Мануал kawasaki z750 2005

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This quick reference guide will assistyou in locating a desired topic or pro-cedure.•Bend the pages back to match theblack tab of the desired chapter num-ber with the black tab on the edge ateach table of contents page.•Refer to the sectional table of contentsfor the exact pages to locate the spe-cific topic required.

Quick Reference Guide

General Information 1 j

Periodic Maintenance 2 j

Fuel System (DFI) 3 j

Cooling System 4 j

Engine Top End 5 j

Clutch 6 j

Engine Lubrication System 7 j

Engine Removal/Installation 8 j

Crankshaft/Transmission 9 j

Wheels/Tires 10 j

Final Drive 11 j

Brakes 12 j

Suspension 13 j

Steering 14 j

Frame 15 j

Electrical System 16 j

Appendix 17 j

Z750

All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, ortransmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,without the prior written permission of Quality Assurance Department/Consumer Products & MachineryCompany/Kawasaki Heavy Industries, Ltd., Japan.No liability can be accepted for any inaccuracies or omissions in this publication, although every possible

care has been taken to make it as complete and accurate as possible.The right is reserved to make changes at any time without prior notice and without incurring an obligation

to make such changes to products manufactured previously. See your Motorcycle dealer for the latestinformation on product improvements incorporated after this publication.All information contained in this publication is based on the latest product information available at the time

of publication. Illustrations and photographs in this publication are intended for reference use only and maynot depict actual model component parts.

© 2003 Kawasaki Heavy Industries, Ltd. First Edition (1) : Sep. 16, 2003 (M)

LIST OF ABBREVIATIONSA ampere(s) lb pound(s)

ABDC after bottom dead center m meter(s)

AC alternating current min minute(s)

ATDC after top dead center N newton(s)

BBDC before bottom dead center Pa pascal(s)

BDC bottom dead center PS horsepower

BTDC before top dead center psi pound(s) per square inch

°C degree(s) Celsius r revolution

DC direct current rpm revolution(s) per minute

F farad(s) TDC top dead center

°F degree(s) Fahrenheit TIR total indicator reading

ft foot, feet V volt(s)

g gram(s) W watt(s)

h hour(s) Ω ohm(s)

L liter(s)

Read OWNER’S MANUAL before operating.

Foreword

This manual is designed primarily for use bytrained 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 andrepair work. A basic knowledge of mechanics,the proper use of tools, and workshop proce-dures must be understood in order to carry outmaintenance and repair satisfactorily. When-ever the owner has insufficient experience ordoubts his ability to do the work, all adjust-ments, maintenance, and repair should be car-ried out only by qualified mechanics.In order to perform the work efficiently and

to avoid costly mistakes, read the text, thor-oughly familiarize yourself with the proceduresbefore starting work, and then do the work care-fully in a clean area. Whenever special tools orequipment are specified, do not use makeshifttools or equipment. Precision measurementscan only be made if the proper instruments areused, and the use of substitute tools may ad-versely affect safe operation.For the duration of the warranty period,

we recommend that all repairs and scheduledmaintenance be performed in accordance withthis service manual. Any owner maintenance orrepair procedure not performed in accordancewith this manual may void the warranty.To get the longest life out of your vehicle:

• Follow the Periodic Maintenance Chart in theService Manual.

• Be alert for problems and non-scheduledmaintenance.

•Use proper tools and genuine Kawasaki Mo-torcycle parts. Special tools, gauges, andtesters that are necessary when servicingKawasaki motorcycles are introduced by theSpecial Tool Catalog or Manual. Genuineparts provided as spare parts are listed in theParts Catalog.

• Follow the procedures in this manual care-fully. Don’t take shortcuts.

•Remember to keep complete records of main-tenance and repair with dates and any newparts installed.

How to Use This ManualIn preparing this manual, we divided the prod-

uct into its major systems. These systems be-came the manual’s chapters. All informationfor a particular system from adjustment throughdisassembly and inspection is located in a sin-gle chapter.The Quick Reference Guide shows you all

of the product’s system and assists in locatingtheir chapters. Each chapter in turn has its owncomprehensive Table of Contents.The Periodic Maintenance Chart is located in

the Periodic Maintenance chapter. The chartgives a time schedule for required maintenanceoperations.If you want spark plug information, for exam-

ple, go to the Periodic Maintenance Chart first.The chart tells you how frequently to clean andgap the plug. Next, use the Quick ReferenceGuide to locate the Periodic Maintenance chap-ter. Then, use the Table of Contents on the firstpage of the chapter to find the Spark Plug sec-tion.Whenever you see these WARNING and

CAUTION symbols, heed their instructions!Always follow safe operating and maintenancepractices.

WARNINGThis warning symbol identifies specialinstructions or procedures which, if notcorrectly followed, could result in per-sonal injury, or loss of life.

CAUTION

This caution symbol identifies specialinstructions or procedures which, if notstrictly observed, could result in dam-age to or destruction of equipment.

This manual contains four more symbols (inaddition toWARNING andCAUTION) which willhelp you distinguish different types of informa-tion.

NOTEThis note symbol indicates points of par-ticular interest for more efficient and con-venient operation.

• Indicates a procedural step or work to bedone.Indicates a procedural sub-step or how to dothe work of the procedural step it follows. Italso precedes the text of a NOTE.Indicates a conditional step or what action totake based on the results of the test or inspec-tion in the procedural step or sub-step it fol-lows.

In most chapters an exploded view illustrationof the system components follows the Table ofContents. In these illustrations you will find theinstructions indicating which parts require spec-ified tightening torque, oil, grease or a lockingagent during assembly.

GENERAL INFORMATION 1-1

1General Information

Table of Contents

Before Servicing ……………………………………………………………………………………………………… 1-2Model Identification………………………………………………………………………………………………….. 1-7General Specifications……………………………………………………………………………………………… 1-8Technical Information – Air Inlet System …………………………………………………………………….. 1-10Technical Information – New Ignition Interlock Sidestand ……………………………………………… 1-12Technical Information – Tail/Brake Lights Employing LED …………………………………………….. 1-13Technical Information – KAWASAKI LOW EXHAUST EMISSION SYSTEM ……………………. 1-15Unit Conversion Table ……………………………………………………………………………………………… 1-16

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 have been included in each chapter wherevernecessary. This section explains the items that require particular attention during the removal andreinstallation or disassembly and reassembly of general parts.Especially note the following:

Battery GroundBefore completing any service on the motorcycle, discon-

nect the battery wires from the battery to prevent the enginefrom accidentally turning over. Disconnect the ground wire(–) first and then the positive (+). When completed with theservice, first connect the positive (+) wire to the positive (+)terminal of the battery then the negative (–) wire to the neg-ative terminal.

Edges of PartsLift large or heavy parts wearing gloves to prevent injury

from possible sharp edges on the parts.

SolventUse a high flush point solvent when cleaning parts. High

flush point solvent should be used according to directionsof the solvent manufacturer.

Cleaning vehicle before disassemblyClean the vehicle thoroughly before disassembly. Dirt or

other foreign materials entering into sealed areas during ve-hicle disassembly can cause excessive wear and decreaseperformance of the vehicle.

GENERAL INFORMATION 1-3

Before Servicing

Arrangement and Cleaning of Removed PartsDisassembled parts are easy to confuse. Arrange the

parts according to the order the parts were disassembledand clean the parts in order prior to assembly.

Storage of Removed PartsAfter all the parts including subassembly parts have been

cleaned, store the parts in a clean area. Put a clean clothor plastic sheet over the parts to protect from any foreignmaterials that may collect before re-assembly.

InspectionReuse of worn or damaged parts may lead to serious ac-

cident. Visually inspect removed parts for corrosion, discol-oration, or other damage. Refer to the appropriate sectionsof this manual for service limits on individual parts. Replacethe parts if any damage has been found or if the part is be-yond its service limit.

Replacement PartsReplacement parts must be KAWASAKI genuine or

recommended by KAWASAKI. Gaskets, O-rings, oil seals,grease seals, circlips or cotter pins must be replaced withnew ones whenever disassembled.

Assembly OrderIn most cases assembly order is the reverse of disassem-

bly, however, if assembly order is provided in this ServiceManual, follow the procedures given.

1-4 GENERAL INFORMATION

Before Servicing

Tightening SequenceBolts, nuts, or screws must be tightened according to the

specified sequence to prevent case warpage or deformationwhich can lead to malfunction. If the specified tighteningsequence is not indicated, tighten the fasteners alternatingdiagonally.

Tightening TorqueIncorrect torque applied to a bolt, nut, or screw may

lead to serious damage. Tighten fasteners to the specifiedtorque using a good quality torque wrench. Often, thetightening sequence is followed twice-initial tightening andfinal tightening with torque wrench.

ForceUse common sense during disassembly and assembly,

excessive force can cause expensive or hard to repair dam-age. When necessary, remove screws that have a non-permanent locking agent applied using an impact driver.Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ringHardening, shrinkage, or damage of both gaskets

and O-rings after disassembly can reduce sealing per-formance. Remove old gaskets and clean the sealingsurfaces thoroughly so that no gasket material or othermaterial remains. Install new gaskets and replace usedO-rings when re-assembling

Liquid Gasket, Locking AgentFor applications that require Liquid Gasket or a Locking

agent, clean the surfaces so that no oil residue remains be-fore applying liquid gasket or locking agent. Do not applythem excessively. Excessive application can clog oil pas-sages and cause serious damage.

GENERAL INFORMATION 1-5

Before Servicing

PressFor 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 usesmooth movements when installing.

Ball Bearing and Needle BearingDo not remove pressed ball or needle unless removal is

absolutely necessary. Replace with new ones wheneverremoved. Press bearings with the manufacturer and sizemarks facing out. Press the bearing into place by puttingpressure on the correct bearing race as shown.Pressing the incorrect race can cause pressure between

the inner and outer race and result in bearing damage.

Oil Seal, Grease SealDo not remove pressed oil or grease seals unless removal

is necessary. Replace with new ones whenever removed.Press new oil seals with manufacture and size marks facingout. Make sure the seal is aligned properly when installing.

Circlips, Cotter PinsReplace circlips or cotter pins that were removedwith new

ones. Install the circlip with its sharp edge facing outwardand its chamfered side facing inward to prevent the clip frombeing pushed out of its groove when loaded. Take carenot to open the clip excessively when installing to preventdeformation.

LubricationIt 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, applythe specific oil or grease as specified.

1-6 GENERAL INFORMATION

Before Servicing

Direction of Engine RotationWhen rotating the crankshaft by hand, the free play

amount of rotating direction will affect the adjustment. Ro-tate the crankshaft to positive direction (clockwise viewedfrom output side).

Electrical WiresA two-color wire is identified first by the primary color and

then the stripe color. Unless instructed otherwise, electricalwires must be connected to those of the same color.

GENERAL INFORMATION 1-7

Model Identification

ZR750–J1 Left Side View:

ZR750–J1 Right Side View:

1-8 GENERAL INFORMATION

General Specifications

Items ZR750–J1

Dimensions:

Overall length 2 080 mm (81.9 in.)

Overall width 780 mm (30.7 in.)

Overall height 1 055 mm (41.5 in.)

Wheelbase 1 425 mm (56.1 in.)

Road clearance 165 mm (6.5 in.)

Seat height 815 mm (32.1 in.)

Dry mass 195 kg (430.0 lb)

Curb mass: Front 111 kg (244.8 lb)

Rear 107 kg (235.9 lb)

Fuel tank capacity 18 L (5.0 US gal.)

Performance:

Minimum turning radius 2.9 m (9.5 ft)

Engine:

Type 4-stroke, DOHC, 4-cylinder

Cooling system Liquid-cooled

Bore and stroke 68.4 × 50.9 mm (2.7 × 2.0 in.)

Displacement 748 mL (45.64 cu in.)

Compression ratio 11.3

Maximum horsepower 79 kW (107 PS) @10 500 r/min (rpm),

(MY, AU) 80 kW (109 PS) @11 000 r/min (rpm)

(HR) 78.2 kW (106 PS) @11 000 r/min (rpm)

Maximum torque 75 N·m (7.6 kgf·m, 55 ft·lb) @8 200 r/min (rpm),

(HR) 73 N·m (7.4 kgf·m, 54 ft·lb) @8 200 r/min (rpm)

Carburetion system FI (Fuel Injection) KEIHIN TTK34 × 4

Starting system Electric starter

Ignition system Battery and coil (transistorized)

Timing advance Electronically advanced (digital igniter)

Ignition timing From 10° BTDC @1 100 r/min (rpm) to 37° BTDC@5 800 r/min (rpm)

Spark plug NGK CR9EK or ND U27ETR

Cylinder numbering method Left to right, 1-2-3-4

Firing order 1-2-4-3

Valve timing:

Inlet Open 38° BTDC

Close 66° ABDC

Duration 284°

Exhaust Open 57° BBDC

Close 31° ATDC

Duration 268°

Lubrication system Forced lubrication (wet sump)

Engine oil:

Type API SE, SF or SG

API SH or SJ with JASO MA

GENERAL INFORMATION 1-9

General Specifications

Items ZR750–J1

Viscosity SAE 10W-40

Capacity 3.8 L (4.0 US qt)

Drive Train:

Primary reduction system:

Type Gear

Reduction ratio 1.714 (84/49)

Clutch type Wet multi disc

Transmission:

Type 6-speed, constant mesh, return shift

Gear ratios: 1st 2.571 (36/14)

2nd 1.941 (33/17)

3rd 1.555 (28/18)

4th 1.333 (28/21)

5th 1.200 (24/20)

6th 1.095 (23/21)

Final drive system:

Type Chain drive

Reduction ratio 2.867 (43/15)

Overall drive ratio 5.382 @Top gear

Frame:

Type Tubular, diamond

Caster (rake angle) 24.5°

Trail 104 mm (4.1 in.)

Front tire: Type Tubeless

Size 120/70 ZR17 M/C (58W)

Rear tire: Type Tubeless

Size 180/55 ZR17 M/C (73W)

Front suspension: Type Telescopic fork (upside-down)

Wheel travel 120 mm (4.7 in.)

Rear suspension: Type Swingarm (uni-trak)

Wheel travel 126 mm (5.0 in.)

Brake Type: Front Dual discs

Rear Single disc

Electrical Equipment:

Battery 12 V 8 Ah

Headlight: Type Semi-sealed beam

Bulb 12 V 55 W × 2/55 W (Hi/Lo)

Tail/brake light 12 V 0.5/3.8 W (LED), (CA) 12 V 0.5/5W (LED)

Alternator: Type Three-phase AC

Rated output 24 A/14 V @5 000 r/min (rpm)

Specifications are subject to change without notice, and may not apply to every country.(AU): Australia Model(CA): Canada Model(MY):Malaysia Model(HR): with Honeycomb Catalytic Converter Model (Restricted model)

1-10 GENERAL INFORMATION

Technical Information – Air Inlet System

Subthrottle Control SystemThe ZR750–J1 employs large bore throttle bodies to increase power output. However, sudden

changes in throttle opening can cause hesitation and jerky throttle response with a single butterflyvalve in a large bore. Therefore two throttle valves are placed in each inlet tract, the main throttlevalve located closest to the cylinder and a subthrottle valve placed further up the inlet tract. The mainthrottle valve is operated by the rider when the throttle grip is turned clockwise or counterclockwise,while the subthrottle valve is operated by a stepping motor controlled by the ECU. The subthrottlevalve automatically adjusts air inlet to more precisely match engine demand, so that when the mainthrottle is opened quickly there is no hesitation or jerky response.The subthrottle valves allow the fuel injection system to provide smooth throttle response, similar to

that of a constant velocity carburetor, no matter how quickly the throttle is opened.

A. Main Throttle ValveB. Subthrottle ValveC. Throttle Valve

D. Vacuum PistonE. Inlet Air

GENERAL INFORMATION 1-11

Technical Information – Air Inlet System

OperationThe subthrottle control system consists of the subthrottle valve, subthrottle valve actuator with a

stepping motor built in it, ECU, and subthrottle sensor. The subthrottle valve is built in the each throttlebody.The subthrottle control system operates on the signal supplied from the ECU. The open/close oper-

ation of the subthrottle valve is performed by the subthrottle actuator which is controlled by the ECUto change the current direction into the motor of the subthrottle valve actuator.The subthrottle sensor detects the subthrottle valve actuator movement by measuring voltage and

the ECU determines the subthrottle valve angle based on the operation map.When turning the ignition switch ON, every time the ECU automatically drives the subthrottle valve

from fully closed position to fully opened position. The ECU memorizes these positions and turnsback the subthrottle valve to the original point to confirm the subthrottle valve idling voltage.

A. Subthrottle ValvesB. Subthrottle Valve ActuatorC. Subthrottle SensorD. Main Throttle Sensor

E. ECU (Electric Control Unit)F. Air Cleaner SideG. Crankshaft SensorH. Speed Sensor

1-12 GENERAL INFORMATION

Technical Information – New Ignition Interlock Sidestand

OutlineThe New Ignition Interlock Sidestand System applied to ZR750–J1 models that cannot function if

gears are engaged and/or the sidestand is not lifted upward even though clutch lever pulled in, whichdiffers from the traditional one. Refer to the tables below as to the engine starts and/or the driving ateach condition.

New Ignition Interlock Sidestand SystemSide Stand Gear Position Clutch Lever Engine Start Engine Run

A Up Neutral Released Starts Continue running

B Up Neutral Pulled in Starts Continue running

C Up In Gear Released Doesn’t start Continue running

D Up In Gear Pulled in Starts Continue running

E Down Neutral Released Starts Continue running

F Down Neutral Pulled in Starts Continue running

G Down In Gear Released Doesn’t start Stops

H Down In Gear Pulled in Doesn’t start Stops

Current Ignition Interlock Sidestand SystemSide Stand Gear Position Clutch Lever Engine Start Engine Run

A Up Neutral Released Starts Continue running

B Up Neutral Pulled in Starts Continue running

C Up In Gear Released Doesn’t start Continue running

D Up In Gear Pulled in Starts Continue running

E Down Neutral Released Starts Continue running

F Down Neutral Pulled in Starts Continue running

G Down In Gear Released Doesn’t start Stops

H Down In Gear Pulled in Start Continue running

GENERAL INFORMATION 1-13

Technical Information – Tail/Brake Lights Employing LED

OutlineThis model employs a tail/brake light containing 21 Light Emitting Diodes (LED). The LED emits

luminous beams over a longer life span than those emitted from a traditional electric heated bulb(more than 5 times longer), uses lower voltage, expends lower wattage (approx. 1/5), and is quickerresponsing.

Due Position of LED Installation

The resistors, the diodes, and the Zener diodes aremounted in the electronic circuits [A] of the LED, whichsupplies the steady current and voltage to the light.

Light Emitting Diode (LED)The Light Emitting Diode (LED) [A] is an element of semi-

conductor diode that converts applied voltage to light.

The LED emits luminous beams by the collision of nega-tive charge electrons [A] and positive charge holes [B] whenapplied the forward voltage and current to the PN junctiondiode [C].

1-14 GENERAL INFORMATION

Technical Information – Tail/Brake Lights Employing LED

The emitting color differs according to the materials ofsemi-conductors.

Materials of Semi-Conductor and Emitting Color

Materials of Semi-Conductor Emitting Color

GaAsP,

GaAlAsRed

GaP Green

GaN Blue

Ga: GalliumAs: ArsenicP: PhosphorusN: NitrogenAl: Aluminum

GENERAL INFORMATION 1-15

Technical Information – KAWASAKI LOW EXHAUST EMISSION SYSTEM

Since the emission regulations become more severe, Kawasaki has adopted a type of simplifiedKAWASAKI LOW EXHAUST EMISSION SYSTEM (KLEEN), which have no catalyst protection sys-tem, according to each regulation of different countries.The muffler with built-in catalyst has the same durability as the conventional muffler, however, do

not use leaded gasoline and do not coast with the ignition system OFF. Running the engine withoutignition damages catalyst.Refer to the ZX900E Service Manual (Part No. 99924–1255) for more information about the KLEEN

(theory, maintenance, and handling precautions), including the secondary air injection system.

Honeycomb Type Catalytic ConverterThe converter is a three-way catalytic converter, and its surface is covered with alumina upon whichplatinum and rhodium are applied, and has a cylindrical metallic honeycomb structure made bybending a corrugated sheet and a flat sheet of stainless steel into a spiral of increasing diameter.The honeycomb structure is convenient for the catalytic converter because it has a large surfacearea but small size to react effectively and has low exhaust resistance. In addition, its inherentstrength helps resist vibration, and has simple structure welded directly on the silencer.Generally, the temperature of the exhaust gas must be higher than activation temperature, so theconverters are installed in the exhaust manifold rear end where the temperature of exhaust gas isstill high. And, the converters will be activated even under low load conditions.After the exhaust gas is diluted with the secondary air injection, the catalytic converter works wellbecause of rich oxygen to reduce CO, HC, and NOx. Accordingly, we can keep the exhaust gasemission within regulation.This type of converter works more efficiently as a three-way catalytic converter to reduce CO, HC,and NOx than the pipe type catalytic converter because of its more and denser catalysts.

1. Manifold2. Silencer3. Honeycomb Type Catalyst4. Mark for Manifold5. Mark for Silencer

1-16 GENERAL INFORMATION

Unit Conversion Table

Prefixes for Units:

Prefix Symbol Powermega M × 1 000 000kilo k × 1 000centi c × 0.01milli m × 0.001micro µ × 0.000001

Units of Mass:kg × 2.205 = lbg × 0.03527 = oz

Units of Volume:L × 0.2642 = gal (US)L × 0.2200 = gal (imp)L × 1.057 = qt (US)L × 0.8799 = qt (imp)L × 2.113 = pint (US)L × 1.816 = pint (imp)mL × 0.03381 = oz (US)mL × 0.02816 = oz (imp)mL × 0.06102 = cu in

Units of Force:N × 0.1020 = kgN × 0.2248 = lbkg × 9.807 = Nkg × 2.205 = lb

Units of Length:km × 0.6214 = milem × 3.281 = ftmm × 0.03937 = in

Units of Torque:N·m × 0.1020 = kgf·mN·m × 0.7376 = ft·lbN·m × 8.851 = in·lbkgf·m × 9.807 = N·mkgf·m × 7.233 = ft·lbkgf·m × 86.80 = in·lb

Units of Pressure:kPa × 0.01020 = kgf/cm²kPa × 0.1450 = psikPa × 0.7501 = cmHgkgf/cm² × 98.07 = kPakgf/cm² × 14.22 = psicmHg × 1.333 = kPa

Units of Speed:km/h × 0.6214 = mph

Units of Power:kW × 1.360 = PSkW × 1.341 = HPPS × 0.7355 = kWPS × 0.9863 = HP

Units of Temperature:

PERIODIC MAINTENANCE 2-1

2

Periodic Maintenance

Table of Contents

Periodic Maintenance Chart ………….. 2-2Torque and Locking Agent…………….. 2-5Specifications ……………………………… 2-10Special Tools ………………………………. 2-12Periodic Maintenance Procedures….. 2-13Fuel System (DFI)……………………… 2-13Fuel Hose and ConnectionInspection……………………………. 2-13

Throttle Control SystemInspection……………………………. 2-14

Idle Speed Inspection ……………… 2-15Engine Vacuum SynchronizationInspection……………………………. 2-15

Air Cleaner Element Cleaning…… 2-18Cooling System…………………………. 2-20Radiator Hose and ConnectionInspection……………………………. 2-20

Coolant Change ……………………… 2-20Engine Top End ………………………… 2-22Air Suction Valve Inspection …….. 2-22Valve Clearance Inspection ……… 2-22

Clutch………………………………………. 2-23Clutch Adjust Inspection ………….. 2-23

Engine Lubrication System…………. 2-24Engine Oil Change………………….. 2-24Oil Filter Change …………………….. 2-25

Wheels/Tires…………………………….. 2-25Tire Wear Inspection ……………….. 2-25Air Pressure Inspection……………. 2-26

Final Drive………………………………… 2-27Drive Chain Slack Inspection ……. 2-27Drive Chain Slack Adjustment ….. 2-27

Drive Chain Wear Inspection ……. 2-28Drive Chain Lubrication……………. 2-29

Brakes……………………………………… 2-29Brake Pad Wear Inspection ……… 2-29Rear Brake Light SwitchInspection/Adjustment…………… 2-29

Caliper Fluid Seal Damage………. 2-30Caliper Dust Seal/Friction BootDamage………………………………. 2-30

Master Cylinder Inspection (VisualInspection)…………………………… 2-31

Brake Fluid Level Inspection…….. 2-32Brake Fluid Change ………………… 2-32Brake Line Bleeding………………… 2-34Brake Hoses and ConnectionsInspection……………………………. 2-36

Suspension ………………………………. 2-37Front Fork Oil Leak Check ……….. 2-37Rear Shock Absorber Oil LeakCheck …………………………………. 2-37

Steering …………………………………… 2-37Steering Inspection …………………. 2-37Steering Adjustment………………… 2-37Steering Stem BearingLubrication…………………………… 2-38

Electrical System ………………………. 2-39Spark Plug Inspection ……………… 2-39

General Lubrication …………………… 2-41Lubrication …………………………….. 2-41

Nut, Bolt, and Fastener Tightness .. 2-42Tightness Inspection ……………….. 2-42

2-2 PERIODIC MAINTENANCE

Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the motorcycle ingood running condition. The initial maintenance is vitally important and must not be neglected.

Periodic Inspection:FREQUENCY Whichever

comesfirst

* ODOMETER READINGkm × 1000 (mile × 1000)

1 6 12 18 24 30 36 See

INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) Page

Steering system:

Steering play — inspect year • • • • 2–37

Steering stem bearings — lubricate 2 years • 2–38

Brake system:

Brake hoses leak — inspect • • • • • • • 2–36

Brake hoses damage — inspect • • • • • • • 2–36

Brake hose installation condition — inspect • • • • • • • 2–36

Brake operation (effectiveness, play-drag)- inspect

year • • • • • • • —

Brake pad wear — inspect # • • • • • • 2–29

Brake fluid level — inspect 6 month • • • • • • • 2–32

Brake light switch operation — inspect • • • • • • • 2–29

Wheels and tires:

Tire air pressure — inspect year • • • 2–26

Wheels/tires damage — inspect • • • 2–25

Tire tread wear, abnormal wear — inspect • • • 2–25

Wheel bearings damage — inspect year • • • —

Suspensions:

Front forks/rear shock absorber operation(damping and smooth stroke) • • • —

Front forks/rear shock absorber oil leak -inspect

year • • • 2–37

Rocker arm wear — inspect • • • —

Rocker arm operation • • • —

Tie rods operation • • • —

Drive train:

Drive chain lubrication condition — inspect # 1 000 km 2–29

Drive chain slack — inspect # 1 000 km 2–27

Drive chain wear — inspect # • • • 2–28

Drive chain guide wear — inspect • • • —

Electrical system:

Spark plug condition — inspect • • • 2–39

Lights and switches operation year • • • —

Headlight aiming — inspect year • • • —

Side stand switch operation year • • • —

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

FREQUENCY Whichevercomesfirst

* ODOMETER READINGkm × 1000 (mile × 1000)

1 6 12 18 24 30 36 See

INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) Page

Engine stop switch operation year • • • —

Fuel system (DFI):

Air cleaner element — clean # • 2–18

Throttle control system (play, smoothreturn, no drag) — inspect

year • • • • 2–14

Choke operation — inspect year • • • • —

Engine vacuum synchronization — inspect • • • 2–15

Engine vacuum synchronization — adjust When necessary 2–15

Idle speed — inspect • • • • 2–15

Fuel hoses leak — inspect • • • • 2–13

Fuel hoses damage — inspect year • • • • 2–13

Fuel hoses installation condition — inspect year • • • 2–13

Cooling system:

Coolant level — inspect • • • • —

Radiator hoses leak — inspect year • • • • 2–20

Radiator hoses damage — inspect year • • • • 2–20

Radiator hoses installation condition -inspect

year • • • • 2–20

Engine top end:

Air suction system damage — inspect • • • 2–22

Intake/exhaust valve clearance — inspect • 2–22

Chassis:

Chassis parts lubricate year • • • 2–41

Bolts and nuts tightness — inspect • • • • 2–42

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

Periodic Replacement Parts:FREQUENCY Whichever

comesfirst

* ODOMETER READINGkm × 1000 (mile × 1000)

1 12 24 36 48 See

CHANGE/REPLACE ITEM Every (0.6) (7.5) (15) (24) (30) Page

Brake hoses 4 years • 2–36

Brake fluid (front and rear) 2 years • • 2–32

Rubber parts of master cylinder and caliper 4 years • 2–30

Spark plug • • • • 2–39

Air cleaner element # • 2–18

Engine oil # year • • • • • 2–24

Oil filter year • • • • • 2–25

Fuel hoses 4 years • 2–13

Coolant 3 years • 2–20

Radiator hoses and O-rings 3 years • 2–20

# : Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed orfrequent starting/stopping.

Throttle control system inspection: Inspection of throttle grip play.

