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Kawasaki Z800 ABS Service Manual

Other manuals for Z800 ABS: Owner's Manual, Owner's Manual

Summary of Z800 ABS

  • Page 1

    Z800 z800 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: Z800

    Z800 z800 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) in. Inch(s) abdc after bottom dead center km/h kilometers per hour abs antilock brake system l liter(s) ac alternating current lcd liquid crystal display ah ampere hour led light emitting diode atdc after top dead center lb pound(s) bbdc before bottom dead center m ...

  • Page 7: Foreword

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

  • Page 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 zr800ad (europe) left side view zr800ad (europe) right side view.

  • Page 16

    1-8 general information model identification zr800bd (europe) left side view zr800bd (europe) right side view.

  • Page 17

    General information 1-9 model identification zr800cd left side view zr800cd right side view.

  • Page 18

    1-10 general information model identification zr800dd left side view zr800dd right side view frame number engine number.

  • Page 19

    General information 1-11 general specifications items zr800ad/bd/cd/dd dimensions overall length 2 100 mm (82.68 in.) overall width 800 mm (31.50 in.) overall height 1 050 mm (41.34 in.) wheelbase 1 445 mm (56.89 in.) road clearance 150 mm (5.91 in.) seat height 834 mm (32.83 in.) curb mass: zr800a ...

  • Page 20

    1-12 general information general specifications items zr800ad/bd/cd/dd spark plug ngk cr9ek, nd u27etr cylinder numbering method left to right, 1-2-3-4 firing order 1-2-4-3 valve timing: intake: open 38° btdc close 66° abdc duration 284° exhaust: open 51° bbdc close 25° atdc duration 256° lubricatio...

  • Page 21

    General information 1-13 general specifications items zr800ad/bd/cd/dd rear tire: type tubeless size 180/55zr17 m/c (73w) rim size j17m/c × mt5.50 front suspension: type telescopic fork wheel travel 120 mm (4.72 in.) rear suspension: type swingarm (uni-trak) wheel travel 137 mm (5.39 in.) brake type...

  • Page 22

    1-14 general information unit conversion table prefixes for units: prefix symbol power mega m × 1 000 000 kilo k × 1 000 centi c × 0.01 milli m × 0.001 micro µ × 0.000001 units of mass: kg × 2.205 = lb g × 0.03527 = oz units of volume: l × 0.2642 = gal (us) l × 0.2200 = gal (imp) l × 1.057 = qt (us)...

  • Page 23: Periodic Maintenance

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

  • Page 24

    2-2 periodic maintenance steering system .................................................................................................................. 2-55 steering play inspection ................................................................................................... 2-55 steering ...

  • Page 25

    Periodic maintenance 2-3 periodic maintenance chart the scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic inspection *a: service at number of years shown o...

  • Page 26

    2-4 periodic maintenance periodic maintenance chart odometer reading (*b) × 1 000 km (× 1 000 mile) items year (*a) 1 (0.6) 6 (3.8) 12 (7.6) 18 (11.4) 24 (15.2) see page final drive drive chain lubrication condition (*c) : every 600 km (400 mile) 2-38 drive chain slack (*c) : every 1 000 km (600 mil...

  • Page 27

    Periodic maintenance 2-5 torque and locking agent the following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “remarks” column mean: ad: apply adhesive (see the text). Al: tighten the two clamp bo...

  • Page 28

    2-6 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks water pump impeller bolt 9.8 1.0 87 in·lb water pump cover bolts 11 1.1 97 in·lb coolant drain bolt (water pump) 11 1.1 97 in·lb engine top end air suction valve cover bolts 9.8 1.0 87 in·lb cylinder head cover...

  • Page 29

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks oil passage plugs 20 2.0 15 l oil pipe holder bolts 13 1.3 115 in·lb l water pump cover bolts 11 1.1 97 in·lb coolant drain bolt (water pump) 11 1.1 97 in·lb water pump impeller bolt 9.8 1.0 87 in·lb oil pressu...

  • Page 30

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks shift pedal mounting bolt 25 2.5 18 wheels/tires front axle clamp bolt 20 2.0 15 front axle 108 11.0 79.7 rear axle nut 108 11.0 79.7 final drive engine sprocket cover bolts 6.9 0.70 61 in·lb engine sprocket nu...

  • Page 31

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks piston rod assy stopper 17.5 1.78 12.9 ad cylinder unit 70 7.1 52 ad swingarm pivot shaft nut 108 11.0 79.7 swingarm pivot shaft 9.8 1.0 87 in·lb swingarm pivot shaft locknut 98 10 72 rear shock absorber nut (u...

  • Page 32

    2-10 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks timing rotor bolt 39 4.0 29 starter motor mounting bolts 11 1.1 97 in·lb crankshaft sensor cover bolts 11 1.1 97 in·lb crankshaft sensor bolts 5.9 0.60 52 in·lb oil pressure switch terminal bolt 2.0 0.20 18 in...

  • Page 33

    Periodic maintenance 2-11 specifications item standard service limit fuel system (dfi) throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 1 100 ±50 r/min (rpm) – – – bypass screws (turn out) – – – – – – throttle body vacuum 35.3 ±1.3 kpa (265 ±10 mmhg) at idle speed – – – air cleane...

  • Page 34

    2-12 periodic maintenance specifications item standard service limit air pressure (when cold): front up to 180 kg (397 lb) load: 250 kpa (2.50 kgf/cm², 36 psi) – – – rear up to 180 kg (397 lb) load: 290 kpa (2.90 kgf/cm², 42 psi) – – – final drive drive chain slack 20 ∼ 30 mm (0.8 ∼ 1.2 in.) – – – d...

  • Page 35

    Periodic maintenance 2-13 special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 pilot screw adjuster, a: 57001-1239 oil filter wrench: 57001-1249 vacuum gauge: 57001-1369 throttle sensor setting adapter: 57001-1538 extension tube: 57001-1578.

  • Page 36

    2-14 periodic maintenance 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. Warning if dirt or dust is allowed to pass through into the throttle assy, the throttle may bec...

  • Page 37

    Periodic maintenance 2-15 periodic maintenance procedures • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) bolts [a] fuel tank bracket [b] • remove the air cleaner duct screws [a]. • remove the air cleaner duct [b] backward. • discard the air cleaner element [a]. • instal...

  • Page 38

    2-16 periodic maintenance periodic maintenance procedures • fit the tongue [a] of the air cleaner duct into the slot [b] of the air cleaner housing. • tighten: torque - air cleaner duct screws: 3.8 n·m (0.39 kgf·m, 34 in·lb) idle speed inspection • start the engine and warm it up thoroughly. • with ...

  • Page 39

    Periodic maintenance 2-17 periodic maintenance procedures if the free play is incorrect, adjust the throttle cable as follows. • loosen the locknuts [a] [b]. • screw both throttle cable adjusters [c] [d] to give the throttle grip plenty of play. • turn the decelerator cable adjuster [c] until there ...

  • Page 40

    2-18 periodic maintenance periodic maintenance procedures • connect a vacuum gauge (special tool) and hoses [a] to the fittings on the throttle body. Special tool - vacuum gauge: 57001-1369 • connect a highly accurate tachometer [b] to one of the stick coil primary leads. • connect the following par...

  • Page 41

    Periodic maintenance 2-19 periodic maintenance procedures if any vacuum is not within specifications, adjust the by- pass screws [a]. Upside view [b] special tool - pilot screw adjuster, a: 57001-1239 • adjust the each vacuum (#1 ∼ #4) to the standard value. • open and close the throttle valves afte...

  • Page 42

    2-20 periodic maintenance periodic maintenance procedures • back out the same number of turns counted when first turned in. This is to set the screw to its original position. Note ○ a throttle body has different “turns out” of the bypass screw for each individual unit. On setting the bypass screw, u...

  • Page 43

    Periodic maintenance 2-21 periodic maintenance procedures • check that the hoses are routed according to cable, wire, and hose routing section in the appendix chapter. Replace the hose if it has been sharply bent or kinked. Hose joints [a] fuel outlet hose [b] fuel intake hose [c] front [d] • check ...

  • Page 44

    2-22 periodic maintenance periodic maintenance procedures fuel hose replacement warning fuel is flammable and explosive under certain con- ditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is dis- connected...

  • Page 45

    Periodic maintenance 2-23 periodic maintenance procedures • pull the joint lock [a] as shown. • pull the fuel outlet hose joint [b] out of the delivery pipe. • clean the delivery pipe [a]. • cover the delivery pipe with the vinyl bag [b] to keep it clean. • install a new fuel intake hose [a] so that...

  • Page 46

    2-24 periodic maintenance periodic maintenance procedures • replace the fuel outlet hose with a new one. • pull [a] the joint lock [b] fully as shown. • insert the fuel outlet hose joint [a] straight onto the deliv- ery pipe until the hose joint clicks. • push [b] the joint lock [c] until the hose j...

  • Page 47

    Periodic maintenance 2-25 periodic maintenance procedures cooling system coolant level inspection note ○ check the level when the engine is cold (room or ambi- ent temperature). • check the coolant level in the reserve tank [a] with the motorcycle held perpendicular (do not use the side stand.). If ...

  • Page 48

    2-26 periodic maintenance periodic maintenance procedures • remove the left lower fairing (see lower fairing removal (zr800a/b models) in the frame chapter). • place a container under the coolant drain bolt [a], then remove the drain bolt. • remove the fuel tank (see fuel tank removal in the fuel sy...

  • Page 49

    Periodic maintenance 2-27 periodic maintenance procedures • fill the radiator up to the filler neck [a] with coolant. Note ○ pour in the coolant slowly so that it can expel the air from the engine and radiator. • check the cooling system for leaks. • tap the water hoses to force any air bubbles caug...

  • Page 50

    2-28 periodic maintenance periodic maintenance procedures water 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 oil pump removal in the engine lubrication system ch...

  • Page 51

    Periodic maintenance 2-29 periodic maintenance procedures • position the crankshaft at 1,4 piston tdc. Tdc mark [a] for #1, 4 pistons timing mark [b] (crankcase halves mating surface) • using the thickness gauge [a], measure the valve clear- ance between the cam and the valve lifter. Valve clearance...

  • Page 52

    2-30 periodic maintenance periodic maintenance procedures valve clearance adjustment • to change the valve clearance, remove the camshaft chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. Note ○ mark and record the locations of the valve lifters and sh...

  • Page 53

    Periodic maintenance 2-31 periodic maintenance procedures valve clearance adjustment chart intake valve 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where t...

  • Page 54

    2-32 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 55

    Periodic maintenance 2-33 periodic maintenance procedures notice be sure to remeasure the clearance after selecting a shim according to the table. If the clearance is out of the specified range, use the additional shim. ○ if there is no valve clearance, use a shim that is a few sizes smaller, and re...

  • Page 56

    2-34 periodic maintenance periodic maintenance procedures warning the engine and exhaust system get extremely hot during normal operation and can cause serious burns. 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 th...

  • Page 57

    Periodic maintenance 2-35 periodic maintenance procedures recommended engine oil type: api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity: sae 10w-40 capacity: 3.1 l (3.3 us qt) (when filter is not removed) 3.4 l (3.6 us qt) (when filter is removed) 3.8 l (4.0 us qt) (when engine is complet...

  • Page 58

    2-36 periodic maintenance periodic maintenance procedures wheels/tires air pressure inspection • remove the air valve cap. • measure the tire air pressure with an air pressure gauge [a] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours...

  • Page 59

    Periodic maintenance 2-37 periodic maintenance procedures tread depth standard: front 4.0 mm (0.16 in.) rear 5.5 mm (0.22 in.) service limit: front 1 mm (0.04 in.) (at, ch, de) 1.6 mm (0.06 in.) rear up to 130 km/h (80 mph): 2 mm (0.08 in.) over 130 km/h (80 mph): 3 mm (0.12 in.) warning some replac...

  • Page 60

    2-38 periodic maintenance periodic maintenance procedures final drive drive chain lubrication condition inspection • if a special lubricant is not available, a heavy oil such as sae 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. • if the cha...

  • Page 61

    Periodic maintenance 2-39 periodic maintenance procedures drive chain slack adjustment • remove the cotter pin [a], and loosen the axle nut [b]. • loosen the both chain adjuster locknuts [c]. If the chain is too loose, turn in the left and right chain adjusters [d] evenly. If the chain is too tight,...

  • Page 62

    2-40 periodic maintenance periodic maintenance procedures wheel alignment inspection • check that the notch [a] on the left alignment indicator [b] aligns with the same swingarm mark or position [c] that the right alignment indicator notch aligns with. If they do not, adjust the chain slack and alig...

  • Page 63

    Periodic maintenance 2-41 periodic maintenance procedures chain guide wear inspection • remove: shift pedal (see shift pedal removal in the crank- shaft/transmission chapter) footpeg bracket bolts [a] left footpeg bracket [b] chain cover (see drive chain removal/installation in the final drive chapt...

  • Page 64

    2-42 periodic maintenance periodic maintenance procedures brakes brake system brake fluid leak (brake hose and pipe) inspection • for abs equipped models; note the following. • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) right side fairing (see side fairing removal in ...

  • Page 65

    Periodic maintenance 2-43 periodic maintenance procedures brake hose and pipe damage and installation condi- tion inspection • for abs equipped models; note the following. • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) right side fairing (see side fairing removal in the...

  • Page 66

    2-44 periodic maintenance periodic maintenance procedures if the fluid level is lower than the lower level line, fill the reservoir to the upper level line [a]. • check that the brake fluid level in the rear brake reservoir [a] is above the lower level line [b]. If the fluid level is lower than the ...

  • Page 67

    Periodic maintenance 2-45 periodic maintenance procedures • level the brake fluid reservoir. • remove the reservoir cap, diaphragm plate and di- aphragm. • remove the rubber cap from the bleed valve [a] on the caliper. • attach a clear plastic hose [b] to the bleed valve, and run the other end of th...

  • Page 68

    2-46 periodic maintenance periodic maintenance procedures brake hose and pipe replacement notice brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • remove: upper fairing (see upper fairing removal in the frame chapter) brake hose ban...

  • Page 69

    Periodic maintenance 2-47 periodic maintenance procedures master cylinder rubber parts replacement front master cylinder disassembly • remove the front master cylinder (see front master cylin- der removal in the brakes chapter). • remove: front master cylinder reservoir cap screws [a] reservoir cap ...

  • Page 70

    2-48 periodic maintenance periodic maintenance procedures • apply brake fluid to the new parts and to the inner wall of the cylinder. • take care not to scratch the piston or the inner wall of the cylinder. • apply silicone grease to the followings. Front: brake lever pivot bolt rear: dust cover of ...

  • Page 71

    Periodic maintenance 2-49 periodic maintenance procedures front caliper assembly (zr800a/b/d models) • clean the caliper parts except for the pads. Notice for cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • install the bleed valve and rubber cap. Torque - bleed ...

  • Page 72

    2-50 periodic maintenance periodic maintenance procedures warning the piston in the brake caliper can crush hands and fingers. Never place your hand or fingers in front of the piston. ○ pull out the pistons by hand. • remove the dust seals [a] and fluid seals [b]. • remove the bleed valve [c] and ru...

  • Page 73

    Periodic maintenance 2-51 periodic maintenance procedures • using compressed air, remove the piston. ○ cover the piston area with a wooden board [a]. ○ blow compressed air [b] into the hole for the banjo bolt to remove the piston. Warning the piston in the brake caliper can crush hands and fingers. ...

  • Page 74

    2-52 periodic maintenance periodic maintenance procedures brake pad wear inspection • remove the brake pads (see front/rear brake pad re- moval in the brakes chapter). • check the lining thickness [a] of the pads in each caliper. If the lining thickness of either pad is less than the service limit [...

  • Page 75

    Periodic maintenance 2-53 periodic maintenance procedures • while holding the switch body, turn the adjusting nut to adjust the switch. Switch body [a] adjusting nut [b] light sooner as the body rises [c] light later as the body lowers [d] notice to avoid damaging the electrical connections in- side...

  • Page 76

    2-54 periodic maintenance periodic maintenance procedures front fork oil leak inspection • visually inspect the front forks [a] for oil leakage. Replace or repair any defective parts, if necessary. Rear shock absorber oil leak inspection • visually inspect the shock absorber [a] for oil leakage. If ...

  • Page 77

    Periodic maintenance 2-55 periodic maintenance procedures steering system steering play inspection • raise the front wheel off the ground with the jack (see front wheel removal in the wheels/tires chapter). • with the front wheel pointing straight ahead, alternately tap each end of the handlebars. T...

  • Page 78

    2-56 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 79

    Periodic maintenance 2-57 periodic maintenance procedures electrical system lights and switches operation inspection first step • turn the ignition switch on. • the following lights should go on according to below table. City lights [a] go on taillight (led) [b] goes on license plate light [c] goes ...

  • Page 80

    2-58 periodic maintenance periodic maintenance procedures • turn the turn signal switch [a] (left or right position) on. • the left or right turn signal lights [b] (front and rear) ac- cording to the switch position should blink. • the green turn signal indicator light (led) [c] in the meter unit sh...

  • Page 81

    Periodic maintenance 2-59 periodic maintenance procedures • set the dimmer switch to high beam position. • the low beam [a] and high beam [b] headlights should go on. • the blue high beam indicator light (led) [c] should go on. If the high beam headlight and/or blue high beam indicator light (led) d...

  • Page 82

    2-60 periodic maintenance periodic maintenance procedures side stand switch operation inspection • inspect the side stand switch [a] operation accordance to the following table. Side stand switch operation side stand gear position clutch lever engine start engine run up neutral released starts conti...

  • Page 83

    Periodic maintenance 2-61 periodic maintenance procedures engine stop switch operation inspection first step • turn the ignition switch on. • 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 84

    2-62 periodic maintenance periodic maintenance procedures • replace the spark plug with a new one. Standard spark plug type: ngk cr9ek or nd u27etr • insert the new spark plug in the plug hole, and finger -tighten it first. • using the plug wrench [a] vertically, tighten the plug. Notice the insulat...

