, and hose routing 1. Put the alternator lead connector to the inside of the left frame cover and left subframe. 2. Left frame cover 3. Left subframe 4. Run the alternator lead over the frame cross pipe. 5. Frame cross pipe 6. Sidestand switch lead connector 7. Clamp (hold t...

  • Page 626

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

  • Page 627

    Appendix 17-11 cable, wire, and hose routing 1. Frame cross pipe 2. Run the starter motor cable and battery negative cable under the frame cross pipe. 3. Frame cross pipe 4. Run the sidestand switch lead under the frame cross pipe. 5. Oil pan.

  • Page 628

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

  • Page 629

    Appendix 17-13 cable, wire, and hose routing 1. Air switching valve hose (from air switching valve to air cleaner housing) 2. Subthrottle valve actuator lead connector 3. Run the subthrottle valve actuator and fuel injector leads under the air switching valve hose (from air switching valve to air cl...

  • Page 630

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

  • Page 631

    Appendix 17-15 cable, wire, and hose routing 1. Put the rear brake light switch lead connector to the inside of the right sub side cover. 2. Put the rear wheel rotation sensor lead connector to the inside of the right frame cover. 3. Dust covers 4. Exhaust butterfly valve open cable (white) 5. Exhau...

  • Page 632

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

  • Page 633

    Appendix 17-17 cable, wire, and hose routing 1. Oxygen sensor lead connector 2. Oil pressure switch/crankshaft sensor lead connector 3. Install the oxygen sensor and oil pressure switch/crankshaft sensor lead connectors to the bracket. 4. After installing the connectors to the bracket, tighten the b...

  • Page 634

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

  • Page 635

    Appendix 17-19 cable, wire, and hose routing 1. Left front turn signal light lead (run the right and left front turn signal light leads inside the fairing bracket). 2. Run the horn lead inside the radiator hose. 3. Horn lead 4. Run the horn lead outside the subframe..

  • Page 636

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

  • Page 637

    Appendix 17-21 cable, wire, and hose routing 1. Fuel outlet hose 2. Run the fuel pump lead to the outside of the fuel outlet hose. 3. Fuel pump lead connector 4. Fuel tank bottom 5. Install the fuel inlet hose so that the white mark side faces outlet pipe of the fuel tank. 6. Fuel inlet hose 7. Mete...

  • Page 638

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

  • Page 639

    Appendix 17-23 cable, wire, and hose routing 1. Put the rubber cover to the inside of the frame as shown in the figure. 2. Run the throttle cables under the immobilizer antenna and stick coil leads. 3. Run the immobilizer antenna, ignition switch and radiator fan motor leads under the left side of t...

  • Page 640

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

  • Page 641

    Appendix 17-25 cable, wire, and hose routing 1. Frame cross pipe 2. Fuel tank bracket 3. Run the abs hydraulic unit lead under the fuel tank bracket and frame cross pipe. 4. Run the main harness (to fuse box 1) under the fuel tank bracket and frame cross pipe. 5. Fuse box 1 6. Put the abs kawasaki s...

  • Page 642

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

  • Page 643

    Appendix 17-27 cable, wire, and hose routing 1. Main harness (to fuse box 1) 2. Run the main harness (to fuse box 1) over the frame. 3. Hold the main harness (to fuse box 1) and reserve tank hose. 4. Run the main harness (to fuse box 1) under the frame and over the reserve tank hose. 5. Fuse box 1.

  • Page 644

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

  • Page 645

    Appendix 17-29 cable, wire, and hose routing 1. Turn signal relay (position the turn signal relay lead in the lower side.) 2. Fuse box 2 3. Tail/brake light (led) lead connector 4. Immobilizer/kawasaki diagnostic system connector 5. Run the tail/brake light (led) lead over the reserve tank overflow ...

  • Page 646

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

  • Page 647

    Appendix 17-31 cable, wire, and hose routing 1. Ground lead connector 2. Battery positive lead connector 3. Battery positive cable 4. Battery negative cable 5. Run the battery negative cable and starter motor cable into the clamp. 6. Run the battery negative cable and starter motor cable to the outs...

  • Page 648

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

  • Page 649

    Appendix 17-33 cable, wire, and hose routing 1. Rear seat lock cable 2. Run the rear seat lock cable under the front seat bracket. 3. Front seat lock cables 4. Bracket 5. Run the reserve tank hose to the inside of the bracket. 6. Run the rear seat lock cable to the outside of the reserve tank hose..

  • Page 650

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

  • Page 651

    Appendix 17-35 cable, wire, and hose routing 1. Rear seat lock cable 2. Right rear turn signal light lead 3. After inserting the dampers in the brackets, run the right and left turn signal light leads into the dampers. 4. Left rear turn signal light lead.

  • Page 652

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

  • Page 653

    Appendix 17-37 cable, wire, and hose routing 1. Clamp (install the clamp with the meter mounting screw and hold the right and left switch housing leads.) 2. Left switch housing lead connector 3. Position the left switch housing lead connector inside the clamp. 4. Clamp (install the clamp with the me...

  • Page 654

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

  • Page 655

    Appendix 17-39 cable, wire, and hose routing 1. Clutch cable 2. Main harness 3. Ignition switch and immobilizer antenna leads 4. Throttle cables 5. From head pipe side, run the clutch cable, ignition switch and immobilizer antenna leads, throttle cables and main harness. 6. From chassis upper side, ...