PERIODIC MAINTENANCE 2-5

Torque and Locking Agent

The following tables list the tightening torquefor the major fasteners requiring use of a non-permanent locking agent or liquid gasket.

Letters used in the “Remarks” column mean:AL: Tighten the two clamp bolts alternately

two times to ensure even tighteningtorque.

G: Apply grease to the threads.L: Apply a non-permanent locking agent tothe threads.

MO: Apply molybdenum disulfide grease oilsolution.

O: Apply oil to the threads and seating sur-face.

R: Replacement PartsS: Tighten the fasteners following the speci-fied sequence.

Si: Apply silicone grease (ex. PBC grease).SS: Apply silicone sealant.

The table below, relating tightening torque tothread diameter, lists the basic torque for thebolts and nuts. Use this table for only the boltsand nuts which do not require a specific torquevalue. All of the values are for use with drysolvent-cleaned threads.

Basic Torque for General FastenersThreads Torque

dia.(mm)

N·m kgf·m ft·lb

5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb8 14 ∼ 19 1.4 ∼ 1.9 10.0 ∼ 13.510 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 2512 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 4514 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 7216 115 ∼ 155 11.5 ∼ 16.0 83 ∼ 11518 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 16520 225 ∼ 325 23 ∼ 33 165 ∼ 240

TorqueFastener

N·m kgf·m ft·lbRemarks

Fuel System:

Inlet air pressure sensor bolt 12 1.2 104 in·lb

Water temperature sensor 25 2.5 18

Vehicle-down sensor bolts 2.0 0.20 17 in·lb

Camshaft position sensor bolt 12 1.2 104 in·lb

Camshaft position sensor rotor bolt 12 1.2 104 in·lb L

Throttle cable plate bolt 6.0 0.60 52 in·lb

Throttle body assy holder clamp bolts 2.0 0.20 17 in·lb

Choke link holder screws 2.1 0.21 18 in·lb

Delivery pipe screws 3.4 0.35 30 in·lb

Bypass screws 0.2 0.02 1.7 in·lb

Air cleaner duct holder screws 3.8 0.39 34 in·lb

Air cleaner housing mounting bolts 9.8 1.0 87 in·lb

Air cleaner duct clamp bolts 2.0 0.20 17 in·lb

Air cleaner housing screws 1.2 0.12 10 in·lb

Air cleaner housing tapping screws 1.2 0.12 10 in·lb

Speed sensor bolt 6.9 0.70 62 in·lb L

Fuel pump bolts 9.8 1.0 87 in·lb L, S

Fuel level sensor bolts 6.9 0.70 62 in·lb

Cooling System:

Radiator hose clamp screws 2.0 0.20 17 in·lb

Radiator fan bolts 8.3 0.85 74 in·lb

Water pump impeller bolt 9.8 1.0 87 in·lb

Water pump cover bolts 11 1.1 95 in·lb

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

TorqueFastener

N·m kgf·m ft·lbRemarks

Water pump drain bolt 11 1.1 95 in·lb

Water pipe bolts 11 1.1 95 in·lb

Thermostat housing ground bolt 7.0 0.70 61 in·lb

Thermostat bracket bolt 7.0 0.70 61 in·lb

Radiator upper bolts 7.0 0.70 61 in·lb

Radiator lower bolts 7.0 0.70 61 in·lb

Radiator screen bolt 7.0 0.70 61 in·lb

Coolant reserve tank screws 7.0 0.70 61 in·lb

Radiator fan switch 18 1.8 13

Water temperature sensor 25 2.5 18

Engine Top End:

Air suction valve cover bolts 9.8 1.0 87 in·lb

Cylinder head cover bolts 9.8 1.0 87 in·lb S

Camshaft cap bolts 12 1.2 104 in·lb S

Camshaft chain guide bolts 12 1.2 104 in·lb S

Cylinder head bolts (M10 new bolts) 54 5.5 40 MO, S

(Washer)

Cylinder head bolts (M10 used bolts) 49 5.0 36 MO, S

(Washer)

Cylinder head bolts (M6) 12 1.2 104 in·lb S

Cylinder head jacket plugs 22 2.2 16 L

Throttle body holder bolts 13 1.3 113 in·lb

Throttle body assy holder clamp bolts 2.0 0.20 17 in·lb

Camshaft sensor bolt 12 1.2 104 in·lb

Camshaft sensor rotor bolt 12 1.2 104 in·lb L

Front camshaft chain guide bolt (upper) 25 2.5 18

Front camshaft chain guide bolt (lower) 12 1.2 104 in·lb

Rear camshaft chain guide bolt 25 2.5 18

Camshaft chain tensioner mounting bolts 11 1.1 95 in·lb

Camshaft chain tensioner cap bolt 28 2.9 21

Spark plugs 13 1.3 113 in·lb

Coolant drain plug (Cylinder) 9.8 1.0 87 in·lb

Exhaust pipe manifold holder nuts 17 1.7 12

Muffler body clamp bolt 17 1.7 12

Muffler body mounting bolt 30 3.0 22

Crankshaft sensor cover bolts 11 1.1 95 in·lb

Clutch:

Clutch lever clamp bolts 7.8 0.80 69 in·lb

Clutch cover mounting bolts 11 1.1 95 in·lb

Oil filler plug 1.5 0.15 13 in·lb

Clutch spring bolts 8.8 0.90 78 in·lb

Clutch hub nut 135 14 100 R

PERIODIC MAINTENANCE 2-7

Torque and Locking Agent

TorqueFastener

N·m kgf·m ft·lbRemarks

Engine Lubrication:

Oil filler plug 1.5 0.15 13 in·lb

Engine oil drain bolt 20 2.0 14

Oil filter 31 3.2 23 EO, R

Holder mounting bolt 76 7.8 56 EO

Oil pan bolts 11 1.1 95 in·lb

Oil pipe holder bolts 13 1.3 113 in·lb L

Oil pressure relief valve 15 1.5 11 L

Oil pressure switch 15 1.5 11 SS

Oil pressure switch terminal bolt 1.5 0.15 13 in·lb

Water pump cover bolts 11 1.1 95 in·lb

Water pump impeller bolt 9.8 1.0 87 in·lb

Coolant drain plug (water pump) 11 1.1 95 in·lb

Oil passage plugs 20 2.0 14 L

Engine Removal/Installation:

Adjusting collar locknut 49 5.0 36 S

Engine mounting bolts and nuts 44 4.5 33 S

Front engine bracket bolts 44 4.5 33 S

Rear engine bracket bolts 25 2.5 18 S

Engine ground cable terminal bolt 9.8 1.0 87 in·lb

Crankshaft/Transmission:

Breather plate bolts 9.8 1.0 87 in·lb L

Crankcase bolts (M9, L = 81 mm) 42 4.3 31 MO, S

Crankcase bolts (M9, L = 95 mm) 42 4.3 31 MO, S

Crankcase bolts (M8) 27 2.8 20 S

Crankcase bolts (M7) 20 2.0 14 S

Crankcase bolts (M6) 12 1.2 104 in·lb S

Starter motor clutch bolts 12 1.2 104 in·lb L

Oil pipe holder bolts 13 1.3 113 in·lb L

Shift drum bearing holder bolt 13 1.3 113 in·lb L

Shift drum bearing holder screw 5.4 0.55 48 in·lb L

Connecting rod big end nuts see the text ← ← ←Crankshaft position rotor bolt 40 4.1 30

Oil pressure switch 15 1.5 11 SS

Oil pressure switch terminal bolt 1.5 0.15 13 in·lb

Oil passage plugs 20 2.0 14 L

Crankshaft sensor cover bolts 11 1.1 95 in·lb

Shift pedal mounting bolt 34 3.5 25 L

Gear positioning lever bolt 12 1.2 104 in·lb

Shift shaft return spring pin 29 3.0 22 L

Shift drum cam holder bolt 12 1.2 104 in·lb L

Footpeg bracket bolts 34 3.5 25 L

Shift lever bolt 6.9 0.70 61 in·lb

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

TorqueFastener

N·m kgf·m ft·lbRemarks

Tie-rod locknuts 6.9 0.70 61 in·lb

Neutral switch 15 1.5 11

Wheels/Tires:

Front axle clamp bolt 34 3.5 25

Front axle 108 11 80

Rear axle nut 108 11 80

Final Drive:

Engine sprocket nut 125 13 92 MO

Engine sprocket cover bolts 9.8 1.0 87 in·lb

Speed sensor cover bolts 6.9 0.70 61 in·lb L

Rear sprocket nuts 59 6.0 43

Speed sensor bolt 6.9 0.70 61 in·lb L

Brakes:

Bleed valves 7.8 0.80 69 in·lb

Brake hose banjo bolts 25 2.5 18

Brake lever pivot bolt 1.0 0.10 9 in·lb

Brake lever pivot bolt locknut 5.9 0.60 52 in·lb

Front brake reservoir cap screws 1.0 0.10 9 in·lb

Front brake light switch screws 1.0 0.10 9 in·lb

Front master cylinder clamp bolts 8.8 0.90 78 in·lb S

Front caliper mounting bolts 34 3.5 25

Front brake disc mounting bolts 27 2.8 20 L

Rear brake disc mounting bolts 27 2.8 20 L

Rear Caliper mounting bolts 25 2.5 18

Rear master cylinder mounting bolts 25 2.5 18

Rear master cylinder push rod locknut 18 1.8 13

Suspension:

Front fork clamp bolts (Upper) 20 2.0 14

Front fork clamp bolts (Lower) 20 2.0 14 AL

Front fork top plugs 25 2.5 18

Front fork bottom Allen bolts 30 3.1 22 L

Front axle clamp bolt 34 3.5 25

Rear shock absorber nuts (upper andlower)

34 3.5 25

Swingarm pivot shaft nut 108 11 80

Swingarm pivot shaft locknut 98 10 72

Uni-trak

Rocker arm nut 34 3.5 25

Tie-rod nuts 59 6.0 43

Steering:

Steering stem head bolt 108 11 80

Steering stem nut 27 2.8 20

Handlebar clamp bolts 25 2.5 18 S

PERIODIC MAINTENANCE 2-9

Torque and Locking Agent

TorqueFastener

N·m kgf·m ft·lbRemarks

Handlebar lower clamp nuts 34 3.5 25

Switch housing screws 3.5 0.36 31 in·lb

Front fork clamp bolts (Upper) 20 2.0 14

Front fork clamp bolts (Lower) 20 2.0 14 AL

Frame:

Footpeg bracket bolts 34 3.5 25 L

Side stand bolt 44 4.5 33

Side stand switch bolt 8.8 0.90 78 in·lb

Front fender bracket bolts 8.8 0.90 78 in·lb L

Front fender bolts 3.9 0.40 35 in·lb L

Side stand bracket bolts 49 5.0 36

Electrical System:

Spark plugs 13 1.3 113 in·lb

Alternator rotor bolt 110 11 81

Stator coil bolts 11 1.1 95 in·lb

Alternator lead holding plate bolt 11 1.1 95 in·lb L

Engine ground cable terminal bolt 9.8 1.0 87 in·lb

Alternator cover bolts 11 1.1 95 in·lb

Crankshaft sensor cover bolts 11 1.1 95 in·lb

Crankshaft sensor bolts 5.9 0.60 52 in·lb

Camshaft position sensor bolt 12 1.2 104 in·lb L

Timing rotor bolt 39 4.0 29

Starter motor mounting bolts 11 1.1 95 in·lb

Switch housing screws 3.5 0.36 31 in·lb

Radiator fan switch 18 1.8 13

Water temperature sensor 25 2.5 18 SS

Oil pressure switch 15 1.5 11 SS

Oil pressure switch terminal bolt 1.5 0.15 13 in·lb G

Neutral switch 15 1.5 11

Speed sensor bolt 6.9 0.70 61 in·lb

Fuel level sensor bolts 6.9 0.70 61 in·lb

Front brake light switch screw 1.0 0.10 9 in·lb

Meter mounting screws 1.2 0.12 10 in·lb

Tail/brake light mounting screws 1.2 0.12 10 in·lb

License plate light mounting screws 1.2 0.12 10 in·lb

Headlight mounting bolts 5.9 0.60 52 in·lb

Starter lockout switch screws – – – L

Starter motor clutch bolts 12 1.2 104 in·lb L

Starter relay cable terminal bolts 3.9 0.40 35 in·lb L

Regulator/rectifier bolts 6.9 0.70 61 in·lb

Regulator/rectifier bracket bolts 6.9 0.70 61 in·lb

Speed sensor cover bolts 6.9 0.70 61 in·lb L

Side stand switch bolt 8.8 0.90 78 in·lb

2-10 PERIODIC MAINTENANCE

Specifications

Item Standard Service Limit

Fuel System:

Throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – –

Idle speed 1 100 ±50 r/min (rpm) – – –

Bypass screws (turn out) 2 ±1/4 (for reference) – – –

Engine vacuum 29.7 ±1.333 kPa (225 ±10 mmHg) – – –

Air cleaner element Paper filter – – –

Cooling System:

Coolant:

Type (recommended) Permanent type of antifreeze – – –

Color Green – – –

Mixed ratio Soft water 50%, Coolant 50% – – –

Freezing point –35°C (–31°F) – – –

Total amount 2.9 L (3.1 US qt) – – –

Engine Top End:

Valve clearance:

Inlet 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.) – – –

Exhaust 0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.) – – –

Clutch:

Clutch lever free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – –

Engine Lubrication System:

Engine oil:

Type API SE, SF or SG – – –

API SH or SJ with JASO MA

Viscosity SAE 10W-40 – – –

Capacity 3.1 L (3.3 US qt) – – –

(when filter is not removed)

3.3 L (3.5 US qt) – – –

(when filter is removed)

3.8 L (4.0 US qt) – – –

(when engine is completely dry)

Level Between upper and lower level lines(after idling or running)

– – –

Wheels/Tires:

Tread depth:

Front

BRIDGESTONE 3.4 mm (0.13 in.) 1 mm (0.04 in.)

1.6 mm (0.06 in.)

(AT, CH, DE)

Rear

BRIDGESTONE 5.8 mm (0.23 in.) Up to 130 km/h (80 mph):

2 mm (0.08 in.)

Over 130 km/h (80 mph):

3 mm (0.12 in.)

PERIODIC MAINTENANCE 2-11

Specifications

Item Standard Service Limit

Air pressure: (when cold)

Front Up to 180 kg (397 lb) load:

250 kPa (2.5 kgf/cm², 36 psi)– – –

Rear Up to 180 kg (397 lb) load:

290 kPa (2.9 kgf/cm², 42 psi)– – –

Final Drive:

Drive chain slack 25 ∼ 35 mm (1.0 ∼ 1.4 in.) – – –

Drive chain 20-link length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.)

Brakes:

Brake fluid:

Grade DOT4 – – –

Brake pad lining thickness:

Front 4.5 mm (0.18 in.) 1 mm (0.04 in.)

Rear 5 mm (0.20 in.) 1 mm (0.04 in.)

Brake light timing:

Front Pulled ON – – –

RearON after about 10 mm (0.39 in.) ofpedal travel

– – –

Electrical System:

Spark plug gap 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 mm) – – –

AT: Republic of AustriaCH: Swiss ConfederationDE: Federal Republic of Germany

2-12 PERIODIC MAINTENANCE

Special Tools

Steering Stem Nut Wrench:57001–1100

Jack:57001–1238

Oil Filter Wrench:57001–1249

Pilot Screw Adjuster, C:57001–1292

Hand Tester:57001–1394

Spark Plug Wrench (Owner’s Tool):92110–1146

PERIODIC MAINTENANCE 2-13

Periodic Maintenance Procedures

Fuel System (DFI)Fuel Hose and Connection InspectionThe fuel hoses are designed to be used throughout themotorcycle’s life without any maintenance, however, if themotorcycle is not properly handled, the high pressure in-side the fuel line can cause fuel to leak [A] or the hoseto burst. Remove the fuel tank (see Fuel System (DFI)chapter) and check the fuel hoses.Replace the hose if any fraying, cracks [B] or bulges [C]are noticed.

•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]Pump Outlet Hose [B]Pump Inlet Hose [C]Front [D]

• Insert the pump outlet hose joint [A] straight onto the de-livery pipe [B] until the hose joint clicks [C].Front [D]

• Push and pull [A] the hose joint [B] back and forth morethan two times, and make sure it is locked and doesn’tcome off. When the hose joint is correctly installed, itshould slide on the delivery pipe about 5 mm (0.20 in.).If it does not slide, reinstall the hose joint.

WARNINGMake sure the hose joint is installed correctly on thedelivery pipe by sliding the joint, or the fuel couldleak.

•Check that the inlet hose [A] is onto the pipe fully and theplate clamps [B] are installed beyond the raised rib [C].1 ∼ 2 mm (0.039 ∼ 0.079 in.) [D]

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Throttle Control System InspectionThrottle Grip Play Inspection

•Check the throttle grip free play [A].If the free play is incorrect, adjust the throttle cable.

Throttle Grip Free PlayStandard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

•Check that the throttle grip moves smoothly from close tofull open, and the throttle closes quickly and completelyin all steering positions by the return spring.If the throttle grip doesn’t return properly, check the throt-tle cable routing, grip free play, and cable damage. Thenlubricate the throttle cable.

• Run the engine at the idle speed, and turn the handlebarall the way to the right and left to ensure that the idle speeddoesn’t change.If the idle speed increases, check the throttle grip free playand the cable routing.

If necessary, adjust the throttle cable as follows.

• Loosen the locknut [A].• Turn the adjuster [B] until the proper amount of free playcan be obtained.

• Tighten the locknut against the adjuster securely.If the throttle grip free play can not be adjusted with theadjuster, use the adjusters in the middle of the throttlecables.

• Loosen the locknut, and screw the adjuster at the upperend of the accelerator cable all the way in.

• Tighten the locknut against the adjuster securely.• Remove the fuel tank (see Fuel System (DFI) chapter).• Loosen the locknuts [A], and turn the lower adjusters [B]until the proper amount of throttle grip free play is ob-tained.

• Tighten the locknuts against the adjusters securely.If the throttle grip free play can not be adjusted with thelower adjusters, use the adjuster at the upper end of thecable again.

PERIODIC MAINTENANCE 2-15

Periodic Maintenance Procedures

Idle Speed Inspection

•Start the engine and warm it up thoroughly.

•With the engine idling, turn the handlebar to both sides.If handlebar movement changes the idle speed, thethrottle cables may be improperly adjusted or incorrectlyrouted or damaged. Be sure to correct any of theseconditions before riding (see Cable, Wire, and HoseRouting section in the Appendix chapter).

WARNINGOperation with improperly adjusted, incorrectlyrouted or damaged cables could result in an unsaferiding condition.

•Check idle speed.If the idle speed is out of the specified range, adjust it.

Idle SpeedStandard: 1 100 ±50 r/min (rpm)

Engine Vacuum Synchronization Inspection

NOTEThese procedures are explained on the assumption thatthe inlet and exhaust systems of the engine are in goodcondition.

•Situate the motorcycle so that it is vertical.• Remove the fuel tank (see Fuel System (DFI) chapter).• Pull off the vacuum hoses and the rubber cap(s) from theright fitting of each throttle body.

• Pull off the vacuum switch valve hose (thick) [A] from theair cleaner housing [B].Front [C]

CAUTION

Do not remove the inlet air pressure sensor hoseson the left fitting of each throttle body.

•Connect a commercially available vacuum gauge to theseright fittings of the throttle body as shown.

•Connect a highly accurate tachometer to one of the stickcoil primary leads.

• Plug:Vacuum Switch Valve Hose (thick) and its Air CleanerHousing HoleVacuum Hoses of Throttle Assy (see the next figure)Vacuum Switch Valve Hose (small) [A]Inlet Air Pressure Sensor Hose [B]Front [C]Vacuum Gauge [D]Plugs [E]

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

• Install the fuel tank (see Fuel System (DFI) chapter).• Start the engine and warm it up thoroughly.

• Check the idle speed.Tachometer [A]If the idle speed is out of the specified range, adjust it.

CAUTION

Do not measure the idle speed by the tachometer ofthe meter unit.

While idling the engine, inspect the engine vacuum, usingthe vacuum gauge [B].

Engine VacuumStandard: 29.7 ±1.333 kPa (225 ±10 mmHg) at Idle

Speed 1 100 ±50 r/min (rpm)

If any vacuum is not within the specifications, first syn-chronize the #3 and #4 throttle valves to the #1 and #2throttle valves by using the center adjusting screw [A].

Special Tool — Pilot Screw Adjuster, C: 57001–1292 [B]

Front [C]Example:#1: 165 mmHg#2: 190 mmHg#3: 170 mmHg#4: 200 mmHg

•With the engine at the correct idle speed, equalize thehighest vacuum of #3 and #4 (example 200 mmHg) tothe highest vacuum of #1 and #2 (example 190 mmHg)by turning the center adjusting screw.

NOTEAfter adjustment, the final vacuum measurement be-tween the highest throttle valves may not be 200 mmHg(in this example). The goal is to have the highest twovacuums between the left (1 and 2) and right (3 and 4)banks be the same.

•Open and close the throttle after each measurement andadjust the idle speed as necessary.

•Once the throttle valves have been synchronized, inspectthe main throttle sensor’s output voltage to ensure properoperation (procedure is at the end of this section).

PERIODIC MAINTENANCE 2-17

Periodic Maintenance Procedures

If any one vacuum measurement is out of the standardmeasurement after synchronization, adjust the bypassscrews [A].Front [B]

Special Tool — Pilot Screw Adjuster, C: 57001–1292

•Adjust the lowest vacuum between #1 and #2 to the high-est of #1 and #2.

• Adjust the lowest vacuum between #3 and #4 to the high-est of #3 and #4.

•Open and close the throttle valves after each measure-ment and adjust the idle speed as necessary.

• Inspect the vacuums as before.If all vacuums are within the specification, finish the en-gine vacuum synchronization.If any vacuum can not be adjusted within the specification,remove the bypass screws #1 ∼ #4 and clean them.

Turn in the bypass screw and count the number of turnsuntil it seats fully but not tightly. Record the number ofturns.

Torque — Bypass Screw: 0.2 N·m (0.02 kgf·m, 1.7 in·lb)

CAUTION

Do not over tighten them. They could be damaged,requiring replacement.

•Remove the bypass screw [A], spring [B], washer [C] andO-ring [D].Check the bypass screw and its hole for carbon deposits.If any carbon accumulates, wipe the carbon off the bypassscrew and the hole, using a cotton pad penetrated with ahigh-flash point solvent.Replace the O-ring with a new one.Check the tapered portion [E] of the bypass screw forwear or damage.If the bypass screw is worn or damaged, replace it.

• Turn in the bypass screw until it seats fully but not tightly.Torque — Bypass Screw: 0.2 N·m (0.02 kgf·m, 1.7 in·lb)

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•Back out the same number of turns counted when firstturned in. This is to set the screw to its original position.

NOTEA throttle body has different “turns out” of the bypassscrew for each individual unit. When setting the bypassscrew, use the “turns out” determined during disassem-bly. Use the specifications in this manual only if the orig-inal number is unknown.

•Repeat the same procedure for other bypass screws.• Repeat the synchronization.If the vacuums are correct, check the output voltage ofthe main throttle sensor (see Output Voltage Inspection ofMain Throttle Sensor in the Fuel System (DFI) chapter).

Main Throttle Sensor Output VoltageConnections to ECU

Meter (+)→ Y/W lead (terminal 2)

Meter (–)→ BR/BK lead (terminal 14)

Standard:

0.99 ∼ 1.03 V DC (at idle throttle opening)

If the output voltage is out of the range, check the throttleinput voltage (see Input Voltage Inspection of Main Throt-tle Sensor in the Fuel System (DFI) chapter).

• Remove the vacuum gauge hoses and install the vacuumhoses and rubber caps on the original position as shown.Vacuum Switch Valve Hose (small) [A]Inlet Air Pressure Sensor Hose [B]Front [C]

Air Cleaner Element Cleaning

NOTEIn dusty areas, the element should be cleaned morefrequently than the recommended interval.After riding through rain or on muddily roads, the ele-ment should be cleaned immediately.

WARNINGIf dirt or dust is allowed to pass through into thethrottle assy, the throttle may become stuck, possi-bly causing accident.

CAUTION

If dirt gets through into the engine, excessive en-gine wear and possibly engine damage will occur.

WARNINGClean the element in a well-ventilated area, and takecare that there are no sparks or flame anywherenear the working area; this includes any appliancewith a pilot light.Because of the danger of highly flammable liquids,do not use gasoline or a low flash-point solvent toclean the element.

PERIODIC MAINTENANCE 2-19

Periodic Maintenance Procedures

•Remove the fuel tank (see Fuel System (DFI) chapter).• Remove the fuel tank bracket bolts and bracket [A].

• Remove:Air Cleaner Duct Holder Screws [A]

•Remove the air cleaner duct holder [B] backward.

•Clean the element by tapping it lightly to loosen dust.• Blow away the remaining dust by applying compressedair [A] from the outside to the inside (from the clean sideto the dirty side).

• Visually inspect the element for no tears or no breaks andinspect the sponge gaskets [B] also.If the element or gasket has any tears or breaks, replacethe element.

• Install the element [A] with the flat side [B], facing for-wards.

• Fit the tongue [C] of the air cleaner duct holder into theslot of the housing the air cleaner duct holder.

Torque — Air Cleaner Duct Holder Screws: 3.8 N·m (0.39kgf·m, 34 in·lb)

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Cooling SystemRadiator Hose and Connection InspectionThe high pressure inside the radiator hose can causecoolant to leak [A] or the hose to burst if the line is notproperly maintained. Visually inspect the hoses for signsof deterioration. Squeeze the hoses. A hose should notbe hard and brittle, nor should it be soft or swollen.Replace the hose if any fraying, cracks [B] or bulges [C]are noticed.

• Check that the hoses are securely connected and clampsare tightened correctly.

Torque — Radiator HoseClampScrews: 2.0 N·m (0.20 kgf·m,17 in·lb)

Coolant Change

WARNINGTo avoid burns, do not remove the radiator cap ortry to change the coolant when the engine is stillhot. Wait until it cools down.Coolant on tires will make them slippery and cancause an accident and injury.Since coolant is harmful to the human body, do notuse for drinking.

•Place a container under the water pump drain bolt [A],then remove the drain bolt.

• Remove the fuel tank (see Fuel System (DFI) chapter).• Remove the radiator cap [A] in two steps. First turn thecap counterclockwise to the first stop. Then push and turnit further in the same direction and remove the cap.The coolant will drain from the radiator and engine.

• Remove :Left Side Cover (see Frame chapter)Reserve Tank Screws [A]

• Turn over [B] the reserve tank, remove the cap [C], andpour the coolant into a suitable container.

• Install the reserve tank.Torque — Coolant Reserve Tank Screws: 7.0 N·m ( 0.70

kgf·m, 61 in·lb)

• Tighten the drain bolt with the gasket.Replace the drain bolt gasket with a new one.Torque — Water PumpDrainBolt: 11 N·m (1.1 kgf·m, 95 in·lb)

PERIODIC MAINTENANCE 2-21

Periodic Maintenance Procedures

•When filling the coolant, choose a suitable mixture ratioby referring to the coolant manufacturer’s directions.