  • Page 85

    Periodic maintenance 2-63 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 86

    2-64 periodic maintenance periodic maintenance procedures condition of 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 tightne...

  • Page 87: Fuel System (Dfi)

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

  • Page 88

    3-2 fuel system (dfi) vehicle-down sensor installation ...................................................................................... 3-72 vehicle-down sensor input voltage inspection................................................................. 3-73 vehicle-down sensor output voltage ins...

  • Page 89

    Fuel system (dfi) 3-3 dfi power source .................................................................................................................. 3-111 ecu fuse removal .......................................................................................................... 3-111 ecu fuse i...

  • Page 90

    3-4 fuel system (dfi) exploded view.

  • Page 91

    Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 throttle cable plate bolt 5.9 0.60 52 in·lb 2 throttle body cover mounting bolts 4.0 0.41 35 in·lb 3 delivery pipe assy mounting screws 3.5 0.36 31 in·lb 4 throttle body assy holder clamp bolts 1.1 0.11 10 in·lb 5 air ...

  • Page 92

    3-6 fuel system (dfi) exploded view.

  • Page 93

    Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 vehicle-down sensor bolts 5.9 0.60 52 in·lb 2 throttle cable plate bolt 5.9 0.60 52 in·lb 3 water temperature sensor 12 1.2 106 in·lb 4 oxygen sensor 44 4.5 32 5 speed sensor bolt 12 1.2 106 in·lb 6 crankshaft sensor b...

  • Page 94

    3-8 fuel system (dfi) exploded view.

  • Page 95

    Fuel system (dfi) 3-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 fuel pump bolts 9.8 1.0 87 in·lb l, s 2 fuel level sensor bolts 6.9 0.70 61 in·lb l 3 exhaust butterfly valve actuator mounting bolts 6.9 0.70 61 in·lb 4 exhaust butterfly valve actuator pulley bolt 4.9 0.50 43 in·lb 5...

  • Page 96

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

  • Page 97

    Fuel system (dfi) 3-11 dfi system 1. Ecu 2. Battery 12 v 8 ah 3. Pressure regulator 4. Fuel filter 5. Water temperature sensor 6. Intake air pressure sensor #2 7. Intake air pressure sensor #1 8. Fuel flow 9. Fuel pump 10. Delivery pipe assy 11. Subthrottle sensor 12. Air switching valve 13. Fuel in...

  • Page 98

    3-12 fuel system (dfi) dfi system dfi system wiring diagram (zr800a/b models).

  • Page 99

    Fuel system (dfi) 3-13 dfi system part names 1. Oxygen sensor 2. Joint connector e 3. Ecu 4. Joint connector d 5. Exhaust butterfly valve actuator 6. Immobilizer/kawasaki diagnostic system connector 7. Frame ground 4 8. Frame ground 3 9. Frame ground 2 10. Frame ground 1 11. Engine ground 12. Batter...

  • Page 100

    3-14 fuel system (dfi) dfi system ○ color codes: bk: black bl: blue br: brown ch: chocolate dg: dark green g: green gy: gray lb: light blue lg: light green o: orange p: pink pu: purple r: red v: violet w: white y: yellow terminal numbers of ecu connectors (zr800a/b models) terminal names 1. Subthrot...

  • Page 101

    Fuel system (dfi) 3-15 dfi system 26. Main throttle sensor: y/w 27. Subthrottle sensor: bl/w 28. Exhaust butterfly valve actuator sensor: gy 29. Water temperature sensor: o 30. Ground for ecu: bk/bl 31. Warning indicator light (led) (meter unit): br/r 32. Oxygen sensor: bl/y 33. Ground for sensors: ...

  • Page 102

    3-16 fuel system (dfi) dfi system dfi system wiring diagram (zr800c/d models).

  • Page 103

    Fuel system (dfi) 3-17 dfi system part names 1. Oxygen sensor 2. Joint connector e 3. Ecu 4. Joint connector d 5. Immobilizer/kawasaki diagnostic system connector 6. Frame ground 4 7. Frame ground 3 8. Frame ground 2 9. Frame ground 1 10. Engine ground 11. Battery 12 v 8 ah 12. Starter relay 13. Mai...

  • Page 104

    3-18 fuel system (dfi) dfi system ○ color codes: bk: black bl: blue br: brown ch: chocolate dg: dark green g: green gy: gray lb: light blue lg: light green o: orange p: pink pu: purple r: red v: violet w: white y: yellow terminal numbers of ecu connectors (zr800c/d models) terminal names 1. Subthrot...

  • Page 105

    Fuel system (dfi) 3-19 dfi system 26. Main throttle sensor: y/w 27. Subthrottle sensor: bl/w 28. Unused 29. Water temperature sensor: o 30. Ground for ecu: bk/bl 31. Warning indicator light (led) (meter unit): br/r 32. Oxygen sensor: bl/y 33. Ground for sensors: g 34. Injector #2: bl/r 35. Starter b...

  • Page 106

    3-20 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] ignition key (transponder) [a] ignition switch [b] immobilizer antenna [c] yellow warning indicator light (led) [d] stick coils #1, #2, ...

  • Page 107

    Fuel system (dfi) 3-21 dfi parts location water temperature sensor [a] intake air pressure sensor #2 [b] intake air pressure sensor #1 [c] immobilizer amplifier [d] vehicle-down sensor [e] intake air temperature sensor [a] exhaust butterfly valve actuator (zr800a/b models) [a] fuse box 2 [b] (radiat...

  • Page 108

    3-22 fuel system (dfi) specifications item standard digital fuel injection system idle speed 1 100 ±50 r/min (rpm) throttle body assy: throttle valve dual throttle valve bore 34 mm (1.34 in.) throttle body vacuum 35.3 ±1.3 kpa (265 ±10 mmhg) at idle speed bypass screws (turn out) – – – ecu: make den...

  • Page 109

    Fuel system (dfi) 3-23 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 subthrottle valve full clos...

  • Page 110

    3-24 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 111

    Fuel system (dfi) 3-25 special tools and sealant fuel hose: 57001-1607 speed sensor measuring adapter: 57001-1667 oxygen sensor measuring adapter: 57001-1682 measuring adapter: 57001-1700 liquid gasket, tb1211: 56019-120

  • Page 112

    3-26 fuel system (dfi) dfi servicing precautions dfi servicing precautions there are a number of important precautions that should be followed servicing the dfi system. ○ this dfi system is designed to be used with a 12 v sealed battery as its power source. Do not use any other battery except for a ...

  • Page 113

    Fuel system (dfi) 3-27 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 intake hose [a] fuel outlet hose [b] replace ...

  • Page 114

    3-28 fuel system (dfi) troubleshooting the dfi system outline when a problem occurs with dfi system, the yellow en- gine warning indicator light (led) [a] goes on to alert the rider. When a problem occurs with immobilizer system, the red warning indicator light (led) [a] blinks and immobi- lizer war...

  • Page 115

    Fuel system (dfi) 3-29 troubleshooting the dfi system when the service code [a] is displayed, for first ask the rider about the conditions [b] of trouble, and then start to determine the cause [c] of problem. As a pre-diagnosis inspection, check the ecu for ground and power supply, the fuel line for...

  • Page 116

    3-30 fuel system (dfi) troubleshooting the dfi system • when checking the dfi parts, use a digital meter which can be read two decimal place voltage or resistance. ○ the dfi part connectors [a] have seals [b], including the ecu. When measuring the input or output voltage with the connector joined, u...

  • Page 117

    Fuel system (dfi) 3-31 troubleshooting the dfi system • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. • check the wiring for continuity. ○ use the...

  • Page 118

    3-32 fuel system (dfi) troubleshooting the dfi system dfi diagnosis flow chart inquiries to rider ○ each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ try to find out exactly what problem occurred under exactly what condi...

  • Page 119

    Fuel system (dfi) 3-33 troubleshooting the dfi system sample diagnosis sheet rider name: registration no. (license plate no.): year of initial registration: model: engine no.: frame no.: date problem occurred: mileage: environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ al...

  • Page 120

    3-34 fuel system (dfi) troubleshooting the dfi system □ very low idle speed, □ very high idle speed, □ rough idle speed. □ battery voltage is low (charge the battery). □ spark plug loose (tighten it). □ spark plug dirty, broken, or gap maladjusted (remedy it). □ backfiring. □ afterfiring. □ hesitati...

  • Page 121

    Fuel system (dfi) 3-35 dfi system troubleshooting guide note ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in dfi system. ○ the ecu may be involved in t...

  • Page 122

    3-36 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) fuel pressure regulator trouble inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged inspect and repair (see chapter 3). Intake air pressure sensor #1 trouble inspect (see ...

  • Page 123

    Fuel system (dfi) 3-37 dfi system troubleshooting guide symptoms or possible causes actions (chapter) subthrottle sensor trouble inspect (see chapter 3). Subthrottle valve actuator trouble inspect (see chapter 3). Intake air pressure sensor #1 trouble inspect (see chapter 3). Intake air pressure sen...

  • Page 124

    3-38 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) other: intermittent any dfi fault and its recovery check that dfi connectors are clean and tight, and examine leads for signs of burning or fraying (see chapter 3). Poor running or no power at high ...

  • Page 125

    Fuel system (dfi) 3-39 dfi system troubleshooting guide symptoms or possible causes actions (chapter) intake air temperature sensor trouble inspect (see chapter 3). Miscellaneous: subthrottle sensor trouble inspect (see chapter 3). Subthrottle valve actuator trouble inspect (see chapter 3). Speed se...

  • Page 126

    3-40 fuel system (dfi) self-diagnosis self-diagnosis outline the self-diagnosis system is monitoring the following mechanisms. Dfi system and ignition system immobilizer system the following warning indicator lights (led) are used for symbols of below table. Led color warning indicator symbols red [...

  • Page 127

    Fuel system (dfi) 3-41 self-diagnosis dealer mode the lcd (liquid crystal display) displays the service code(s) [a] to show the problem(s) which the above system has at the moment of diagnosis. Self-diagnosis procedures note ○ use a fully charged battery when conducting self-diagnosis. Otherwise, th...

  • Page 128

    3-42 fuel system (dfi) self-diagnosis • push the left button [a] to display the odometer. • push the left button 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-diagnosis. ○ when the service code is ...

  • Page 129

    Fuel system (dfi) 3-43 self-diagnosis self-diagnosis flow chart.

  • Page 130

    3-44 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 131

    Fuel system (dfi) 3-45 self-diagnosis service code table service code system problems 11 fi main throttle sensor malfunction, wiring open or short 12 fi intake air pressure sensor #1 malfunction, wiring open or short 13 fi intake air temperature sensor malfunction, wiring open or short 14 fi water t...

  • Page 132

    3-46 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 133

    Fuel system (dfi) 3-47 self-diagnosis service codes parts output signal usable range or criteria backups by ecu 34 exhaust butterfly valve actuator sensor (zr800a/b models) output voltage 0.1 ∼ 4.9 v if the exhaust butterfly valve sensor system fails (the output voltage is out of the usable range, w...

  • Page 134

    3-48 fuel system (dfi) self-diagnosis service codes parts output signal usable range or criteria backups by ecu 67 oxygen sensor heater the oxygen sensor heater raises temperature of the sensor for its earlier activation. If the oxygen sensor heater fails (wiring short or open), the ecu stops the cu...

  • Page 135

    Fuel system (dfi) 3-49 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 136

    3-50 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 connectors. ○ disconnect the ecu and sensor connectors. Wiring inspection ecu connector [a] ←→ main throttle sensor connector [...

  • Page 137

    Fuel system (dfi) 3-51 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 0.995 ∼ 1.025 v at idle throttle opening dc 4.05 ∼ 4.48 v at fu...

  • Page 138

    3-52 fuel system (dfi) main throttle sensor (service code 11) main throttle sensor circuit 1. Main throttle sensor 2. Water proof joint 1 3. Water proof joint 2 4. Ecu.

  • Page 139

    Fuel system (dfi) 3-53 intake air pressure sensor #1 (service code 12) intake air pressure sensor #1 removal notice never drop the intake air pressure sensor espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove the fuel tank (see fuel tank removal). • disconnect the int...

  • Page 140

    3-54 fuel system (dfi) intake air pressure sensor #1 (service code 12) intake air pressure sensor #1 input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the fuel tank (see fuel tank removal). • disconnect the intake air pressure sensor #1 co...

  • Page 141

    Fuel system (dfi) 3-55 intake air pressure sensor #1 (service code 12) intake air pressure sensor #1 output voltage inspection • measure the output voltage at the intake air pressure sen- sor #1 in the same way as input voltage inspection, note the following. ○ disconnect the intake air pressure sen...

  • Page 142

    3-56 fuel system (dfi) intake air pressure sensor #1 (service code 12) if the wiring is good, check the sensor for various vacuum. • remove the intake air pressure sensor #1 [a] and discon- nect the vacuum hose from the sensor. • connect an auxiliary hose [b] to the intake air pressure sensor #1. • ...

  • Page 143

    Fuel system (dfi) 3-57 intake air pressure sensor #1 (service code 12) id: idling ps: standard atmospheric pressure (absolute) pv: throttle vacuum pressure (absolute) st: standard of sensor output voltage (v) to: throttle full open ur: usable range of sensor output voltage (v) vv: intake air pressur...

  • Page 144

    3-58 fuel system (dfi) intake air pressure sensor #1 (service code 12) intake air pressure sensor circuit 1. Water proof joint 1 2. Water proof joint 2 3. Intake air pressure sensor 4. Ecu.

  • Page 145

    Fuel system (dfi) 3-59 intake air temperature sensor (service code 13) intake air temperature sensor removal/instal- lation notice never drop the intake air temperature sensor espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove the fuel tank (see fuel tank removal). • ...

  • Page 146

    3-60 fuel system (dfi) intake air temperature sensor (service code 13) • turn the ignition switch off. If the reading is within the standard, check the ecu for its ground and power supply (see ecu power supply in- spection). If the ground and power supply are good, replace the ecu (see ecu removal/i...

  • Page 147

    Fuel system (dfi) 3-61 intake air temperature sensor (service code 13) intake air temperature sensor circuit 1. Intake air temperature sensor 2. Water proof joint 2 3. Ecu.

  • Page 148

    3-62 fuel system (dfi) water temperature sensor (service code 14) water temperature sensor removal/installation notice never drop the water temperature sensor especially on a hard surface. Such a shock to the sensor can damage it. • drain the coolant (see coolant change in the periodic maintenance c...

  • Page 149

    Fuel system (dfi) 3-63 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 connectors. ○ disconnect the ecu and sensor connectors. Wiring inspection ecu connector [a] ←→ water temperature sensor con...

  • Page 150

    3-64 fuel system (dfi) intake air pressure sensor #2 (service code 16) intake air pressure sensor #2 removal notice never drop the intake air pressure sensor #2 espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove the fuel tank (see fuel tank removal). • disconnect: wat...

  • Page 151

    Fuel system (dfi) 3-65 intake air pressure sensor #2 (service code 16) intake air pressure sensor #2 input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • disconnect the intake air pressure sensor #2 connector and connect the measuring adapter [a] be...

  • Page 152

    3-66 fuel system (dfi) intake air pressure sensor #2 (service code 16) intake air pressure sensor #2 output voltage inspection • measure the output voltage at the intake air pressure sen- sor #2 in the same way as input voltage inspection, note the following. ○ disconnect the intake air pressure sen...

  • Page 153

    Fuel system (dfi) 3-67 intake air pressure sensor #2 (service code 16) intake air pressure sensor #2 circuit 1. Water proof joint 1 2. Water proof joint 2 3. Intake air pressure sensor #2 4. Ecu.

  • Page 154

    3-68 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 155

    Fuel system (dfi) 3-69 speed sensor (service code 24) 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. • disconnect t...

  • Page 156

    3-70 fuel system (dfi) speed sensor (service code 24) 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 connector...

  • Page 157

    Fuel system (dfi) 3-71 speed sensor (service code 24) speed sensor circuit 1. Speed sensor 2. Water proof joint 1 3. Water proof joint 2 4. Ecu.

  • Page 158

    3-72 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) 3-73 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

    3-74 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. Special tool - measuring adapter: 57001-1...

  • Page 161

    Fuel system (dfi) 3-75 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 con- nectors. ○ disconnect the ecu and sensor connectors. Wiring inspection ecu connector [a] ←→ vehicle-down sensor connector [...

  • Page 162

    3-76 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) 3-77 subthrottle sensor (service code 32) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main harness connectors. ○ disconnect the ecu and sensor connectors. Wiring inspection ecu connector [a] ←→ subthrottle sensor connector [b] b...

  • Page 164

    3-78 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 counter- clockwise [b...

  • Page 165

    Fuel system (dfi) 3-79 subthrottle sensor (service code 32) subthrottle sensor resistance inspection • turn the ignition switch off. • disconnect the subthrottle sensor connector. • connect a digital meter [a] to the subthrottle sensor con- nector [b]. • measure the subthrottle sensor resistance. Su...

  • Page 166

    3-80 fuel system (dfi) oxygen sensor - not activated (service code 33) oxygen sensor removal/installation • refer to the oxygen sensor removal/installation in the electrical system chapter. Oxygen sensor inspection • turn the ignition switch off. • remove the right frame cover (see frame cover remov...

  • Page 167

    Fuel system (dfi) 3-81 oxygen sensor - not activated (service code 33) • remove the fuel outlet hose (see fuel hose replacement in the periodic maintenance chapter). • connect the following parts temporary. Fuel pump lead connector [a] fuel level sensor lead connector [b] extension tube [c] special ...

  • Page 168

    3-82 fuel system (dfi) oxygen sensor - not activated (service code 33) oxygen sensor circuit 1. Ignition switch 2. Water proof joint 2 3. Oxygen sensor 4. Joint connector e 5. Ecu 6. Frame ground 4 7. Frame ground 1 8. Engine ground 9. Battery 12 v 8 ah 10. Starter relay 11. Main fuse 30 a 12. Ecu f...

  • Page 169

    Fuel system (dfi) 3-83 exhaust butterfly valve actuator sensor (service code 34, zr800a/b models) 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. Remov...