  • Page 656

    17-40 appendix cable, wire, and hose routing.

  • Page 657

    Appendix 17-41 cable, wire, and hose routing 1. Clutch cable 2. Run the clutch cable and left switch housing lead inside the guide of the upper fairing bracket. Run the left switch housing lead to the front of the clutch cable. 3. Left switch housing lead 4. Insert the clamp from backside of the cha...

  • Page 658

    17-42 appendix cable, wire, and hose routing.

  • Page 659

    Appendix 17-43 cable, wire, and hose routing 1. Run the throttle cables under the upper fairing bracket. 2. Run the brake hose outside the guide of the upper fairing bracket. 3. Run the throttle cables and right switch housing lead inside the guide of the upper fairing bracket. 4. Run the left switc...

  • Page 660

    17-44 appendix cable, wire, and hose routing.

  • Page 661

    Appendix 17-45 cable, wire, and hose routing 1. Clamps 2. Brake hose (from front master cylinder to right front caliper) 3. Brake hose (from right front caliper to left front caliper) 4. Viewed front side 5. Bracket 6. Brake hose (from rear master cylinder to rear caliper) 7. Clamps 8. Upper fairing...

  • Page 662

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

  • Page 663

    Appendix 17-47 cable, wire, and hose routing 1. Brake hose (from front master cylinder to abs hydraulic unit) 2. Clamps 3. Brake pipes 4. Front wheel rotation sensor lead 5. Brake hose (from right front caliper to left front caliper) 6. Viewed front side 7. Viewed back side 8. Abs hydraulic unit 9. ...

  • Page 664

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

  • Page 665

    Appendix 17-49 cable, wire, and hose routing 1. Abs hydraulic unit 2. Clamps 3. Brake hose (from abs hydraulic unit to rear caliper) 4. Rear wheel rotation sensor lead 5. Rear wheel rotation sensor.

  • Page 666

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

  • Page 667

    Appendix 17-51 cable, wire, and hose routing 1. Clamps 2. Bands 3. To rear master cylinder 4. To rear caliper 5. To front master cylinder 6. To right front caliper 7. Abs hydraulic unit 8. Viewed front side 9. Left side 10. Right side 11. Viewed upper side 12. Front 13. Brackets.

  • Page 668

    17-52 appendix cable, wire, and hose routing abs equipped models.

  • Page 669

    Appendix 17-53 cable, wire, and hose routing 1. Clamps 2. Brake hose (from abs hydraulic unit to right front caliper) 3. Brake hose (from right front caliper to left front caliper) 4. Clamp (hold the brake hose (from right front caliper to left front caliper) and front wheel rotation sensor lead on ...

  • Page 670

    17-54 appendix cable, wire, and hose routing abs equipped models.

  • Page 671

    Appendix 17-55 cable, wire, and hose routing 1. Run the brake hose (from front master cylinder to abs hydraulic unit) between the steering stem head and guide of the upper fairing bracket. 2. Clamps 3. Brake hose (from abs hydraulic unit to right front caliper) 4. Front wheel rotation sensor lead 5....

  • Page 672

    17-56 appendix cable, wire, and hose routing abs equipped models.

  • Page 673

    Appendix 17-57 cable, wire, and hose routing 1. Clamps 2. Brake pipe 3. One white paint mark 4. One blue paint mark 5. Bracket 6. Brake pipe 7. Brake hoses (one white paint mark) 8. Bands 9. Grommets 10. Clamp 11. Bracket.

  • Page 674

    17-58 appendix cable, wire, and hose routing abs equipped models.

  • Page 675

    Appendix 17-59 cable, wire, and hose routing 1. Bracket 2. Brake pipe (one white paint mark) 3. Clamps 4. Brake hose (two blue paint marks) 5. Brake hose (two white paint marks) 6. Grommets 7. Bands 8. Brake pipe (two white paint marks) 9. Brake pipe (one blue paint mark) 10. Brake pipe (two blue pa...

  • Page 676

    17-60 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 677

    Appendix 17-61 troubleshooting guide 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 gasket damaged cylinder head warped val...

  • Page 678

    17-62 appendix troubleshooting guide air cleaner clogged compression high: carbon built up in combustion chamber engine load faulty: clutch slipping engine oil level too high engine oil viscosity too high drive train trouble brake dragging lubrication inadequate: engine oil level too low engine oil ...

  • Page 679

    Appendix 17-63 troubleshooting guide exhaust pipe leaking at cylinder head con- nection crankshaft runout excessive engine mount loose crankshaft bearing worn primary gear worn or chipped camshaft chain tensioner trouble camshaft chain, sprocket, guide worn air suction valve damaged air switching va...

  • Page 680

    17-64 appendix troubleshooting guide front fork oil insufficient and/or leaking front fork oil viscosity too low rear shock adjustment too soft front fork, rear shock absorber spring weak rear shock absorber oil leaking brake doesn’t hold: air in the brake line pad or disc worn brake fluid leakage d...

  • Page 681

    Model application year model beginning frame no. 2007 zr750l7f jkazrdl1 □ 7a000001 jkazr750lla000001 zr750l-000001 2007 zr750m7f jkazr750lma000001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1381-01 printed in japan.