CAUTION

Soft or distilled water must be used with the an-tifreeze in the cooling system.If hard water is used in the system, it causes scaleaccumulation in the water passages, and consider-ably reduces the efficiency of the cooling system.

Water and Coolant Mixture Ratio (when shipping)Soft Water : 50%

Coolant : 50%

Freezing Point : −35°C (−31°F)

Total Amount : 2.9 L (3.1 US qt)

•Fill the radiator up to the filler neck [A] with coolant.NOTE

Pour in the coolant slowly so that it can expel the airfrom the engine and radiator.

•Check the cooling system for leaks.

• Tap the radiator hoses to force any air bubbles caughtinside.

• Fill the radiator up to the filler neck with coolant.• Fill the reserve tank up to the “F” (full) level line [A] withcoolant and install the cap [B].

• Install the fuel tank (see Fuel System (DFI) chapter).

• Start the engine and warm it up thoroughly until the radi-ator fan turns on and then stop the engine.

•Check the coolant level in the reserve tank several timeswhile the engine is cooling down, and replenish as nec-essary.If the coolant level is lower than the “L” level line, addcoolant to the “F” level line.

CAUTION

Do not add more coolant above the “F” level line.

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Engine Top EndAir Suction Valve Inspection

•Remove the air suction valve (see Engine Top End chap-ter).

• Visually inspect the reeds for cracks, folds, warps, heatdamage or other damage.If there is any doubt as to the condition of the reeds [A],replace the air suction valve as an assembly.

• Check the reed contact areas [B] of the valve holder forgrooves, scratches, any signs of separation from theholder or heat damage.

• If there is any doubt as to the condition of the reed contactareas, replace the air suction valve as an assembly.

• If any carbon or other foreign particles have accumulatedbetween the reed and the reed contact area, wash thevalve assembly clean with a high-flash point solvent.

CAUTION

Do not scrape off the deposits with a scraper as thiscould damage the rubber, requiring replacement ofthe suction valve assembly.

Valve Clearance Inspection

NOTEValve clearance must be checked and adjusted whenthe engine is cold (at room temperature).

•Remove:Pickup Coil CoverCylinder Head Cover (see Engine Top End chapter)

• Position the crankshaft at 1,4 piston TDC.TDC Mark [A] for #1, 4 PistonsTiming Mark (crankcase halves mating surface) [B]

• Using the thickness gauge [A], measure the valve clear-ance between the cam and the valve lifter.

Valve ClearanceStandard:

Inlet: 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.)Exhaust: 0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)

PERIODIC MAINTENANCE 2-23

Periodic Maintenance Procedures

When positioning #4 piston TDC at the end of thecompression stroke:Inlet valve clearance of #2 and #4 cylindersExhaust valve clearance of #3 and #4 cylindersMeasuring Valve [A]

When positioning #1 piston TDC at the end of thecompression stroke:Inlet valve clearance of #1 and #3 cylindersExhaust valve clearance of #1 and #2 cylindersMeasuring Valve [A]

If the valve clearance is not within the specified range,first record the clearance, and then adjust it.

ClutchClutch Adjust Inspection

•Pull the clutch lever just enough to take up the free play[A].

•Measure the gap between the lever and the lever holder.If the gap is too wide, the clutch may not release fully. Ifthe gap is too narrow, the clutch may not engage fully. Ineither case, adjust it.

Clutch Lever Free PlayStandard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

WARNINGTo avoid a serious burn, never touch the engine orexhaust pipe during clutch adjustment.

•Turn the adjuster [A] so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) [B]of threads are visible.

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•Slide the dust cover [A] at the clutch cable lower end outof place.

• Loosen both adjusting nuts [B] at the clutch cover as faras they will go.

• Pull the clutch outer cable [C] tight and tighten the adjust-ing nuts against the cover [D].

• Slip the rubber dust cover back onto place.• Turn the adjuster at the clutch lever until the free play iscorrect.

• Push the release lever [A] toward the front of the motor-cycle until it becomes hard to turn.At this time, the release lever should have the proper an-gle shown.60° [B]If the angle is wrong, check the clutch and release partsfor wear.

WARNINGBe sure that the outer cable end at the clutch leveris fully seated in the adjuster at the clutch lever, orit could slip into place later, creating enough cableplay to prevent clutch disengagement.

•After the adjustment, start the engine and check that theclutch does not slip and that it releases properly.

Engine Lubrication SystemEngine Oil Change

•Situate the motorcycle so that it is vertical after warmingup the engine.

• Remove the engine oil drain bolt [A] to drain the oil.The oil in the oil filter can be drained by removing the filter(see Oil Filter Change).Replace the drain bolt gasket [B] with a new one.

• Tighten the drain bolt.Torque — Engine Oil Drain Bolt: 20 N·m (2.0 kgf·m, 14 ft·lb)

•Pour in the specified type and amount of oil.Engine OilGrade: API SE, SF or SG

API SH or SJ with JASO MA

Viscosity: SAE 10W-40

Capacity: 3.1 L (3.3 US qt) (when filter is not removed)

3.3 L (3.5 US qt) (when filter is removed)

3.8 L (4.0 US qt) (when engine is completelydry)

PERIODIC MAINTENANCE 2-25

Periodic Maintenance Procedures

NOTEAlthough 10W-40 engine oil is the recommended oilfor most conditions, the oil viscosity may need to bechanged to accommodate atmospheric conditions inyour riding area.

Oil Filter Change

•Drain the engine oil (see Engine Oil Change).•Remove the oil filter [A] with the oil filter wrench [B].Special Tool — Oil Filter Wrench: 57001–1249

•Replace the filter with a new one.• Apply engine oil to the gasket [A] before installation.• Tighten the filter with the oil filter wrench.Torque — Oil Filter: 31 N·m (3.2 kgf·m, 23 ft·lb)

NOTEHand tightening of the oil filter can not be allowed sinceit does not reach to this tightening torque.

•Pour in the specified type and amount of oil (see EngineOil Change).

Wheels/TiresTire Wear InspectionAs the tire tread wears down, the tire becomes more sus-

ceptible to puncture and failure. An accepted estimate isthat 90% of all tire failures occur during the last 10% of treadlife (90% worn). So it is false economy and unsafe to usethe tires until they are bald.

•Remove any imbedded stones or other foreign particlesfrom the tread.

• Visually inspect the tire for cracks and cuts, replacing thetire in case of damage. Swelling or high spots indicateinternal damage, requiring tire replacement.

•Measure the tread depth at the center of the tread with adepth gauge [A]. Since the tire may wear unevenly, takemeasurement at several places.If any measurement is less than the service limit, replacethe tire.

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Tread DepthFront:

Standard: 3.4 mm (0.13 in.)

Service Limit: 1 mm (0.04 in.)

1.6 mm (0.06 in.) (AT, CH, DE)

Rear:

Standard: 5.8 mm (0.23 in.)

Service Limit: 2 mm (0.08 in.)

(Up to 130 km/h (80 mph))

3 mm (0.12 in.)

(Over 130 km/h (80 mph))

WARNINGTo ensure safe handling and stability, use only therecommended standard tires for replacement, in-flated to the standard pressure.

NOTEMost countries may have their own regulations a mini-mum tire tread depth: be sure to follow them.Check and balance the wheel when a tire is replacedwith a new one.

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 motorcyclehas not been ridden more than a mile during the past 3hours).Adjust the tire air pressure according to the specificationsif necessary.

Air Pressure (when cold)

Front 250 kPa (2.5 kgf/cm², 36 psi)

RearUp to 180 kg(397 lb) 290 kPa (2.9 kgf/cm², 42 psi)

• Install the air valve cap certainly after air pressure inspec-tion.

Torque — Air Valve Cap: 0.15 N·m (0.015 kgf·m, 1.3 in·lb)

PERIODIC MAINTENANCE 2-27

Periodic Maintenance Procedures

Final DriveDrive Chain Slack Inspection

NOTECheck the slack with the motorcycle setting on its sidestand.Clean the chain if it is dirty, and lubricate it if it appearsdry.

•Check the wheel alignment (seeWheel Alignment Inspec-tion).

•Rotate the rear wheel to find the position where the chainis tightest.

•Measure the vertical movement (chain slack) [A] midwaybetween the sprockets.If the chain slack exceeds the standard, adjust it.

Chain SlackStandard: 25 ∼ 35 mm (1.0 ∼ 1.4 in.)

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 out the left and right chainadjuster [D] evenly.If the chain is too tight, turn in the left and right chainadjusters evenly, and kick the wheel forward.

• Turn both chain adjusters evenly until the drive chain hasthe correct amount of slack. To keep the chain and wheelproperly aligned, the notch [E] on the left wheel alignmentindicator [F] should align with the same swingarm mark orposition [G] that the right indicator notch aligns with.

WARNINGMisalignment of the wheel will result in abnormalwear and may result in an unsafe riding condition.

•Tighten both chain adjuster locknuts securely.• Tighten the axle nut.Torque — Rear Axle Nut: 108 N·m (11 kgf·m, 80 ft·lb)

•Turn the wheel, measure the chain slack again at the tight-est position, and readjust if necessary.

• Insert a new cotter pin [A].NOTE

When inserting the cotter pin, if the slots in the nut donot align with the cotter pin hole in the axle, tighten thenut clockwise [B] up to next alignment.It should be within 30 degree.Loosen once and tighten again when the slot goes pastthe nearest hole.

2-28 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•Bend the cotter pin [A] over the nut.WARNING

If the rear axle nut is not securely tightened or thecotter pin is not installed, an unsafe riding condi-tion may result.

Drive Chain Wear Inspection

•Remove:Chain Cover Screws [A]Chain Cover [B]Mud Guard [C] (see Frame chapter)

• Rotate the rear wheel to inspect the drive chain for dam-aged rollers, and loose pins and links.If there is any irregularity, replace the drive chain.Lubricate the drive chain if it appears dry.

• Stretch the chain taut by hanging a 98 N (10 kg, 20 lb)weight [A] on the chain.

•Measure the length of 20 links [B] on the straight part [C] ofthe chain from the pin center of the 1st pin to the pin centerof the 21st pin. Since the chain may wear unevenly, takemeasurements at several places.If any measurements exceed the service limit, replace thechain. Also, replace the front and rear sprockets when thedrive chain is replaced.

Drive Chain 20-link LengthStandard: 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)Service Limit: 323 mm (12.7 in.)

WARNINGIf the drive chain wear exceeds the service limit, re-place the chain or an unsafe riding condition mayresult. A chain that breaks or jumps off the sprock-ets could snag on the engine sprocket or lock therear wheel, severely damaging the motorcycle andcausing it to go out of control.For safely, use only the standard chain. It is an end-less type and should not be cut for installation.

Standard ChainMake: ENUMA

Type: EK520MVXL

Link: 112 Links

PERIODIC MAINTENANCE 2-29

Periodic Maintenance Procedures

Drive Chain Lubrication

• If a special lubricant is not available, a heavy oil such asSAE 90 is preferred to a lighter oil because it will stay onthe chain longer and provide better lubrication.

• If the chain appears especially dirty, clean it before lubri-cation.

CAUTION

The O-rings between the side plates seal in the lu-bricant between the pin and the bushing. To avoiddamaging the O-rings and resultant loss of lubri-cant, observe the following rules.Use only kerosene or diesel oil for cleaning an O-ring drive chain. Any other cleaning solution suchas gasoline or trichloroethylene will cause deterio-ration and swelling of the O-ring. Immediately blowthe chain dry with compressed air after cleaning.Complete cleaning and drying the chain within 10minutes.

•Apply oil to the sides of the rollers so that oil will penetrateto the rollers and bushings. Apply the oil to the O-rings sothat the O-rings will be coated with oil.

•Wipe off any excess oil.Oil Applied Areas [A]O-rings [B]

BrakesBrake Pad Wear Inspection

•Remove the brake pads (see Brakes chapter).• Check the lining thickness [A] of the pads in each caliper.If the lining thickness of either pad is less than the servicelimit [B], replace both pads in the caliper as a set.

Pad Lining ThicknessStandard: Front 4.5 mm (0.18 in.)

Rear 5 mm (0.20 in.)

Service Limit: 1 mm (0.04 in.)

Rear Brake Light Switch Inspection/Adjustment

•Turn on the ignition switch.•Check the operation of the rear brake light switch by de-pressing the brake pedal. The brake light should go onafter about 10 mm (0.39 in.) of the pedal travel [A].

2-30 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

If it does not, adjust and inspect the brake light switch.

•While holding the switch body, turn the adjusting nut [A]to adjust the switch.

CAUTION

To avoid damaging the electrical connections in-side the switch, be sure that the switch body doesnot turn during adjustment.

•Remove the right side cover (see Frame chapter).• Disconnect the connector [A].• Using a hand tester, inspect to see that only the connec-tion shown in the table have continuity (about zero ohms).

Special Tool — Hand Tester: 57001–1394

Rear Brake Light Switch Connections:

If the switch has an open or short, replace it with a newone.

Caliper Fluid Seal DamageThe fluid seals [A] around the piston maintain the proper

pad/disc clearance. If the seals are not satisfactory, padwear will increase, and constant pad drag on the disc willraise brake and brake fluid temperature.

• Remove the calipers (see Brakes chapter).• Replace the fluid seals under any of the following condi-tions; (a) fluid leakage around the pad; (b) brakes over-heat (c) there is a large difference in inner and outer padwear; (d) the seal is stuck to the piston.If the fluid seal is replaced, replace the dust seals [B] aswell. Also, replace all seals every other time the pads arechanged.

Caliper Dust Seal/Friction Boot Damage

•Remove the calipers (see Brakes chapter).• Check that the dust seals [B] and friction boots [C] are notcracked, worn, swollen, or otherwise damaged.

• If they show any damage, remove the caliper bracket andreplace them.

PERIODIC MAINTENANCE 2-31

Periodic Maintenance Procedures

Master Cylinder Inspection (Visual Inspection)

•Remove the master cylinders (see Brakes chapter).• Disassemble the front and rear master cylinders.•Check that there are no scratches, rust or pitting on theinner wall [A] of each master cylinder and on the outsideof each piston [B].If a master cylinder or piston shows any damage, replacethem.

• Inspect the primary cup [C] and secondary cup [D].If a cup is worn, damaged softened (rotted), or swollen,the piston assembly should be replaced to renew thecups.If fluid leakage is noted at the brake lever, the piston as-sembly should be replaced to renew the cups.Front Master Cylinder [J]

•Check the dust covers [E] for damage.If they are damaged, replace them.

•Check the piston return springs [F] for any damage.If the springs are damaged, replace them.

•Check that relief port [G] and supply port [H] are notplugged.If the relief port becomes plugged, the brake pads willdrag on the disc. Blow the ports clean with compressedair.Rear Master Cylinder [K]

2-32 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Brake Fluid Level Inspection

•Check that the brake fluid level in the front brake reservoir[A] is above the lower level line [B].

NOTEHold the reservoir horizontal by turning the handlebarwhen checking brake fluid level.

If the fluid level is lower than the lower level line, fill thereservoir to the upper level line [C] in the reservoir.

• Check that the brake fluid level in the rear brake reservoir[A] is above the lower level line [B].If the fluid level is lower than the lower level line, removethe seats and fill the reservoir to the upper level line [C].

WARNINGDo not mix two brands of fluid. Change the brakefluid in the brake line completely if the brake fluidmust be refilled but the type and brand of the brakefluid that is already in the reservoir are unidentified.After changing the fluid, use only the same type andbrand of fluid thereafter.

Recommended Disc Brake FluidGrade: DOT4

• Follow procedure below to rear brake fluid reservoir capcorrectly.First, tighten the rear brake fluid reservoir cap [B] clock-wise [C] by hand until slight resistance is felt indicatingthat the cap is seated on the reservoir body, then tightenthe cap an additional 1/6 turn [D] while holding the brakefluid reservoir body [A].

Brake Fluid Change

NOTEThe procedure to change the front brake fluid is as fol-lows. Changing the rear brake fluid is the same as forthe front brake.

PERIODIC MAINTENANCE 2-33

Periodic Maintenance Procedures

•Level the brake fluid reservoir.• Remove the reservoir cap and diaphragm.•Remove the rubber cap from the bleed valve [A] on thecaliper.

• Attach a clear plastic hose [B] to the bleed valve, and runthe other end of the hose into a container.

• Fill the reservoir with fresh specified brake fluid.

•Change the brake fluid:Repeat this operation until fresh brake fluid comes outfrom the plastic hose or the color of the fluid changes.

1. Open the bleed valve [A].2. Apply the brake and hold it [B].3. Close the bleed valve [C].4. Release the brake [D].

NOTEThe fluid level must be checked often during the chang-ing operation and replenished with fresh brake fluid. Ifthe fluid in the reservoir runs out any time during thechanging operation, the brakes will need to be bledsince air will have entered the brake line.Front Brake: Repeat the above steps for the othercaliper.Rear Brake: Repeat the above steps for the other bleedvalve.

•Remove the clear plastic hose.• Install the reservoir cap.• Tighten:Torque — Front Brake Reservoir Cap Screws: 1.0 N·m (0.10

kgf·m, 9 in·lb)

•Follow procedure below to rear brake fluid reservoir capcorrectly.First, tighten the rear brake fluid reservoir cap [B] clock-wise [C] by hand until slight resistance is felt indicatingthat the cap is seated on the reservoir body, then tightenthe cap an additional 1/6 turn [D] while holding the brakefluid reservoir body [A].

• Tighten the bleed valve, and install the rubber cap.Torque — Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

•After changing the fluid, check the brake for good brakingpower, no brake drag, and no fluid leakage.If necessary, bleed the air from the lines.

2-34 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Brake Line BleedingThe brake fluid has a very low compression coefficient so

that almost all the movement of the brake lever or pedalis transmitted directly to the caliper for braking action. Air,however, is easily compressed. When air enters the brakelines, brake lever or pedal movement will be partially usedin compressing the air. This will make the lever or pedal feelspongy, and there will be a loss in braking power.

WARNINGBe sure to bleed the air from the brake line when-ever brake lever or pedal action feels soft orspongy after the brake fluid is changed, or when-ever a brake line fitting has been loosened for anyreason.

NOTEThe procedure to bleed the front brake line is as follows.Bleeding the rear brake line is the same as for the frontbrake.

•Remove the reservoir cap and diaphragm.• Fill the reservoir with fresh brake fluid to the upper levelline in the reservoir.

•With the reservoir cap off, slowly pump the brake leverseveral times until no air bubbles can be seen rising upthrough the fluid from the holes at the bottom of the reser-voir.Bleed the air completely from the master cylinder by thisoperation.

• Remove the rubber cap from the bleed valve on thecaliper.

• Attach a clear plastic hose to the bleed valve, and run theother end of the hose into a container.

PERIODIC MAINTENANCE 2-35

Periodic Maintenance Procedures

•Bleed the brake line and the caliper:Repeat this operation until no more air can be seen com-ing out into the plastic hose.1. Pump the brake lever until it becomes hard, and applythe brake and hold it [A].

2. Quickly open and close [B] the bleed valve while hold-ing the brake applied.

3. Release the brake [C].

NOTEThe fluid level must be checked often during the bleed-ing operation and replenished with fresh brake fluid asnecessary. If the fluid in the reservoir runs completelyout any time during bleeding, the bleeding operationmust be done over again from the beginning since airwill have entered the line.Tap the brake hose lightly from the caliper to the reser-voir for more complete bleeding.Front Brake: Repeat the above steps for the othercaliper.

•Remove the clear plastic hose.• Install the reservoir cap.• Tighten:Torque — Front Brake Reservoir Cap Screws: 1.0 N·m (0.10

kgf·m, 9 in·lb)

•Follow procedure below to rear brake fluid reservoir capcorrectly.First, tighten the rear brake fluid reservoir cap [B] clock-wise [C] by hand until slight resistance is felt indicatingthat the cap is seated on the reservoir body, then tightenthe cap an additional 1/6 turn [D] while holding the brakefluid reservoir body [A].

• Tighten the bleed valve, and install the rubber cap.Torque — Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

•Check the fluid level.• After bleeding is done, check the brake for good brakingpower, no brake drag, and no fluid leakage.

2-36 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

WARNINGWhen working with the disc brake, observe the pre-cautions listed below.1. Never reuse old brake fluid.2. Do not use fluid from a container that has been leftunsealed or that has been open for a long time.

3. Do not mix two types and brands of fluid for use inthe brake. This lowers the brake fluid boiling pointand could cause the brake to be ineffective. It mayalso cause the rubber brake parts to deteriorate.

4. Don’t leave the reservoir cap off for any length oftime to avoid moisture contamination of the fluid.

5. Don’t change the fluid in the rain or when a strongwind is blowing.

6. Except for the disc pads and disc, use only discbrake fluid, isopropyl alcohol, or ethyl alcohol forcleaning of the brake parts. Do not use any otherfluid for cleaning these parts. Gasoline, engine oil,or any other petroleum distillate will cause deterio-ration of the rubber parts. Oil spilled on any part willbe difficult to wash off completely and will eventuallydeteriorate the rubber used in the disc brake.

7. When handling the disc pads or disc, be careful thatno disc brake fluid or any oil gets on them. Clean offany fluid or oil that inadvertently gets on the pads ordisc with a high-flash point solvent. Do not use onewhich will leave an oily residue. Replace the padswith new ones if they cannot be cleaned satisfacto-rily.

8. Brake fluid quickly ruins painted surfaces; anyspilled fluid should be completely wiped up imme-diately.

9. If any of the brake line fittings or the bleed valve isopened at any time, theAIRMUSTBEBLED FROMTHE BRAKE LINE.

Brake Hoses and Connections Inspection

• Inspect the brake hose and fittings for deterioration,cracks and signs of leakage.The high pressure inside the brake line can cause fluid toleak [A] or the hose to burst if the line is not properly main-tained. Bend and twist the rubber hose while examiningit.Replace the hose if any cracks [B] or bulges [C] are no-ticed.Tighten any loose fittings.

PERIODIC MAINTENANCE 2-37

Periodic Maintenance Procedures

SuspensionFront Fork Oil Leak Check

•Visually inspect the front forks [A] for oil leakage, scoringor scratches on the inner surface of the inner tubes.Replace or repair any defective parts, if necessary.

Rear Shock Absorber Oil Leak Check

•Visually inspect the shock absorber [A] for oil leakage.If the oil leakage is found on it, replace the shock absorberwith a new one.

SteeringSteering Inspection

•Lift the front wheel off the ground using the jack.Special Tool — Jack: 57001–1238

•With the front wheel pointing straight ahead, alternatelytap each end of the handlebar. The front wheel shouldswing fully left and right from the force of gravity until thefork hits the stop.If the wheel binds or catches before the stop, the steeringis too tight.

• Feel for steering looseness by pushing and pulling theforks.If you feel looseness, the steering is too loose.

NOTEThe cables and wiring will have some effect on the mo-tion of the fork which must be taken into account.Be sure the wires and cables are properly routed.The bearings must be in good condition and properlylubricated in order for any test to be valid.

Steering AdjustmentAdjust the steering, if necessary.

•Remove:Inner Cover (see Frame chapter)Fairing and Bracket (see Frame chapter)Handlebar (see Steering chapter)

• Loosen the upper fork clamp bolts [A] on both side.•Remove the steering stem head bolt plug and the stemhead bolt [B].

• Remove the steering stem head [C] together with the han-dlebar installed.

2-38 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•Bend the claw washer tabs [A].• Remove the steering stem locknut [B] and claw washer[C].

• Adjust the steering.Special Tool — Steering Stem Nut Wrench: 57001–1100 [B]

If the steering is too tight, loosen the stem nut [A] a fractionof a turn.If the steering is too loose, tighten the stem nut a fractionof a turn.

NOTETurn the stem nut 1/8 turn at time maximum.

• Install the claw washer [A] so that its bent side [B] facesupward, and engage the bent claws with the grooves ofstem locknut [C].

• Hand tighten the stem locknut until it touches the clawwasher.

• Tighten the stem locknut clockwise until the claws arealigned with the grooves (ranging from 2nd to 4th) of stemnut [D], and bend the 2 claws downward [E].

• Tighten:Torque — Steering Stem Head Bolt: 108 N·m (11 kgf·m, 80

ft·lb)Front Fork Clamp Bolts (Upper): 20 N·m (2.0kgf·m, 14 ft·lb)

•Check the steering again.If the steering is still too tight or too loose, repeat the ad-justment.

Steering Stem Bearing Lubrication

•Remove the steering stem (see Steering chapter).

• Using a high flash-point solvent, wash the upper andlower ball bearings in the cages, and wipe the upper andlower outer races, which are press-fitted into the framehead pipe, clean off grease and dirt.

• Visually check the outer races and the ball bearings.Replace the bearing assemblies if they show wear ordamage.

• Pack the upper and lower ball bearings [A] in the cageswith grease, and apply a light coat of grease to the upperand lower outer races.

• Install the steering stem, and adjust the steering.

PERIODIC MAINTENANCE 2-39

Periodic Maintenance Procedures

Electrical SystemSpark Plug Inspection

•Remove:Fuel Tank (see Fuel System (DFI) chapter)

•Unscrew the thermostat bracket bolt [A].• Disconnect:Water Temperature Sensor Connector [B]Left Switch Housing Connector [C]

If removing the spark plug #2 or #3.

•Disconnect:Stick Coil Connectors [A]

• Pull out the stick coil #1 [B].• Take out the camshaft position sensor connector [C] fromthe bracket.

• Pull out the stick coil #2 [D].CAUTION

Do not pry the connector part of the coil while re-moving the coil.

•Remove the stick coil sub harness connector [A] from thebracket.

•Remove:Stick Coil Connector #4 [B] (disconnect)Stick Coil #4 [C]Stick Coil Connector #3 [D] (disconnect)

• Pull the main harness upward and remove the stick coil#3.

•Remove the spark plugs using the 16 mm plug wrench[A].

Owner’s Tool — Spark Plug Wrench, 16 mm: 92110–1146

2-40 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•Clean the spark plug, preferably in a sandblasting device,and then clean off any abrasive particles. The plug mayalso be cleaned using a high-flash point solvent and a wirebrush or other suitable tool.If the spark plug center electrode [A] and/or side electrode[B] are corrected or damaged, or if the insulator [C] iscracked, replace the plug. Use the standard spark plugor its equivalent.

•Measure the gaps [D] with a wire-type thickness gauge.If the gap is incorrect, carefully bend the side electrodewith a tool to obtain the correct gap.

Spark Plug Gap: 0.7 ~ 0.8 mm (0.028 ~ 0.031 in.)

• Insert the spark plug vertically into the plug hole with thespark plug installed in the plug wrench [A].

Owner’s Tool — Spark Plug Wrench, 16 mm: 92110–1146

• Tighten:Torque — Spark Plugs: 13 N·m (1.3 kgf·m, 113 in·lb)

• Insert the coils as shown being careful of the coil heads[A] direction.Fit the coils securely.

CAUTION

Do not tap the coil head while installing the coil.

Be sure the stick coils are installed by pulling up [A] itlightly.

• Connect the connectors.• Install:Thermostat Bracket Bolt (see Cooling System chapter)Fuel Tank (see Fuel System (DFI) chapter)

PERIODIC MAINTENANCE 2-41

Periodic Maintenance Procedures

General LubricationLubrication

•Before lubricating each part, clean off any rusty spots withrust remover and wipe off any grease, oil, dirt, or grime.

• Lubricate the points listed below with indicated lubricant.NOTE

Whenever the vehicle has been operated underwet or rainy conditions, or especially after using ahigh-pressure water spray, perform the general lubri-cation.