  • Page 170

    3-84 fuel system (dfi) exhaust butterfly valve actuator sensor (service code 34, zr800a/b models) 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). • disc...

  • Page 171

    Fuel system (dfi) 3-85 exhaust butterfly valve actuator sensor (service code 34, zr800a/b models) 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 digit...

  • Page 172

    3-86 fuel system (dfi) immobilizer amplifier (service code 35) 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: bk lead ←→ bk/w ...

  • Page 173

    Fuel system (dfi) 3-87 blank key detection (service code 36) • this code appears in the following conditions. ○ the transponder [a] in the ignition key is malfunction. ○ when the spare key of unregistration is used. ○ when the ignition key is registered in the registered ecu. • therefore, the servic...

  • Page 174

    3-88 fuel system (dfi) blank key detection (service code 36) immobilizer system circuit 1. Ignition switch 2. Joint connector e 3. Ecu 4. Immobilizer/kawasaki diagnostic system con- nector 5. Frame ground 1 6. Frame ground 4 7. Engine ground 8. Battery 12 v 8 ah 9. Stater relay 10. Main fuse 30 a 11...

  • Page 175

    Fuel system (dfi) 3-89 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

    3-90 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) 3-91 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

    3-92 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) 3-93 subthrottle valve actuator (service code 62) subthrottle valve actuator removal notice do not remove the subthrottle valve actuator [a] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy especially on a hard surface. Such a shoc...

  • Page 180

    3-94 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 harness con- nector and connect the harness adapter [a] bet...

  • Page 181

    Fuel system (dfi) 3-95 subthrottle valve actuator (service code 62) subthrottle valve actuator circuit 1. Subthrottle valve actuator 2. Ecu.

  • Page 182

    3-96 fuel system (dfi) exhaust butterfly valve actuator (service code 63, zr800a/b models) exhaust butterfly valve actuator removal notice never drop the exhaust butterfly valve actuator es- pecially on a hard surface. Such a shock to the ac- tuator can damage it. • slide the dust covers [a]. • loos...

  • Page 183

    Fuel system (dfi) 3-97 exhaust butterfly valve actuator (service code 63, zr800a/b models) • install the pulley [a] on the actuator as shown. • tighten the pulley bolt [b] while holding the pulley with the suitable tool [c]. Torque - exhaust butterfly valve actuator pulley bolt: 4.9 n·m (0.50 kgf·m,...

  • Page 184

    3-98 fuel system (dfi) exhaust butterfly valve actuator (service code 63, zr800a/b models) if the position is not within the specified angle above, ad- just the angle as follows. ○ disconnect: 2 pins connector 3 pins connector ○ connect the 12 v battery to the 2 pins connector termi- nals. Connect t...

  • Page 185

    Fuel system (dfi) 3-99 exhaust butterfly valve actuator (service code 63, zr800a/b models) exhaust butterfly valve actuator resistance inspection • turn the ignition switch off. • disconnect the exhaust butterfly valve actuator lead con- nector (2 pins connector) [a]. • set the hand tester to the × ...

  • Page 186

    3-100 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. ...

  • Page 187

    Fuel system (dfi) 3-101 oxygen sensor heater (service code 67) 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 in the electrical system chapter). Oxygen s...

  • Page 188

    3-102 fuel system (dfi) oxygen sensor heater (service code 67) if the fuse and wiring are good, remove the ecu and check the wiring for continuity between main harness con- nectors. ○ disconnect the ecu and sensor connectors. Wiring inspection ecu connector [a] ←→ oxygen sensor connector [b] p/bk le...

  • Page 189

    Fuel system (dfi) 3-103 oxygen sensor - incorrect output voltage (service code 94) oxygen sensor removal/installation • refer to the oxygen sensor removal/installation in the electrical system chapter. Oxygen sensor inspection • turn the ignition switch off. • remove the right frame cover (see frame...

  • Page 190

    3-104 fuel system (dfi) oxygen sensor - incorrect output voltage (service code 94) • remove the fuel outlet hose (see fuel hose replacement in the periodic maintenance chapter). • connect the following parts temporary. Fuel pump lead connector [a] fuel level sensor lead connector [b] extension tube ...

  • Page 191

    Fuel system (dfi) 3-105 oxygen sensor - incorrect output voltage (service code 94) oxygen sensor circuit 1. Ignition switch 2. Water proof joint 2 3. Oxygen sensor 4. Joint connector e 5. Ecu 6. Frame ground 4 7. Frame ground 1 8. Engine ground 9. Battery 12 v 8 ah 10. Starter relay 11. Main fuse 30...

  • Page 192

    3-106 fuel system (dfi) warning indicator light (led) yellow engine warning indicator light (led) inspection yellow engine warning indicator light (led) [a] • refer to the electronic combination meter unit inspection in the electrical system chapter. Warning indicator light (led) circuit 1. Meter un...

  • Page 193

    Fuel system (dfi) 3-107 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 (zr800a/b mode...

  • Page 194

    3-108 fuel system (dfi) ecu ecu installation • connect the ecu connectors [a]. • install the ecu [b] (in rubber protector [c]). • insert the slits of the rubber protector to the projections [d]. Ecu power supply inspection • remove the relay box (see relay box removal in the electrical system chapte...

  • Page 195

    Fuel system (dfi) 3-109 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 196

    3-110 fuel system (dfi) ecu ecu power source circuit 1. Ignition switch 2. Frame ground 1 3. Joint connector e 4. Ecu 5. Joint connector d 6. Frame ground 4 7. Frame ground 3 8. Engine ground 9. Battery 12 v 8 ah 10. Starter relay 11. Main fuse 30 a 12. Ecu fuse 15 a 13. Relay box 14. Ecu main relay...

  • Page 197

    Fuel system (dfi) 3-111 dfi power source ecu fuse removal • refer to the 30 a main/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. • ...

  • Page 198

    3-112 fuel system (dfi) 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 199

    Fuel system (dfi) 3-113 fuel line • start the engine, and let it idle. • measure the fuel pressure with the engine idling. Fuel pressure (with engine idling) standard: 294 kpa (3.0 kgf/cm², 43 psi) note ○ the gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum in...

  • Page 200

    3-114 fuel system (dfi) fuel line • open the fuel tank cap [a] to lower the pressure in the tank. • remove the fuel outlet hose from the fuel pump (see fuel tank removal). ○ be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump. Warning fuel is flammable and explosive under ...

  • Page 201

    Fuel system (dfi) 3-115 fuel pump fuel pump removal warning gasoline is extremely flammable and can be explo- sive under certain conditions, creating the potential for serious burns. Make sure the area is well venti- lated and free from any source of flame or sparks; this includes any appliance with...

  • Page 202

    3-116 fuel system (dfi) fuel pump fuel pump installation • remove dirt or dust from the fuel pump [a] by lightly ap- plying compressed air. • replace the fuel pump gasket with a new one. • check that the fuel pump terminal [a] and band [b] are in place. Front [c] • apply a non-permanent locking agen...

  • Page 203

    Fuel system (dfi) 3-117 fuel pump fuel pump operating voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the right subframe cover (see subframe cover removal in the frame chapter). • disconnect the fuel pump lead connector and connect the harness...

  • Page 204

    3-118 fuel system (dfi) fuel pump pressure regulator removal ○ the pressure regulator [a] is built into the fuel pump [b] and can not be removed. Pump screen, fuel filter cleaning ○ the pump screen [a] and fuel filter [b] are built into the pump and can not be cleaned or checked. If the pump screen ...

  • Page 205

    Fuel system (dfi) 3-119 fuel pump fuel pump circuit 1. Ignition switch 2. Engine stop switch 3. Frame ground 1 4. Joint connector e 5. Ecu 6. Joint connector d 7. Frame ground 3 8. Engine ground 9. Battery 12 v 8 ah 10. Starter relay 11. Main fuse 30 a 12. Ecu fuse 15 a 13. Fuel pump 14. Relay box 1...

  • Page 206

    3-120 fuel system (dfi) fuel injectors fuel injector removal/installation • refer to the throttle body assy disassembly/assembly. Fuel injector audible inspection note ○ be sure the battery is fully charged. • start the engine, and let it idle. • apply the tip of a screwdriver [a] to the fuel inject...

  • Page 207

    Fuel system (dfi) 3-121 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. Main harness [b] fuel injecto...

  • Page 208

    3-122 fuel system (dfi) fuel injectors fuel injector output voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the ecu (see ecu removal). ○ do not disconnect the ecu connector. • connect a digital meter [a] to the connector [b] with the needle ad...

  • Page 209

    Fuel system (dfi) 3-123 fuel injectors if the reading is out of the specification, remove the ecu and check the wiring for continuity between main harness connectors. ○ disconnect the ecu and injector connectors. Wiring inspection ecu connector [a] ←→ fuel injector connector [b] for fuel injector #1...

  • Page 210

    3-124 fuel system (dfi) 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 211

    Fuel system (dfi) 3-125 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 212

    3-126 fuel system (dfi) 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 213

    Fuel system (dfi) 3-127 throttle body assy • remove: throttle body cover mounting bolt [a] quick rivet [b] right throttle body cover [c] • remove: throttle body cover mounting bolt [a] left throttle body cover [b] • remove the intake air pressure sensor #1/#2 (see intake air pressure sensor #1/#2 re...

  • Page 214

    3-128 fuel system (dfi) throttle body assy • remove the throttle cable upper ends [a]. • remove: fuel tank bracket (see air cleaner element replace- ment in the periodic maintenance chapter) air cleaner housing mounting bolt [a] (both sides) • loosen the air duct clamp bolts [a]. • move [b] the air ...

  • Page 215

    Fuel system (dfi) 3-129 throttle body assy throttle body assy installation • apply a thin coating of grease to the throttle cable lower ends. • fit the accelerator cable end [a] and the decelerator cable end [b] into the throttle pulley. • install the throttle body assy holder clamp bolts in the di-...

  • Page 216

    3-130 fuel system (dfi) throttle body assy • apply a thin coating of grease to the throttle cable upper ends. • install the upper ends of the throttle cables in the grip. • fit the projection [a] of the right switch housing into the hole [b] of the handlebars. • turn the throttle grip and make sure ...

  • Page 217

    Fuel system (dfi) 3-131 throttle body assy • remove the throttle body assy (see throttle body assy removal). • cut the band [a]. • remove the delivery pipe assy mounting screws [b] to pull out the injectors from the throttle body assy together with the delivery pipe assy [c]. Note ○ do not damage th...

  • Page 218

    3-132 fuel system (dfi) 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: 3.5 n·m (0.36 kgf·m, 31 in·lb) • co...

  • Page 219

    Fuel system (dfi) 3-133 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 220

    3-134 fuel system (dfi) fuel tank fuel tank removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a...

  • Page 221

    Fuel system (dfi) 3-135 fuel tank • open the fuel tank cap [a] to lower the pressure in the tank. ○ during tank removal, keep the tank cap open to release pressure in the tank. This makes fuel spillage less. • draw the fuel out from the fuel tank with a commercially available pump [a]. ○ use a soft ...

  • Page 222

    3-136 fuel system (dfi) fuel tank • pull the joint lock [a] fully as shown. Notice prying or excessively widening the joint lock ends for fuel hose removal will permanently deform the joint lock, resulting in a loose or incomplete lock that may allow fuel to leak and create the potential for a fire ...

  • Page 223

    Fuel system (dfi) 3-137 fuel tank • when installing the dampers [a], position the thick side [b] to frame side [c]. • remove the vinyl bag on the pipe and fuel hose joint. • check the joint lock for deformation and wear. If the joint lock is deformed, replace the fuel hose with a new one. • check th...

  • Page 224

    3-138 fuel system (dfi) fuel tank fuel tank and cap inspection • open the tank cap. • 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...

  • 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 thermostat bracket bolt 6.9 0.70 61 in·lb 2 reserve tank bolts 9.8 1.0 87 in·lb 3 thermostat housing screws 2.6 0.27 23 in·lb 4 thermostat housing clamp bolt 6.9 0.70 61 in·lb 5 water temperature sensor 12 1.2 106 in·lb 6...

  • Page 228

    4-4 cooling system coolant flow chart.

  • Page 229

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

  • Page 230

    4-6 cooling system specifications item standard coolant provided when shipping type (recommended) permanent type 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 poi...

  • 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 left side fairing (see side fairing 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 coo...

  • 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 • remove the left lower fairing (see lower fairin...

  • 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 notice do not reuse the mechanical seal and oil seal. • apply high-temperature grease to the oil seal lips [a]. • press the new oil seal into the housing with a bearing driver [...

  • Page 236

    4-12 cooling system radiator radiator and radiator fan removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove the side fairings (see side fairing removal in the frame chapter). • disconnect the radiator fan motor lead connector [a]. • loosen the water hose cla...

  • Page 237

    Cooling system 4-13 radiator radiator and radiator fan installation • installation is the reverse of removal. • install the rubber dampers [a] and radiator bracket collars [b] as shown. Larger [c] smaller [d] • run the radiator fan motor lead correctly (see cable, wire, and hose routing section in t...

  • Page 238

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

  • Page 239

    Cooling system 4-15 thermostat thermostat removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove the side fairings (see side fairing removal in the frame chapter). • loosen the water hose clamp screws [a]. • disconnect the water hoses [b]. • disconnect the imm...

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

  • Page 243: Engine Top End

    Engine top end 5-1 5 engine top end table of contents exploded view................................... 5-2 exhaust system................................. 5-8 specifications .................................... 5-10 special tools and sealant ................. 5-12 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 cylinder head cover bolts 9.8 1.0 87 in·lb s 3 camshaft cap bolts (l = 45 mm) 12 1.2 106 in·lb s 4 camshaft cap bolts (l = 40 mm) 12 1.2 106 in·lb s 5 spark plugs 13 1.3 11...

  • Page 246

    5-4 engine top end exploded view zr800a/b models.

  • Page 247

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 exhaust butterfly valve actuator mounting bolts 6.9 0.70 61 in·lb 2 exhaust butterfly valve actuator pulley bolt 4.9 0.50 43 in·lb 3 exhaust butterfly valve cable adjuster locknuts 6.9 0.70 61 in·lb 4 muffler body mountin...

  • Page 248

    5-6 engine top end exploded view zr800c/d models.

  • Page 249

    Engine top end 5-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 muffler body mounting bolts 34 3.5 25 2 muffler body end cover bolts 11 1.1 97 in·lb 3 muffler body cover bolts 6.9 0.70 61 in·lb 4 exhaust pipe manifold holder nuts 17 1.7 13 s 5 muffler body clamp bolt 17 1.7 13 r: repl...

  • Page 250

    5-8 engine top end exhaust system exhaust system.

  • Page 251

    Engine top end 5-9 exhaust system manifold mark position [a] honeycomb type catalyst position [a] muffler body mark position [a] manifold [a] with hole [b] for oxygen sensor [c]..

  • Page 252

    5-10 engine top end specifications item standard service limit camshafts cam height: exhaust 35.742 ∼ 35.858 mm (1.4072 ∼ 1.4117 in.) 35.64 mm (1.403 in.) intake 35.942 ∼ 36.058 mm (1.4150 ∼ 1.4196 in.) 35.84 mm (1.411 in.) camshaft journal, camshaft cap clearance 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 i...

  • Page 253

    Engine top end 5-11 specifications item standard service limit cylinder, pistons cylinder inside diameter 70.992 ∼ 71.008 mm (2.7950 ∼ 2.7956 in.) 71.11 mm (2.7996 in.) piston diameter 70.974 ∼ 70.984 mm (2.7942 ∼ 2.7946 in.) 70.82 mm (2.7882 in.) piston/cylinder clearance 0.008 ∼ 0.034 mm (0.0003 ∼...

  • Page 254

    5-12 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 255

    Engine top end 5-13 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 valve guide driver: 57001-1564 valve guide driver attachme...

  • Page 256

    5-14 engine top end clean air system air suction valve removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) side fairings (see side fairing removal in the frame chapter) • disconnect the hose [a]. • remove: thermostat housing (see thermostat removal in the cooling sys...

  • Page 257

    Engine top end 5-15 clean air system air suction valve inspection • remove the air suction valve (see air suction valve re- moval). • visually inspect the reeds for cracks, folds, warps, heat damage or other damage. If there is any doubt as to the condition of the reeds [a], replace the air suction ...

  • Page 258

    5-16 engine top end clean air system air switching valve unit test • refer to the air switching valve unit test in the electrical system chapter. Clean air system hose inspection • be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the air cl...

  • Page 259

    Engine top end 5-17 cylinder head cover cylinder head cover removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) thermostat housing (see thermostat removal in the cooling system chapter) coolant reserve tank (see coolant change in the peri- odic maintenance chapter) s...

  • Page 260

    5-18 engine top end cylinder head cover • tighten the cover bolts following the specified tightening sequence. Torque - cylinder head cover bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install the removed parts (see appropriate chapters)..

  • Page 261

    Engine top end 5-19 camshaft chain tensioner camshaft chain tensioner removal notice this is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below. When removing the tens...

  • Page 262

    5-20 engine top end camshaft, camshaft chain camshaft removal • remove: cylinder head cover (see cylinder head cover re- moval) crankshaft sensor cover (see crankshaft sensor re- moval in the electrical system chapter) • position the crankshaft at #1, 4 piston tdc. Tdc mark [a] for #1, 4 pistons tim...

  • Page 263

    Engine top end 5-21 camshaft, camshaft chain • position the crankshaft at #1, 4 piston tdc. • pull the tension side (exhaust side) [a] of the chain taut to install the chain. • engage the camshaft chain with the camshaft sprockets so that the timing marks on the sprockets are positioned as shown. ○ ...

  • Page 264

    5-22 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 265

    Engine top end 5-23 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 266

    5-24 engine top end cylinder head cylinder head removal • remove: engine (see engine removal in the engine removal/in- stallation chapter) cylinder head cover (see cylinder head cover re- moval) camshafts (see camshaft removal) • drain the coolant from the cylinder. ○ place a container under the dra...