Pivots: Lubricate with Motor OilRear Brake Rod Joint

Points: Lubricate with GreaseThrottle and Choke Inner Cable Upper Ends [A]Clutch Lever PivotBrake Lever Pivot (Apply silicone grease)Brake Pedal PivotSide Stand

Cables: Lubricate with Cable LubricantChoke CableThrottle CablesClutch Cable

• Lubricate the cables by seeping the oil between the cableand housing.The cable may be lubricated by using a commerciallyavailable pressure cable lubricator with an aerosol cablelubricant.

•With the cable disconnected at both ends, the cableshould move freely [A] within the cable housing.If cable movement is not free after lubricating, if the cableis frayed [B] or if the cable housing is kinked [C], replacethe cable.

2-42 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Nut, Bolt, and Fastener TightnessTightness Inspection

•Check the tightness of the bolts and nuts listed here. Also,check to see that each cotter pin is in place and in goodcondition.

NOTEFor the engine fasteners, check the tightness of themwhen the engine is cold (at room temperature).

If there are loose fasteners, retighten them to the spec-ified torque, following the specified tightening sequence.Refer to the appropriate chapter for torque specifications.If torque specifications are not in the appropriate chapter,see the Standard Torque Table in this section. For eachfastener, first loosen it by 1/2 turn, then tighten it.If cotter pins are damaged, replace them with new ones.

Nut, Bolt and Fastener to be checkedWheels:Front AxleFront Axle Clamp BoltRear Axle NutRear Axle Nut Cotter PinBrakes:Front Master Cylinder Clamp BoltsCaliper Mounting BoltsRear Master Cylinder Mounting BoltsBrake Lever Pivot NutBrake Pedal BoltBrake Rod Joint Cotter PinSuspension:Front Fork Clamp BoltsFront Fender Mounting BoltsRear Shock Absorber Mounting NutsSwingarm Pivot Shaft NutSwingarm Pivot Shaft Lock NutUni-trak Link NutsSteering:Stem Head BoltHandlebar Clamp BoltsEngine:Throttle Cable Adjuster LocknutsEngine Mounting Bolts and NutsMuffler Mounting BoltsExhaust Pipe Holder NutsMuffler Connecting Clamp BoltClutch Lever Pivot NutRadiator Upper and Lower BoltsOthers:Sidestand BoltFootpeg Stay Bolts

FUEL SYSTEM (DFI) 3-1

3

Fuel System (DFI)

Table of Contents

Exploded View………………………………………………………………………………………………………… 3-4DFI Parts Location…………………………………………………………………………………………………… 3-8DFI Wiring Diagram…………………………………………………………………………………………………. 3-10Specifications …………………………………………………………………………………………………………. 3-12Special Tools ………………………………………………………………………………………………………….. 3-14DFI Servicing Precautions ………………………………………………………………………………………… 3-15

DFI Servicing Precautions …………………………………………………………………………………… 3-15Troubleshooting the DFI System ……………………………………………………………………………….. 3-17Outline ………………………………………………………………………………………………………………… 3-17Outline………………………………………………………………………………………………………………. 3-17

Inquiries to Rider…………………………………………………………………………………………………… 3-21Inquiries to Rider………………………………………………………………………………………………… 3-21

DFI System Troubleshooting Guide …………………………………………………………………………… 3-24DFI System Troubleshooting Guide………………………………………………………………………. 3-24

Self-Diagnosis ………………………………………………………………………………………………………… 3-33Self-diagnosis Outline……………………………………………………………………………………………. 3-33Self-diagnosis Outline …………………………………………………………………………………………. 3-33

Self-diagnosis Procedures……………………………………………………………………………………… 3-33Self-diagnosis Procedures …………………………………………………………………………………… 3-33

Service Code Clearing Procedures …………………………………………………………………………. 3-34Service Code Clearing Procedures……………………………………………………………………….. 3-34

How to Read Service Codes…………………………………………………………………………………… 3-36How to Read Service Codes………………………………………………………………………………… 3-36

How to Erase Service Codes………………………………………………………………………………….. 3-36How to Erase Service Codes ……………………………………………………………………………….. 3-36

Service Code Table……………………………………………………………………………………………….. 3-37Service Code Table…………………………………………………………………………………………….. 3-37

Backups ………………………………………………………………………………………………………………. 3-38Backups ……………………………………………………………………………………………………………. 3-38

Main Throttle Sensor (Service Code 11) …………………………………………………………………….. 3-40Main Throttle Sensor Removal/Adjustment ……………………………………………………………. 3-40Input Voltage Inspection………………………………………………………………………………………. 3-40Output Voltage Inspection……………………………………………………………………………………. 3-41Resistance Inspection…………………………………………………………………………………………. 3-42

Inlet Air Pressure Sensor (Service Code 12)……………………………………………………………….. 3-43Removal……………………………………………………………………………………………………………. 3-43Installation…………………………………………………………………………………………………………. 3-43Input Voltage Inspection………………………………………………………………………………………. 3-43Output Voltage Inspection……………………………………………………………………………………. 3-44

Inlet Air Temperature Sensor (Service Code 13)………………………………………………………….. 3-47Removal/Installation……………………………………………………………………………………………. 3-47Output Voltage Inspection……………………………………………………………………………………. 3-47Sensor Resistance Inspection ……………………………………………………………………………… 3-48

Water Temperature Sensor (Service Code 14) ……………………………………………………………. 3-49Removal/Installation……………………………………………………………………………………………. 3-49Output Voltage Inspection……………………………………………………………………………………. 3-49

3-2 FUEL SYSTEM (DFI)

Sensor Resistance Inspection ……………………………………………………………………………… 3-50Atmospheric Pressure Sensor (Service Code 15)………………………………………………………… 3-51

Removal……………………………………………………………………………………………………………. 3-51Input Voltage Inspection………………………………………………………………………………………. 3-51Output Voltage Inspection……………………………………………………………………………………. 3-52

Crankshaft Sensor (Service Code 21)………………………………………………………………………… 3-54Crankshaft Sensor Removal/Installation………………………………………………………………… 3-54Crankshaft Sensor Inspection………………………………………………………………………………. 3-54

Camshaft Position Sensor (Service Code 23) ……………………………………………………………… 3-55Camshaft Position Sensor Removal/Installation ……………………………………………………… 3-55Camshaft Position Sensor Inspection ……………………………………………………………………. 3-55

Speed Sensor (Service Code 24, 25)…………………………………………………………………………. 3-56Speed Sensor Removal/Installation………………………………………………………………………. 3-56Speed Sensor Inspection…………………………………………………………………………………….. 3-56Input Voltage Inspection………………………………………………………………………………………. 3-56Output Voltage Inspection……………………………………………………………………………………. 3-56

Vehicle-down Sensor (Service Code 31)…………………………………………………………………….. 3-58Removal……………………………………………………………………………………………………………. 3-58Installation…………………………………………………………………………………………………………. 3-58Inspection………………………………………………………………………………………………………….. 3-58

Subthrottle Sensor (Service Code 32)………………………………………………………………………… 3-61Subthrottle Sensor Removal/Adjustment ……………………………………………………………….. 3-61Input Voltage Inspection………………………………………………………………………………………. 3-61Output Voltage Inspection……………………………………………………………………………………. 3-62Resistance Inspection…………………………………………………………………………………………. 3-63

Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) ……………………………………………… 3-64Removal/Installation……………………………………………………………………………………………. 3-64Input Voltage Inspection………………………………………………………………………………………. 3-64

Subthrottle Valve Actuator (Service Code 62) ……………………………………………………………… 3-66Subthrottle Valve Actuator Removal ……………………………………………………………………… 3-66Audible Inspection………………………………………………………………………………………………. 3-66Visual Inspection………………………………………………………………………………………………… 3-66Resistance Inspection…………………………………………………………………………………………. 3-66Input Voltage Inspection………………………………………………………………………………………. 3-67

FI Indicator LED Light………………………………………………………………………………………………. 3-68LED Light Inspection…………………………………………………………………………………………… 3-69

ECU………………………………………………………………………………………………………………………. 3-70ECU Removal ……………………………………………………………………………………………………. 3-70ECU Installation …………………………………………………………………………………………………. 3-70ECU Power Supply Inspection……………………………………………………………………………… 3-70

DFI Power Source …………………………………………………………………………………………………… 3-73ECU Fuse Removal ……………………………………………………………………………………………. 3-73ECU Fuse Installation …………………………………………………………………………………………. 3-73ECU Fuse Inspection ………………………………………………………………………………………….. 3-73ECU Main Relay Removal …………………………………………………………………………………… 3-73ECU Main Relay Inspection …………………………………………………………………………………. 3-73

Fuel Line………………………………………………………………………………………………………………… 3-74Fuel Pressure Inspection …………………………………………………………………………………….. 3-74Fuel Flow Rate Inspection …………………………………………………………………………………… 3-75

Fuel Pump ……………………………………………………………………………………………………………… 3-77Fuel Pump Removal …………………………………………………………………………………………… 3-77Fuel Pump Installation ………………………………………………………………………………………… 3-77Operation Inspection…………………………………………………………………………………………… 3-78Operating Voltage Inspection……………………………………………………………………………….. 3-78Pressure Regulator Removal……………………………………………………………………………….. 3-79Pump Screen, Fuel Filter Cleaning ……………………………………………………………………….. 3-79

Fuel Pump ……………………………………………………………………………………………………………… 3-80

FUEL SYSTEM (DFI) 3-3

3

Fuel Pump Relay Removal ………………………………………………………………………………….. 3-80Fuel Pump Relay Inspection ………………………………………………………………………………… 3-80

Fuel Injectors ………………………………………………………………………………………………………….. 3-81Removal/Installation……………………………………………………………………………………………. 3-81Audible Inspection………………………………………………………………………………………………. 3-81Power Source Voltage Inspection …………………………………………………………………………. 3-81Output Voltage Inspection……………………………………………………………………………………. 3-82Injector Signal Test……………………………………………………………………………………………… 3-83Injector Resistance Inspection ……………………………………………………………………………… 3-84Injector Unit Test ………………………………………………………………………………………………… 3-84Injector Fuel Line Inspection ………………………………………………………………………………… 3-84

Throttle Grip and Cables ………………………………………………………………………………………….. 3-87Throttle Grip Play Inspection/Adjustment……………………………………………………………….. 3-87Choke Lever Operation……………………………………………………………………………………….. 3-87Choke Lever Play Inspection ……………………………………………………………………………….. 3-87Choke Lever Play Adjustment………………………………………………………………………………. 3-87Cable Removal/Installation ………………………………………………………………………………….. 3-87Cable Lubrication and Inspection………………………………………………………………………….. 3-87

Throttle Body Assy ………………………………………………………………………………………………….. 3-88Idle Speed Inspection …………………………………………………………………………………………. 3-88Engine Vacuum Synchronization Inspection/ Adjustment…………………………………………. 3-88High Altitude Performance Adjustment ………………………………………………………………….. 3-88Throttle Body Assy Removal………………………………………………………………………………… 3-88Throttle Body Assy Installation……………………………………………………………………………… 3-90Throttle Body Assy Disassembly ………………………………………………………………………….. 3-91Throttle Body Assy Assembly ………………………………………………………………………………. 3-92

Air Cleaner……………………………………………………………………………………………………………… 3-93Element Removal/Installation ………………………………………………………………………………. 3-93Air Cleaner Oil Draining ………………………………………………………………………………………. 3-93Air Cleaner Housing Removal………………………………………………………………………………. 3-93

Fuel Tank……………………………………………………………………………………………………………….. 3-94Fuel Tank Removal …………………………………………………………………………………………….. 3-94Fuel Tank Installation ………………………………………………………………………………………….. 3-95Fuel Tank and Cap Inspection ……………………………………………………………………………… 3-96Fuel Tank Cleaning …………………………………………………………………………………………….. 3-96

3-4 FUEL SYSTEM (DFI)

Exploded View

FUEL SYSTEM (DFI) 3-5

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Throttle cable plate bolt 6.0 0.60 52 in·lb

2 Throttle body assy holder clamp bolts 2.0 0.20 17 in·lb

3 Choke link holder screws 2.1 0.21 18 in·lb

4 Delivery pipe screws 3.4 0.35 30 in·lb

5 Fuel pump bolts 9.8 1.0 87 in·lb L,S

6 Fuel level sensor bolts 6.9 0.7 62 in·lb

7 Bypass screws 0.2 0.02 1.7 in·lb

8. Center adjusting screw9. FI indicator LED light10. Meter unit11. Throttle cable (accelerator)12. Throttle cable (decelerator)13. Choke cable14. Injector connectors15. Main throttle sensor connector (grey)16. Subthrottle sensor connector (black)17. Subthrottle valve actuator connector18. Throttle body assy connector19. Main throttle sensor20. Subthrottle sensor21. InjectorsCL: Apply cable lubricant.EO: Apply engine oil to the seals and O-rings.G: Apply grease.L: Apply a non-permanent locking agent.S: Follow the specified tightening sequence.

3-6 FUEL SYSTEM (DFI)

Exploded View

FUEL SYSTEM (DFI) 3-7

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Inlet air pressure sensor bolt 12 1.2 104 in·lb

2 Water temperature sensor 25 2.5 18

3 Vehicle down sensor bolts 2.0 0.20 17 in·lb

4 Camshaft position sensor bolt 12 1.2 104 in·lb

5 Camshaft position sensor rotor bolt 12 1.2 104 in·lb L

6 Air cleaner duct holder screws 3.8 0.39 34 in·lb

7 Air cleaner housing mounting bolts 9.8 1.0 87 in·lb

8 Air cleaner duct clamp bolts 2.0 0.20 17 in·lb

9 Air cleaner housing screws 1.2 0.12 10 in·lb

10 Air cleaner housing tapping screws 1.2 0.12 10 in·lb

11 Speed sensor bolt 6.9 0.70 62 in·lb L

12. Inlet air pressure sensor13. Stick coils (see Electrical System chapter)14. ECU15. Fuel pump relay16. ECU main relay17. Atmospheric pressure sensor18. Crankshaft sensor (see Electrical System chapter)19. Inlet air temperature sensor20. Vacuum switch valve (see Engine Top End chapter)21. Air suction valves22. GrommetL: Apply a non-permanent locking agent.

3-8 FUEL SYSTEM (DFI)

DFI Parts Location

DFI: DFI Parts (this chapter)1. Water temperature Sen-sor (DFI)

2. Inlet Air Pressure Sensor(DFI)

3. Injectors (DFI)4. Fuel Pump (DFI)5. Inlet Air TemperatureSensor (DFI)

6. Sealed Battery7. Junction Box8. ECU Fuse 15 A9. ECU (DFI)

10. Stick Coils11. Throttle Body Assy12. Self-diagnosis Terminal13. Neutral Switch14. Vehicle Down Sensor

(DFI)15. Atmospheric Pressure

Sensor (DFI)16. Delivery Pipe17. ECU Main Relay18. Fuel Pump Relay (DFI)19. Turn Signal Relay20. Subthrottle Sensor (DFI)

21. Main Throttle Sensor(DFI)

22. Ignition Switch23. FI Indicator LED Light

(DFI)24. Crankshaft Sensor25. Camshaft Position Sen-

sor26. Fuel Pump Screen27. Return Fuel Check Valve28. Pressure Regulator29. Fuel Filter

FUEL SYSTEM (DFI) 3-9

DFI Parts Location

[1], [2], [10], [13], [22] and [24] are not included.

3-10 FUEL SYSTEM (DFI)

DFI Wiring Diagram

FUEL SYSTEM (DFI) 3-11

DFI Wiring Diagram

Terminal Names1. Power Supply to Sensors2. Main Throttle Sensor Signal3. Subthrottle Sensor Signal4. Atmospheric Pressure Sensor Signal5. Water Temperature Sensor Signal (+)6. Unused7. Ignition Switch Signal8. Unused9. Camshaft Position Sensor Signal (+)10. Unused11. Crankshaft Sensor Signal (+)12. Unused13. Power Supply to ECU, Injectors, and Fuel

Pump14. Ground to sensors15. Unused16. Vehicle-down Sensor Signal17. Inlet Air Pressure Sensor Signal18. Inlet Air Temperature Sensor Signal (+)19. Unused20. Speed Sensor Signal21. Unused22. Camshaft Position Sensor Signal (–)23. Unused24. Crankshaft Sensor Signal (–)25. Unused26. ECUPower Source Circuit Ground to Bat-

tery (–) Terminal

27. Engine Stop Switch Signal28. Starter Lockout Switch Signal29. Electric Starter Button Signal30. Fuel Pump Relay Signal31. Subthrottle Valve Actuator Drive Signal32. Subthrottle Valve Actuator Drive Signal33. Unused34. Tachometer Signal35. Injector #2 Signal36. Injector #1 Signal37. Stick Coil #3 Signal38. Stick Coil #2 Signal39. Stick Coil #1 Signal40. Interlock Circuit Signal41. Self-diagnosis Signal (generated by

grounding this terminal and shown byFI indicator LED light)

42. Unused43. Battery Power ON-OFF Signal44. Subthrottle Valve Actuator Drive Signal45. Subthrottle Valve Actuator Drive Signal46. External Diagnosis System Signal47. FI Indicator LED Light Signal48. Injector #4 Signal49. Injector #3 Signal50. DFI System Ground51. Ignition System Ground52. Stick Coil #4 Signal

Part NameA. ECU (Electronic Control Unit)B. Crankshaft SensorC. Inlet Air Pressure SensorD. Water Temperature SensorE. Atmospheric Pressure SensorF. Inlet Air Temperature SensorG. Camshaft Position SensorH. Speed SensorI. Main Throttle SensorJ. Subthrottle SensorK. Injectors #1, #2, #3, #4L. Subthrottle Valve ActuatorM. Stick Coils #1, #2, #3, #4N. Engine Stop SwitchO. Joint Connector DP. see Electrical System chapterQ. Ground TerminalR. Ground TerminalS. ECU Main Relay

T. Ignition SwitchU. FI Indicator LED LightV. TachometerW. SpeedometerX. Ignition Fuse 10 AY. Junction BoxZ. Fuel Pump Relaya. ECU Fuse 15 Ab. Vehicle-down Sensord. Starter Relaye. Joint Connector Cf. Sealed Batteryg. Fuel Pumph. Self-diagnosis Terminalj. Joint Connector Bk. Main Fuse 30 Am. Throttle Body Assy Connectorn: Connector Locksp: ECU Connector

3-12 FUEL SYSTEM (DFI)

Specifications

Item Standard

Digital Fuel Injection System

Idle Speed 1 100 ±50 r/min (rpm)

Throttle Assy:

Type Four barrel type

Bore 34 mm (1.34 in.)

ECU (Electronic Control Unit):

Make Denso

Type Digital memory type, with built in IC igniter, sealed with resin

Usable engine speed 100 ∼ 12 240 r/min (rpm)Fuel Pressure (high pressure line):

Right after Ignition SW ON 310 kPa (3.2 kgf/cm², 46 psi) with fuel pump running

After 3 sec from Ignition SW ON 290 kPa (2.9 kgf/cm², 43 psi) with fuel pump stopped

With engine idling 310 kPa (3.2 kgf/cm², 46 psi) with fuel pump running

Fuel Pump:

Type In-tank friction pump

Discharge 67 mL or more for 3 seconds

Fuel Injectors:

Type INP-285

Nozzle type One spray type with 4 holes

Resistance about 11.7 ∼ 12.3 Ω at 20°C (68°F)Main Throttle Sensor: Non-adjustable and non-removable

Input voltage 4.75 ∼ 5.25 V DC between BL and BR/BK leadsOutput voltage at idle throttleopening

0.99 ∼ 1.03 V DC between Y/W and BR/BK leads

Output voltage at full throttle 4.19 ∼ 4.39 V DC between Y/W and BR/BK leads

opening

Resistance 4 ∼ 6 kΩInlet Air Pressure Sensor orAtmospheric Pressure Sensor:

Input voltage 4.75 ∼ 5.25 V DC between BL and BR/BK leadsOutput voltage 3.74 ∼ 4.26 V DC at standard atmospheric pressure (see

this text for details)

Inlet Air Temperature Sensor:

Resistance 1.6 ∼ 3.7 kΩ at 20°C (68°F)0.24 ∼ 0.43 kΩ at 80°C (176°F)

Output voltage at ECU about 2.25 ∼ 2.50 V @20°C (68°F)Water Temperature Sensor:

Resistance see Electrical System chapter

Output voltage at ECU about 2.80 ∼ 2.97 V @20°C (68°F)Speed Sensor:

Input voltage at sensor about 9 ∼ 11 V DC at Ignition SW ON

Output voltage at sensor about 0.05 ∼ 0.07 V DC at Ignition SW ON and 0 km/h

Vehicle-down Sensor:

Detection method Magnetic flux detection method

Detection angle More than 60 ∼ 70° for each bank

FUEL SYSTEM (DFI) 3-13

Specifications

Item Standard

Detection time Within 0.5 ∼ 1.0 sec.Output voltage with the sensor tilted 60 ∼ 70° or more: 3.7 ∼ 4.4 V

with sensor arrow mark pointed up: 0.4 ∼ 1.4 VSubthrottle Sensor: Non-adjustable and non-removal

Input voltage 4.75 ∼ 5.25 V DC between BL and BR/BK leadsOutput voltage at idle throttle 0.48 ∼ 0.52 V DC between BR and BR/BK leadsopening

Output voltage at full throttle 3.6 ∼ 3.8 V DC between BR and BR/BK leadsopening

Resistance 4 ∼ 6 kΩSubthrottle Valve Actuator:

Resistance about 5 ∼ 7 kΩInput voltage about 8.5 ∼ 10.5 V DC

Throttle Grip and Cables

Throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.)Choke Cable

Choke cable free play 0 ∼ 0.5 mm (0 ∼ 0.02 in.)

3-14 FUEL SYSTEM (DFI)

Special Tools

Oil Pressure Gauge:57001–125

Fork Oil Level Gauge:57001–1290

Hand Tester:57001–1394

Throttle Sensor Setting Adapter:57001–1400

Fuel Pressure Gauge Adapter:57001–1417

Needle Adapter Set:57001–1457

Throttle Sensor Setting Adapter:57001–1538

Sensor Harness Adapter:57001–1561

Kawasaki Bond (Silicone Sealant):56019–120

FUEL SYSTEM (DFI) 3-15

DFI Servicing Precautions

DFI Servicing PrecautionsThere 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 sealedbattery as its power source. Do not use any other batteryexcept for a 12 V sealed battery as a power source.Do not reverse the battery cable connections. This willdamage the ECU.To prevent damage to the DFI parts, do not disconnect thebattery cables or any other electrical connections whenthe ignition SW (switch) is on or while the engine is run-ning.Take care not to short the leads that are directly con-nected to the battery positive (+) terminal to the chassisground.When charging, remove the battery from the motorcycle.This is to prevent ECU damage by excessive voltage.Do not turn the ignition SW ON while any of the DFI elec-trical connectors are disconnected. The ECU memorizesservice codes.Do not spray water on the electrical parts, DFI parts, con-nectors, leads, and wiring. Never water a vehicle withconnectors unplugged because seals don’t work and ter-minals could corrode.If a transceiver is installed on the motorcycle, make surethat the operation of the DFI system is not influenced byelectric wave radiated from the antenna. Check operationof the system with the engine at idle. Locate the antennaas far as possible away from the ECU.When any fuel hose is disconnected, do not turn on theignition SW. Otherwise, the fuel pump will operate andfuel will spout from the fuel hose.Do not operate the fuel pump if the pump is completelydry. This is to prevent pump seizure.Before removing the fuel system parts, blow the outer sur-faces of these parts clean with compressed air.When any fuel hose is disconnected, fuel may spout outby residual pressure in the fuel line. Cover the hose jointwith a piece of clean cloth to prevent fuel spillage.To prevent corrosion and deposits in the fuel system, donot add to fuel any fuel antifreeze chemicals.Whenever the DFI electrical connections are to be discon-nected, first turn off the ignition SW (switch). Conversely,make sure that all the DFI electrical connections are firmlyreconnected before starting the engine.

3-16 FUEL SYSTEM (DFI)

DFI Servicing Precautions

Whenever the DFI electrical connections are to be discon-nected, first turn off the ignition SW (switch), and discon-nect the battery (–) terminal. Do not pull the lead, only theconnector. Conversely, make sure that all the DFI elec-trical connections are firmly reconnected before startingthe engine.When disconnecting the vehicle-down sensor connector,raise the lock of the connector. Push the lock of the otherconnectors.

To maintain the correct fuel/air mixture (F/A), there mustbe no inlet air leaks in the DFI system. Be sure to installthe oil filler plug [A] after filling the engine oil.Clutch Cover [B]

Torque — Oil Filler Plug: 1.5 N·m (0.15 kgf·m, 13 in·lb)

FUEL SYSTEM (DFI) 3-17

Troubleshooting the DFI System

OutlineOutlineWhen an abnormality in the system occurs, the FI indica-

tor LED (Light Emitting Diode) light goes on to alert the rideron the meter panel. In addition, the condition of the problemis stored in the memory of the ECU (electronic control unit).With the engine stopped and turned in the self-diagnosismode, the service code [A] is indicated by the number oftimes the FI indicator LED light blinks.When due to a malfunction, the FI indicator LED light re-

mains lit, ask the rider about the conditions [B] under whichthe problem occurred and try to determine the cause [C].

• First, conduct a self-diagnosis inspection and then a non-self-diagnosis inspection. The non–self–diagnosis itemsare not indicated by the FI indicator LED light. Don’t relysolely on the DFI self-diagnosis function, use commonsense.

Even when the DFI system is operating normally, the FIindicator LED light [A] may light up under strong electrical in-terference. No repair needed. Turn the ignition SW (switch)OFF to stop the indicator light.When the FI indicator LED light goes on and the motor-

cycle is brought in for repair, check the service codes.When the repair has been done, the LED light doesn’t go

on. But the service codes stored in memory are not erasedto preserve the problem history, and the LED light can dis-play the codes in the self-diagnosis mode. The problemhistory is referred when solving unstable problems.When the motorcycle is down, the vehicle-down sensor

is turned OFF and the ECU shuts off the fuel injectors andignition system. The FI indicator LED light blinks but thefault code cannot be displayed. The ignition SW is left ON.If the starter button is pushed, the electric starter turns butthe engine doesn’t start. To start the engine again, raisethe motorcycle, turn the ignition SWOFF, and then ON. Thevehicle-down sensor is turned ON and the LED light goesOFF.

3-18 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

The DFI part connectors [A] have seals [B], including theECU.

• Join the connector and insert the needle adapters (specialtool) [C] inside the seals [B] from behind the connectoruntil the adapter reaches the terminal.

Special Tool — Needle Adapter Set: 57001–1457

CAUTION

Insert the needle adapter straight along the terminalin the connector to prevent short-circuit betweenterminals.

•Make sure that measuring points are correct in the con-nector, noting the position of the lock [D] and the leadcolor before measurement. Do not reverse connectionsof the hand tester or a digital meter.

• Be careful not to short-circuit the leads of the DFI or elec-trical system parts by contact between adapters.

• Turn the ignition SW ON and measure the voltage withthe connector joined.

CAUTION

Incorrect, reverse connection or short circuit byneedle adapters could damage the DFI or electricalsystem parts.

After measurement, remove the needle adapters and ap-ply silicone sealant to the seals [A] of the connector [B]for waterproofing.

Silicone Sealant (Kawasaki Bond: 56019–120) – Sealsof Connector

•Always check battery condition before replacing the DFIparts. A fully charged battery is a must for conductingaccurate tests of the DFI system.

• Trouble may involve one or in some cases all items.Never replace a defective part without determining whatCAUSED the problem. If the problem was caused bysome other item or items, they too must be repaired orreplaced, or the new replacement part will soon fail again.

•Measure coil winding resistance when the DFI part is cold(at room temperature)

•Make sure all connectors in the circuit are clean and tight,and examine wires for signs of burning, fraying, short,etc. Deteriorated wires and bad connections can causereappearance of problems and unstable operation of theDFI system.If any wiring is deteriorated, replace the wiring.

FUEL SYSTEM (DFI) 3-19

Troubleshooting the DFI System

•Pull each connector [A] apart and inspect it for corrosion,dirt, and damage.If the connector is corroded or dirty, clean it carefully. If itis damaged, replace it. Connect the connectors securely.