  • Page 267

    Engine top end 5-25 cylinder head • tighten the m10 cylinder head bolts following the tighten- ing sequence [1 ∼ 10]. ○ first, tighten the bolts with 10 n·m (1.0 kgf·m, 15 ft·lb) of torque. ○ next, in accordance with the following table tighten the bolts with the specified torque. And using a torque...

  • Page 268

    5-26 engine top end 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 269

    Engine top end 5-27 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 270

    5-28 engine top end 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). Notice do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the c...

  • Page 271

    Engine top end 5-29 valves valve-to-guide clearance measurement (wobble method) if a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. • insert a new valve [a] into the guide [b] and set a dial g...

  • Page 272

    5-30 engine top end valves valve seat repair • repair the valve seat with the valve seat cutters [a]. Special tools - valve seat cutter holder bar [b]: 57001 -1128 valve seat cutter holder, 4 [c]: 57001-1275 [for exhaust valve seat] valve seat cutter, 45° - 24.5: 57001-1113 valve seat cutter, 32° - ...

  • Page 273

    Engine top end 5-31 valves operating procedures • clean the seat area carefully. • coat the seat with machinist’s dye. • fit a 45° cutter into the holder and slide it into the valve guide. • press down lightly on the handle and turn it right or left. Grind the seating surface only until it is smooth...

  • Page 274

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

  • Page 275

    Engine top end 5-33 valves • lap the valve to the seat, once the seat width and outside diameter are within the ranges specified above. ○ put a little coarse grinding compound on the face of the valve in a number of places around the valve head. ○ spin the valve against the seat until the grinding c...

  • Page 276

    5-34 engine top end valves.

  • Page 277

    Engine top end 5-35 cylinder, pistons cylinder removal • remove the cylinder head (see cylinder head removal). • loosen the water hose clamp screw [a]. • remove: water pipe bolt [b] water pipe [c] and water hose cylinder [d] cylinder installation note ○ if a new cylinder is used, use new piston ring...

  • Page 278

    5-36 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 279

    Engine top end 5-37 cylinder, pistons • do not mix up the top and second ring. • install the top ring [a] so that the “1r” mark [b] faces up. • install the second ring [c] so that the “2r” mark [d] faces up. ○ apply molybdenum disulfide oil solution to the piston rings. Note ○ if a new piston is use...

  • Page 280

    5-38 engine top end cylinder, pistons piston ring, piston ring groove wear inspection • 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 gro...

  • Page 281

    Engine top end 5-39 cylinder, pistons piston ring end gap inspection • 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 wi...

  • Page 282

    5-40 engine top end throttle body holder throttle body holder installation • apply grease to the new o-rings [a]. • be sure to install the o-rings. • install the holders [b] as shown. Clamp [c] • tighten: torque - throttle body assy holder bolts [d]: 13 n·m (1.3 kgf·m, 115 in·lb) • install the clamp...

  • Page 283

    Engine top end 5-41 muffler warning the muffler can become extremely hot during nor- mal operation and cause severe burns. Do not re- move the muffler while it is hot. Muffler body removal zr800a/b models • remove the right frame cover (see frame cover removal in the frame chapter). • slide the dust...

  • Page 284

    5-42 engine top end muffler • loosen the locknuts [a]. • remove the exhaust butterfly valve cable lower ends [b] from the pulley [c]. Zr800c/d models • remove: muffler body cover bolts [a] muffler body cover [b] • loosen the clamp bolt [a]. • remove the mounting bolts [b] and nut, and pull out the m...

  • Page 285

    Engine top end 5-43 muffler muffler body installation zr800a/b models • replace the muffler body gasket [a] and nut [b] with new ones. • install the muffler body gasket until it is bottomed so that the inside chamfer side faces rear [c]. • install the muffler body clamp [d] so that the insert the pr...

  • Page 286

    5-44 engine top end muffler • adjust the exhaust butterfly cables (see exhaust butterfly valve cable installation). • thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts and nut. Zr800c/d models • replace the muffler body gasket [a] and nut [b] with new ones. • i...

  • Page 287

    Engine top end 5-45 muffler • when installing the pads, note the following. ○ install the pads [a] first. Next, install the pad [b] as shown. Muffler body cover [c] • install the muffler body cover [a]. • tighten: torque - muffler body cover bolts: 6.9 n·m (0.70 kgf·m, 61 in·lb) l = 27 mm (1.06 in.)...

  • Page 288

    5-46 engine top end muffler exhaust pipe installation • replace the exhaust pipe gaskets [a] and muffler body gasket with new ones and install them. • install the exhaust pipe [b]. • tighten the exhaust pipe manifold holder nuts [c] follow- ing the specified tightening sequence. ○ do not deform the ...

  • Page 289

    Engine top end 5-47 muffler • remove: clamp [a] exhaust butterfly valve cable upper ends [b] • remove: exhaust butterfly valve cable lower ends (see muffler body removal) exhaust butterfly valve cables exhaust butterfly valve cable installation (zr800a/b models) • confirm whether pulley [a] is an an...

  • Page 290

    5-48 engine top end muffler • stretch the open cable (white) [a] first by using the ad- juster [b]. ○ turn the adjuster counterclockwise until the play of the open cable becomes no play. Locknut of white [c] notice to keep the correct exhaust butterfly valve position, adjust the open cable first. Do...

  • Page 291: Clutch

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

  • Page 292

    6-2 clutch exploded view.

  • Page 293

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 clutch lever clamp bolts 11 1.1 97 in·lb s 2 oil filler plug 2.0 0.20 18 in·lb 3 clutch cover mounting bolts 11 1.1 97 in·lb 4 clutch spring bolts 8.8 0.90 78 in·lb 5 clutch hub nut 135 13.8 100 r cl: apply cable lubricant. Eo: a...

  • Page 294

    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 0.15 m...

  • Page 295

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

  • Page 296

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

  • Page 297

    Clutch 6-7 clutch cover clutch cover removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: right subframe cover (see subframe cover removal in the frame chapter) right lower fairing (see lower fairing removal (zr800a/b models) in the frame chapter) c...

  • Page 298

    6-8 clutch clutch cover release shaft installation • apply high-temperature grease to the oil seal lips on the upper ridge of the clutch cover. • apply engine oil to the needle bearings in the hole of the clutch cover. • apply molybdenum disulfide grease to the pusher-holding portion [a] on the rele...

  • Page 299

    Clutch 6-9 clutch clutch removal • remove: clutch cover (see clutch cover removal) clutch spring bolts [a] clutch springs clutch spring plate [b] (with thrust bearing, pusher [c], spring and washer) • remove: friction plates and steel plates clutch hub nut [a] ○ holding the clutch hub [b], remove th...

  • Page 300

    6-10 clutch clutch ○ install the spacer [a] so that the tapered side [b] faces inward. ○ install the spacer [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 301

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

  • Page 302

    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 303: Engine Lubrication System

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

  • Page 304

    7-2 engine lubrication system exploded view.

  • Page 305

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oil jet nozzle bolts 6.9 0.70 61 in·lb l 2 oil filler plug 2.0 0.20 18 in·lb 3 oil filter 17 1.7 13 4 oil filter holder 78 8.0 58 l 5 oil pressure switch terminal bolt 2.0 0.20 18 in·lb hg 6 oil pressure switch...

  • Page 306

    7-4 engine lubrication system engine oil flow chart.

  • Page 307

    Engine lubrication system 7-5 engine oil flow chart 1. Camshaft oil passage 2. Oil filter 3. Oil jet 4. Crankshaft oil passage 5. Oil pressure switch 6. Breather hose 7. Drive shaft oil passage 8. Oil pipe 9. Main oil passage 10. Output shaft oil passage 11. Oil pump 12. Oil pressure relief valve 13...

  • Page 308

    7-6 engine lubrication system specifications item standard engine oil type api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity sae 10w-40 capacity: 3.1 l (3.3 us gt) (when filter is not removed) 3.4 l (3.6 us gt) (when filter is removed) 3.8 l (4.0 us gt) (when engine is completely dry) leve...

  • Page 309

    Engine lubrication system 7-7 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 liquid gasket, tb1211: 56019-120

  • Page 310

    7-8 engine lubrication system engine oil and oil filter warning vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter accordin...

  • Page 311

    Engine lubrication system 7-9 oil pan oil pan removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: lower fairings (see lower fairing removal (zr800a/b models) in the frame chapter) muffler body (see muffler body removal in the engine top end chapter...

  • Page 312

    7-10 engine lubrication system 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 i...

  • Page 313

    Engine lubrication system 7-11 oil pump oil pump removal • drain: coolant (see coolant change in the periodic mainte- nance chapter) engine oil (see engine oil change in the periodic main- tenance chapter) • remove the water pipe bolts [a]. • disconnect the water pipes [b]. • remove: water pump cove...

  • Page 314

    7-12 engine lubrication system oil pump • replace the o-ring [a] with a new one. • apply grease to the o-ring. • install: pins [b] water pump body [c] • 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) • replace the o-rings [c...

  • Page 315

    Engine lubrication system 7-13 oil pressure measurement oil pressure measurement • remove the right lower fairing (see lower fairing re- moval (zr800a/b models) in the frame chapter). • remove the oil passage plug, and attach the adapter [a] and gauge [b] to the plug hole. Special tools - oil pressu...

  • Page 316

    7-14 engine lubrication system oil pressure switch oil pressure switch removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: right lower fairing (see lower fairing removal (zr800a/b models) in the frame chapter) switch cover [a] switch terminal bolt ...

  • Page 317: Engine Removal/installation

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

  • Page 318

    8-2 engine removal/installation exploded view.

  • Page 319

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front engine bracket bolts 11 1.1 97 in·lb 2 upper engine bracket bolts 44 4.5 32 s 3 subframe bolts 25 2.5 18 s 4 adjusting collar locknuts 49 5.0 36 s 5 front engine mounting bolts 44 4.5 32 s 6 upper adjus...

  • Page 320

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

  • Page 321

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

  • Page 322

    8-6 engine removal/installation engine removal/installation • remove the engine sprocket [a] (see engine sprocket removal in the final drive chapter). • disconnect: crankshaft sensor lead connector and oil pressure switch lead terminal (see crankshaft sensor removal in the electrical system chapter)...

  • Page 323

    Engine removal/installation 8-7 engine removal/installation • remove the right front engine mounting bolt [a]. • using the nut wrench [a], loosen the lock nut [b]. Special tool - engine mount nut wrench: 57001-1450 • using the hexagon wrench, turn the upper adjusting col- lar [a] counterclockwise to...

  • Page 324

    8-8 engine removal/installation 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 lower adjusting col- lar [a] counterclockwise to make the gap between the en- gine and lower adjusti...

  • Page 325

    Engine removal/installation 8-9 engine removal/installation engine installation • support the engine with a suitable stand. ○ put a plank onto the suitable stand for engine balance. • screw the lower adjusting collar [a] to the frame. • screw the upper adjusting collar [b] to the subframe. • hang th...

  • Page 326

    8-10 engine removal/installation engine removal/installation • install the engine mounting bolts and nuts, following the specified installing sequence. ○ 1st, install the rear engine bracket [a] and tighten the bolts [b] temporarily. ○ 2nd, install the left upper engine bracket [c], left subframe [d...

  • Page 327

    Engine removal/installation 8-11 engine removal/installation ○ 16th, loosen the subframe bolt [t], and tighten the sub- frame bolt [t]. Torque - subframe bolt [t]: 25 n·m (2.5 kgf·m, 18 ft·lb) ○ 17th, loosen the subframe bolt [u], and tighten the sub- frame bolt [u]. Torque - subframe bolt [u]: 25 n...

  • Page 328

    8-12 engine removal/installation engine removal/installation • install the front engine bracket and horn. • tighten: torque - front engine bracket bolts: 11 n·m (1.1 kgf·m, 97 in·lb) • when installing the trim [a], note the following. ○ touch the trim to the horn bracket [b]. • run the leads, cables...

  • Page 329: Crankshaft/transmission

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

  • Page 330

    9-2 crankshaft/transmission exploded view.

  • Page 331

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oil jet nozzle bolts 6.9 0.70 61 in·lb l 2 crankcase bolts (m6) 12 1.2 106 in·lb s 3 crankcase bolts (m7) 20 2.0 15 s 4 side breather plate bolts 5.9 0.60 52 in·lb l 5 connecting rod big end nuts see the text ← ←...

  • Page 332

    9-4 crankshaft/transmission exploded view.

  • Page 333

    Crankshaft/transmission 9-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 shift drum bearing holder screw 5.9 0.60 52 in·lb l 2 shift drum bearing holder bolt 12 1.2 106 in·lb l 3 shift drum cam holder bolt 12 1.2 106 in·lb l 4 neutral switch 15 1.5 11 5 shift lever bolt 6.9 0.70 61 in...

  • Page 334

    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 335

    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 336

    9-8 crankshaft/transmission special tools and sealant bearing puller: 57001-135 outside circlip pliers: 57001-144 bearing puller adapter: 57001-317 bearing driver, 32: 57001-382 flywheel holder: 57001-1313 liquid gasket, tb1216b: 92104-1064 liquid gasket, tb1207b: 92104-2068.

  • Page 337

    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: oil pressure switch terminal (see oil press...

  • Page 338

    9-10 crankshaft/transmission crankcase splitting crankcase assembly notice the upper and lower crankcase halves are ma- chined at the factory in the assembled state, so the crankcase halves must be replaced as a set. • using a high flash-point solvent, clean off the mating sur- faces of the crankcas...

  • Page 339

    Crankshaft/transmission 9-11 crankcase splitting • install the side breather plate [a]. • apply a non-permanent locking agent to the threads of the side breather plate bolts [b] and tighten them. Torque - side breather plate bolts: 5.9 n·m (0.60 kgf·m, 52 in·lb) • replace the o-rings [a] with new on...

  • Page 340

    9-12 crankshaft/transmission crankcase splitting • using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. • apply liquid gasket [a] to the mating surface of the lower crankcase half. Sealant - liquid gasket, tb1216b: 92...

  • Page 341

    Crankshaft/transmission 9-13 crankcase splitting • tighten the m9 crankcase bolts following the tightening sequence [1 ∼ 10]. L = 81 mm (3.19 in.) [1 ∼ 6] l = 95 mm (3.74 in.) [7 ∼ 10] ○ first, tighten the bolts with 10 n·m (1.0 kgf·m, 89 ft·lb) of torque. ○ next, in accordance with the following ta...

  • Page 342

    9-14 crankshaft/transmission crankcase splitting • tighten the upper crankcase bolts in the order listed. Torque - crankcase bolts (m8) [a]: 27 n·m (2.8 kgf·m, 20 ft·lb) crankcase bolts (m7) [b] [c]: 20 n·m (2.0 kgf·m, 15 ft·lb) crankcase bolts (m6) [d] [e] [f]: 12 n·m (1.2 kgf·m, 106 in·lb) l= 85 m...

  • Page 343

    Crankshaft/transmission 9-15 crankshaft and connecting rods crankshaft removal • split the crankcase (see crankcase splitting). • remove the crankshaft [a]. Crankshaft installation notice if the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts...

  • Page 344

    9-16 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 345

    Crankshaft/transmission 9-17 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 gasoline...

  • Page 346

    9-18 crankshaft/transmission crankshaft and connecting rods • dent both bolt head and bolt tip with a punch as shown. • before tightening, use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt stretch. Connecting rod [a] mark here with a punc...

  • Page 347

    Crankshaft/transmission 9-19 crankshaft and connecting rods • apply a small amount of molybdenum disulfide oil solution to the following. Threads [a] of nuts and bolts seating surfaces [b] of nuts and connecting rods • install new bolts in the connecting rods. • first, tighten the nuts to the specif...

  • Page 348

    9-20 crankshaft/transmission crankshaft and connecting rods connecting rod twist inspection • with the big-end arbor [a] still on v block [c], hold the connecting rod horizontally and measure the amount that the arbor [b] varies from being paralleled with the surface plate over a 100 mm (3.94 in.) l...

  • Page 349

    Crankshaft/transmission 9-21 crankshaft and connecting rods if the clearance is within the standard, no bearing replace- ment is required. If the clearance is between 0.072 mm (0.0028 in.) and the service limit (0.11 mm, 0.0043 in.), replace the bear- ing inserts [a] with inserts painted blue [b]. C...

  • Page 350

    9-22 crankshaft/transmission crankshaft and connecting rods • measure the connecting rod big end inside diameter, and mark each connecting rod big end in accordance with the inside diameter. • tighten the connecting rod big end nuts to the specified torque (see connecting rod installation). Note ○ t...

  • Page 351

    Crankshaft/transmission 9-23 crankshaft and connecting rods crankshaft runout inspection • measure the crankshaft runout. If the measurement exceeds the service limit, replace the crankshaft. Crankshaft runout standard: tir 0.02 mm (0.0008 in.) or less service limit: tir 0.05 mm (0.0020 in.) cranksh...

  • Page 352

    9-24 crankshaft/transmission crankshaft and connecting rods • measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. Crankcase main bearing inside diameter marks: “ ○ ” or no mark. • tighten the crankcase bolts to the specified torque (s...

  • Page 353

    Crankshaft/transmission 9-25 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 354

    9-26 crankshaft/transmission transmission shift pedal removal • remove: shift lever bolt [a] shift lever [b] if the tie-rod is removed from the shift pedal and shift lever, note the following. ○ the following portions have left-hand threads. Locknut [c] of shift lever side ball joint [d] of shift le...

  • Page 355

    Crankshaft/transmission 9-27 transmission external shift mechanism removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: shift lever (see shift pedal removal) clutch (see clutch removal in the clutch chapter) oil pipe holder bolts [a] oil pipe holder...

  • Page 356

    9-28 crankshaft/transmission transmission external shift mechanism inspection • examine the shift shaft [a] for any damage. If the shaft is bent, straighten or replace it. If the serration [b] are damaged, replace the shaft. If the springs [c] are damaged in any way, replace them. If the shift mecha...

  • Page 357

    Crankshaft/transmission 9-29 transmission • install the drive shaft and output shaft into the upper crankcase half. • apply engine oil to the bearings. ○ the bearing set pins and rings must match properly with the holes or grooves in the bearing outer races. When they are properly matched, there is ...