•Check the wiring for continuity.Use the wiring diagram to find the ends of the lead whichis suspected of being a problem.Connect the hand tester between the ends of the leads.Set the tester to the × 1 Ω range, and read the tester.If the tester does not read 0 Ω, the lead is defective. Re-place the lead or the main harness or the sub harness.

If both ends of a harness [A] are far apart, ground [B] theone end [C], using a jumper lead [D] and check the con-tinuity between the end [E] and the ground [F]. This en-ables to check a long harness for continuity. If the harnessis open, repair or replace the harness.

When checking a harness [A] for short circuit, open oneend [B] and check the continuity between the other end[C] and ground [D]. If there is continuity, the harness hasa short circuit to ground, and it must be repaired or re-placed.

•Narrow down suspicious locations by repeating the con-tinuity tests from the ECU connectors.If no abnormality is found in the wiring or connectors, theDFI parts are the next likely suspects. Check the part,starting with input and output voltages. However, there isno way to check the ECU itself.If an abnormality is found, replace the affected DFI part.If no abnormality is found in the wiring, connectors, andDFI parts, replace the ECU.

Lead Color Codes:BK: Black G: Green P: Pink

BL: Blue GY: Gray PU: Purple

BR: Brown LB: Light blue R: Red

CH: Chocolate LG: Light green W: White

DG: Dark green O: Orange Y: Yellow

3-20 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

There are two ways to inspect the DFI system. One isvoltage Check Method and the other is Resistance CheckMethod.

(Voltage Check Method)This method is conducted by measuring the input voltage[B] to a sensor [A] first, and then the output voltage [C]from the sensor.Sometimes this method can detect a fault of the ECU.• Refer to each sensor inspection section for detail in thischapter.

• Use a fully charged battery and a digital meter [D] whichcan be read two decimal places voltage or resistance.

(Resistance Check Method)This method is simple. No need for a fully charged batteryand the needle adapter. Just do the following especiallywhen a sensor [A] is suspect.

• Turn the ignition SW OFF and disconnect the connectors.

• Inspect the sensor resistance, using a digital meter (seeeach sensor inspection in this chapter).

• Inspect the wiring and connectors [B] for continuity, usingthe hand tester [C] (analog tester) rather than a digitalmeter.

Special Tool — Hand Tester: 57001–1394

If the sensor, the wiring and connections are good, in-spect the ECU for its ground and power supply (see thischapter). If the ground and power supply are good, theECU is suspect. Replace the ECU.

FUEL SYSTEM (DFI) 3-21

Troubleshooting the DFI System

DFI Diagnosis Flow Chart

Inquiries to RiderInquiries to RiderEach rider reacts to problems in different ways, so it is important to confirm what kind of symptomsthe rider has encountered.Try to find out exactly what problem occurred under exactly what conditions by asking the rider;knowing this information may help you reproduce the problem.The following sample diagnosis sheet will help prevent you from overlooking any areas, and willhelp you decide if it is a DFI system problem, or a general engine problem.

3-22 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

Sample Diagnosis SheetRider 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, always, other:Temperature hot, warm, cold, very cold, alwaysProblem chronic, often, oncefrequency

Road street, highway, mountain road ( uphill, downhill), bumpy, pebbleAltitude normal, high (about 1000 m or more)

Motorcycle conditions when problem occurred.

FI indicator light up immediately after ignition SW ON, and goes off after 1 ∼ 2 secondsLED light (normal)

lights blinks immediately after ignition SW ON, and stays on (DFI problem)

lights up immediately after ignition SW ON, but goes off after about 10

seconds (DFI problem)

unlights (LED light, ECU or its wiring fault) sometimes lights up (probably wiring fault)

Starting starter motor not rotatingdifficulty starter motor rotating but engine doesn’t turn over

starter motor and engine don’t turn over no fuel flow ( no fuel in tank, no fuel pump sound) engine flooded (do not crank engine with throttle opened, which promotes engineflooding)

no spark choke lever is not pulled fully when using the lever (pull it fully when using) other

Engine stops right after starting when opening throttle grip when closing throttle grip when moving off when stopping the motorcycle when cruising other

FUEL SYSTEM (DFI) 3-23

Troubleshooting the DFI System

Poor running choke lever pulled out fully (push it in fully)at low speed very low choke speed (adjust choke cable)

very low idle speed, very high idle speed, rough idle speed battery voltage is low (charge the battery) spark plug loose (tighten it) spark plug dirty, broken, or gap maladjusted (remedy it) backfiring afterfiring hesitation when acceleration engine oil viscosity too high brake dragging engine overheating clutch slipping other

Poor running choke lever pulled out fully (push it in fully)or no power spark plug loose (tighten it)at high speed spark plug dirty, broken, or gap maladjusted (remedy it)

spark plug incorrect (replace it) knocking (fuel poor quality or incorrect,→ use high-octane gasoline)

brake dragging clutch slipping engine overheating engine oil level too high engine oil viscosity too high other

3-24 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

DFI System Troubleshooting Guide

NOTEThis is not an exhaustive list, giving every possible cause for each problem listed. It is meantsimply as a rough guide to assist the troubleshooting for some of the more common difficulties.The ECU may be involved in the DFI electrical and ignition system troubles. If these parts andcircuits checked out good, be sure to check the ECU for ground and power supply. If the groundand power supply are checked good, replace the ECU.

Engine Doesn’t Start, Starting DifficultySymptoms or possible Causes Actions (chapter)

Starter motor not rotating:

Ignition and engine stop switches not ON Turn both switches ON.

Starter lockout switch or neutral switch trouble Inspect (see chapter 16)

Starter motor trouble Inspect (see chapter 16).

Battery voltage low Inspect and charge (see chapter 16).

Starter relays not contacting or operating Inspect the starter relay (see chapter 16).

Starter button not contacting Inspect and replace (see chapter 16).

Starter system wiring open or shorted Inspect the wiring (see chapter 16).

Ignition switch trouble Inspect and replace (see chapter 16).

Engine stop switch trouble Inspect and repair or replace (see chapter 16).

Main 30 A or ignition fuse blown Inspect and replace (see chapter 16).

Starter motor rotating but engine doesn’tturn over :

Starter clutch trouble Inspect (see chapter 9).

Starter idle gear trouble Inspect (see chapter 9).

Engine won’t turn over :

Valve seizure Inspect and replace (see chapter 5).

Cylinder, piston seizure Inspect and replace (see chapter 5).

Camshaft seizure Inspect and replace (see chapter 5).

Connecting rod small end seizure Inspect and replace (see chapter 9).

Connecting rod big end seizure Inspect and replace (see chapter 9).

Crankshaft seizure Inspect and replace (see chapter 9).

Transmission gear or bearing seizure Inspect and replace (see chapter 9).

Balancer bearing seizure Inspect and replace (see chapter 9).

No fuel flow :

No or little fuel in tank Supply fuel (see Owner’s Manual).

Fuel pump not rotating Inspect (see chapter 3).

Fuel injector trouble Inspect and replace (see chapter 3).

Fuel tank air vent obstructed Inspect and repair (see chapter 3).

Fuel filter or pump screen clogged Inspect and replace fuel pump (see chapter 3).

Fuel pressure regulator clogged Inspect and replace fuel pump (see chapter 3).

Fuel line clogged Inspect and repair (see chapter 3).

Engine flooded :

Spark plug dirty, broken or gap maladjustedClean spark plugs and adjust plug gap (seechapter 2).

FUEL SYSTEM (DFI) 3-25

DFI System Troubleshooting Guide

Symptoms or possible Causes Actions (chapter)

Starting technique faultyWhen flooded, don’t crank engine with throttlefully opened.

No spark or spark weak :

Ignition and engine stop switches not ON Turn both switches ON .

Clutch lever not pulled in and gear not in neutralwhether sidestand up or not

Pull the lever in and shift the gear in neutral.

Though clutch lever pulled in, sidestand up andgear not in neutral

Sidestand down and clutch lever pulled in whethergear in neutral or not

Vehicle-down sensor coming off Reinstall (see chapter 3).

Vehicle-down sensor trouble Inspect (see chapter 3) .

ECU ground or power supply trouble Inspect (see chapter 3) .

Battery voltage low Inspect and charge (see chapter 16).

Spark plug dirty, broken or gap maladjustedClean spark plug and adjust plug gap (see chapter2).

Spark plug cap trouble Inspect stick coil (see chapter 16).

Spark plug cap shorted or not in good contact Reinstall or inspect stick coil (see chapter 16).

Spark plug incorrect Replace it with the correct plug (see chapter 16).

IC igniter in ECU trouble Inspect (see chapter 16).

Neutral, starter lockout or sidestand switchtrouble

Inspect each switch (see chapter 16).

Crankshaft sensor trouble Inspect (see chapter 16).

Stick coil trouble Inspect (see chapter 16).

Ignition switch shorted Inspect and replace (see chapter 16).

Engine stop switch shorted Inspect and repair or replace (see chapter 16) .

Starter system wiring shorted or open Inspect and repair or replace (see chapter 16).

Main 30 A or ignition fuse blown Inspect and replace (see chapter 16).

Fuel/air mixture incorrect :

Air cleaner clogged, poorly sealed or missing Clean or reinstall (see chapter 3).

Leak from oil filler cap, crankcase breather hoseor air cleaner drain hose

Inspect and repair or replace (see chapter 3).

Water or foreign matter in fuelChange fuel. Inspect and clean fuel system (seechapter 3).

Fuel pressure regulator troubleInspect fuel pressure and replace fuel pump (seechapter 3).

Main throttle sensor trouble Inspect (see chapter 3).

Fuel pressure may be low Inspect (see chapter 3).

Fuel pump trouble Inspect (see chapter 3).

Fuel injector trouble Inspect (see chapter 3).

Inlet air pressure sensor trouble Inspect (see chapter 3).

Atmospheric pressure sensor trouble Inspect (see chapter 3).

Inlet air temperature sensor trouble Inspect (see chapter 3).

Water temperature sensor trouble Inspect (see chapter 3).

Crankshaft sensor trouble Inspect (see chapter 3).

Compression low :

Spark plug loose Reinstall (see chapter 16).

Cylinder head not sufficiently tightened down Tighten (see chapter 5).

3-26 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

Symptoms or possible Causes Actions (chapter)

Cylinder, piston worn Inspect and replace (see chapter 5).

Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapter 5).

Piston ring/groove clearance excessive Inspect and replace (see chapter 5).

Cylinder head gasket damaged Replace (see chapter 5).

Cylinder head warped Inspect and replace (see chapter 5).

No valve clearance Adjust (see chapter 2).

Valve guide worn Inspect and replace (see chapter 5).

Valve spring broken or weak Inspect and replace (see chapter 5).

Valve not seating properly (valve bent, worn orcarbon accumulating on seating surface)

Inspect and repair or replace (see chapter 5).

Poor Running at Low SpeedSymptoms or Possible Causes Actions (chapter)

Spark weak :

Battery voltage low Inspect and charge (see chapter 16).

Spark plug dirty, broken or gap maladjustedClean spark plugs and adjust plug gap (seechapter 2).

Spark plug cap trouble Inspect the stick coil (see chapter 16).

Spark plug cap shorted or not in good contact Reinstall or inspect stick coil (see chapter 16).

Spark plug incorrect Replace it with the correct plug (see chapter 16).

IC igniter in ECU trouble Inspect (see chapter 16).

Crankshaft sensor trouble Inspect (see chapter 16).

Stick coil trouble Inspect (see chapter 16).

Fuel/air mixture incorrect :

Little fuel in tank Supply fuel (see Owner’s Manual).

Air cleaner clogged, poorly sealed, or missing Clean element or inspect sealing (see chapter 3).

Air cleaner duct loose Reinstall (see chapter 3).

Air cleaner O-ring damaged Replace (see chapter 3).

Fuel tank air vent obstructed Inspect and repair (see chapter 3).

Throttle body assy loose Reinstall (see chapter 3).

Throttle body assy O-ring damage Replace (see chapter 3).

Choke lever pulled Push it (see chapter 3).

Fuel filer or pump screen clogged Inspect and replace fuel pump (see chapter 3).

Fuel pressure regulator cloggedInspect fuel pressure and replace fuel pump (seechapter 3).

Fuel line clogged Inspect and repair (see chapter 3).

Inlet air pressure sensor trouble Inspect (see chapter 3).

Inlet air temperature sensor trouble Inspect (see chapter 3).

Thermostat trouble Inspect and replace (see chapter 4).

Unstable (rough) idling :

Fuel injector trouble Inspect (see chapter 3).

Main throttle sensor trouble Inspect (see chapter 3).

Crankshaft sensor trouble Inspect (see chapter 3).

Throttle valves not synchronizing Inspect (see chapter 2).

FUEL SYSTEM (DFI) 3-27

DFI System Troubleshooting Guide

Symptoms or Possible Causes Actions (chapter)

Inlet air temperature sensor trouble Inspect (see chapter 3).

Water temperature sensor trouble Inspect (see chapter 3).

Atmospheric pressure sensor trouble Inspect (see chapter 3).

Fuel pressure too low or too high Inspect (see chapter 3).

Battery voltage low Inspect and charge (see chapter 16).

Incorrect idle speed :

Water temperature sensor trouble Inspect (see chapter 3).

Main throttle sensor trouble Inspect (see chapter 3).

Engine stalls easily :

Fuel pump trouble Inspect (see chapter 3).

Fuel injector trouble Inspect (see chapter 3).

Main throttle sensor trouble Inspect (see chapter 3).

Camshaft position sensor trouble Inspect (see chapter 3).

Fuel pressure too low or too high Inspect (see chapter 3).

Inlet air pressure sensor trouble Inspect (see chapter 3).

Water temperature sensor trouble Inspect (see chapter 3).

Inlet air temperature sensor trouble Inspect (see chapter 3).

Fuel line clogged Inspect and repair (see chapter 3).

Fuel pressure too low or too high Inspect (see chapter 3).

Fuel pressure regulator troubleInspect fuel pressure and replace fuel pump (seechapter 3).

Crankshaft sensor trouble Inspect (see chapter 16).

Stick coil trouble Inspect (see chapter 16).

Compression Low :

Spark plug loose Reinstall (see chapter 16).

Cylinder head not sufficiently tightened down Tighten (see chapter 5).

No valve clearance Adjust (see chapter 2).

Cylinder, piston worn Inspect and replace (see chapter 5).

Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapter 5).

Piston ring/groove clearance excessive Inspect and replace (see chapter 5).

Cylinder head gasket damaged Replace (see chapter 5).

Cylinder head warped Inspect and replace (see chapter 5).

Valve guide worn or stem seal damaged Inspect and replace (see chapter 5).

Valve spring broken or weak Inspect and replace (see chapter 5).

Valve not seating properly (valve bent, worn orcarbon accumulating on seating surface)

Inspect and repair or replace (see chapter 5).

Camshaft cam worn Inspect and replace (see chapter 5).

Hesitation :

Too low fuel pressure Inspect (see chapter 3).

Clogged fuel line Inspect and repair (see chapter 3).

Cracked or obstructed inlet air pressure sensorhose

Inspect and repair or replace (see chapter 3).

Fuel pump trouble Inspect (see chapter 3).

Fuel injector trouble Inspect (see chapter 3).

Inlet air temperature sensor trouble Inspect (see chapter 3).

3-28 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

Symptoms or Possible Causes Actions (chapter)

Main throttle sensor trouble Inspect (see chapter 3).

Subthrottle sensor trouble Inspect (see chapter 3).

Subthrottle valve actuator trouble Inspect (see chapter 3).

Water temperature sensor trouble Inspect (see chapter 3).

Atmospheric pressure sensor trouble Inspect (see chapter 3).

Inlet air pressure sensor trouble Inspect (see chapter 3).

Loose injector connectors Remedy (see chapter 3).

Crankshaft sensor trouble Inspect and repair or replace (see chapter 16).

Stick coil trouble Inspect and repair or replace (see chapter 16).

Loose terminal of battery (–) lead or engineground lead

Inspect and repair (see chapter 16).

Delay of ignition timingInspect crankshaft sensor and IC igniter in ECU(see chapter 16).

Poor acceleration :

Choke lever pulled Push it (see chapter 3).

Too low fuel pressure Inspect (see chapter 3).

Water or foreign matter in fuelChange fuel. Inspect and clean fuel system (seechapter 3).

Clogged fuel filter or pump screen Inspect and replace fuel pump (see chapter 3).

Fuel pump trouble Inspect (see chapter 3).

Fuel injector trouble Inspect (see chapter 3).

Inlet air temperature sensor trouble Inspect (see chapter 3).

Water temperature sensor trouble Inspect (see chapter 3).

Atmospheric pressure sensor trouble Inspect (see chapter 3).

Subthrottle sensor trouble Inspect (see chapter 3).

Subthrottle valve actuator trouble Inspect (see chapter 3).

Stick coil trouble Inspect and replace (see chapter 16).

Engine oil level to high Repair (see chapter 7).

Spark plug dirty, broken or gap maladjustedClean spark plugs and adjust plug gap (seechapter 2).

Stumble :

Too low fuel pressure Inspect (see chapter 3).

Fuel injector trouble Inspect (see chapter 3).

Main throttle sensor malfunction Inspect (see chapter 3).

Subthrottle sensor trouble Inspect (see chapter 3).

Subthrottle valve actuator trouble Inspect (see chapter 3).

Water temperature sensor trouble Inspect (see chapter 3).

Inlet air pressure sensor trouble Inspect (see chapter 3).

Surge :

Unstable fuel pressureFuel pressure regulator trouble (Inspect andreplace fuel pump) or kinked fuel line (Inspect andrepair fuel line) (see chapter 3).

Fuel injector trouble Inspect (see chapter 3).

Water temperature sensor trouble Inspect (see chapter 3).

Backfiring when deceleration :

FUEL SYSTEM (DFI) 3-29

DFI System Troubleshooting Guide

Symptoms or Possible Causes Actions (chapter)

Spark plug dirty, broken or gap maladjustedClean spark plugs and adjust plug gap (seechapter 2).

Too low fuel pressure Inspect (see chapter 3).

Fuel pump trouble Inspect (see chapter 3).

Main throttle sensor trouble Inspect (see chapter 3).

Inlet air temperature sensor trouble Inspect (see chapter 3).

Water temperature sensor trouble Inspect (see chapter 3).

Atmospheric pressure sensor trouble Inspect (see chapter 3).

Inlet air pressure sensor trouble Inspect (see chapter 3).

Vacuum switch valve broken Inspect and replace (see chapter 5).

Air suction valve trouble Inspect and replace (see chapter 5).

After fire :

Crankshaft sensor trouble Inspect (see chapter 16).

Spark plug burned or gap maladjusted Adjust plug gap or replace plug (see chapter 2).

Inlet air temperature sensor trouble Inspect (see chapter 3).

Water temperature sensor trouble Inspect (see chapter 3).

Atmospheric pressure sensor trouble Inspect (see chapter 3).

Inlet air pressure sensor trouble Inspect (see chapter 3).

Fuel injector trouble Inspect (see chapter 3).

Run-on (dieseling) :

Ignition switch trouble Inspect and replace (see chapter 16).

Engine stop switch trouble Inspect and repair or replace (see chapter 16).

Fuel injector trouble Inspect (see chapter 3).

Loose terminal of battery (–) lead or ECUground lead

Inspect and repair (see chapter 16).

Carbon accumulating on valve seating surface Repair (see chapter 5).

Engine overheating(see Overheating of Troubleshooting Guide, seechapter 17)

Other :

Engine oil viscosity too high Change (see chapter 2).

Drive train troubleInspect drive chain (see chapter 2) and sprocket(see chapter 11).

Brake draggingInspect caliper fluid seal damage or cloggingof master cylinder relief and supply ports (seechapter 12).

Clutch slipping Inspect friction plates for wear (see chapter 6).

Engine overheating(see Overheating of Troubleshooting Guide, seechapter 17)

Vacuum switch valve trouble Inspect and replace (see chapter 5).

Air suction valve trouble Inspect and replace (see chapter 5).

Intermittent any DFI fault and its recoveryCheck that DFI connectors are clean and tight,and examine wires for signs of burning or fraying(see chapter 3).

3-30 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

Poor Running or No Power at High Speed:Symptoms or Possible Causes Actions (chapter)

Firing incorrect :

Spark plug dirty, broken or maladjustedClean spark plug and adjust plug gap (see chapter2).

Spark plug cap trouble Inspect stick coil (see chapter 16).

Spark plug cap shorted or not in good contact Reinstall or inspect stick coil (see chapter 16).

Spark plug incorrect Replace it with the correct plug (see chapter 16).

IC igniter in ECU trouble Inspect (see chapter 16).

Crankshaft sensor trouble Inspect (see chapter 16).

Stick coil trouble Inspect (see chapter 16).

Fuel/air mixture incorrect :

Choke lever pulled Push it (see chapter 3).

Air cleaner clogged, poorly sealed or missing Clean element or inspect sealing (see chapter 3).

Air cleaner duct loose Reinstall (see chapter 3).

Air cleaner O-ring damaged Replace (see chapter 3).

Water or foreign matter in fuelChange fuel. Inspect and clean fuel system (seechapter 3).

Throttle body assy loose Reinstall (see chapter 3).

Throttle body assy O-ring damaged Replace (see chapter 3).

Fuel tank air vent obstructed Inspect and repair (see chapter 3).

Fuel line clogged Inspect and repair (see chapter 3).

Fuel pump operates intermittently and oftenECU fuse blows.

Pump bearings may wear. Replace the pump (seechapter 3).

Fuel pump trouble Inspect (see chapter 3).

Inlet air temperature sensor trouble Inspect (see chapter 3).

Main throttle sensor trouble Inspect (see chapter 3).

Atmospheric pressure sensor trouble Inspect (see chapter 3).

Inlet air pressure sensor trouble Inspect (see chapter 3).

Cracked or obstructed inlet air pressure sensorhose

Inspect and repair or replace (see chapter 3).

Injector clogged Visually inspect and replace (see chapter 3).

Compression low :

Spark plug loose Reinstall (see chapter 16).

Cylinder head not sufficiently tightened down Tighten (see chapter 5).

No valve clearance Adjust (see chapter 2).

Cylinder, piston worn Inspect and replace (see chapter 5).

Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapter 5).

Piston ring/groove clearance excessive Inspect and replace (see chapter 5).

Cylinder head gasket damaged Replace (see chapter 5) .

Cylinder head warped Inspect and replace (see chapter 5).

Valve spring broken or weak Inspect and replace (see chapter 5).

Valve not seating properly (valve bent , worn orcarbon accumulating on the seating surface)

Inspect and repair or replace (see chapter 5).

Knocking :

Carbon built up in combustion chamber Repair (see chapter 5).

FUEL SYSTEM (DFI) 3-31

DFI System Troubleshooting Guide

Symptoms or Possible Causes Actions (chapter)

Fuel poor quality or incorrect (Use the gasolinerecommended in the Owner’s Manual)

Change fuel (see chapter 3).

Spark plug incorrect Replace it with the correct plug (see chapter 16).

Stick coil trouble Inspect (see chapter 16).

IC igniter in ECU trouble Inspect (see chapter 16).

Inlet air temperature sensor trouble Inspect (see chapter 3).

Atmospheric pressure sensor trouble Inspect (see chapter 3).

Miscellaneous :

Subthrottle sensor trouble Inspect (see chapter 3).

Subthrottle valve actuator trouble Inspect (see chapter 3).

Speed sensor trouble Inspect (see chapter 3).

Throttle valves won’t fully openInspect throttle cable and lever linkage (seechapter 3).

Brake draggingInspect caliper fluid seal damage or cloggingof master cylinder relief and supply ports (seechapter 12).

Clutch slipping Inspect friction plates for wear (see chapter 6).

Engine overheating — water temperature sensor,crankshaft sensor or speed sensor trouble

(see Overheating of Troubleshooting Guide inchapter 17).

Engine oil level too high Repair (see chapter 7).

Engine oil viscosity too high Change (see chapter 3).

Drive train troubleInspect drive chain (see chapter 2) and sprockets(see chapter 11).

Camshaft cam worn Inspect and replace (see chapter 5).

Vacuum switch valve trouble Inspect and replace (see chapter 5).

Air suction valve trouble Inspect and replace (see chapter 5).

Catalytic converters melt down due to muffleroverheating (KLEEN)

Replace muffler (see chapter 5).

Exhaust Smokes Excessively :

(White smokes)

Piston oil ring worn Inspect and replace (see chapter 5).

Cylinder worn Inspect and replace (see chapter 5).

Valve oil seal damaged Replace (see chapter 5).

Valve guide worn Replace the guide (see chapter 5).

Engine oil level too high Repair (see chapter 7).

(Black smoke)

Air cleaner clogged Clean (see chapter 3).

Choke lever pulled Push it (see chapter 3).

Too high fuel pressure Inspect (see chapter 3) .

Injector stuck open Inspect (see chapter 3).

Water temperature sensor trouble Inspect and replace (see chapter 3).

Inlet air temperature sensor trouble Inspect and replace (see chapter 3).

(Brown smoke)

Air cleaner duct loose Reinstall (see chapter 3).

Air cleaner O-ring damaged Replace (see chapter 3).

3-32 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

Symptoms or Possible Causes Actions (chapter)

Too low fuel pressure Inspect fuel line and fuel pump (see chapter 3).

Water temperature sensor trouble Inspect and replace (see chapter 3).

Inlet air temperature sensor trouble Inspect and replace (see chapter 3).

FUEL SYSTEM (DFI) 3-33

Self-Diagnosis

Self-diagnosis OutlineSelf-diagnosis OutlineThe self-diagnosis system has three modes and can be

switched to another mode by grounding the self-diagnosisterminal.

User Mode:The ECU notifies the rider of troubles in DFI system and

ignition system by lighting the FI indicator when DFI systemand ignition system parts are faulty, and initiates fail-safefunction. In case of serious troubles, the ECU stops theinjection/ignition/starter motor operation.Dealer Mode 1:The FI indicator LED light emits service code(s) to show

the problem(s) which the DFI system and ignition systemhas at the moment of diagnosis.Dealer Mode 2:The FI indicator light LED emits service code(s) to show

the problem(s) which the DFI system and ignition systemhad in the past.

Self-diagnosis ProceduresSelf-diagnosis ProceduresWhen a problem occurs with the DFI system and ignitionsystem, the DFI indicator LED light [A] goes on.

NOTEUse a fully charged battery when conductingself-diagnosis. Otherwise, the LED light blinks veryslowly or doesn’t blink.Keep the self-diagnosis terminal grounded during self-diagnosis, with an auxiliary lead.

•Remove the seats (see Frame chapter).•Ground [A] the self-diagnosis terminal [B] (yellow lead) tothe battery (–) terminal [C] or battery (–) lead connector,using a wire.

• Turn on the ignition switch.•Connect an auxiliary lead [E] to the self-diagnosis terminal[G] for grounding.

• To enter the self-diagnosis dealer mode 1, ground [A] theself-diagnosis indicator terminal to the battery (–) terminalfor more than 2 seconds [C], and then keep it groundedcontinuously [D].Count the blinks of the LED light to read the service code.Keep the auxiliary lead ground until you finish reading theservice code.

3-34 FUEL SYSTEM (DFI)

Self-Diagnosis

• To enter the self-diagnosis dealer mode 2, open [B] andground [A] the lead more than five times [F] within 2 sec-onds [C] after the lead is first grounded, and then keep itgrounded continuously [D] for more than 2 seconds.Count the blinks of the LED light to read the service code.Keep the auxiliary lead ground until you finish reading theservice code.Auxiliary Lead [E]Self-diagnosis Terminal [G]

NOTETo enter the dealer mode 2 from the dealer mode 1, turnoff the ignition switch once.

Service Code Clearing ProceduresService Code Clearing Procedures

•Enter the self-diagnosis dealer mode 2 (see Self-diagnosis Procedures).

NOTEMake sure to keep the grounding until the followingopening and grounding starts.

•Pull the clutch lever in more than 5 seconds, and thenrelease it.

• Repeat opening [B] and grounding [A] the lead(self-diagnosis terminal) more than five times [F] within 2seconds [C] after the lead is grounded, and then keep itgrounded continuously [D] for more than 2 seconds.Auxiliary Lead [E]Self-diagnosis Terminal [G]

FUEL SYSTEM (DFI) 3-35

Self-Diagnosis

3-36 FUEL SYSTEM (DFI)

Self-Diagnosis

How to Read Service CodesHow to Read Service CodesService codes are shown by a series of long and short blinks of the FI indicator LED light as shownbelow.Read 10th digit and unit digit as the FI indicator LED light blinks.When there are a number of problems, all the service codes can be stored and the display willbegin starting from the lowest number service code in the numerical order. Then after completingall codes, the display is repeated until the self-diagnosis indicator terminal is open.If there is no problem, no code and unlight.For example, if two problems occurred in the order of 21, 12, the service codes are displayed fromthe lowest number in the order listed.(12 → 21) → (12 → 21) → · · · (repeated)

If the problem is with the following parts, the ECU cannot memorize these problems, the FI indicatorLED light doesn’t go on, and no service codes can be displayed.FI Indicator LED LightFuel PumpFuel Pump RelayDFI Main RelayECU Power Source Wiring and Ground Wiring (see ECU Inspection in this chapter)Fuel Injectors

How to Erase Service CodesHow to Erase Service CodesEven if the ignition SW is turned OFF, the battery or the ECU are disconnected or the problem issolved, all service codes remain in the ECU.Refer to the Service Code Clearing Procedure for the service code erasure.

FUEL SYSTEM (DFI) 3-37

Self-Diagnosis

Service Code TableService Code Table

ServiceCode

FI Indicator LED Light Problems

11 Main throttle sensor malfunction, wiring open or short

12Inlet air pressure sensor malfunction, wiring open orshort

13Inlet air temperature sensor malfunction, wiring openor short

14Water temperature sensor malfunction, wiring openor short

15Atmospheric pressure sensor malfunction, wiringopen or short

21 Crankshaft sensor malfunction, wiring open or short

23Camshaft position sensor malfunction, wiring openor short

24and25

+Speed sensor malfunction, wiring open or shortFirst 24 is displayed and then 25, repeatedly

31Vehicle-down sensor, malfunction, wiring open orshort

32 Subthrottle sensor malfunction, wiring open or short

51Stick (Ignition) coil #1 malfunction, wiring open orshort

52Stick (Ignition) coil #2 malfunction, wiring open orshort

53Stick (Ignition) coil #3 malfunction, wiring open orshort

54Stick (Ignition) coil #4 malfunction, wiring open orshort

62Subthrottle valve actuator malfunction, wiring openor short

Notes:The ECU may be involved in these problems. If all the parts and circuits checked out good, be sureto check the ECU for ground and power supply. If the ground and power supply are checked good,replace the ECU.When no service code is displayed, the electrical parts of the DFI system has no fault, and themechanical parts of the DFI system and the engine are suspect.

3-38 FUEL SYSTEM (DFI)

Self-Diagnosis

BackupsBackupsThe ECU takes the following measures to prevent engine damage when the DFI or the ignitionsystem parts have troubles.

ServiceCodes

PartsOutput Signal UsableRange or Criteria

Backups by ECU

11MainThrottleSensor

Main Throttle SensorOutput Voltage0.2 ∼ 4.8 V

If the main throttle sensor system fails (the signalis out of the usable range, wiring short or open),the ECU locks ignition timing into the ignitiontiming at closed throttle position and sets the DFIin the D-J method.Also, the main throttle sensor system and inlet airpressure fails, the ECU locks ignition timing intothe ignition timing at closed throttle position andsets the DFI in the α-N method.

12Inlet AirPressureSensor

Inlet Air Pressure(absolute)Pv = 100 mmHg ~ 900mmHg

If the inlet air pressure sensor system fails (thesignal Pv is out of the usable range, wiring shortor open), the ECU sets the DFI in the α — Nmethod.

13Inlet AirTempera-ture Sensor

Inlet Air TemperatureTa = –47°C ∼ +178°C

If the inlet air temperature sensor fails (the signalis out of the usable range, wiring short or open),the ECU sets Ta at 40°C.

14Water Tem-peratureSensor

Water TemperatureTw = –30C° ∼ +120°C

If the water temperature sensor system fails (thesignal is out of the usable range, wiring short oropen), the ECU sets Tw at 80°C.

15

Atmo-sphericPressureSensor

Absolute AtmosphericPressurePa = 100 mmHg ∼ 900mmHg

If the atmospheric pressure sensor system fails(the signal is out of the usable range, wiring shortor open), the ECU sets Pa at 760 mmHg (thestandard atmospheric pressure).

21CrankshaftSensor

Crankshaft sensor mustsend 23 signals (outputsignal) to the ECU at theone cranking.

If crankshaft sensor generates other than 23signals, the engine stops by itself.

23CamshaftPositionSensor

Cam sensor must sendone signal (output signal)to the ECU at the twocranking

If the camshaft position sensor system fails(the signal is missing, wiring short or open), theECU continues to ignite cylinders in the samesequence following the last good signal.

24and25

SpeedSensor

Speed sensor must send4 signals (output signal)to the ECU at the onerotation of the enginesprocket.The gear position isdecided by the signal ofthe speed sensor.

If the speed sensor system fails (no signal, wiringshort or open), the speedometer shows 0, andthe ECU sets the top (6) gear position.

31Vehicle-downSensor

Vehicle-down SensorOutput Voltage (signal)Vd = 0.4 V ∼ 4.4 V

If the vehicle-down sensor system has failures(the output voltage Vd is more than usable range,wiring open), the ECU shuts off the fuel pump,the fuel injectors and the ignition system.

FUEL SYSTEM (DFI) 3-39

Self-Diagnosis

ServiceCodes

PartsOutput Signal UsableRange or Criteria

Backups by ECU

32Subthrottlesensor

Subthrottle SensorOutput Voltage0.15 ∼ 4.85 V

If the subthrottle sensor system fails (the signalis out of the usable range, wiring short or open),the actuator locks sub throttle valve at full openposition.

51Stick Coil#1 (IgnitionCoil)*

The stick coil primarywinding must sendsignals (output voltage)continuously to the ECU.

If the ignition primary winding #1 has failures (nosignal, wiring short or open), the ECU shuts offthe injector #1 to stop fuel to the cylinder #1,though the engine keeps running.

52Stick Coil#2 (IgnitionCoil)*

The stick coil primarywinding must sendsignals (output voltage)continuously to the ECU.

If the ignition primary winding #2 has failures (nosignal, wiring short or open), the ECU shuts offthe injector #2 to stop fuel to the cylinder #2,though the engine keeps running.

53Stick Coil#3 (IgnitionCoil)*

The stick coil primarywinding must sendsignals (output voltage)continuously to the ECU.

If the ignition primary winding #3 has failures (nosignal, wiring short or open), the ECU shuts offthe injector #3 to stop fuel to the cylinder #3,though the engine keeps running.

54Stick Coil#4 (IgnitionCoil) *

The stick coil primarywinding must sendsignals (output voltage)continuously to the ECU.

If the ignition primary winding #4 has failures (nosignal, wiring short or open), the ECU shuts offthe injector #4 to stop fuel to the cylinder #4,though the engine keeps running.

62SubthrottleValveActuator

The actuator operatesopen and close of thesubthrottle valve by thepulse signal from theECU.

If the subthrottle valve actuator fails (the signal isout of the usable range, wiring short or open), theECU stops the current to the actuator.

Note:(1) D-J Method and α – N Method: When the engine load is light like at idling or low speed, the ECU

determines the injection quantity by calculating from the throttle vacuum (inlet air pressure sensoroutput voltage) and engine speed (crankshaft sensor output voltage). This method is called D-Jmethod (low-speed mode). As the engine speed increases, and the engine load turns middle toheavy, the ECU determines the injection quantity by calculating from the throttle opening (throttlesensor output voltage) and the engine speed. This method is called α – N method (high-speedmode).

(*) This depends on the number of stopped cylinders.

3-40 FUEL SYSTEM (DFI)

Main Throttle Sensor (Service Code 11)

Main Throttle Sensor Removal/Adjustment

CAUTION

Do not remove or adjust the main throttle sensor [A]since it has been adjusted and set with precision atthe factory.Never drop the sensor, especially on a hard surface.Such a shock to the sensor can damage it.

Main Throttle Sensor Connector (gray) [B]

Input Voltage Inspection

NOTEBe sure the battery is fully charged.• Turn the ignition switch OFF.• Disconnect the main throttle sensor (gray) [A] and con-nect the harness adapter [B] between these connectors.

• Connect a digital meter to the harness adapter lead.Special Tool — Throttle Sensor Harness Adapter :

57001–1538

•Measure the sensor input voltage with the engine stoppedand with the connector joined.

• Turn the ignition switch ON.Main Throttle Sensor Input VoltageConnections to Adapter

Meter (+)→ R (sensor BL) lead

Meter (–)→ BK (sensor BR/BK) lead

Standard : 4.75 ∼ 5.25 V DC

• Turn the ignition switch OFF.If the input voltage is normal, check the sensor outputvoltage.If the input voltage is less than the standard, remove theECU and check the wiring between these connectors.Disconnect the ECU and sensor connectors.Wiring ConnectionECU Connector [A]←→ Throttle Sensor Connector [B]

BL lead (ECU terminal 1)

BR/BK lead (ECU terminal 14)

If the wiring is good, check the ECU for its ground andpower supply (see ECU section).

FUEL SYSTEM (DFI) 3-41

Main Throttle Sensor (Service Code 11)

Output Voltage Inspection

•Measure the output voltage at the main throttle sensorin the same way as input voltage inspection, Note thefollowing.

•Disconnect the main throttle sensor (gray) [A] and con-nect the harness adapter [B] between these connectors.

Special Tool — Throttle Sensor Harness Adapter :57001–1538

•Start the engine and warm it up thoroughly.

•Check idle speed to ensure the throttle opening is correct.Idle SpeedStandard: 1 100 ±50 r/min (rpm)

If the idle speed is out of the specified range, adjust it(see Idle Speed Inspection in the Periodic Maintenancechapter).

• Turn off the ignition switch.•Measure the output voltage of the sensor with the enginestopped, and with the connector joined.

• Turn the ignition SW ON.

Main Throttle Sensor Output VoltageConnections to Adapter

Meter (+) → W (sensor Y/W) lead

Meter (–) → BK (sensor BR/BK) lead

Standard :

0.99 ∼ 1.03 V DC (at idle throttle opening)4.19 ∼ 4.39 V DC (at full throttle opening)

If the output voltage is out of the standard, inspect themain throttle sensor resistance.If the output voltage is normal, check the wiring for conti-nuity.

Wiring ConnectionECU Connector [A]←→ Throttle Sensor Connector [B]

Y/W lead (ECU terminal 2)

BR/BK lead (ECU terminal 14)

If the wiring is good, check the ECU for its ground andpower supply (see ECU section).

3-42 FUEL SYSTEM (DFI)

Main Throttle Sensor (Service Code 11)

Resistance Inspection

• Turn the ignition switch OFF.• Disconnect the main throttle sensor connector.• Connect a digital meter [A] to the main throttle sensorconnector [B].

•Measure the main throttle sensor resistance.Main Throttle Sensor ResistanceConnections: BL lead [C]←→ BR/BK lead [D]

Standard: 4 ∼ 6 kΩIf the reading is out of the range, replace the throttle bodyassy.If the reading is within the range, but the problem stillexists, replace the ECU (see this chapter).

A. ECUI. Main Throttle Sensorm. Throttle Body Assy Connector

FUEL SYSTEM (DFI) 3-43

Inlet Air Pressure Sensor (Service Code 12)

CAUTION

Never drop the sensor, especially on a hard surface.Such a shock to the part can damage it.

Removal

•Remove:Fuel Tank (see Fuel System chapter)Water Temperature Sensor Connector [A]Inlet Air Pressure Sensor Bolt [B]

•Raise the inlet air pressure sensor [C] and disconnect theinlet air pressure sensor connector and the vacuum hose.

Installation

NOTEThe inlet air pressure sensor is the same part as the at-mospheric sensor except that the sensor has a vacuumhose and different wiring.

• Install:Vacuum HoseInlet Air Pressure Sensor

Torque — Inlet Air Pressure Sensor Bolt: 12 N·m (1.2 kgf·m,104 in·lb)

Input Voltage Inspection

NOTEBe sure the battery is fully charged.The inspection is the same as “Input Voltage Inspection”of the main throttle sensor or the atmospheric pressuresensor.

•Turn the ignition switch OFF.•Remove the ECU (see this chapter). Do not disconnectthe ECU connectors.

•Connect a digital voltmeter [A] to the connector [B] withthe needle adapter set.

Special Tool — Needle Adapter Set: 57001–1457

•Measure the input voltage with the engine stopped, andwith the connectors joined.

• Turn the ignition switch ON.Inlet Air Pressure Sensor Input VoltageConnections to ECU

Meter (+)→ BL lead (terminal 1)

Meter (–) → BR/BK lead (terminal 14)

Standard: 4.75 ∼ 5.25 V DC

If the reading is within the standard range, check the sen-sor output voltage.If the reading is less than the standard range, remove theECU and check the wiring between these connectors.If the wiring is good, check the ECU for its ground andpower supply (see ECU section).

3-44 FUEL SYSTEM (DFI)

Inlet Air Pressure Sensor (Service Code 12)

Output Voltage Inspection

NOTEThe output voltage changes according to the local at-mospheric pressure.

•Measure the output voltage at the ECU in the same wayas input voltage inspection. Note the following.

Inlet Air Pressure Sensor Output VoltageConnections to ECU

Meter (+) → Y/BL lead (terminal 17)

Meter (–)→ BR/BK lead (terminal 14)

Usable Range: 3.74 ∼ 4.26 V DC at the standardatmospheric pressure (101.32 kPa,76 cmHg abs.)

• Turn the ignition switch OFF.If the output voltage is within the usable range, check theECU for its ground, and power supply (see this chapter).If the output voltage is out of the usable range, removethe fuel tank and check the wiring. If the output voltage is4.8 V, the ECU is normal.

If the wiring is good, check the sensor for various vacuum.If the output voltage for various vacuum is normal checkthe ECU for its ground, and power supply (see ECU sec-tion).

• Remove the inlet air pressure sensor [A] and disconnectthe vacuum hose from the sensor.Do not disconnect the sensor connector.• Connect an auxiliary hose [B] to the inlet air pressure sen-sor.

• Temporarily install the inlet air pressure sensor.Connect a commercially available digital meter [C], vac-uum gauge [D], the fork oil level gauge [E] and the har-ness adapter to the inlet air pressure sensor.

Special Tools — Fork Oil Level Gauge: 57001–1290Sensor Harness Adapter: 57001–1561

Inlet Air Pressure Sensor Output Voltage

Connection to Adapter

Meter (+)→ BL (sensor Y/BL) lead

Meter (–)→ Y/W (sensor BR/BK) lead

Turn the ignition switch ON.Measure the inlet air pressure sensor output voltage from various vacuum readings, while pullingthe handle of the fork oil level gauge.Check the inlet air pressure sensor output voltage, using the following formula and chart.Suppose:Pg : Vacuum Pressure (gauge) to SensorPl : Local Atmospheric Pressure (absolute) measured by a barometerPv : Vacuum Pressure (absolute) to SensorVv : Sensor Output Voltage (v)

FUEL SYSTEM (DFI) 3-45

Inlet Air Pressure Sensor (Service Code 12)

thenPv = Pl – Pg

For example, suppose the following data is obtained:Pg = 8 cmHg (vacuum gauge reading)Pl = 70 cmHg (barometer reading)Vv = 3.2 V (digital volt meter reading)

thenPv = 70 – 8 = 62 cmHg (abs)

Plot this Pv (62 cmHg) at a point [1] on the chart and draw a vertical line through the point. Then, youcan get the usable range [2] of the sensor output voltage.Usable range = 3.04 ∼ 3.49 V

Plot Vv (3.2 V) on the vertical line. → Point [3].Results: In the chart, Vv is within the usable range and the sensor is normal.Pv = 24 ∼ 55 cmHg

3-46 FUEL SYSTEM (DFI)

Inlet Air Pressure Sensor (Service Code 12)

Pv = 55 ∼ 86 cmHg

Vv: Inlet Air Pressure Sensor Output Volt-age (V) (Digital Meter Reading)

ID: Idling

Pv: Throttle Vacuum Pressure (absolute) TO: Throttle Full Open

Ps: Standard Atmospheric Pressure (abso-lute)

ST: Standard of Sensor Output Voltage (v)

UR: Usable Range of Sensor Output Voltage (v)

A. ECUC. Inlet Air Pressure Sensor

FUEL SYSTEM (DFI) 3-47

Inlet Air Temperature Sensor (Service Code 13)

Removal/Installation

CAUTION

Never drop the sensor, especially on a hard surface.Such a shock to the sensor can damage it.

•Remove the fuel tank (see Fuel Tank Removal).• Disconnect the connector [A] from the inlet air tempera-ture sensor.

• Pull out the inlet air temperature sensor.• Put the inlet air temperature sensor into the grommet.Output Voltage Inspection

NOTEBe sure the battery is fully charged.The output voltage changes according to the inlet airtemperature.

•Remove the ECU (see this chapter). Do not disconnectthe ECU connectors.

•Connect a digital voltmeter to the ECU connector, usingneedle adapter set.

Special Tool — Needle Adapter Set: 57001–1457

•Measure the sensor output voltage with the enginestopped and the connector joined.

• Turn the ignition switch ON.Inlet Air Temperature Sensor Output VoltageConnections to ECU Connector

Meter (+) → Y lead (terminal 18)

Meter (–) → BR/BK lead (terminal 14)

Standard:about 2.25 ∼ 2.50 V at inlet air temperature20°C (68°F)

•Turn the ignition switch OFF.If the output voltage is out of the standard, remove thefuel tank and check the wiring. And if the output voltageis 4.8 V, the ECU is normal.

If the output voltage is within the standard, check the ECUfor its ground, and power supply (see ECU section in thischapter).If the wiring is good, check the sensor resistance.

•Remove the needle adapter set, and apply siliconesealant to the seals of the connector for waterproofing.

Silicone Sealant (Kawasaki Bond: 56019–120) –

Seals of ECU Connectors

3-48 FUEL SYSTEM (DFI)

Inlet Air Temperature Sensor (Service Code 13)

Sensor Resistance Inspection

•Remove the inlet air temperature sensor (see this sec-tion).

• Suspend the sensor [A] in a container of machine oil sothat the heat-sensitive portion is submerged.

• Suspend a thermometer [B] with the heat-sensitive por-tion [C] located in almost the same depth with the sensor.

NOTEThe sensor and thermometer must not touch the con-tainer side or bottom.

•Place the container over a source of heat and graduallyraise the temperature of the oil while stirring the oil gentlyfor even temperature.

• Using a digital meter, measure the internal resistanceof the sensor across the terminals at the temperaturesshown in the table.

Inlet Air Temperature Sensor ResistanceStandard: 1.6 ∼ 3.7 kΩ at 20°C (68°F)

0.24 ∼ 0.43 kΩ at 80°C (176°F)

If themeasurement is out of the range, replace the sensor.If the measurement is within the specified, replace theECU.

A. ECUF. Inlet Air Temperature Sensor

FUEL SYSTEM (DFI) 3-49

Water Temperature Sensor (Service Code 14)

Removal/Installation

CAUTION

Never drop the sensor, especially on a hard surface.Such a shock to the sensor can damage it.

•Remove the fuel tank (see Fuel Tank Removal).• Drain the coolant (see Cooling System chapter).

• Disconnect the sensor connector, and unscrew the watertemperature sensor [A].

Torque — Water Temperature Sensor: 25 N·m (2.5 kgf·m, 18ft·lb)

•Fill the engine with coolant and bleed the air from the cool-ing system (see Coolant Change in the Periodic Mainte-nance chapter).

Output Voltage Inspection

NOTEBe sure the battery is fully charged.•Remove the ECU (see this chapter). Do not disconnectthe connectors.

•Connect a digital voltmeter [A] to the ECU connector [B]with the needle adapter set.

Special Tool — Needle Adapter Set: 57001–1457

•Measure the sensor output voltage with the enginestopped and the connector joined.

• Turn the ignition switch ON.Water Temperature Sensor Output VoltageConnections to ECU

Meter (+) → O lead (terminal 5)

Meter (–) → BR/BK lead (terminal 14)

Standard: about 2.80 ∼ 2.97 V at 20°C (68°F)

NOTEThe output voltage changes according to the coolanttemperature in the engine.

•Turn the ignition switch OFF.If the output voltage is within the standard, check the ECUfor its ground, and power supply (see this chapter).If the output voltage is out of the standard, remove thefuel tank and check the wiring. And if the output voltageis 4.8 V, the ECU is normal.

If the wiring is good, check the water temperature sensorresistance.

•Remove the needle adapter set, and apply siliconesealant to the seals of the connector for waterproofing.

Silicone Sealant (Kawasaki Bond: 56019–120) –

Seals of ECU Connectors

3-50 FUEL SYSTEM (DFI)

Water Temperature Sensor (Service Code 14)

A. ECUD. Water Temperature SensorV. Coolant Temperature Gauge in Tachometer

Sensor Resistance Inspection

•Remove the water temperature sensor (see this section).• Refer to the Electrical System chapter for water temper-ature sensor inspection.

FUEL SYSTEM (DFI) 3-51

Atmospheric Pressure Sensor (Service Code 15)

CAUTION

Never drop the sensor, especially on a hard surface.Such a shock to the sensor can damage it.

NOTEThe atmospheric pressure sensor is the same part asthe inlet air pressure sensor except that the inlet airpressure sensor has the vacuum hose and differentwiring.

Removal

•Turn the ignition switch off.• Remove the seat cover (see Frame chapter).• Remove the atmospheric pressure sensor [A] from therubber damper in the frame.

•Disconnect the sensor connector.

Input Voltage Inspection

NOTEBe sure the battery is fully charged.The inspection is the same as “Input Voltage Inspection”of the throttle sensor and the inlet air pressure sensor.

•Turn the ignition switch OFF.•Remove the ECU (see this chapter). Do not disconnectthe ECU connectors.

•Connect a digital voltmeter [A] to the connector [B], withthe needle adapter set.

Special Tool — Needle Adapter Set: 57001–1457

•Measure the input voltage with the engine stopped, andwith the connectors joined.

• Turn the ignition switch ON.Atmospheric Pressure Sensor Input VoltageConnections to ECU

Meter (+) → BL lead (terminal 1)

Meter (–) → BR/BK lead (terminal 14)

Standard: 4.75 ∼ 5.25 V DCIf the reading is within the standard range, check the sen-sor output voltage.If the reading of input voltage is less than the standardrange, remove the ECU and check the wiring betweenthese connections.If the wiring is good, check the ECU for its ground andpower supply (see ECU section).

3-52 FUEL SYSTEM (DFI)

Atmospheric Pressure Sensor (Service Code 15)

Output Voltage Inspection

•Measure the output voltage at the ECU in the same wayas input voltage inspection. Note the following.Digital Meter [A]ECU Connector [B]

Atmospheric Pressure Sensor Output VoltageConnections to ECU

Meter (+)→ G/W lead (terminal 4)

Meter (–)→ BR/BK lead (terminal 14)

Usable Range: 3.74 ~ 4.26 V DC at the standardatmospheric pressure (101.32 kPa,76 cmHg abs.)

NOTEThe output voltage changes according to the local at-mospheric pressure.

• Turn the ignition switch OFF.If the output voltage is within the usable range, check theECU for its ground, and power supply (see this chapter).

If the output voltage is out of the standard, remove theseat cover and check the wiring. And if the output voltageis 4.8 V, the ECU is normal.

If the wiring is good, check the sensor for various vacuum.If the output voltage for various vacuum is normal, check the ECU for its ground, and power supply(see ECU section).Determine the local altitude (elevation).If you know the local atmospheric pressure using a barometer, substitute the atmospheric pressurefor Pv (throttle vacuum) in the vacuum sensor chart (see inlet air pressure sensor section in thischapter).Get the usable range of the atmospheric pressure sensor output voltage in the same way as OutputVoltage Inspection of the inlet air pressure sensor and check if Va (output voltage) is within theusable range or not.If you know the local altitude, use the following chart.

For example:Suppose the local altitude is 1300 m (4200 ft) and the sensor output voltage Va is 3.3 V.Plot this H (1300 m) at a point [1] on the following chart and draw a vertical line through the point.Then, you can get the usable range [2] of the sensor output voltage.Usable Range = 3.2 ∼ 3.64 V

Plot Va (3.3 V) on the vertical line → Point [3]Results: In the chart, Va is within the usable range and the sensor is normal.

FUEL SYSTEM (DFI) 3-53

Atmospheric Pressure Sensor (Service Code 15)

Va: Atmospheric Pressure Sensor OutputVoltage (v)

ST: Standard of Sensor Output Voltage (v)

H: Altitude (m or feet) UR: Usable Range of Sensor Output Voltage (v)

A. ECUE. Atmospheric Pressure Sensor

3-54 FUEL SYSTEM (DFI)

Crankshaft Sensor (Service Code 21)

Start the engine and switch the diagnosis mode to Dealer1 mode to know all the problem that the DFI system has atthe time of self-diagnosis. If the engine cannot be started,the self-diagnosis system does not detect dynamic condi-tion of the crankshaft sensor. In this case, turn off the igni-tion switch and turn it on again to enter the Dealer 2 mode.In this mode, the system tells all the troubles which the DFIsystem had in both static and dynamic conditions.

Crankshaft Sensor Removal/Installation

•See the Ignition System section in the Electrical Systemchapter.

Crankshaft Sensor InspectionThe crankshaft sensor has no power source, and whenthe engine stops, the crankshaft sensor generates no sig-nals.

• Crank the engine and measure the peak voltage of thecrankshaft sensor (see Electrical System chapter) in or-der to check the sensor.

• Check the wiring for continuity, using the following dia-gram.

A. ECUB. Crankshaft Sensor

FUEL SYSTEM (DFI) 3-55

Camshaft Position Sensor (Service Code 23)

Start the engine and switch the diagnosis mode to Dealer1 mode to know all the problem that the DFI system has atthe time of self-diagnosis. If the engine cannot be started,the self-diagnosis system does not detect dynamic condi-tion of the camshaft position sensor. In this case, turn offthe ignition switch and turn it on again to enter the Dealer 2mode. In this mode, the system tells all the troubles whichthe DFI system had in both static and dynamic conditions.

Camshaft Position Sensor Removal/InstallationThe camshaft position sensor detects the position of the

camshaft, and distinguishes the cylinder.

• See the Ignition system section in the Electric Systemchapter.

Camshaft Position Sensor InspectionThe camshaft position sensor has no power source, andwhen the engine stops, the camshaft position sensor gen-erates no signal.

• Crank the engine and measure the peak voltage of thecamshaft position sensor (see Electrical System chapter)in order to check the sensor.

•Check the wiring for continuity, using the following dia-gram.

A. ECUG. Camshaft Position Sensor

3-56 FUEL SYSTEM (DFI)

Speed Sensor (Service Code 24, 25)

Speed Sensor Removal/Installation

•See the Switches and Sensors section in the ElectricalSystem chapter.

Speed Sensor Inspection

•See the Switches and Sensors section in the ElectricalSystem chapter.

Input Voltage Inspection

NOTEBe sure the battery is fully charged.• Turn the ignition switch OFF.• Disconnect the speed sensor connector [A] and connectthe harness adapter [B] between the harness connectorand speed sensor connector.Engine Sprocket Cover [C]

• Connect a digital meter to the harness adapter leads.Special Tool — Throttle Sensor Setting Adapter:

57001–1400

•Measure the sensor input voltage with the enginestopped, and with the connector joined.