  • Page 358

    9-30 crankshaft/transmission transmission • remove the collar [a] together with the ball bearing [b] from output shaft. Special tool - bearing puller [c]: 57001-135 • discard the bearing. Transmission shaft assembly • install the new ball bearing [a] and collar [b] (output shaft) on the each shafts,...

  • Page 359

    Crankshaft/transmission 9-31 transmission • the drive shaft gears can be recognized by size: the gear with the smallest diameter is 1st gear, and the largest one is 6th gear. Be sure that all parts are put back in the cor- rect sequence and all circlips and washers are properly in place. • install t...

  • Page 360

    9-32 crankshaft/transmission transmission 1. Needle bearing 2. Circlip 3. Bearing outer race 4. Thrust washer, 30 mm (1.18 in.) 5. 2nd gear 6. Circlip, 29 mm (1.14 in.) 7. Toothed washer, 35 mm (1.38 in.) 8. Bushing 9. 6th (top) gear 10. Toothed washer, 31 mm (1.22 in.) 11. 4th gear 12. 3rd gear 13....

  • Page 361

    Crankshaft/transmission 9-33 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 362

    9-34 crankshaft/transmission transmission shift fork bending inspection • visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [a] shift fork/gear groove wear inspectio...

  • Page 363: Wheels/tires

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

  • Page 364

    10-2 wheels/tires exploded view.

  • Page 365

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

  • Page 366

    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 367

    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 368

    10-6 wheels/tires wheels (rims) front wheel removal • remove: front caliper mounting bolts [a] (both sides) front caliper [b] (both sides) ○ zr800a/b/d models [c] ○ zr800c model [d] • for abs equipped models, remove the front wheel rota- tion sensor (see front wheel rotation sensor removal in the br...

  • Page 369

    Wheels/tires 10-7 wheels (rims) front wheel installation note ○ the direction of the wheel rotation [a] is shown by an arrow [b] on the wheel hub. • check the wheel rotation mark on the front wheel and install it. • apply high-temperature grease to the grease seal lips. • fit the collars [a] on the ...

  • Page 370

    10-8 wheels/tires wheels (rims) • remove: cotter pin [a] axle nut [b] washer axle [c] (from right side) wheel alignment indicator [d] (both sides) • for abs equipped models, remove the rear wheel rota- tion sensor from the caliper bracket (see rear wheel ro- tation sensor removal in the brakes chapt...

  • Page 371

    Wheels/tires 10-9 wheels (rims) • bend the cotter pin [a] over the nut [b]. Warning a loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper torque and install a new cotter pin. • adjust the drive chain slack after installation (see drive chai...

  • Page 372

    10-10 wheels/tires wheels (rims) wheel inspection • raise the front/rear wheel off the ground (see front/rear wheel removal). • spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings (see hub bearing removal/installation). • inspect the...

  • Page 373

    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 374

    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 375

    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 376

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

  • Page 377

    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 378

    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]. Notice do not lay th...

  • Page 379

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

  • Page 381: Final Drive

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

  • Page 382

    11-2 final drive exploded view.

  • Page 383

    Final drive 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine sprocket cover bolts 6.9 0.70 61 in·lb 2 engine sprocket nut 167 17.0 123 mo 3 chain adjuster locknuts 16.5 1.68 12.2 4 rear axle nut 108 11.0 79.7 5 rear sprocket nuts 59 6.0 44 r hg: apply high-temperature grease. ...

  • Page 384

    11-4 final drive specifications item standard service limit drive chain drive chain slack 20 ∼ 30 mm (0.8 ∼ 1.2 in.) – – – drive chain wear (20-link length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 319 mm (12.6 in.) standard chain: make enuma – – – type ek520mvxl2 – – – link 114 links – – – sprockets re...

  • Page 385

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

  • Page 386

    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 387

    Final drive 11-7 drive chain • grind [a] the pin head to make it flat. • set the cutting and riveting pin [b] as shown. • screw the pin holder until it touches chain pin. • be sure that the cutting pin hits center of chain pin. • screw the handlebar [a] into body. • turn the pin holder with wrench [...

  • Page 388

    11-8 final drive drive chain • fit the plate holder (a) to link plate. • turn the pin holder by hand until plate holder (b) touches the other link plate. • turn the pin holder by wrench clockwise until two pins of link come into groove of plate holder (a). • take off the plate holder. • set the plat...

  • Page 389

    Final drive 11-9 drive chain • after staking, check the staked area of the link pin for cracks. • measure the outside diameter [a] of the link pin and link plates width [b]. Link pin outside diameter standard: 5.7 ∼ 6.0 mm (0.22 ∼ 0.24 in.) link plates outside width standard: 17.25 ∼ 17.45 mm (0.679...

  • Page 390

    11-10 final drive sprocket, coupling engine sprocket removal • remove: left frame cover (see frame cover removal in the frame chapter) engine sprocket cover bolts [a] bracket [b] engine sprocket cover [c] • flatten out the bended washer [a]. • remove the engine sprocket nut [b] and washer. Note ○ wh...

  • Page 391

    Final drive 11-11 sprocket, coupling • be sure to install the dowel pins [a]. • install the engine sprocket cover [a]. • install the bracket [b] as shown, and tighten the cover bolts [c]. Torque - engine sprocket cover bolts: 6.9 n·m (0.70 kgf·m, 61 in·lb) • adjust the drive chain slack after instal...

  • Page 392

    11-12 final drive sprocket, coupling coupling installation • apply high-temperature grease to the following. Coupling grease seal lips [a] coupling internal surface [b] • replace the o-ring [a] with a new one. • apply grease to the o-ring. • install the collar [b]. Coupling bearing removal • remove:...

  • Page 393

    Final drive 11-13 sprocket, coupling • replace the grease seal with a new one. • press in the grease seal so that the seal surface is flush with the end of the hole. ○ apply high-temperature grease to the grease seal lips. Special tool - bearing driver set: 57001-1129 coupling bearing inspection sin...

  • Page 394

    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, and rotate [c] the rear wheel to measure the sprocket runout (warp). The ...

  • Page 395: Brakes

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

  • Page 396

    12-2 brakes brake hose and pipe inspection....................................................................................... 12-35 anti-lock brake system (equipped models) .......................................................................... 12-36 abs servicing precautions ...................

  • Page 397

    Brakes 12-3 this page intentionally left blank..

  • Page 398

    12-4 brakes exploded view zr800a model.

  • Page 399

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake hose banjo bolts 25 2.5 18 2 front master cylinder reservoir cap screws 1.5 0.15 13 in·lb 3 brake lever pivot bolt 1.0 0.10 8.9 in·lb si 4 brake lever pivot bolt locknut 5.9 0.60 52 in·lb 5 front brake light switch screw 1...

  • Page 400

    12-6 brakes exploded view zr800c model.

  • Page 401

    Brakes 12-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake hose banjo bolts 25 2.5 18 2 front master cylinder reservoir cap screws 1.5 0.15 13 in·lb 3 brake lever pivot bolt 1.0 0.10 8.9 in·lb si 4 brake lever pivot bolt locknut 5.9 0.60 52 in·lb 5 front master cylinder clamp bolt...

  • Page 402

    12-8 brakes exploded view.

  • Page 403

    Brakes 12-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake hose banjo bolts 25 2.5 18 2 rear master cylinder mounting bolts 25 2.5 18 3 brake pedal bolt 8.8 0.90 78 in·lb 4 rear master cylinder push rod locknut 17.2 1.75 12.7 5 rear caliper pin bolt 27 2.8 20 si 6 rear brake disc ...

  • Page 404

    12-10 brakes exploded view abs equipped models.

  • Page 405

    Brakes 12-11 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake hose banjo bolts 25 2.5 18 2 front master cylinder reservoir cap screws 1.5 0.15 13 in·lb 3 brake lever pivot bolt 1.0 0.10 8.9 in·lb si 4 brake lever pivot bolt locknut 5.9 0.60 52 in·lb 5 front master cylinder clamp bol...

  • Page 406

    12-12 brakes exploded view abs equipped models.

  • Page 407

    Brakes 12-13 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake hose banjo bolts (abs hydraulic unit) 33 3.4 24 2 brake hose banjo bolts 25 2.5 18 3 rear caliper pin bolt 27 2.8 20 si 4 bleed valve 7.8 0.80 69 in·lb 5 rear brake pad pin plug 2.5 0.25 22 in·lb 6 rear brake pad pin 17.2...

  • Page 408

    12-14 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 40 mm (1.57 in.) below footpeg top – – – brake pads lining...

  • Page 409

    Brakes 12-15 special tools hand tester: 57001-1394.

  • Page 410

    12-16 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 411

    Brakes 12-17 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 inside of the bushing [a]. • install: washers [b] bushing brake pedal [c] • tighten: t...

  • Page 412

    12-18 brakes calipers front caliper removal zr800a/b/d models • loosen the banjo bolt [a] at the brake hose lower end, and tighten it loosely. • unscrew the caliper mounting bolts [b], and detach the caliper [c] from the disc. Notice do not loosen the caliper assembly bolts. Take out only the calipe...

  • Page 413

    Brakes 12-19 calipers rear caliper • install: rubber boot [a] guide [b] • 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 calipe...

  • Page 414

    12-20 brakes calipers rear caliper assembly • refer to the caliper rubber parts replacement in the pe- riodic maintenance chapter. Caliper fluid seal damage inspection the fluid seal (piston seal) [a] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in...

  • Page 415

    Brakes 12-21 calipers caliper dust seal damage inspection • check that the dust seals [a] are not cracked, worn, swollen, or otherwise damaged. If they show any damage, replace the dust seals with new ones. Pistons [b] fluid seals [c] ○ zr800a/b/d models [d] ○ zr800c model [e] front caliper dust boo...

  • Page 416

    12-22 brakes calipers caliper piston and cylinder damage inspection • visually inspect the pistons [a] and cylinder surfaces [b]. Replace the caliper if the cylinder and piston are badly scores or rusty. ○ zr800a/b/d models [c] ○ zr800c model [d] front caliper holder shaft wear inspection (zr800c mo...

  • Page 417

    Brakes 12-23 calipers rear caliper holder wear inspection the caliper body must slide smoothly on the rear caliper pin bolt [a] and sleeve [b]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake...

  • Page 418

    12-24 brakes brake pads front brake pad removal zr800a/b/d models • remove: pad pin [a] pad spring [b] brake pads [c] zr800c model • remove the pad pin plug [a]. • loosen the pad pin [a]. • remove the caliper mounting bolts [b]. • remove the caliper with the hose installed. • remove: pad pin [a] bra...

  • Page 419

    Brakes 12-25 brake pads • set: inside pad [a] pad spring [b] ○ push down the pin holder [c] and insert the pad pin. Torque - front brake pad pin: 17.2 n·m (1.75 kgf·m, 12.7 ft·lb) warning after servicing, it takes several applications of the brake lever before the brake pads contact the disc, which ...

  • Page 420

    12-26 brakes brake pads rear brake pad removal • unscrew the pad pin plug [a]. • loosen the pad pin [a]. • unscrew the bolt [b]. • remove: pad pin [a] brake pads [b] rear brake pad installation • push the caliper piston in by hand as far as they will go. • install the outside pad [a] and insert the ...

  • Page 421

    Brakes 12-27 brake pads • set: inside pad [a] pad pin [b] • install the caliper (see caliper installation). • tighten the pad pin and plug. Torque - rear brake pad pin: 17.2 n·m (1.75 kgf·m, 12.7 ft·lb) rear brake pad pin plug: 2.5 n·m (0.25 kgf·m, 22 in·lb) warning after servicing, it takes several...

  • Page 422

    12-28 brakes master cylinder front master cylinder removal • remove the banjo bolt [a] to disconnect the brake hose from the master cylinder (see brake hose and pipe re- moval/installation). • unscrew the clamp bolts [b], and take off the master cylin- der [c] as an assembly with the reservoir, brak...

  • Page 423

    Brakes 12-29 master cylinder • remove: cotter pin [a] joint pin [b] bolt [c] rear master cylinder [d] • slide out the clamp [e]. • pull off the reservoir hose lower end, and drain the brake fluid into a container. Rear master cylinder installation • install the reservoir hose lower end, and install ...

  • Page 424

    12-30 brakes master cylinder master cylinder inspection (visual inspection) • remove the master cylinders (see front/rear master cylinder removal). • disassemble the front and rear master cylinders (see master cylinder rubber parts replacement in the peri- odic maintenance chapter). • check that the...

  • Page 425

    Brakes 12-31 brake disc brake disc removal • remove the wheels (see front/rear wheel removal in the wheels/tires chapter). • remove the brake disc mounting bolts, and take off the disc. ○ remove the sensor rotor (abs equipped models). • remove the gaskets. Brake disc installation • replace the gaske...

  • Page 426

    12-32 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 427

    Brakes 12-33 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 428

    12-34 brakes brake fluid warning when working with the disc brake, observe the pre- cautions listed below. • never reuse old brake fluid. • do not use fluid from a container that has been left unsealed or that has been open for a long time. • do not mix two types and brands of fluid for use in the b...

  • Page 429

    Brakes 12-35 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 430

    12-36 brakes anti-lock brake system (equipped models) parts location 1. Abs kawasaki self-diagnosis system connector 2. Fuse box 1 3. Yellow abs indicator light (led) 4. Front wheel rotation sensor rotor 5. Front wheel rotation sensor 6. Abs hydraulic unit 7. Rear wheel rotation sensor 8. Rear wheel...

  • Page 431

    Brakes 12-37 anti-lock brake system (equipped models) abs system wiring diagram 1. Ignition switch 2. Front brake switch 3. Rear wheel rotation sensor 4. Rear brake switch 5. Frame ground 5 6. Frame ground 1 7. Engine ground 8. Battery 12 v 8 ah 9. Starter relay 10. Main fuse 30 a 11. Abs kawasaki s...

  • Page 432

    12-38 brakes anti-lock brake system (equipped models) abs hydraulic unit terminal names 2. Unused 3. Unused 4. Front and rear brake light switch signal: bl/r 5. Abs kawasaki self-diagnosis system terminal: p 6. Power supply to rear wheel rotation sensor: w/g 7. Power supply: br/w 8. Power supply to ...

  • Page 433

    Brakes 12-39 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 434

    12-40 brakes anti-lock brake system (equipped models) warning air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If any of the brake line fittings, including the abs hydraulic unit joint nuts, or the bleed valve is opened at any time, the air ...

  • Page 435

    Brakes 12-41 anti-lock brake system (equipped models) ○ the yellow abs indicator light (led) may come on if the engine is run with the motorcycle on its stand and the transmission in gear. If the indicator light comes on, just turn the ignition switch off, then clear service code 42, which indicates...

  • Page 436

    12-42 brakes anti-lock brake system (equipped models) even when the abs is operating normally, the yellow abs indicator light (led) may light up under the conditions listed below. Turn the ignition switch off to stop the indicator light. If the motorcycle runs without erasing the service code, the l...

  • Page 437

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

  • Page 438

    12-44 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 439

    Brakes 12-45 anti-lock brake system (equipped models) pre-diagnosis inspection 1.

  • Page 440

    12-46 brakes anti-lock brake system (equipped models) pre-diagnosis inspection 2 self-diagnosis outline when the yellow abs indicator light (led) has blinked or come on, the abs hydraulic unit mem- orizes and stores the service code for the service person to troubleshoot easily. The service code mem...

  • Page 441

    Brakes 12-47 anti-lock brake system (equipped models) • the abs hydraulic unit can be store the service codes including previous ones. • to read out the current service code, erase the stored service codes once prior reading the service code (see service code clearing procedures). • test ride the mo...

  • Page 442

    12-48 brakes anti-lock brake system (equipped models) erasing of service code.

  • Page 443

    Brakes 12-49 anti-lock brake system (equipped models) self-diagnosis flow chart.

  • Page 444

    12-50 brakes anti-lock brake system (equipped models) how to read service codes ○ service codes are shown by a series of long and short blinks of the yellow abs indicator light (led) as shown below. ○ read 10th digit and unit digit as the yellow abs indicator light (led) blinks. ○ when there are a n...

  • Page 445

    Brakes 12-51 anti-lock brake system (equipped models) service code table service code yellow abs indicator light (led) problems light state – stays on* (error function after the ignition switch turned on) main harness, meter unit, wheel rotation sensor(s) or abs unit abnormal on – does not go on (wh...

  • Page 446

    12-52 brakes anti-lock brake system (equipped models) yellow abs indicator light (led) inspection ○ in this model, the yellow abs indicator light (led) [a] goes on or blinks by the control of the abs hydraulic unit. Yellow abs indicator light (led) stays on (error func- tion after the ignition switc...

  • Page 447

    Brakes 12-53 anti-lock brake system (equipped models) step 3-2 • check for continuity between the terminal 9 (bk) [a] of the abs hydraulic unit connector and a frame ground [b]. If there is no continuity, repair or replace the main har- ness. If there is continuity, replace the abs hydraulic unit. S...

  • Page 448

    12-54 brakes anti-lock brake system (equipped models) step 2 • disconnect the abs hydraulic unit connector [a] and check the yellow abs indicator light (led) for function. ○ the yellow abs indicator light (led) should goes on when the ignition switch turned on. If the indicator does not goes on, go ...

  • Page 449

    Brakes 12-55 anti-lock brake system (equipped models) abs unit solenoid valve inspection (service code 13, 14, 17, 18) ○ these codes indicate there is a problem in the solenoid valves, which integrated into the abs hydraulic unit. Therefore the solenoid valves cannot be checked directly. • check the...

  • Page 450

    12-56 brakes anti-lock brake system (equipped models) step 3 • measure the front and rear wheel rotation sensor air gaps (see wheel rotation sensor air gap inspection). If the air gap is not within the specification, recheck the hub bearing, sensor, sensor rotor and sensor installation condition. If...

  • Page 451

    Brakes 12-57 anti-lock brake system (equipped models) step 3 • check the front and rear tire/wheel conditions for tire pres- sure, tire size/types, abnormal wear and deformations (see wheels/tires in the periodic maintenance chapter). If the tire and/or wheel are in bad condition, correct them if ne...