• Turn the ignition switch ON.Speed Sensor Input VoltageConnection to Adapter

Meter (+) → BL (sensor P) lead [C]

Meter (−)→ BK/BL (sensor BK) lead [D]

Standard: About 9 ∼ 11 V DC at Ignition SW ON

If the reading is out of the range, check the wiring (seewiring diagram in this section), and meter (see ElectricalSystem chapter).If the reading is good, check the output voltage.

• Turn the ignition switch OFF.Output Voltage Inspection

•Before this inspection, inspect the input voltage (see InputVoltage Inspection).

NOTEBe sure the battery is fully charged.• Turn the ignition switch OFF.

FUEL SYSTEM (DFI) 3-57

Speed Sensor (Service Code 24, 25)

•Disconnect the speed sensor connector [A] and connectthe harness adapter [B] between the harness connectorand speed sensor connector.Engine Sprocket Cover [C]

•Connect a digital meter to the harness adapter leads.Special Tool — Throttle Sensor Setting Adapter:

57001–1400

•Measure the sensor output voltage with the enginestopped, and with the connector joined.

• Turn the ignition switch ON.Speed Sensor Output Voltage at SensorConnections to Adapter

Meter (+)→ Y/W (sensor Y) lead [C]

Meter (–)→ BK/BL (sensor BK) lead [D]

Standard: About 0.05 ∼ 0.07 V DC

NOTEIf you rotate the engine sprocket, the output voltage willbe increased.

If the reading is out of the range, check the speed sensoroperation (see Electrical System chapter) and the wiringto ECU (see wiring diagram in this section).If the reading, speed sensor operation and wiring aregood, check the ECU for its ground, and power supply(see ECU section).

A. ECU H. Speed Sensor W. Speedometer Unit

3-58 FUEL SYSTEM (DFI)

Vehicle-down Sensor (Service Code 31)

Removal

CAUTION

Never drop the down-sensor, especially on a hardsurface. Such a shock to the sensor can damage it.

•Remove:Connection and Vehicle-down Sensor [A]Bolts [B]

Installation

• The UP mark [A] of the sensor should face upward.Torque — Vehicle-down Sensor Bolts: 2.0 N·m (0.20 kgf·m,

17 in·lb)

WARNINGIncorrect installation of the vehicle-down sensorcould cause sudden loss of engine power. Therider could lose balance during certain riding situ-ations like leaning over in a turn with the potentialfor an accident resulting in injury or death. Ensurethat the down sensor is held in place by the sensorbrackets.

Inspection

NOTEBe sure the battery is fully charged.

•Connect a digital volt meter [A] to the connector of thevehicle-down sensor [B] with the needle adapter set [C].

Vehicle-down Sensor Power Source VoltageConnections to Sensor

Meter (+) → W/Y lead [D]

Meter (–) → BK/Y lead [E]

• Turn the ignition switch ON, and measure the powersource voltage with the connector joined.

Power Source Voltage at SensorStandard: Battery Voltage (12.6 V or more)

• Turn the ignition switch OFF.If there is no battery voltage, check the following:Battery (see Electrical System chapter)ECU Main Fuse 15 AWiring for Vehicle-down Sensor Power Source (see nextdiagram)If the power source is normal, check the output voltage.

FUEL SYSTEM (DFI) 3-59

Vehicle-down Sensor (Service Code 31)

•Turn the ignition switch OFF.•Remove the sensor.•Connect a digital volt meter [A] to the connector with nee-dle adapter set [B].

Special Tool — Needle Adapter Set: 57001–1457

Vehicle-down Sensor Output VoltageConnections to Sensor

Meter (+) → Y/G lead [D]

Meter (–) → BK/Y lead [E]

•Hold the sensor vertically.• Turn the ignition switch ON, and measure the output volt-age with the connector joined.Tilt the sensor 60 ~ 70° or more [C] right or left, then holdthe sensor almost vertical with the arrow mark pointed up,and measure the output voltage.

Output Voltage at SensorStandard: with sensor tilted 60 ∼ 70° or more right or

left: 3.7 ∼ 4.4 Vwith sensor arrow mark pointed up: 0.4 ∼1.4 V

NOTEIf you need to test again, turn the ignition switch OFF,and then ON.

•Turn the ignition switch OFF.•Remove the needle adapter set, and apply siliconesealant to the seals of the connector for waterproofing.

Silicone Sealant (Kawasaki Bond: 56019–120) –

Seals of Vehicle-down Sensor Connector

If the output voltage is normal, the wiring is suspect.Check the wiring.If the wiring is good, check the ECU for its ground andpower supply (see ECU section).If the output voltage is out of the specified, replace thevehicle-down sensor.

3-60 FUEL SYSTEM (DFI)

Vehicle-down Sensor (Service Code 31)

A. ECUS. ECU Main RelayT. Ignition Switch

a. ECU Fuse 15 Ab. Vehicle-down Sensord. Starter Relay

f. Sealed Batteryj. Joint Connector Bk. Main Fuse 30 A

FUEL SYSTEM (DFI) 3-61

Subthrottle Sensor (Service Code 32)

Subthrottle Sensor Removal/Adjustment

CAUTION

Do not remove or adjust the subthrottle sensor [A]since it has been adjusted and set with precision atthe factory.Never drop the sensor, especially on a hard surface.Such a shock to the sensor can damage it.

Subthrottle Sensor Connector (black) [B]

Input Voltage Inspection

NOTEBe sure the battery is fully charged.•Turn the ignition switch OFF.•Disconnect the subthrottle sensor (black) [A] and connectthe harness adapter [B] between these connectors.

•Connect a digital meter to the harness adapter lead.Special Tool — Throttle Sensor Harness Adapter :

57001–1538

•Measure the sensor input voltage with the engine stoppedand with the connector joined.

• Turn the ignition switch ON.Subthrottle Sensor Input VoltageConnections to Adapter

Meter (+) → R (sensor BL) lead

Meter (–) → BK (sensor BR/BK) lead

Standard : 4.75 ∼ 5.25 V DC

•Turn the ignition switch OFF.If the input voltage is normal, check the sensor outputvoltage.If the input voltage is less than the standard, remove theECU and check the wiring between these connectors.Disconnect the ECU and sensor connectors.Wiring ConnectionECU Connector [A] ←→Subthrottle Sensor Connector [B]

BL lead (ECU terminal 1)

BR/BK lead (ECU terminal 14)

If the wiring is good, check the ECU for its ground andpower supply (see ECU section).

3-62 FUEL SYSTEM (DFI)

Subthrottle Sensor (Service Code 32)

Output Voltage Inspection

•Remove the throttle body assy (see Throttle Body AssyRemoval).

•Measure the output voltage at the subthrottle sensor inthe same way as input voltage inspection. Note the fol-lowing.

• Disconnect the subthrottle sensor (black) [A] and (black)connect the harness adapter [B] between these connec-tors.

Special Tool — Throttle Sensor Harness Adapter:57001–1538

•Measure the output voltage of the sensor with the enginestopped, and with the connector joined.

• Turn the ignition switch ON.•Measure the output voltage when the subthrottle valve isfully opened or completely closed by hand.

Main Throttle Sensor Output VoltageConnections to Adapter

Meter (+)→ W (sensor BR) lead

Meter (–)→ BK (sensor BR/BK) lead

Standard :

0.48 ∼ 0.52 V DC (at idle throttle opening)3.6 ∼ 3.8 V DC (at full throttle opening)

If the output voltage is out of the standard, inspect thesubthrottle sensor resistance.If the output voltage is normal, check the wiring for conti-nuity.

Wiring ConnectionECU Connector [A] ←→Subthrottle Sensor Connector [B]

BR lead (ECU terminal 3)

BR/BK lead (ECU terminal 14)

If the wiring is good, check the ECU for its ground andpower supply (see ECU section).

FUEL SYSTEM (DFI) 3-63

Subthrottle Sensor (Service Code 32)

Resistance Inspection

•Turn the ignition switch OFF.•Disconnect the subthrottle sensor connector.•Connect a digital meter [A] to the subthrottle sensor con-nector [B].

•Measure the subthrottle sensor resistance.Throttle Sensor ResistanceConnections: BL lead [C]←→ BR/BK lead [D]

Standard: 4 ∼ 6 kΩIf the reading is out of the range, replace the throttle bodyassy.If the reading is within the range, but the problem stillexists, replace the ECU (see this chapter).

A. ECU L. Subthrottle Valve Actuator

J. Subthrottle Sensor m. Throttle Body Assy Connector

3-64 FUEL SYSTEM (DFI)

Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54)

Stick Coil #1: Ignition Coil (Service Code 51)Stick Coil #2: Ignition Coil (Service Code 52)Stick Coil #3: Ignition Coil (Service Code 53)Stick Coil #4: Ignition Coil (Service Code 54)

Removal/Installation

CAUTION

Never drop the stick coils, especially on a hard sur-face. Such a shock to the stick coil can damage it.

•See the Ignition System section in the Electrical Systemchapter.

Input Voltage Inspection

NOTEBe sure the battery is fully charged.

• Turn the ignition switch OFF.• Remove the ECU (see this chapter). Do not disconnectthe ECU connector.

• Connect a digital voltmeter [A] as shown, with the needleadapter set [B].Measure the input voltage to each primary winding of theignition coils with the engine stopped, and with the con-nectors joined.

• Turn the ignition switch ON.Stick Coil Input Voltage at ECUConnections for Stick Coil #1

Meter (+)→ BK lead (terminal 39)

Meter (–) → BK/Y lead (terminal 51)

Connections for Stick Coil #2

Meter (+) → BK/G lead (terminal 38)

Meter (–) → BK/Y lead (terminal 51)

Connections for Stick Coil #3

Meter (+) → BK/W lead (terminal 37)

Meter (–) → BK/Y lead (terminal 51)

Connections for Stick Coil #4

Meter (+) → BK/O lead (terminal 52)

Meter (–) → BK/Y lead (terminal 51)

Input Voltage at ECUStandard: Battery Voltage (12.6 V or more)

If the reading is out of the standard, check the wiring (seenext wiring diagram).If the reading is good, the input voltage is normal. Crankthe engine, and check the peak voltage of the stick coils(see Electrical System chapter) in order to check the pri-mary coils.

FUEL SYSTEM (DFI) 3-65

Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54)

A. ECUM. Stick CoilsN. Engine Stop SwitchT. Ignition Switch

X. Ignition Fuse 10 AY. Junction Boxd. Starter Relaye. Joint Connector C

f. Sealed Batteryk. Main Fuse 30 A

3-66 FUEL SYSTEM (DFI)

Subthrottle Valve Actuator (Service Code 62)

Subthrottle Valve Actuator Removal

CAUTION

Do not remove the subthrottle valve actuator [A]since it has been adjusted and set with precisionat the factory.Never drop the actuator , especially on a hard sur-face. Such a shock to the actuator can damage it.

Audible Inspection

NOTEBe sure the battery is fully charged.• Turn the ignition switch ON and ensure that the actuatorvalves open and close (make light sounds) several timeswithin seconds, and then close at the idle throttle openingposition.

• Turn the ignition switch OFF.If the actuator does not work as described above, do thevisual inspection.

Visual Inspection

•Remove the throttle body assy (see Throttle Body AssyRemoval).

• Turn the ignition switch ON.• Check to see that all the subthrottle valves [A] open andclose smoothly.If the subthrottle valves do not operate, check the actuatorinternal resistance (see Resistance Inspection).

Resistance Inspection

• Turn the ignition switch OFF.• Remove the throttle body assy (see Throttle Body AssyRemoval).

• Disconnect the subthrottle valve actuator connector [A].

• Connect a digital meter to the subthrottle valve actuatorconnector [A].

•Measure the subthrottle valve actuator resistance.Subthrottle Valve Actuator ResistanceConnections: BK/BL lead [1]←→ P/BL lead [2]

G lead [3] ←→ W/BL lead [4]

Standard: About 5 ∼ 7 kΩ

Special Tool — Hand Tester : 57001–1394

If the reading is out of the range, replace the actuatoralong with the throttle body assy.If the reading is within the range, check the input voltage(see Input Voltage Inspection).

FUEL SYSTEM (DFI) 3-67

Subthrottle Valve Actuator (Service Code 62)

Input Voltage Inspection

NOTEBe sure the battery is fully charged.•Turn the ignition switch OFF.•Remove the throttle body assy (see Throttle Body AssyRemoval).

• Connect the peak voltage adapter [A] and a digital meter[B] to the connector [C], using the needle adapter set [D].

Recommended Tool — Peak Voltage AdapterType: KEK-54–9–BBrand: KOWA SEIKI

Special Tool — Needle Adapter Set: 57001–1457

Subthrottle Valve Actuator Input VoltageConnections to Harness Connector

(I) Meter (+) → BK/BL lead [1]

Meter (–) → P/BL lead [2]

(II) Meter (+) → G lead [3]

Meter (–) → W/BL lead [4]

•Measure the actuator input voltage with the enginestopped, and with the connector joined.

• Turn the ignition switch ON.Input Voltage at ActuatorStandard: about 8.5 ∼ 10.5 V DC

If the reading is within the standard but the actuatordoesn’t operate, replace it.If the reading is out of the range, check the wiring to ECU(see wiring diagram in this section).If the wiring is good, check the ECU for its ground andpower supply (see ECU section).

A. ECU L. Subthrottle Valve Actuator

J. Subthrottle Sensor m. Throttle Body Assy Connector

3-68 FUEL SYSTEM (DFI)

FI Indicator LED Light

Inspection Flow Chart

FUEL SYSTEM (DFI) 3-69

FI Indicator LED Light

LED Light Inspection

•Remove the meter unit (see Electrical System chapter).• Using two auxiliary leads, supply battery power to the FIindicator LED light [A].12 V Battery [B]

FI Indicator LED Light CheckConnector: Meter Connector [C] (disconnected)

Connection:BR/W Lead Terminal [1] of the Meter→Battery (+) Terminal

BR/R Lead Terminal [6] of the Meter→Battery (–) Terminal

Criterion: The LED light should light.

If the LED light does not go on, replace the meter unit.

A. ECUT. Ignition SwitchU. FI Indicator LED Light

X. Ignition Fuse 10 AY. Junction Boxd. Starter Relay

e. Joint Connector Cf. Sealed Batteryk. Main Fuse 30 A

3-70 FUEL SYSTEM (DFI)

ECU

CAUTION

Never drop the ECU, especially on a hard surface.Such a shock to the ECU can damage it.

ECU Removal

•Remove:Seats (see Frame chapter)Junction Box [A]

• Take the ECU [A] out along with the harness.• Disconnect the ECU lead connectors [B].

ECU Installation

•Connect the ECU connectors, noting the length of thelocks.Longer Lock [A]Shorter Lock [B]

ECU Power Supply Inspection

•Visually inspect the terminals [A] of the ECU connectors.If the connector is clogged with mud or dust, blow it offwith compressed air.Replace the main harness if the terminals of the mainharness connectors are cracked, bent, or otherwise dam-aged.Replace the ECU if the terminals of the ECU connectorsare cracked, bent, or otherwise damaged.

FUEL SYSTEM (DFI) 3-71

ECU

•With the ECU connectors [A] connected, check the fol-lowing ground lead for continuity with the ignition switchOFF, using a tester and needle adapter set.

ECU Grounding Inspection26, 50, or 51 (BK/Y)Terminal

←→ Battery (–) Terminal: 0 Ω

Engine Ground ←→ Battery (–) Terminal: 0 ΩIf no continuity, check the connector, the engine groundlead, or main harness, and repair or replace them if nec-essary.Battery [B]Tester [C]

Special Tool — Needle Adapter Set: 57001–1457

•Check the ECU power source voltage with a digital meter[A].Position the terminal in accordance with terminal numbersof ECU connectors [B] in this chapter figure.Battery [C]

ECU Power Source InspectionMeterConnections:

between Terminal 13 (W/Y) andBattery (–) Terminal

between Terminal 43 (W/BK) andBattery (–) Terminal

Ignition SW OFF: Terminal 13 (W/Y) : 0 V,

Terminal 43 (W/BK) : 12.6 V or more

Ignition SW ON:Both: Battery Voltage (12.6 V ormore)

If the meter does not read as specified, check the follow-ing:Main Fuse 30 A (see Electrical System chapter)ECU Fuse 15 A (see DFI Power Source section)ECU Main Relay (see DFI Power Source section)Power Source Wiring (see wiring diagram below)If the inspection checks good, the ECU is damaged. Re-place the ECU. The ECU itself cannot be checked or ser-viced.

3-72 FUEL SYSTEM (DFI)

ECU

ECU Power Source Circuit

A. ECUS. ECU Main RelayT. Ignition Switch

a. ECU Fuse 15 Ad. Starter Relaye. Joint Connector C

f. Sealed Batteryj. Joint Connector Bk. Main Fuse 30 A

FUEL SYSTEM (DFI) 3-73

DFI Power Source

ECU Fuse Removal

•Refer to the Electrical System chapter for the ECU fuseremoval.

ECU Fuse InstallationIf a fuse fails during operation, inspect the DFI system todetermine the cause, and then replace it with a new fuseof proper amperage.

•Refer to the Electrical System chapter for the ECU fuseinstallation.

ECU Fuse Inspection

•Refer to the Electrical System chapter for the ECU fuseinspection.

ECU Main Relay Removal

CAUTION

Never drop the relay, especially on a hard surface.Such a shock to the relay can damage it.

•Remove the seat cover (see Frame chapter).• Remove the ECU main relay [A] from the tongue of thestorage compartment and disconnect the connector.

ECU Main Relay Inspection

•Remove the ECU main relay (see above).•Connect the hand tester [A] and one 12 V battery [B] tothe relay connector [C] as shown.

Special Tool — Hand Tester: 57001–1394

Relay Coil Terminals [1] and [2]Relay Switch Terminals [3] and [4]

Testing RelayTester range: 1 Ω range

Criteria: When battery is connected→ 0 ΩWhen battery is disconnected→ ∞ Ω

If the relay does not work as specified, replace the relay.

3-74 FUEL SYSTEM (DFI)

Fuel Line

Fuel Pressure Inspection

NOTEThis inspection can determine which trouble the DFIsystem has, mechanical or electrical trouble.It is preferable to measure the fuel pressure while run-ning the motorcycle just when trouble occurred in orderto know symptom well.Be sure the battery is fully charged.•Remove the fuel tank (see Fuel Tank Removal).• Be sure to place a piece of cloth around the pump outletpipe and the delivery pipe.

• Remove the fuel pump outlet hose [A].Front [B]

WARNINGBe prepared for fuel spillage; any spilled fuel mustbe completely wiped up immediately.When the fuel hose is disconnected, fuel spills outfrom the hose and the pipe because of residualpressure. Cover the hose connection with a pieceof clean cloth to prevent fuel spillage.

• Install the fuel pressure gauge adapter [A] between thefuel pump outlet pipe [B] and the delivery pipe [C].

• Connect the pressure gauge [D] to the fuel pressuregauge adapter (right side view).

Special Tools — Oil Pressure Gauge: 57001–125Fuel Pressure Gauge Adapter: 57001–1417

WARNINGDo not try to start the engine with the fuel hosesdisconnected.

• Temporarily, install the fuel tank [E]Clamps [F]

• Turn the ignition switch ON. The fuel pump will turn for 3seconds, and then stop.

CAUTION

Do not drive the fuel pump without the fuel in thefuel tank.

•Measure the fuel pressure with the engine stopped.Fuel PressureRight after Ignition SW ON, with pump running:

Standard: 310 kPa (3.2 kgf/cm², 44 psi)

After 3 seconds from Ignition SW ON, with pumpstopped:

Standard: 290 kPa (3.0 kgf/cm², 43 psi) (residualfuel pressure)

The system should hold the residualpressure about 30 seconds.

FUEL SYSTEM (DFI) 3-75

Fuel Line

•Start the engine, and let it idle.•Measure the fuel pressure with the engine idling.Fuel Pressure (idling)Standard: 310 kPa (3.2 kgf/cm², 46 psi)

NOTEThe gauge needle will fluctuate. Read the pressure atthe average of the maximum and minimum indications.

If the fuel pressure is normal, the fuel circulation system(fuel pump, pressure regulator, and oil passage) is nofaults. Check the DFI electronic control system (injectors,sensors, crankshaft sensor, and ECU).If the fuel pressure is much lower than specified, checkthe following:Fuel Pump Inlet Hose CloggingFuel Line LeakageFuel Pump Operation (check the sound of the pump)Amount of Fuel Flow (see Fuel Flow Rate Inspection)If the fuel pressure is much higher than specified, checkthe following:Delivery Pipe CloggingInjector Clogging

•Remove the fuel pressure gauge and adapter.• Install the fuel tank (see Fuel Tank Installation).Fuel Flow Rate Inspection

NOTEBe sure the battery is fully charged.

WARNINGGasoline is extremely flammable and can be explo-sive under certain conditions. Make sure the areais well-ventilated and free from any source of flameor sparks; this includes any appliance with a pilotlight. Do not smoke. Turn the ignition switch OFF.Be prepared for fuel spillage; any spilled fuel mustbe completely wiped up immediately.

•Turn the ignition switch, and engine stop switch OFF.•Wait until the engine cools down.• Prepare a plastic hose of the inside diameter 7.5 mm(0.30 in.) and a measuring cylinder.

•Remove the fuel tank bolt (see Fuel Tank Removal).

3-76 FUEL SYSTEM (DFI)

Fuel Line

•Open the fuel tank cap [A] to lower the pressure in thetank.

• Be sure to place a piece of cloth around the fuel pumpoutlet hose.

• Remove the fuel pump outlet hose [A] from the fuel pump[B] and the delivery pipe [C] (see Fuel Pump Removal).Front [D]

WARNINGBe prepared for fuel spillage; any spilled fuel mustbe completely wiped up immediately.When the fuel hose is disconnected, fuel spills outfrom the hose and the pipe because of residualpressure. Cover the hose connection with a pieceof clean cloth to prevent fuel spillage.

•Connect the plastic hose [A] to the fuel pump outlet pipe.• Secure the plastic hose with a clamp [B].• Run the other side of the plastic hose into the measuringcylinder [C].Front [D]

WARNINGWipe off spilled out fuel immediately.Be sure to hold the measuring cylinder vertical.

• Temporarily instal the fuel tank and close the fuel tankcap.

•With the engine stopped, turn the ignition switch ON. Thefuel pump should operate for 3 seconds, and then shouldstop. Repeat this several times until the plastic hose isfilled with fuel.

CAUTION

Do not drive the fuel pump without the fuel in thefuel tank.

•Measure the discharge for 3 seconds with the plastic hosefilled with fuel.Repeat this operation several times.Amount of Fuel FlowStandard: 67 mL or more for 3 seconds

If the fuel flow is much less than the specified, check thebattery condition (see Electrical System chapter). If thebattery is good, replace the fuel pump.

• After inspection, install the fuel tank. (see Fuel Tank In-stallation).

• Start the engine and check for fuel leakage.

FUEL SYSTEM (DFI) 3-77

Fuel Pump

Fuel Pump Removal

CAUTION

Never drop the fuel pump, especially on a hard sur-face. Such a shock to the pump can damage it.

WARNINGGasoline is extremely flammable and can be explo-sive under certain conditions. Make sure the areais well-ventilated and free from any source of flameor sparks; this includes any appliance with a pilotlight. Do not smoke. Turn the ignition switch OFF.Disconnect the battery (–) terminal.To make fuel spillage minimum, draw the fuel outfrom the fuel tank when the engine is cold. Beprepared for fuel spillage; any spilled fuel must becompletely wiped up immediately.

•Draw the fuel out from the fuel tank with a commerciallyavailable electric pump.

•Remove the fuel tank (see Fuel Tank Removal).Be careful of fuel spillage from the fuel tank since fuel stillremains in the fuel tank and fuel pump. Plug the fuel pipeof the fuel tank.

• Turn the fuel tank upside down.•Remove the fuel pump inlet hose [A].•Unscrew the fuel pump bolts [B], and take out the fuelpump [C] and gasket.

•Discard the fuel pump gasket.CAUTION

Do not pull the leads (C) of the fuel pump. If theyare pulled, the lead terminals may be damaged.

Fuel Pump Installation

•Remove dirt or dust from the fuel pump [A] by lightly ap-plying compressed air.

3-78 FUEL SYSTEM (DFI)

Fuel Pump

•Replace the fuel pump gasket [A] with a new one.

• Check that the fuel pump (–) terminal [A] and band [B] arein place.Front [C]

• Apply a non-permanent locking agent to the threads ofthe fuel pump bolts.

• Tighten the fuel pump bolts to a snug fit, following thetightening sequence shown.

• Following the tightening sequence, tighten the fuel pumpbolts to the specified torque.

Torque — Fuel Pump Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

• Tighten the pump bolts again to check the tightness in theorder shown.

Operation Inspection

NOTEBe sure the battery is fully charged.Just listen to the pump sound in the fuel tank to confirmpump operation.

• Turn the ignition switch ON and make sure that the fuelpump operates (make light sounds) for 3 seconds, andthen stops.

• Turn the ignition switch OFF.If the pump does not work as described above, inspectthe operating voltage.

Operating Voltage Inspection

NOTEBe sure the battery is fully charged.• Turn the ignition switch OFF.• Remove the fuel tank bolt and lift up the fuel tank.

FUEL SYSTEM (DFI) 3-79

Fuel Pump

•Connect the hand tester (25 V DC) to the fuel pump con-nector [A] with needle adapter set.

Special Tools — Hand Tester: 57001–1394Needle Adapter Set: 57001–1457

Measure the operating voltage with the engine stopped,and with the connector joined.

• Turn the ignition switch ON.The tester needle should indicate battery voltage for 3seconds, and then 0 V.

Pump Operating Voltage at PumpConnections to Pump Connectors

Tester (+) → Y/R Lead

Tester (–) → BK/W Lead

Operating Voltage at Pump Connector

Standard: Battery Voltage (12.6 V or more) for 3seconds, and then 0 V.

If the reading stays on battery voltage, and never shows0 V. Check the ECU and fuel pump relay.If the voltage is in specification, but the pump doesn’twork, replace the pump.If there is still no battery voltage, check the pump relay(see this chapter).

Pressure Regulator RemovalThe pressure regulator [A] is built into the fuel pump [B]and cannot be removed.

Pump Screen, Fuel Filter CleaningThe pump screen [A] and fuel filter [B] are built into thepump and cannot be cleaned or checked.If the pump screen or fuel filter is suspected of cloggingor being damaged, replace it with the fuel pump as a set.

3-80 FUEL SYSTEM (DFI)

Fuel Pump

Fuel Pump Relay Removal

CAUTION

Never drop the relay, especially on a hard surface.Such a shock to the relay can damage it.

•Remove the seat cover (see Frame chapter).• Remove the fuel pump relay [A] from the tongue of thestorage compartment.

• Disconnect the connector.Fuel Pump Relay Inspection

•Remove the fuel pump relay (see above).• Connect the hand tester [A] and one 12 V battery [B] tothe relay connector [C] as shown.

Special Tool — Hand Tester: 57001–1394

Relay Coil Terminals [1] and [2]Relay Switch Terminals [3] and [4]

Testing RelayTester range: 1 Ω range

Criteria: When battery is connected→ 0 ΩWhen battery is disconnected→ ∞ Ω

If the relay does not work as specified, replace the relay.

A. ECUN. Engine Stop SwitchT. Ignition SwitchX. Ignition Fuse 10 A

Y. Junction BoxZ. Fuel Pump Relay (for fuelpump and injectors)

d. Starter Relay

f. Sealed Batteryg. Fuel Pumpj. Joint Connector Bk. Main Fuse 30 A

FUEL SYSTEM (DFI) 3-81

Fuel Injectors

Removal/Installation

•Refer to the Throttle Body Assy Disassembly/Assembly.Audible Inspection

•Start the engine.• Apply the tip of a screwdriver [A] to the injector [C]. Putthe grip end onto your ear, and listen whether the injectoris clicking or not.A sound scope [B] can also be used.•Do the same for the other injectors.If all the injectors click at a regular intervals, the injectorsare good. The trouble may be related to the fuel line,requiring fuel pressure inspection (see Fuel Line sectionin this chapter).The click interval becomes shorter as the engine speedrises.If any injector(s) doesn’t click, the DFI circuit or the injectoris suspect. Perform “Power Source Voltage Inspection”,first.