  • Page 452

    12-58 brakes anti-lock brake system (equipped models) step 2-1 • disconnect the rear wheel rotation sensor connector. • recheck the continuity between the terminal 9 (bk) [a] and terminal 6 (w/g) [b] of the abs hydraulic unit con- nector. If there is continuity, repair or replace the main harness. I...

  • Page 453

    Brakes 12-59 anti-lock brake system (equipped models) step 6 • connect the front wheel rotation sensor connector. • connect the 4.5 ∼ 5.0 v dc power (e.G. Three aa dry battery in series [a]) between the terminal 17 (bk/w) (–) [b] and terminal 8 (w/bk) (+) [c] of the abs hydraulic unit connector to m...

  • Page 454

    12-60 brakes anti-lock brake system (equipped models) step 2 • check for continuity between the terminal 9 (bk) [a] and terminal 6 (w/g) [b] of the abs hydraulic unit connector. If there is continuity, go to next step. If there is no continuity, go to step 3. Step 2-1 • disconnect the rear wheel rot...

  • Page 455

    Brakes 12-61 anti-lock brake system (equipped models) step 5 • with disconnecting the rear wheel rotation sensor con- nector [a], check for continuity between the terminal 15 (bk/o) [b] of the abs hydraulic unit connector [c] and terminal 1 (bk/o) [d] of the rear wheel rotation sensor connector (mai...

  • Page 456

    12-62 brakes anti-lock brake system (equipped models) step 3 • disconnect the abs hydraulic unit connector. • check the voltage between the terminal 9 (bk) (–) [a] and terminal 18 (r/w) (+) [b] of the abs hydraulic unit connector. Special tool - hand tester: 57001-1394 ○ the battery voltage (10 ∼ 16...

  • Page 457

    Brakes 12-63 anti-lock brake system (equipped models) abs hydraulic unit removal notice the abs hydraulic unit [a] has been adjusted and set with precision at the factory. Therefore, it should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface. Be care...

  • Page 458

    12-64 brakes anti-lock brake system (equipped models) • remove the brake hose banjo bolts [a] while holding the abs hydraulic unit [b] with a suitable plier [c]. • remove: bolt [a] abs hydraulic unit assembly [b] • remove: bolts [a] bracket [b] abs hydraulic unit [c] notice the abs hydraulic unit [a...

  • Page 459

    Brakes 12-65 anti-lock brake system (equipped models) abs hydraulic unit installation • installation is the reverse of removal. Notice brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • when installing the hoses and pipes, avoid shar...

  • Page 460

    12-66 brakes anti-lock brake system (equipped models) front wheel rotation sensor removal notice the wheel rotation sensor should be handled care- fully, never struck sharply, as with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made. Be careful not...

  • Page 461

    Brakes 12-67 anti-lock brake system (equipped models) • remove: right side cover (see side cover removal in the frame chapter) • disconnect the connector [a]. • remove: clamp [a] bolts [b] screw [c] • remove: clamp [a] brake hose banjo bolt [b] • clear the brake hose [c] from the hole of the rear in...

  • Page 462

    12-68 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 463

    Brakes 12-69 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 465: Suspension

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

  • Page 466

    13-2 suspension exploded view zr800a/b models.

  • Page 467

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper front fork clamp bolts 20 2.0 15 2 front fork top plugs 22.5 2.29 16.6 3 piston rod nuts 15 1.5 11 4 lower front fork clamp bolts 20.5 2.09 15.1 al 5 cylinder units 70 7.1 52 ad 6 front axle clamp bolt 20 2.0 15 7. Inn...

  • Page 468

    13-4 suspension exploded view zr800c/d models.

  • Page 469

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper front fork clamp bolts 20 2.0 15 2 front fork top plugs 22.5 2.29 16.6 3 piston rod nut 15 1.5 11 4 lower front fork clamp bolts 20.5 2.09 15.1 al 5 piston rod rubber nut 15 1.5 11 6 piston rod assy stopper 17.5 1.78 1...

  • Page 470

    13-6 suspension exploded view.

  • Page 471

    Suspension 13-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 swingarm pivot shaft nut 108 11.0 79.7 2 swingarm pivot shaft 9.8 1.0 87 in·lb 3 swingarm pivot shaft locknut 98 10 72 4 rear shock absorber nut (upper) 34 3.5 25 r 5 rear shock absorber nut (lower) 34 3.5 25 r 6 rocker arm ...

  • Page 472

    13-8 suspension specifications item standard front fork (zr800a/b models, per one unit) fork inner tube diameter 41 mm (1.6 in.) air pressure atmospheric pressure (non-adjustable) rebound damper setting (right front fork only) 12th click from the 1st click of the fully clockwise position (usable ran...

  • Page 473

    Suspension 13-9 specifications item standard spring preload setting position (zr800a/b models): standard spring length: 175.2 mm (6.90 in.) usable range spring length: 170.2 ∼ 180.2 mm (6.70 ∼ 7.09 in.) (stronger to weaker) spring preload setting position (zr800c/d models): standard 4th position usa...

  • Page 474

    13-10 suspension 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 piston rod puller, m12 × 1.25: 57001-1289 fork oil level gauge: 57001-1290 fork piston rod puller, m10 × 1....

  • Page 475

    Suspension 13-11 special tools hook wrench t=3.2 r37: 57001-1539 fork spring compressor: 57001-1540 fork spring compressor: 57001-1587 swingarm pivot nut wrench: 57001-1597 jack attachment: 57001-1608 needle bearing driver, 17/ 18: 57001-1609 needle bearing driver, 28: 57001-1610 spacer, 18: 57001-1...

  • Page 476

    13-12 suspension special tools bar: 57001-1751 fork spring compressor: 57001-1771 fork piston rod stopper holder: 57001-1789.

  • Page 477

    Suspension 13-13 front fork rebound damping force adjustment (zr800a/b models, right front fork only) • to adjust the rebound damping force, turn the rebound damping adjuster [a]. ○ the standard adjuster setting is the 12th click from the fully clockwise position. ○ the damping force can be left sof...

  • Page 478

    13-14 suspension front fork front fork removal (each fork leg) • remove: upper fairing (see upper fairing removal in the frame chapter) front fender (see front fender removal in the frame chapter) front wheel (see front wheel removal in the wheels/tires chapter) loosen the upper front fork clamp bol...

  • Page 479

    Suspension 13-15 front fork • install the clamps [a] as shown. Note ○ set the clamps so that the cutout [b] of the upper side does not touch the tongue shape of stopper, pull up the outer tube [c] to hold it by the clamps, and then tighten the two bolts [d]. The outer tube is used as a guide. Specia...

  • Page 480

    13-16 suspension front fork • lift up the suitable jack until the piston rod nut [a] comes out. • insert the fork spring stopper [b] between the piston rod nut and the holder [c] while holding up the top plug [d]. Special tool - fork spring stopper: 57001-1374 • holding the piston rod nut with a wre...

  • Page 481

    Suspension 13-17 front fork • hold the fork tube upright, press the inner tube [a] and the piston rod all the way down. • pour in the type and amount of fork oil specified. Recommended oil khl15-10 or equivalent amount (per side): when changing oil: approx. 405 ml (13.7 us oz.) after disassembly and...

  • Page 482

    13-18 suspension front fork • screw the fork piston rod puller onto the end of the piston rod. Special tool - fork piston rod puller, m12 × 1.25: 57001 -1289 • pull the puller up above the outer tube top. • install the spring seat [a] with the flat surface [b] facing upward. • install the fork sprin...

  • Page 483

    Suspension 13-19 front fork • hold up the fork piston rod puller. • insert the fork spring stopper [a] between the piston rod nut [b] and the holder [c] while holding up the fork piston rod puller [d]. Special tool - fork spring stopper: 57001-1374 • remove the fork piston rod puller. • install the ...

  • Page 484

    13-20 suspension front fork if using the spring compressor (57001-1587). • install the clamps [a] as shown. Note ○ set the clamps so that the cutout [b] of the upper side does not touch the tongue shape of stopper, pull up the outer tube [c] to hold it by the clamps, and then tighten the two bolts [...

  • Page 485

    Suspension 13-21 front fork • set the holder bar [a] and compression shafts [b]. • screw in the nuts [a] until the piston rod nut [b] comes out. ○ hold up the top plug [c] while screwing in the nut. • insert the fork spring stopper [a] between the piston rod nut [b] and the clamp [c] while holding u...

  • Page 486

    13-22 suspension front fork • screw the rod nut [a] onto the piston rod [b] as shown. 12 mm (0.47 in.) or more [c] • drain the fork oil into a suitable container and remove the spring seat. ○ using the piston rod puller [a], pump the piston rod [b] up and down at least ten times to expel the oil fro...

  • Page 487

    Suspension 13-23 front fork oil level (fully compressed, without spring) standard: right front fork 106 ±2 mm (4.17 ±0.08 in.) (from the top of the outer tube) left front fork 109 ±2 mm (4.29 ±0.08 in.) (from the top of the outer tube) note ○ fork oil lever may also be measured using the fork oil le...

  • Page 488

    13-24 suspension front fork • install the clamps [a] as shown. Special tools - fork spring compressor: 57001-1540 fork spring compressor: 57001-1587 note ○ set the clamps so that the cutouts [b] do not fit the hole [c] of the washer [d], pull up the outer tube [e] to hold it by the clamps, and then ...

  • Page 489

    Suspension 13-25 front fork • check the distance between the bottom end [a] of the top plug and rebound damping adjuster [b] with a pair of vernier caliper (right front fork only). 13 mm (0.51 in.) [c] • replace the o-ring [a] on the top plug [b] with a new one. • apply grease to the new o-ring. • i...

  • Page 490

    13-26 suspension front fork • while holding up the top plug [a] by one person, push down [b] the fork spring compressor and insert the fork spring stopper [c] between the piston rod nut [d] and the spacer [e]. Special tool - fork spring stopper: 57001-1374 • holding the top plug [a] with a wrench [b...

  • Page 491

    Suspension 13-27 front fork • hold the fork tube upright, press the outer tube [a] and the piston rod all the way down. • pour in the type and amount of fork oil specified. Recommended oil khl15-10 or equivalent amount: when changing oil: approx. 410 ml (13.9 us oz.) after disassembly and completely...

  • Page 492

    13-28 suspension front fork • screw on the rod nut [a] fully to the piston rod [b]. • 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 spring seat [a] with the f...

  • Page 493

    Suspension 13-29 front fork • replace the o-ring [a] on the top plug [b] with a new one. • apply grease to the new o-ring. • screw in the top plug stopped onto the piston rod. • holding the top plug [a] with a wrench [b], tighten the piston rod nut [c] against the top plug. Torque - piston rod nut: ...

  • Page 494

    13-30 suspension front fork • using the fork piston rod stopper holder [a], remove the piston rod assy stopper [b]. Special tool - fork piston rod stopper holder: 5700-1789 note ○ install the fork piston rod stopper holder so that the long side [c] faces upward. • remove: piston rod assy [a] fork sp...

  • Page 495

    Suspension 13-31 front fork • screw the adjust nut [a] onto the compression shaft as shown. About 40 mm (1.57 in.) [b] • screw the locknut [c]. • set the other side compression shaft same process. • install the spacer [a] with the flat surface [b] facing up- ward. • install the fork spring [c] with ...

  • Page 496

    13-32 suspension front fork • screw the nuts [a] onto the compression shafts [b] as shown. About 15 mm (0.59 in.) [c] • screw the piston rod assy stopper [d]. • remove the following special tools. Fork spring compressors bar • remove the top plug. • hold the inner tube lower end in a vice. • using t...

  • Page 497

    Suspension 13-33 front fork • separate the inner tube from the outer tube as follows. ○ slide up the dust seal [a]. ○ remove the retaining ring [b] from the outer tube. ○ holding the outer tube [a] by hand, pull the inner tube [b] several times to pull out the outer tube. • remove the following part...

  • Page 498

    13-34 suspension front fork front fork assembly other than zr800c/d models left front fork • using a high flash-point solvent, clean off any oil or dirt that may be on the adhesive coating area. Dry them with a clean cloth. • apply adhesive (threebond: tb1344n or equivalent) to the threads of the cy...

  • Page 499

    Suspension 13-35 front fork inner tube, outer tube inspection • visually inspect the inner tube [a]. If there is any damage, replace the inner tube. Since damage to the inner tube damages the oil seal, and dust seal replace the oil seal and dust seal whenever the inner tube is replaced. Notice if th...

  • Page 500

    13-36 suspension rear shock absorber rebound damping force adjustment (zr800a/b models) • to adjust the rebound damping force, turn the lower damping adjuster [a]. ○ the standard adjuster setting is the 1 1/4 turns out from the fully clockwise position. Rebound damping force adjustment adjuster posi...

  • Page 501

    Suspension 13-37 rear shock absorber • remove: bolts [a] screw [b] • to adjust the spring preload, turn in the adjusting nut to the desired position and tighten the locknut by using hook wrenches [a] with the rear shock absorber attached the frame. Special tool - hook wrench t = 3.2 r37: 57001-1539 ...

  • Page 502

    13-38 suspension rear shock absorber • using the hook wrench [a], turn the adjusting nut [b] to adjust the spring preload. ○ the standard adjuster setting is 4th position. Spring preload setting standard position: 4th position adjustable range: 1st to 7th position • if the compression of the spring ...

  • Page 503

    Suspension 13-39 rear shock absorber • remove the upper shock absorber nut and bolt [a]. • remove the shock absorber [b] from downside. Rear shock absorber installation • replace the rear shock absorber nuts (upper and lower) and tie-rod nut with new ones. • tighten: torque - rear shock absorber nut...

  • Page 504

    13-40 suspension rear shock absorber zr800c/d models warning since the rear shock absorber contains nitrogen gas, do not incinerate the rear shock absorber with- out first releasing the gas or it may explode. Before a rear shock absorber is scrapped, drill a hole at the point [a] shown to release th...

  • Page 505

    Suspension 13-41 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) • raise the rear wheel off the ground with jack. Special tools - jack: 57001-1238 jack attachment: 57001-1608 • remove the...

  • Page 506

    13-42 suspension swingarm • remove: swingarm pivot shaft nut [a] swingarm pivot shaft [b] swingarm swingarm installation • replace the following parts with a new one. Lower shock absorber nut upper tie-rod nut • place the collar [a] on the stopper [b] inside the frame [c]. • insert the pivot shaft i...

  • Page 507

    Suspension 13-43 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 508

    13-44 suspension swingarm • install the needle bearings [a], ball bearing [b] and oil seals [c] position as shown. Circlip [d] 23.5 ±0.4 mm (0.93 ±0.02 in.) [e] 6 ±0.4 mm (0.24 ±0.02 in.) [f] swingarm bearing, sleeve inspection notice do not remove the bearings for inspection. Re- moval may damage t...

  • Page 509

    Suspension 13-45 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 510

    13-46 suspension 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 511

    Suspension 13-47 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 a suitable tool. Tie-rod and rocker arm beari...

  • Page 512

    13-48 suspension 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 ±0.4 mm (0.20 ±0.02 in.) [j] 5.5 mm (0.22 i...

  • Page 513: Steering

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

  • Page 514

    14-2 steering exploded view.

  • Page 515

    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 rear view mirror locknut (upper) 18 1.8 13 lh 3 rear view mirror nut (lower) 30 3.1 22 4 switch housing screws 3.5 0.36 31 in·lb 5 upper front fork clamp bolts 20 2.0 15 6 steering stem hea...

  • Page 516

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

  • Page 517

    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 518

    14-6 steering steering stem stem, stem bearing removal • remove: upper fairing (see upper fairing removal in the frame chapter) bolts [a] clamp [b] clamp [c] (abs equipped models) bracket [d] handlebars (see handlebar removal) steering stem head (see steering play adjustment in the periodic maintena...

  • Page 519

    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. • apply grease to the outer races...

  • Page 520

    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 521

    Steering 14-9 steering stem steering stem warp inspection • 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 inspectio...

  • Page 522

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

  • Page 523

    Steering 14-11 handlebar • put the upper handlebar holder [a] on the flat surface to confirm the installation direction. Front [b] rear [c] • when installing the lower handlebar holders, install the upper handlebar holder [a] and handlebar holder bolts [b] temporarily as shown. Front [c] gap [d] han...

  • Page 524

    14-12 steering handlebar • using a high flash-point solvent, clean of any oil or dirt that may be on the adhesive coating area. Dry them with a clean cloth. • apply adhesive cement to the left side of the handlebars. • install the handlebar grip. ○ wipe off any protruding adhesive cement. • apply a ...

  • Page 525: Frame

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

  • Page 526

    15-2 frame exploded view.

  • Page 527

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear view mirror locknut (upper) 18 1.8 13 lh 2 rear view mirror nut (lower) 30 3.1 22 3 turn signal light mounting screws 1.2 0.12 11 in·lb 4 front fender bolts 3.9 0.40 35 in·lb lh: left-hand threads.

  • Page 528

    15-4 frame exploded view.

  • Page 529

    Frame 15-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 footpeg bracket bolts 30 3.1 22 2 side stand switch bolt 8.8 0.90 78 in·lb l 3 side stand bolt 29 3.0 21 4 side stand nut 44 4.5 32 r 5 lower fairing mounting bolts 9.8 1.0 87 in·lb 6 lower fairing bracket bolts 9.8 1.0 87 in·lb ...

  • Page 530

    15-6 frame exploded view.

  • Page 531

    Frame 15-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 license plate light mounting screws 1.2 0.12 11 in·lb 2 turn signal light mounting screws 1.2 0.12 11 in·lb 3. Au model.

  • Page 532

    15-8 frame 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 533

    Frame 15-9 fairings upper fairing removal • remove: bolts [a] meter cover [b] • remove: bolts [a] bracket [b] • remove the bolts [c] and pull out the upper fairing [d] forward. • disconnect: headlight lead connectors [a] city light lead connectors [b] left and right turn signal light lead connectors...

  • Page 534

    15-10 frame fairings upper fairing assembly • check the pads [a] are in place on the upper fairing. • installation is the reverse of removal. Upper fairing installation • connect: city light lead connectors headlight lead connectors left and right turn signal light lead connectors • fit the projecti...

  • Page 535

    Frame 15-11 fairings ignition switch cover installation • check that the pad [a] is in place on the ignition switch cover [b]. 10 mm (0.39 in.) [c] • fit the hooks [a] of the ignition switch cover [b] on the ribs [c] of the tank cover. • insert the pin [d] on the ignition switch cover into the hole ...

  • Page 536

    15-12 frame fairings • when installing the hook fasteners [a], align the edge of the hook fasteners with the lines [b] of the fuel tank. • check that the grommets [a] are in place on the fuel tank and tank cover. • insert the hook [b] on the fuel tank into the slot [c] of the tank cover. • fit the h...

  • Page 537

    Frame 15-13 fairings • check that the grommet [a] is in place on the fuel tank. • insert the tabs [b] into the slots [c]. • fit the hook fasteners [d]. • insert the projection [e] into the hole [f]. • tighten the bolt. • install the removed parts (see appropriate chapters). Side fairing removal • re...

  • Page 538

    15-14 frame fairings lower fairing removal (zr800a/b models) • remove the bolts [a]. • clear the projection [b] and remove the lower fairing [c]. Lower fairing installation (zr800a/b models) • check that the grommets [a] are in place on the lower fairing [b] and bracket. • insert the projection [c] ...

  • Page 539

    Frame 15-15 side covers side cover removal • remove: seats (see rear/front seat removal) bolt [a] with washer • pull the side cover [b] evenly outward to clear the projec- tions [c]. • pull the side cover backward to clear the hook fasteners [d] and projections [e]..

  • Page 540

    15-16 frame side covers side cover installation • check that the pads [a] and damper [b] are in place on the side covers as follows. ○ install the adhesive surface of the damper to the adhesive surface of the pad. Left side cover [c] right side cover [d] 10 mm (0.39 in.) [e] view from f [f].

  • Page 541

    Frame 15-17 side covers • check that the grommets [a] and pad [b] are in place. • insert the projections [c] into the hole [d]. • fit the hook fasteners [e]. • insert the projections [f] into the holes [g]. • fit the grommet [h] on the bolt [i]. • tighten the bolt with washer..

  • Page 542

    15-18 frame seat covers seat cover removal • remove: seats (see rear/front seat removal) bolts [a] • pull the seat cover [b] backward to clear the hooks [c]. Seat cover installation • check that the pads [a] are in place on the seat cover. • check that the damper [a] is in place on the seat cover [b...

  • Page 543

    Frame 15-19 fenders front fender removal • free the brake hoses [a] from the clamps [b]. • remove: bolts [c] with washers (both sides) front fender [d] 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) • run...

  • Page 544

    15-20 frame fenders • remove the seat lock cable tip [a]. • pull out the bracket [b]. • remove: bracket [c] key cylinder [d] rear fender installation • installation is the reverse of removal. • install the removed parts (see appropriate chapters). • run the cables, leads, harness and hose correctly ...

  • Page 545

    Frame 15-21 fenders • remove the bolts [a]. • remove: trims [a] bracket [b] • remove the bolts [a]. • remove: bolts [a] license plate bracket [b] pad [c] flap bracket [d] • remove: (for au model) bolts [a] license plate bracket [b] pad [c] flap bracket [d] flap [e].

  • Page 546

    15-22 frame fenders • remove: screw [a] washers [b] rear turn signal light assembly [c] • remove: screws [a] washers [b] dampers [c] license plate light assembly [d] flap [e] flap installation • installation is the reverse of removal. ○ check that the grommet [a] is in place on the flap bracket [b]....

  • Page 547

    Frame 15-23 frame frame inspection • visually inspect the frame for cracks, dents, bending, or warp. ○ if there is any damage to the frame, replace it. Warning a repaired frame may fail in use, possibly causing an accident resulting in injury or death. If the frame is bent, dented, cracked, or warpe...

  • Page 548

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

  • Page 549

    Frame 15-25 frame cover subframe cover removal • remove: side cover (see side cover removal) bolts [a] with washers • clear the tabs [b] on the subframe cover [c] by pulling up the lower part of the subframe cover. • clear the tabs [d] on the subframe cover and remove the subframe cover. Subframe co...

  • Page 550

    15-26 frame frame cover frame cover removal • check that the pads [a] are in place on the frame cover. Left frame cover [b] right frame cover [c] • when installing the grommet [a], face the thick side to- ward the inside [b] of the left frame cover [c]. • remove: subframe cover (see subframe cover r...

  • Page 551

    Frame 15-27 rear view mirrors rear view mirror removal • slide the dust cover [a]. • loosen the rear view mirror locknut (upper) [b], and re- move the rear view mirror stay [c] from the rear view mir- ror nut (lower) [d]. ○ the rear view mirror locknut (upper) and rear view mirror stay are left-hand...

  • Page 553: Electrical System

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

  • Page 554

    16-2 electrical system starter motor disassembly................................................................................................ 16-53 starter motor assembly .................................................................................................... 16-54 brush inspection .....

  • Page 555

    Electrical system 16-3 exploded view this page intentionally left blank..

  • Page 556

    16-4 electrical system exploded view.

  • Page 557

    Electrical system 16-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 turn signal light mounting screws 1.2 0.12 11 in·lb 2 meter mounting screws 1.2 0.12 11 in·lb 3 meter assembly screws 0.43 0.044 3.8 in·lb 4 front brake light switch screw 1.2 0.12 11 in·lb 5 license plate light mount...

  • Page 558

    16-6 electrical system exploded view.

  • Page 559

    Electrical system 16-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oxygen sensor 44 4.5 32 2 water temperature sensor 12 1.2 106 in·lb 3 stator coil bolts 12 1.2 106 in·lb l 4 alternator rotor bolt 155 15.8 114 5 starter motor clutch bolts 12 1.2 106 in·lb l 6 timing rotor bolt 39 4....

  • Page 560

    16-8 electrical system exploded view.

  • Page 561

    Electrical system 16-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 starter relay cable terminal bolts 3.9 0.40 35 in·lb 2 starter motor cable terminal nut 4.9 0.50 43 in·lb 3 starter relay bracket bolts 6.9 0.70 61 in·lb 4 side stand switch bolt 8.8 0.90 78 in·lb l 5 regulator/rectif...

  • Page 562

    16-10 electrical system specifications item standard battery type sealed battery model name ftx9-bs capacity 12 v 8 ah voltage 12.6 v or more gross weight 3.0 kg (6.6 lb) electrolyte volume 0.41 l (25 cu in.) charging system type three-phase ac alternator output voltage 39 v or more at 4 000 r/min (...

  • Page 563

    Electrical system 16-11 special tools and sealant hand tester: 57001-1394 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 flywheel puller assembly, m38 × 1.5/m35 × 1.5: 57001-1615 st...

  • Page 564

    16-12 electrical system special tools and sealant liquid gasket, tb1211f: 92104-0004.

  • Page 565

    Electrical system 16-13 parts location this page intentionally left blank..

  • Page 566

    16-14 electrical system parts location.

  • Page 567

    Electrical system 16-15 parts location 1. Meter unit 2. Ignition switch 3. Starter lockout switch 4. Turn signal relay 5. Stick coils 6. Spark plugs 7. Starter motor 8. Speed sensor 9. Frame ground 10. Fuse box 2 11. Battery 12 v 8 ah 12. Relay box 13. Immobilizer/kawasaki diagnostic system connecto...

  • Page 568

    16-16 electrical system wiring diagram (zr800a without gps unit).

  • Page 569

    Electrical system 16-17 wiring diagram (zr800a without gps unit).

  • Page 570

    16-18 electrical system wiring diagram (zr800a with gps unit).

  • Page 571

    Electrical system 16-19 wiring diagram (zr800a with gps unit).

  • Page 572

    16-20 electrical system wiring diagram (zr800b without gps unit).

  • Page 573

    Electrical system 16-21 wiring diagram (zr800b without gps unit).

  • Page 574

    16-22 electrical system wiring diagram (zr800b with gps unit).

  • Page 575

    Electrical system 16-23 wiring diagram (zr800b with gps unit).

  • Page 576

    16-24 electrical system wiring diagram (zr800c).

  • Page 577

    Electrical system 16-25 wiring diagram (zr800c).

  • Page 578

    16-26 electrical system wiring diagram (zr800d).

  • Page 579

    Electrical system 16-27 wiring diagram (zr800d).

  • Page 580

    16-28 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 581

    Electrical system 16-29 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 582

    16-30 electrical system battery battery removal • turn the ignition switch off. • remove: seats (see rear/front seat removal in the frame chap- ter) band [a] • remove the fuse box [b] from the battery case. • take out the battery [c] from the battery case. • disconnect the negative (–) cable [a]. No...

  • Page 583

    Electrical system 16-31 battery battery activation electrolyte filling • make sure that the model name [a] of the electrolyte con- tainer matches the model name [b] of the battery. These names must be the same. Battery model name zr800a/b: ftx9-bs notice each battery comes with its own specific elec...

  • Page 584

    16-32 electrical system battery • place the electrolyte container upside down with the six sealed cells into the filler ports of the battery. Hold the container level, push down to break the seals of all six cells. You will see air bubbles rising into each cell as the ports fill. Note ○ do not tilt ...

  • Page 585

    Electrical system 16-33 battery initial charge • newly activated sealed batteries require an initial charge. Standard charge: 0.9 a × 5 ∼ 10 hours if using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers: battery mate...

  • Page 586

    16-34 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 587

    Electrical system 16-35 battery if the reading is 12.6 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: 12.6 v or more terminal voltage (v) [a] battery charge rate (%) [b] refresh charge is require...

  • Page 588

    16-36 electrical system charging system alternator cover removal • remove: left frame cover (see frame cover removal in the frame chapter) left lower fairing (see lower fairing removal (zr800a/b models) in the frame chapter) • free the hoses [a]. • disconnect the alternator lead connector [b]. • rem...

  • Page 589

    Electrical system 16-37 charging system stator coil removal • remove: alternator cover (see alternator cover removal) holding plate bolt [a] and plate alternator lead grommet [b] stator coil bolts [c] stator coil [d] stator coil installation • apply a non-permanent locking agent to the threads of th...

  • Page 590

    16-38 electrical system charging system • using the flywheel puller [a], remove the alternator rotor [b] from the crankshaft. Special tool - flywheel puller assembly, m38 × 1.5/m35 × 1.5: 57001-1615 notice do not attempt to strike the alternator rotor itself. Striking the rotor can cause the magnets...

  • Page 591

    Electrical system 16-39 charging system • using a cleaning fluid, clean off any oil or dirt on the washer [a] and dry it with a clean cloth. • install the washer. Note ○ confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque. • install the rotor bolt [a]...

  • Page 592

    16-40 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 593

    Electrical system 16-41 charging system • to check the alternator output voltage, do the following procedures. ○ turn the ignition switch off. ○ 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 594

    16-42 electrical system charging system regulator/rectifier inspection • remove: regulator/rectifier bracket bolts [a] regulator/rectifier assembly [b] • disconnect the connector [a]. • remove: regulator/rectifier bolts [b] regulator/rectifier [c] • set the hand tester to the × 1 kΩ range and make t...

  • Page 595

    Electrical system 16-43 charging system charging system circuit 1. Ignition switch 2. Load 3. Frame ground 3 4. Engine ground 5. Battery 12 v 8 ah 6. Main fuse 30 a 7. Starter relay 8. Alternator 9. Regulator/rectifier.

  • Page 596

    16-44 electrical system ignition system warning the ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. Notice do not disconnect the battery cables or any ot...

  • Page 597

    Electrical system 16-45 ignition system crankshaft sensor installation • run the crankshaft sensor lead correctly (see cable, wire, and hose routing section in the appendix chapter). • tighten: torque - crankshaft sensor bolts: 5.9 n·m (0.60 kgf·m, 52 in·lb) • using a high flash-point solvent, clean...

  • Page 598

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

  • Page 599

    Electrical system 16-47 ignition system stick coil removal notice never drop the stick coils especially on a hard sur- face. Such a shock to the stick coils can damage it. • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) side fairings (see side fairing removal in the fram...

  • Page 600

    16-48 electrical system 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 601

    Electrical system 16-49 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 602

    16-50 electrical system ignition system 2nd check • start the engine to the following conditions. Condition: transmission gear → 1st position clutch lever → pulled in side stand → up ○ turn the ignition switch on and push the starter button. ○ then the starter motor should turn when the starter sys-...

  • Page 603

    Electrical system 16-51 ignition system.

  • Page 604

    16-52 electrical system ignition system ignition system circuit 1. Engine stop switch 2. Stick coils 3. Vehicle-down sensor 4. Speed sensor 5. Main throttle sensor 6. Subthrottle sensor 7. Neutral switch 8. Crankshaft sensor 9. Side stand switch 10. Oxygen sensor 11. Joint connector e 12. Ecu 13. Fr...

  • Page 605

    Electrical system 16-53 electric starter system starter motor removal notice do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • remove the throttle body assy (see throttle body assy removal in the fuel system (dfi) chapter). • slide back the rubber cap [a...

  • Page 606

    16-54 electrical system electric starter system ○ the brush plate [a] and brushes come off with the right -hand end cover [b]. • remove the terminal locknut [a] and terminal bolt [b], and then remove the brush with the brush plate [c] from the right-hand end cover. Starter motor assembly • replace t...

  • Page 607

    Electrical system 16-55 electric starter system • install the armature [b] among the brushes [a]. • 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 the end cover. • install the new o-rings and ti...

  • Page 608

    16-56 electrical system electric starter system • measure the diameter [a] of the commutator [b]. If the commutator diameter is less than the service limit, replace the starter motor with a new one. Commutator diameter standard: 28 mm (1.10 in.) service limit: 27 mm (1.06 in.) armature inspection • ...

  • Page 609

    Electrical system 16-57 electric starter system starter relay inspection • remove: battery negative (–) cable (see battery removal) left side cover (see side cover removal in the frame chapter) • disconnect the connector [a]. • remove the starter relay cover [b]. • disconnect the cable terminals [a]...

  • Page 610

    16-58 electrical system electric starter system electric starter circuit 1. Ignition switch 2. Engine stop switch 3. Starter button 4. Neutral switch 5. Side stand switch 6. Joint connector e 7. Joint connector b 8. Frame ground 4 9. Frame ground 1 10. Engine ground 11. Battery 12 v 8 ah 12. Starter...

  • Page 611

    Electrical system 16-59 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 612

    16-60 electrical system 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. Good [c] bad [d] • after installation, adjust the headlight aim (see head...

  • Page 613

    Electrical system 16-61 lighting system • pull out the bulb [a] straight from the socket. Notice do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage then the specified valve. • replace the bulb with a new one. • install the socket securely...

  • Page 614

    16-62 electrical system lighting system • insert the new bulb [a] into the socket [b]. • install the license plate light cover. Headlight/tail light circuit 1. Ignition switch 2. Tail/brake light (led) 3. License plate light 12 v 5 w 4. Joint connector b 5. Frame ground 4 6. Main fuse 30 a 7. Engine...

  • Page 615

    Electrical system 16-63 lighting system turn signal light bulb replacement • remove the screw [a] and remove the lens [b]. • 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 socke...

  • Page 616

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

  • Page 617

    Electrical system 16-65 lighting system turn signal light circuit 1. Ignition switch 2. Main fuse 30 a 3. Starter relay 4. Battery 12 v 8 ah 5. Engine ground 6. Rear right turn signal light 12 v 10 w 7. Rear left turn signal light 12 v 10 w 8. Joint connector b 9. Frame ground 4 10. Turn signal rela...

  • Page 618

    16-66 electrical system air switching valve air switching valve operation test • refer to the air suction system damage inspection in the periodic maintenance chapter. Air switching valve unit test • remove the air switching valve (see air switching valve removal in the engine top end chapter). • se...

  • Page 619

    Electrical system 16-67 air switching valve air switching valve circuit 1. Ignition switch 2. Joint connector e 3. Ecu 4. Frame ground 4 5. Engine ground 6. Battery 12 v 8 ah 7. Starter relay 8. Main fuse 30 a 9. Ecu fuse 15 a 10. Ecu main relay 11. Relay box 12. Fuse box 1 13. Ignition fuse 15 a 14...

  • Page 620

    16-68 electrical system radiator fan system fan motor inspection • remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • disconnect the radiator fan motor lead connector [a]. • using an auxiliary leads, supply battery power to the fan motor. If the fan does not rotate, the...

  • Page 621

    Electrical system 16-69 radiator fan system radiator fan circuit 1. Ignition switch 2. Joint connector c 3. Fan motor 4. Frame ground 2 5. Water-proof joint 2 6. Water temperature sensor 7. Frame ground 1 8. Joint connector e 9. Ecu 10. Engine ground 11. Battery 12 v 8 ah 12. Main fuse 30 a 13. Star...

  • Page 622

    16-70 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. Notic...

  • Page 623

    Electrical system 16-71 meter, gauge, indicator unit electronic combination meter unit inspection • remove the meter unit (see meter unit removal/installa- tion). [1] red warning indicator light (led) ground (–) [2] fuel level sensor [3] unused [4] unused [5] unused [6] tachometer pulse [7] speed se...

  • Page 624

    16-72 electrical system meter, gauge, indicator unit • when the terminals are connected, the meter unit dis- plays the following. ○ all the lcd segments appear for about 1 second. ○ the red warning indicator light (led) [a] and yellow en- gine warning indicator light (led) [b] go on for about 1 seco...

  • Page 625

    Electrical system 16-73 meter, gauge, indicator unit check 2: meter communication line (service code 39) check • connect the leads in the same circuit as check 1. • wait 10 seconds and the yellow engine warning indicator light (led) goes on. • set the odo mode [a] by pushing the left button [b]. • p...

  • Page 626

    16-74 electrical system meter, gauge, indicator unit • by pushing the left button [a] each time, check that the display [b] changes as follows. If the display function does not work, replace the meter assembly. Check 4: mileage indication changing check • connect the leads in the same circuit as che...

  • Page 627

    Electrical system 16-75 meter, gauge, indicator unit • set the odo mode [a] by pushing the left button [b]. • during the right button [c] pushing, the unit of the speed [d], distance [e] and temperature [f] change every time the left button is pushed within 2 seconds. If the meter function does not ...

  • Page 628

    16-76 electrical system meter, gauge, indicator unit • by pushing the right button, check that the hour display decides and minute display [a] starts blinking. • by pushing the left button each time, check that the minute display changes. • by pushing the right button, check that the hour and minute...

  • Page 629

    Electrical system 16-77 meter, gauge, indicator unit • connect the terminal [15] to the battery (+) terminal. • and then, disconnect the terminal [15]. • push the left [a] and right [b] buttons more than 2 second, within 20 seconds after the terminal [15] disconnected. • check that the red warning i...

  • Page 630

    16-78 electrical system meter, gauge, indicator unit • check that the blue high beam indicator light (led) [a] goes on. If the indicator light (led) does not go on, replace the meter assembly. Check 10: green right turn signal indicator light (led) inspection • connect the leads in the same circuit ...

  • Page 631

    Electrical system 16-79 meter, gauge, indicator unit check 12: yellow abs indicator light (led) inspection (equipped models) • connect the leads in the same circuit as check 1. ○ the yellow abs indicator light (led) goes on. • connect the terminal [10] to the battery (–) terminal. • check that the y...

  • Page 632

    16-80 electrical system meter, gauge, indicator unit • check that the segments number of the fuel level gauge [a] matches the resistance value of the variable rheostat. ○ when the terminal [2] is connected, 1 segment in the fuel level gauge should appear about every 15 seconds. Variable rheostat res...

  • Page 633

    Electrical system 16-81 meter, gauge, indicator unit check 17: trip meter inspection • connect the leads in the same circuit as check 15. • set the trip mode [a] by pushing the left button [b]. • raise the input frequency of the oscillator to see the result of odometer inspection. If the value indic...

  • Page 634

    16-82 electrical system meter, gauge, indicator unit fuel level sensor line self-diagnosis mode inspection note ○ usually when the open or short of the fuel level sensor circuit is detected, it becomes the fuel level sensor line self-diagnosis mode. ○ the all segments of the fuel gauge and fuel warn...

  • Page 635

    Electrical system 16-83 meter, gauge, indicator unit meter circuit 1. Ignition switch 2. Speed sensor 3. Water-proof joint 1 4. Water-proof joint 2 5. Neutral switch 6. Water temperature sensor 7. Crankshaft sensor 8. Oil pressure switch 9. Joint connector e 10. Ecu 11. Frame ground 1 12. Engine gro...

  • Page 636

    16-84 electrical system immobilizer system this motorcycle is equipped with an immobilizer system to protect the motorcycle from theft. This system provides a theft proof device by means of matching a code between the inbuilt key transponder and ecu. If the code does not match, ignition system, inje...

  • Page 637

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

  • Page 638

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

  • Page 639

    Electrical system 16-87 immobilizer system • insert the ignition key 2 to the ignition switch and turn it to “on.” ○ if there is any problem in the registration, the red warning indicator light (led) and immobilizer warning symbol [a] blink to display the collation error. Immobilizer amplifier failu...

  • Page 640

    16-88 electrical system immobilizer system • the red warning indicator light (led) [a] goes off. • remove the key registration unit, key registration adapter and install the immobilizer/kawasaki diagnostic system connector cap. Note ○ turn the ignition switch to “on” with the registered igni- tion k...

  • Page 641

    Electrical system 16-89 immobilizer system spare ignition key registration flow chart.

  • Page 642

    16-90 electrical system immobilizer system case 2: when the ignition switch is faulty and to be replaced. • prepare a new ignition switch [a] and two new ignition keys [b]. ○ these parts are available as a set. Prepare the current registered ignition key [c]. • remove: ignition switch (see immobiliz...

  • Page 643

    Electrical system 16-91 immobilizer system ○ the red warning indicator light (led) and immobilizer warning symbol [a] blink 1 time and stops for 1 second and repeats this cycle. Not verified ○ the red warning indicator light (led) and immobilizer warning symbol [a] blink to display the collation err...

  • Page 644

    16-92 electrical system immobilizer system • disconnect the immobilizer antenna connector, then con- nect the antenna connector of the new ignition switch. • insert the ignition key 1 [a] again into the new ignition switch and turn it to “on.” note ○ insert the next key and turn it to “on” within 15...

  • Page 645

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

  • Page 646

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

  • Page 647

    Electrical system 16-95 immobilizer system • replace: ecu [a] (see immobilizer system parts replacement) • insert the current registered ignition key into the ignition switch and turn it to “on.” ○ if there is any problem in the registration, the red warning indicator light (led) and immobilizer war...

  • Page 648

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

  • Page 649

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

  • Page 650

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

  • Page 651

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

  • Page 652

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

  • Page 653

    Electrical system 16-101 immobilizer system all keys initial registration flow chart.

  • Page 654

    16-102 electrical system immobilizer system immobilizer system parts replacement ignition switch replacement • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) side fairings (see fairing removal in the frame chap- ter) • disconnect the lead connectors [a]. • remove the stee...

  • Page 655

    Electrical system 16-103 immobilizer system • tighten a new torx bolt [a] until the bolt head [b] is broken [c]. • run the leads correctly (see cable, wire, and hose rout- ing section in the appendix chapter). • register the more than two ignition keys (see key regis- tration). Immobilizer amplifier...

  • Page 656

    16-104 electrical system immobilizer system • 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]. • check that the pad [a] and trim [b] are in place on the lower [c] and upper [d]...

  • Page 657

    Electrical system 16-105 immobilizer system • connect the connectors to the ecu. • install the lower and upper [a] guards to the ecu. Notice do not pinch the leads. • tighten the new screws [b] using the kawasaki genuine screws of which threads are coated with locking agent. • install the pads [a] o...

  • Page 658

    16-106 electrical system immobilizer system immobilizer system circuit 1. Ignition switch 2. Joint connector e 3. Ecu 4. Immobilizer/kawasaki diagnostic system connector 5. Frame ground 1 6. Frame ground 4 7. Engine ground 8. Battery 12 v 8 ah 9. Starter relay 10. Main fuse 30 a 11. Ecu fuse 15 a 12...

  • Page 659

    Electrical system 16-107 switches and sensors brake light timing inspection • refer to the brake light switch operation inspection in the periodic maintenance chapter. Brake light timing adjustment • refer to the brake light switch operation inspection in the periodic maintenance chapter. Switch ins...

  • Page 660

    16-108 electrical system switches and sensors water temperature sensor inspection • remove the water temperature sensor (see water tem- perature sensor removal/installation in the fuel system (dfi) chapter). • suspend the sensor [a] in a container of coolant so that the threaded portion is submerged...

  • Page 661

    Electrical system 16-109 switches and sensors oxygen sensor removal notice never drop the sensor especially on a hard surface. Such a shock to the sensor can damage it. Notice do not pull strongly, twist, or bend the oxygen sen- sor lead. This may cause the wiring open. • remove: right frame cover (...

  • Page 662

    16-110 electrical system switches and sensors fuel level sensor inspection • remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • open the clamps [a]. • remove: bolts [b] fuel level sensor [c] • check that the float moves up and down smoothly without binding. It should go...

  • Page 663

    Electrical system 16-111 relay box the relay box [a] has relays and diodes. The relays and diodes can not be removed. Relay box removal notice never drop the relay box especially on a hard sur- face. Such a shock to the relay box can damage it. • remove: seat cover (see seat cover removal in the fra...

  • Page 664

    16-112 electrical system relay box relay circuit inspection (with the battery disconnected) tester connection tester reading (Ω) headlight relay 1-3 ∞ 7-6 ∞ ecu main relay 4-5 not ∞* 7-8 ∞ fuel pump relay 9-10 not ∞* 11-16 ∞ starter circuit relay 11-12 ∞ 17-20 ∞ fan relay 18-19 not ∞* *: the actual ...

  • Page 665

    Electrical system 16-113 relay box relay box internal circuit a: headlight circuit relay b: ecu main relay c: fuel pump relay d: starter circuit relay e: radiator fan relay.

  • Page 666

    16-114 electrical system fuse 30 a main/15 a ecu fuse removal • remove: left side cover (see side cover removal in the frame chapter) starter relay cover [a] • pull out the fuses [a] from the starter relay with needle nose pliers. Fuse box fuse removal • remove the seats (see rear/front seat removal...

  • Page 667

    Electrical system 16-115 fuse fuse inspection • remove the fuse (see 30 a main/15 a ecu/fuse box/fuse removal). • inspect the fuse element. If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater t...

  • Page 669: Appendix

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

  • Page 670

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

  • Page 671

    Appendix 17-3 cable, wire, and hose routing 1. Meter lead 2. Run the meter lead to the front of the rubber cover. 3. Cover the city light lead connectors, turn signal light lead connectors, front wheel rotation sensor lead connector (abs equipped models) with the rubber cover. 4. Main harness 5. Cla...

  • Page 672

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

  • Page 673

    Appendix 17-5 cable, wire, and hose routing 1. Front brake hose 2. Right switch housing lead 3. Throttle cable (accelerator) 4. Throttle cable (decelerator) 5. Do not twist the throttle cables. 6. Clutch cable 7. Left switch housing lead 8. Run the main harness, front brake hose, throttle cables and...

  • Page 674

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

  • Page 675

    Appendix 17-7 cable, wire, and hose routing 1. Clamp (hold the right city light lead and right turn signal light lead.) 2. Clamp (hold the left city light lead and left turn signal light lead.) 3. Bend the clamps in the direction of arrows. 4. Horn lead 5. Clamp (hold the right turn signal lead.) 6....

  • Page 676

    17-8 appendix cable, wire, and hose routing 1. Throttle cable (decelerator) 2. Throttle cable (accelerator) 3. Main harness 4. Run the throttle cables to the outside of the main harness and frame. 5. Run the throttle cables under the main harness..

  • Page 677

    Appendix 17-9 cable, wire, and hose routing 1. Run the ignition switch lead and immobilizer antenna lead between the frame and thermostat housing. 2. Fuel tank breather hose 3. Radiator overflow hose 4. Fuel tank drain hose 5. Reserve tank overflow hose 6. Intake air pressure sensor #2 connector 7. ...

  • Page 678

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

  • Page 679

    Appendix 17-11 cable, wire, and hose routing 1. Run the clutch cable to the right side of the thermostat housing. 2. Clutch cable 3. Clamp (hold the fuel injector #4 lead. Insert the projection of the clamp into the hole second from the right. 4. Run the fuel injector #1 lead between the air switchi...

  • Page 680

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

  • Page 681

    Appendix 17-13 cable, wire, and hose routing 1. Left turn signal light lead 2. License plate light lead 3. Right turn signal light lead 4. Tail/brake light lead 5. Cover the turn signal light lead connectors and license plate light lead connector with the rubber cover. 6. Seat lock cable 7. Clamp (h...

  • Page 682

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

  • Page 683

    Appendix 17-15 cable, wire, and hose routing 1. Ignition switch lead 2. Throttle cable (accelerator) 3. Throttle cable (decelerator) 4. Air switching valve lead 5. Run the radiator fan motor lead between the heat insulation rubber plate and engine bracket. 6. Radiator fan motor lead 7. Run the radia...

  • Page 684

    17-16 appendix cable, wire, and hose routing 1. Fuel level sensor lead 2. Run the clutch cable through the clamp. 3. Clutch cable 4. Run the clutch cable under the vehicle-down sensor lead and horn lead. 5. Clamp (hold the horn lead. Bend the clamp as shown.) 6. Horn lead 7. Clamp (hold the horn lea...

  • Page 685

    Appendix 17-17 cable, wire, and hose routing 1. Fuel tank drain hose 2. Reserve tank overflow hose 3. Clamp (hold the reserve tank over flow hose, fuel tank drain hose and fuel tank breather hose in order from the outside. Hold the fuel tank breather hose at the tape position.) 4. Fuel tank breather...

  • Page 686

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

  • Page 687

    Appendix 17-19 cable, wire, and hose routing 1. Reserve tank overflow hose 2. Fuel tank drain hose 3. Fuel tank breather hose 4. Run the reserve tank over flow hose to the outside of the fuel tank drain hose as shown. 5. Run the radiator overflow hose to the left side of the fan motor and clutch cab...

  • Page 688

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

  • Page 689

    Appendix 17-21 cable, wire, and hose routing 1. Reserve tank overflow hose 2. Fuel tank drain hose 3. Fuel tank breather hose 4. Run the three hoses to the inside of the hook of the air cleaner housing. 5. Run the throttle position sensor lead through the hook of the air cleaner housing. 6. Throttle...

  • Page 690

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

  • Page 691

    Appendix 17-23 cable, wire, and hose routing 1. Oxygen sensor lead 2. Clamp (hold the crankshaft sensor/oil pressure switch lead and oxygen sensor lead in order of the outside.) 3. Run the rear brake switch lead to the outside of the exhaust butterfly valve cables.* 4. Rear brake switch lead 5. Set ...

  • Page 692

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

  • Page 693

    Appendix 17-25 cable, wire, and hose routing 1. Run the intake air pressure sensor hose to the right side of the throttle cables. 2. Intake air pressure sensor #1 lead 3. Throttle cable (accelerator) 4. Throttle cable (decelerator) 5. Run the main harness, throttle cables and intake air pressure sen...

  • Page 694

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

  • Page 695

    Appendix 17-27 cable, wire, and hose routing 1. Run the starter relay lead backward the hoses. 2. Starter relay lead 3. Regulator/rectifier lead 4. Run the battery positive (+) cable to the outside of the regulator/rectifier lead. 5. Starter motor cable 6. Battery positive (+) cable 7. Run the start...

  • Page 696

    17-28 appendix cable, wire, and hose routing 1. Run the regulator/rectifier lead to the outside of the battery positive (+) cable. 2. Run the regulator/rectifier lead under the cross pipe. 3. Battery positive (+) cable 4. Regulator/rectifier lead 5. Clamp (hold the regulator/rectifier lead. Insert t...

  • Page 697

    Appendix 17-29 cable, wire, and hose routing 1. Clamps (hold the main harness. Insert the projection of the clamp into the frame.) 2. Fuse box 3. Abs hydraulic unit lead (abs equipped models) 4. Battery negative (–) cable 5. Run the main harness to the outside of the clamp of the battery band. 6. Ru...

  • Page 698

    17-30 appendix cable, wire, and hose routing 1. Thermostat housing 2. Align the white paint of the water hose (from thermostat housing to radiator) with projection of the thermostat housing. 3. Align the white paint of the water hose (from cylinder head to thermostat housing) with rib of the thermos...

  • Page 699

    Appendix 17-31 cable, wire, and hose routing 1. Clamps (install the clamp as shown.) 2. Align the white paint of the water hose (from radiator to water pump) with projection of the water pipe. 3. Face the white paint position of the water hose to the upside. 4. Viewed form a.

  • Page 700

    17-32 appendix cable, wire, and hose routing 1. Meter bracket 2. Front brake hose 3. Clamps (hold the front brake hose.) 4. Zr800a/b/d models 5. Zr800c model.

  • Page 701

    Appendix 17-33 cable, wire, and hose routing 1. Run the rear brake hose to the inside of the mud guard. 2. Damper 3. Rear brake hose 4. Hold the damper with the mud guard. 5. Section a-a.

  • Page 702

    17-34 appendix cable, wire, and hose routing abs equipped models.

  • Page 703

    Appendix 17-35 cable, wire, and hose routing 1. Clamp (hold the front wheel rotation sensor lead.) 2. Clamps (hold the front brake hose and front wheel rotation sensor lead at the white tape position of the front wheel rotation sensor lead.) 3. Clamps (hold the front brake hose.) 4. Meter bracket 5....

  • Page 704

    17-36 appendix cable, wire, and hose routing abs equipped models.

  • Page 705

    Appendix 17-37 cable, wire, and hose routing 1. Clamp (hold the rear brake hose.) 2. Run the rear brake hose of rear master cylinder under the clamp. 3. Clamps (hold the rear brake hoses so that the rear brake hose of the master cylinder is outside.) 4. Clamp (hold the rear brake hose and rear wheel...

  • Page 706

    17-38 appendix cable, wire, and hose routing abs equipped models 1. Do not hold the front wheel rotation sensor with the clamp. 2. Front wheel rotation sensor 3. Clamp (hold the front wheel rotation sensor.) 4. Run the front brake hose through the clamp. 5. Front brake hose.

  • Page 707

    Appendix 17-39 cable, wire, and hose routing abs equipped models 1. Rear wheel rotation sensor lead 2. Run the rear wheel rotation sensor to the inside of the exhaust butterfly valve cables.* 3. Clamps (hold the rear brake hose and rear wheel rotation sensor lead.) 4. Run the rear brake hose and rea...

  • Page 708

    17-40 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 709

    Appendix 17-41 troubleshooting guide 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 valve spring broken or weak valve not...

  • Page 710

    17-42 appendix troubleshooting guide engine load faulty: brake dragging clutch slipping engine oil level too high engine oil viscosity too high drive train trouble lubrication inadequate: engine oil level too low engine oil poor quality or incorrect water temperature meter incorrect: water temperatu...

  • Page 711

    Appendix 17-43 troubleshooting guide crankshaft runout excessive engine mounting portions loose crankshaft bearing worn primary gear worn or chipped camshaft chain tensioner trouble camshaft chain, sprocket, guide worn air suction valve damaged air switching valve damaged alternator rotor loose cata...

  • Page 712

    17-44 appendix troubleshooting guide (too soft) tire air pressure too low 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 p...

  • Page 713

    Model application year model beginning frame no. 2013 zr800ad jkbzr800aada00001 2013 zr800bd jkbzrcb1 □ dda00001 jkbzr800abda00001 2013 zr800cd jkbzr800ccda00001 2013 zr800dd jkbzr800cdda00001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1463-01 printed in jap...