Power Source Voltage Inspection

•Remove the ECU (see ECU section). Do not disconnectthe ECU connector.

•Connect a digital meter [A] to the ECU connector [B], us-ing the needle adapter [C].

Special Tool — Needle Adapter Set: 57001–1457

Measure the power source voltage with the enginestopped, and with the connector joined.

• Turn the ignition switch ON.Injector Power Source Voltage at ECUConnections: Meter (+)→ W/Y (terminal 13)

Meter (–)→ Battery (–) Terminal

Service Limit: Voltage (12.6 V or more)

If the meter doesn’t read as specified, check the following.Main Fuse 30 A (see Electrical System chapter)Fuel Pump Relay (see DFI Power Source section)Power Source Wiring (see Wiring Diagram below)

To check the W/R leads between the injector connectorand the fuel pump relay, remove the fuel tank (see FuelTank Removal) and the seat cover (see Frame chapter).If the power source voltage is normal, check the outputvoltage of the injectors.

3-82 FUEL SYSTEM (DFI)

Fuel Injectors

Output Voltage Inspection

• Turn the ignition switch OFF.• Remove the ECU (see ECU section).• Connect a digital voltmeter [A] to the ECU connector [B]with the needle adapter set [C].

Special Tool — Needle Adapter Set: 57001-1457

Injector Output VoltageConnections to Injector #1

Meter (+) → BL/R lead (terminal 36)

Meter (–) → Battery (–) Terminal

Connections to Injector #2

Meter (+) → BL/G lead (terminal 35)

Meter (–) → Battery (–) Terminal

Connections to Injector #3

Meter (+) → BL/BK lead (terminal 49)

Meter (–) → Battery (–) Terminal

Connections to Injector #4

Meter (+) → BL/Y lead (terminal 48)

Meter (–) → Battery (–) Terminal

• Turn the ignition switch ON.Output Voltage at Injector ConnectorStandard: Battery Voltage (12.6 V or more)

If the output voltage is normal, perform “Injector SignalTest”.If the output voltage is out of the standard, turn the ignitionswitch OFF, remove the fuel tank, and check the injectorwiring for continuity.

Injector Wiring InspectionECU Connector Injector Connectors

Terminal 36 → Injector #1 Terminal (BL/R)

Terminal 35 → Injector #2 Terminal (BL/G)

Terminal 49 → Injector #3 Terminal (BL/BK)

Terminal 48 → Injector #4 Terminal (BL/Y)

If the wiring is good, inspect the resistance of the injectors(see Injector Resistance Inspection in chapter).

• Remove the needle adapter.• Apply silicone sealant to the seals of the ECU connectorfor waterproofing.

FUEL SYSTEM (DFI) 3-83

Fuel Injectors

Injector Signal Test

•Prepare two test light sets with male terminals as shown.Rating of Bulb [A]: 12 V × 3 ∼ 3.4 WTerminal Width [B]: 1.8 mm (0.071 in.)Terminal Thickness [C]: 0.8 mm (0.031 in.)

CAUTION

Do not use larger terminals than specified above. Alarger terminal could damage the injector main har-ness connector (female), leading to harness repairor replacement.Be sure to connect bulbs in series. The bulb worksas a current limiter to protect the solenoid in theinjector from excessive current.

•Remove the fuel tank (see Fuel Tank Removal).• Remove connectors for injector [A].• Connect each test light set [B] to the injector sub harnessconnector [C].

• Turn the ignition switch ON.•While cranking the engine with the starter motor, watchthe test lights.If the test lights flicker at regular intervals, the injectorcircuit in the ECU, and the wiring are good. Perform the“Injector Resistance Inspection”.

Injector signals can be also confirmed by connecting thehand tester (× 10 V AC) instead of the test light set tothe injector main harness (female) connector. Crank theengine with the starter motor, and check to see if the handoscillates at regular intervals.

Special Tool — Hand Tester: 57001–1394

If the test light doesn’t flicker (or the tester needle doesn’toscillates), check the wiring and connectors again. If thewiring is good, check the injector voltage. If the wiring isgood, inspect the ECU for its ground and power supply(see ECU section).

3-84 FUEL SYSTEM (DFI)

Fuel Injectors

Injector Resistance Inspection

•Remove the fuel tank (see Fuel Tank Removal).• Disconnect the connector from the injector [A] (see Throt-tle Body Assy Disassembly/Assembly).

•Measure the injector resistance with the hand tester [B].Special Tool — Hand Tester: 57001–1394

Injector ResistanceConnections to Injector

Meter (+) Meter (–)

#1: W/R ←→ BL/R Terminal

#2: W/R ←→ BL/G Terminal

#3: W/R ←→ BL/BK Terminal

#4: W/R ←→ BL/Y Terminal

Standard: about 11.7 ∼ 12.3 Ω @20°C (68°F)

If the reading is out of the range, perform the “Injector UnitTest”.If the reading is normal, perform the “Injector Unit Test”for confirmation.

Injector Unit Test

•Use two leads [A] and the same test light set [B] as in“Injector Signal Test”.Rating of Bulb [C]: 12 V × (3 ∼ 3.4) W12 V Battery [D]

CAUTION

Be sure to connect the bulb in series. The bulbworks as a current limiter to protect the solenoidin the injector from excessive current.

•Connect the test light set to the injector [E] as shown.•Open and connect [F] the end of the lead to the battery(–) terminal repeatedly. The injector should click.If the injector does not click, replace the injector.If the injector clicks, check the wiring again. If the wiringis good, replace the injector (may be clogged) or ECU.

Injector Fuel Line Inspection

•While pinching the fuel pump outlet hose joint locks [A]with fingers, pull the joint out along the delivery pipe (seeFuel Tank Removal).Cloth [B]Pump Outlet Hose Joint [C]

FUEL SYSTEM (DFI) 3-85

Fuel Injectors

•Check the injector fuel line for leakage as follows:Connect a commercially available vacuum/pressurepump [A] to the nipple of the delivery pipe [B] with ahigh-pressure fuel hose [C] (both ends connected withthe clamps [D]) as shown.

Torque — Fuel Hose Clamp Screws: 1.5 N·m (0.15 kgf·m, 13in·lb)

Apply soap and water solution to the areas [E] as shown.Watching the pressure gauge, squeeze the pump lever[F], and build up the pressure until the pressure reachesthe maximum pressure.

Injector Fuel Line Maximum PressureStandard: 300 kPa (3.06 kgf/cm², 43 psi)

CAUTION

During pressure testing, do not exceed the maxi-mum pressure for which the system is designed.

•Watch the gauge for at least 6 seconds.If the pressure holds steady, the system is good.If the pressure drops at once or if bubbles are found inthe area, the line is leaking. Replace the delivery pipe,injectors and related parts.Repeat the leak test, and check the fuel line for no leak-age.

• Install the pump outlet hose (see Fuel Tank Installation).•Run the hoses correctly (see Cable, Wire, and Hose Rout-ing section in Appendix chapter).

3-86 FUEL SYSTEM (DFI)

Fuel Injectors

A. ECUK. Fuel InjectorsN. Engine Stop SwitchT. Ignition SwitchX. Ignition Fuse 10 A

Y. Junction BoxZ. Fuel Pump Relay (for fuelpump an injectors)

d. Starter Relaye. Joint Connector C

f. Sealed Batteryj. Joint Connector Bk. Main Fuse 30 A

FUEL SYSTEM (DFI) 3-87

Throttle Grip and Cables

Throttle Grip Play Inspection/Adjustment

•Refer to the Throttle Control System Inspection in the Pe-riodic Maintenance chapter.

Choke Lever OperationDo not use the choke lever except when the engine has astarting difficulty like in cold weather (10°C, 50°F or below)or at high altitude. The DFI system has an automaticchoke system, using a water temperature sensor, and anatmospheric pressure sensor, which provide startability.

NOTEPull [A] the choke lever fully when using. The chokedoesn’t work with the lever knob halfway.

When flooded, do not crank the engine with the throt-tle fully opened like a carburetor. This promotes engineflooding because more fuel is supplied automatically bythe DFI system.

Choke Lever Play Inspection

•Push the choke lever [A] fully and ensure by your fingerthat the choke cam [B] has the specified play.

Choke Lever Free PlayStandard: 0 ∼ 0.5 mm (0 ∼ 0.02 in.)

•Pull [C] the choke lever fully and ensure that the chokecam turns the choke link [D].If the free play is incorrect, adjust the choke cable.

Choke Lever Play Adjustment

•Remove the fuel tank (see Fuel Tank Removal).• Loosen the locknut [A], and turn the adjuster [B] until thecable has the proper amount of free play.

• Tighten the locknut against the adjuster securely.

Cable Removal/Installation

•Refer to the Throttle Assy section in this chapter for re-moval/installation of the throttle cables and choke cable.

Cable Lubrication and Inspection

•Refer to the General Lubrication in the Periodic Mainte-nance chapter.

3-88 FUEL SYSTEM (DFI)

Throttle Body Assy

Idle Speed Inspection

•Refer to the Idle Speed Inspection in the Periodic Main-tenance chapter.

Engine Vacuum Synchronization Inspection/Adjustment

•Refer to the Engine Vacuum Synchronization Inspectionin the Periodic Maintenance chapter.

High Altitude Performance Adjustment

•Any modification is not necessary in this model since theatmospheric pressure sensor senses atmospheric pres-sure change due to high altitude and the ECU compen-sates the change.

Throttle Body Assy Removal

WARNINGGasoline is extremely flammable and can be ex-plosive under certain conditions. Turn the ignitionswitch OFF. Disconnect the battery (–) cable ter-minal. Do not smoke. Make sure the area iswell-ventilated and free from any source of flameor sparks; this includes any appliance with a pilotlight.Be prepared for fuel spillage: any spilled fuel mustbe completely wiped up immediately.

•Remove:Fuel Tank (see Fuel Tank Removal)Vacuum Switch Valve VacuumHose [A] (from air cleanerhousing [B])Front [C]

• Remove the vacuum hoses from the positions [A] shown.Front [B]

FUEL SYSTEM (DFI) 3-89

Throttle Body Assy

•Loosen:Throttle Assy Holder Clamp Bolts [A]Air Cleaner Duct Clamp Bolts [B]

•Remove:Right and Left Side Covers (see Frame chapter)Coolant Reserve Tank (see Cooling System in the Peri-odic Maintenance chapter)Crankcase Breather HoseRight and Left Air Cleaner Housing Mounting Bolts [A]

•Move [A] the air cleaner housing backwards.• Pull [B] the throttle body assy out of the holders [C].

• Slide [A] the throttle body assy [B] right and remove it.

• Loosen the locknut and screw in the throttle cable adjusterfully to give the cables plenty of play.

•Remove the right handlebar switch housing and take outthe accelerator cable upper end [A] and the deceleratorcable upper end [B].

3-90 FUEL SYSTEM (DFI)

Throttle Body Assy

•Remove the bolt [A] and the throttle cable plate [B] fromthe throttle body front side.

• Remove the throttle cable lower ends from the throttlepulley.

• Remove:Choke Cable Upper End (From choke lever)Choke Cable Lower End [A]

• After removing the throttle body assy, stuff pieces of lint-free, clean cloth into the throttle body holders.

CAUTION

If dirt gets into the engine, excessive engine wearand possible engine damage will occur.

Throttle Body Assy Installation

• Install the holder clamp bolts [A] in the direction shownwith each bolt heads, facing outwards.Cylinder Head [B]

• Tighten:Torque — Throttle Body Assy Holder Clamp Bolts: 2.0 N·m

(0.20 kgf·m, 17 in·lb)

• Tighten:Torque — Air Cleaner Duct Clamp Bolts [A]: 2.0 N·m (0.20

kgf·m, 17 in·lb)

•Run the vacuum hoses as shown in the Cable, Wire, andHose Routing section of the Appendix chapter.

• Fit the accelerator cable end [A] and the decelerator cableend [B] into the throttle pulley.

• Tighten the throttle plate bolt.• Check fuel leakage from the throttle body assy.

WARNINGFuel spilled from the carburetors is hazardous.

FUEL SYSTEM (DFI) 3-91

Throttle Body Assy

•Apply a thin coating of grease to the throttle cable upperends.

• Install the upper ends of the throttle cables in the grip.• Fit the projection [A] of the right switch housing into thehole [B] of the handlebar.

• Turn the throttle grip andmake sure that the throttle valvesmove smoothly and return by spring force.

•Check the throttle grip free play (see Throttle Grip FreePlay Inspection).

WARNINGOperation with an incorrectly routed cable could re-sult in an unsafe riding condition.

•Adjust:Throttle Grip Free PlayChoke Lever Free PlayIdle Speed

Throttle Body Assy Disassembly

CAUTION

Do not remove, disassemble or adjust the mainthrottle sensor [A], subthrottle sensor [B], sub-throttle valve actuator [C], throttle link mechanism[D] and throttle body assy [E], because they areadjusted or set at the manufacturer. Adjustmentof these parts could result in poor performance,requiring replacement of the throttle body assy.

•Remove the throttle body assy (see Throttle Body AssyRemoval).

• Push the lock and disconnect:Main Throttle Connector (gray) [A]Subthrottle Connector (black) [B]Subthrottle Valve Actuator Connector

CAUTION

Never drop the throttle body assy , especially on ahard surface. Such a shock to the body assy candamage it.

•Push the lock and disconnect the injector connectors [A].•Remove:Screws [B]Delivery Pipe [C] along with harness [D] and injectorsIf necessary, cut straps and take the harness off the de-livery pipe.

3-92 FUEL SYSTEM (DFI)

Throttle Body Assy

CAUTION

Never drop the injector, especially on a hard sur-face. Such a shock to the injector can damage it.

•Pull out the injectors along with the delivery pipe [A].If necessary, remove the injectors from the delivery pipe.Replace the O-rigs of the indicators.If necessary, cut straps and take the harness off the de-livery pipe.

Throttle Body Assy AssemblyReplace the O-rings [A] of injectors and the seals [B] withthe new ones.

• Before assembling, blow away dirt or dust from the throttlebody and delivery pipe by applying compressed air.

• Apply engine oil to the new O-rings of each injector [C],insert them into the delivery pipe [D] and confirm whetherthe injectors turn smoothly or not.

• Install the injectors along with the delivery pipe assy intothe throttle bodies [E].

Torque — Delivery Pipe Screws: 3.4 N·m (0.35 kgf·m, 30in·lb)

•Connect all the connectors [A], including the subthrot-tle valve actuator connector [B] and bind the leads withstraps [C].

• Insert the each hoses onto the throttle body fittings.• Install the throttle body assy (see Throttle Body Assy In-stallation).

FUEL SYSTEM (DFI) 3-93

Air Cleaner

Element Removal/Installation

•Refer to the Air Cleaner Element Cleaning in the PeriodicMaintenance chapter.

Air Cleaner Oil DrainingA drain hose is connected to the bottom of the air cleaner

to drain water or oil accumulated in the cleaner part.

• Visually check the drain hose [A] if the water or oil accu-mulates.If any water or oil accumulates in the hose, remove theplug [B] from the drain hose and drain it.

WARNINGBe sure to reinstall the plug in the drain hose afterdraining. Oil on tires will make them slippery andcan cause an accident and injury.

Air Cleaner Housing Removal

•Remove the engine (see Engine Removal/Installationchapter).The throttle body assy is removed during engine removal.• Remove the right and left air cleaner housing bolts.•Move the air cleaner housing [A] forwards and remove itfrom the right side of the frame.

3-94 FUEL SYSTEM (DFI)

Fuel Tank

Fuel Tank Removal

WARNINGGasoline is extremely flammable and can be explo-sive under certain conditions. Make sure the areais well-ventilated and free from any source of flameor sparks; this includes any appliance with a pilotlight. Do not smoke. Turn the ignition switch OFF.Be prepared for fuel spillage; any spilled fuel mustbe completely wiped up immediately.

•Remove:Seats (see Frame chapter)Fuel Tank Bolt [A]Fuel Tank Drain Hose

•Disconnect the battery (–) terminal.• Turn both ignition switch, and engine stop switch OFF.•Wait until the engine cools down.•Open the fuel tank cap [A] to lower the pressure in thetank.During tank removal, keep the tank cap open to releasepressure in the tank. This makes fuel spillage less.

• Draw the fuel out from the fuel tank with a commerciallyavailable pump [A].Use a soft plastic hose [B] as a pump inlet hose in orderto insert the hose smoothly.Put the hose through the fill opening [C] into the tank anddraw the fuel out.Front [D]

WARNINGThe fuel could not be removed completely from thefuel tank. Be careful for remained fuel spillage.

•Raise the fuel tank and disconnect the fuel pump leadconnector [A] and fuel level sensor lead connector [B].

FUEL SYSTEM (DFI) 3-95

Fuel Tank

•Be sure to place a piece of cloth [A] around the fuel hosepump outlet joint [B].

•While pinching the hose joint locks [C] with fingers, pullthe joint out along the delivery pipe.

WARNINGBe prepared for fuel spillage; any spilled fuel mustbe completely wiped up immediately.When the fuel hose is disconnected, fuel spills outfrom the hose and the pipe because of residualpressure. Cover the hose connection with a pieceof clean cloth to prevent fuel spillage.

•Close the fuel tank cap.•Remove the fuel tank, and place it on a flat surface.Do not remove the pump inlet hose [A].

Fuel Tank Installation

•Note the above WARNING (see Fuel Tank Removal).• Route the hoses correctly (see Appendix chapter).• Check that the rubber dampers [A] are on the frame andthe fuel tank.

•Check that the dampers [A] are in place on the fuel tankas well.If the dampers are damaged or deteriorated, replacethem.

3-96 FUEL SYSTEM (DFI)

Fuel Tank

• Insert the pump outlet hose joint [A] straight onto the de-livery pipe [B] until the hose joint clicks [C].Front [D]

• Push and pull [A] the hose joint [B] back and forth morethan two times and make sure it is locked and doesn’tcome off. When the hose joint is correctly installed, itshould slide on the delivery pipe about 5 mm (0.2 in.).

WARNINGMake sure the hose joint is installed correctly on thedelivery pipe by sliding the joint, or the fuel couldleak.

If it does not slide, reinstall the hose joint.

• Connect the fuel pump and the fuel level sensor connec-tors and the battery (–) lead terminal.

Fuel Tank and Cap Inspection

•Visually inspect the gasket [A] on the tank cap for anydamage.Replace the gasket if it is damaged.

• Check to see if the water drain pipe [B] and fuel breatherpipe [C] in the tank are not clogged. Check the tank capbreather also.If they are clogged, remove the tank and drain it, and thenblow the breather free with compressed air.

CAUTION

Do not apply compressed air to the air vent holes[D] in the tank cap. This could cause damage andclogging of the labyrinth in the cap.

Fuel Tank Cleaning

WARNINGClean the tank in a well-ventilated area, and takecare that there are no sparks or flame anywherenear the working area. Because of the danger orhighly flammable liquids, do not use gasoline orlow-flash point solvents to clean the tank.

•Remove the fuel tank (see Fuel Tank Removal).• Remove the fuel pump inlet hose and the fuel pump (seeFuel Pump section in this chapter).

• Pour some high flash-point solvent into the fuel tank andshake the tank to remove dirt and fuel deposits.

• Draw the solvent out of the fuel tank.• Dry the tank with compressed air.• Install the fuel pump (see Fuel Pump Installation).• Install the fuel tank (see Fuel Tank Installation).

COOLING SYSTEM 4-1

4

Cooling System

Table of Contents

Exploded View………………………………………………………………………………………………………… 4-2Coolant Flow Chart………………………………………………………………………………………………….. 4-4Specifications …………………………………………………………………………………………………………. 4-6Special Tools and Sealant ………………………………………………………………………………………… 4-7Coolant ………………………………………………………………………………………………………………….. 4-8

Coolant Deterioration Inspection…………………………………………………………………………… 4-8Coolant Level Inspection……………………………………………………………………………………… 4-8Coolant Draining ………………………………………………………………………………………………… 4-8Coolant Filling ……………………………………………………………………………………………………. 4-8Pressure Testing ………………………………………………………………………………………………… 4-9Cooling System Flushing …………………………………………………………………………………….. 4-9Coolant Reserve Tank Removal/Installation …………………………………………………………… 4-9

Water Pump……………………………………………………………………………………………………………. 4-10Water Pump Removal …………………………………………………………………………………………. 4-10Water Pump Installation………………………………………………………………………………………. 4-10Water Pump Inspection……………………………………………………………………………………….. 4-10Water Pump Impeller Disassembly/Assembly ………………………………………………………… 4-10Water Pump Impeller Inspection…………………………………………………………………………… 4-10Water Pump Housing Disassembly ………………………………………………………………………. 4-10Water Pump Housing Assembly …………………………………………………………………………… 4-11Mechanical Seal Inspection …………………………………………………………………………………. 4-11

Radiator …………………………………………………………………………………………………………………. 4-12Radiator and Radiator Fan Removal …………………………………………………………………….. 4-12Radiator and Radiator Fan Installation ………………………………………………………………….. 4-13Radiator Inspection …………………………………………………………………………………………….. 4-13Radiator Cap Inspection ……………………………………………………………………………………… 4-13Radiator Filler Neck Inspection …………………………………………………………………………….. 4-14

Thermostat …………………………………………………………………………………………………………….. 4-15Thermostat Removal…………………………………………………………………………………………… 4-15Thermostat Installation………………………………………………………………………………………… 4-15Thermostat Inspection ………………………………………………………………………………………… 4-15

Hoses and Pipes …………………………………………………………………………………………………….. 4-17Hose Installation ………………………………………………………………………………………………… 4-17Hose Inspection …………………………………………………………………………………………………. 4-17

Radiator Fan Switch, Water Temperature Sensor ………………………………………………………… 4-18Radiator Fan Switch Removal ……………………………………………………………………………… 4-18Radiator Fan Switch Installation …………………………………………………………………………… 4-18Radiator Fan Switch Inspection ……………………………………………………………………………. 4-18Water Temperature Sensor Removal…………………………………………………………………….. 4-18Water Temperature Sensor Inspection ………………………………………………………………….. 4-18

4-2 COOLING SYSTEM

Exploded View

COOLING SYSTEM 4-3

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Radiator hose clamp screws 2.0 0.20 17 in·lb

2 Radiator fan bolts 8.3 0.85 74 in·lb

3 Water pump impeller bolt 9.8 1.0 87 in·lb

4 Water pump cover bolts 11 1.1 95 in·lb

5 Water pump drain bolt 11 1.1 95 in·lb

6 Water pipe bolts 11 1.1 95 in·lb

7 Thermostat housing ground bolt 7.0 0.70 61 in·lb

8 Thermostat bracket bolt 7.0 0.70 61 in·lb

9 Radiator upper bolts 7.0 0.70 61 in·lb

10 Radiator lower bolts 7.0 0.70 61 in·lb

11 Radiator screen bolt 7.0 0.70 61 in·lb

12 Coolant reserve tank screws 7.0 0.70 61 in·lb

13 Radiator fan switch 18 1.8 13

14 Water temperature sensor 25 2.5 18

15. Mechanical seal16. Oil pump rotor17. Thermostat18. To cylinder head19. To cylinderG: Apply grease.

4-4 COOLING SYSTEM

Coolant Flow Chart

COOLING SYSTEM 4-5

Coolant Flow Chart

1. Drain Bolt2. Water Pump3. Cylinder Jacket4. Cylinder Head Jacket5. Thermostat Housing6. Radiator Cap7. Radiator8. Oil Filter9. Reserve Tank

10. Reserve Tank Hose11. Reserve Tank Overflow Hose12. Radiator Fan13. Water Temperature Sensor14. Radiator Fan Switch15. Hot Coolant16. Cold Coolant17. Front

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

thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.When coolant temperature is 55°C (131°F) or more, the thermostat closes so that the coolant flow isrestricted through the air bleeder hole, causing the engine to warm up more quickly. When coolanttemperature is more than 58 ∼ 62°C (136 ∼ 144°F), the thermostat opens and the coolant flows.When the coolant temperature goes up beyond 95 ∼ 101°C (203 ∼ 214°F), the radiator fan switch

conducts to operate the radiator fan. The radiator fan draws air through the radiator core when thereis not sufficient air flow such as at low speeds. This increases up the cooling action of the radiator.When the coolant temperature goes down from the operation temperature by 3 ∼ 8°C (37 ∼ 46°F), thefan switch opens and the radiator fan stops.In this way, this system controls the engine temperature within narrow limits where the engine op-

erates most efficiently even if the engine load varies.The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles

which can cause engine overheating. As the engine warms up, the coolant in the radiator and thewater jacket expands. The excess coolant flows through the radiator cap and hose to the reserve tankto be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator andthe water jacket contracts, and the stored coolant flows back to the radiator from the reserve tank.The radiator cap has two valves. One is a pressure valve which holds the pressure in the system

when the engine is running. When the pressure exceeds 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 14 ∼ 17.8psi), the pressure valve opens and releases the pressure to the reserve tank. As soon as pressureescapes, the valve closes, and keeps the pressure at 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 14 ∼ 17.8psi). When the engine cools down, another small valve (vacuum valve) in the cap opens. As thecoolant cools, the coolant contracts to form a vacuum in the system. The vacuum valve opens andallows the coolant from the reserve tank to enter the radiator.

4-6 COOLING SYSTEM

Specifications

Item Standard

Coolant provided when shipping:

Type (recommended)Permanent type of antifreeze (soft water and ethylene glycolplus corrosion and rust inhibitor chemicals for aluminumengines and radiators)

Color Green

Mixed ratio Soft water 50%, coolant 50%

Freezing point –35°C (–31°F)

Total amount 2.9 L (3.1 US qt)

(reserve tank full level, including radiator and engine)

Radiator cap

Relief pressure: 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 14 ∼ 17.8 psi)Thermostat:

Valve opening temperature 58 ∼ 62°C (136 ∼ 144°F)Valve full opening lift 8 mm (0.31 in.) or more @75°C (167°F)

COOLING SYSTEM 4-7

Special Tools and Sealant

Bearing Driver:57001–382

Bearing Driver Set:57001–1129

Kawasaki Bond (Silicone Sealant):56019–120

4-8 COOLING SYSTEM

Coolant

Coolant Deterioration Inspection

•Remove the left side cover (see Frame chapter).• Visually inspect the coolant [A] in the reserve tank.If whitish cotton-like wafts are observed, aluminum partsin the cooling system are corroded. If the coolant isbrown, iron or steel parts are rusting. In either case, flushthe cooling system.If the coolant gives off an abnormal smell, check for acooling system leak. It may be caused by exhaust gasleaking into the cooling system.

Coolant Level Inspection

NOTECheck the level when the engine is cold (room or ambi-ent temperature).

•Check the coolant level in the reserve tank [A] with themotorcycle held perpendicular (Do not use the sidestand).If the coolant level is lower than the “L” level line [B], un-screw the reserve tank cap and add coolant to the “F”level line [C].“L”: low”F”: full

CAUTION

For refilling, add the specified mixture of coolantand soft water. Adding water alone dilutes thecoolant and degrades its anticorrosion properties.The diluted coolant can attack the aluminum en-gine parts. In an emergency, soft water alone canbe added. But the diluted coolant must be returnedto the correct mixture ratio within a few days.If coolant must be added often or the reservoir tankhas run completely dry, there is probably leakage inthe cooling system. Check the system for leaks.Coolant ruins painted surfaces. Immediately washaway any coolant that spills on the frame, engine,wheels or other painted parts.

Coolant Draining

•Refer to the Cooling System in the Periodic Maintenancechapter.

Coolant Filling

•Refer to the Cooling System in the Periodic Maintenancechapter.

COOLING SYSTEM 4-9

Coolant

Pressure Testing

•Remove the fuel tank (see Fuel System (DFI) chapter).• Remove the radiator cap, and install a cooling systempressure tester [A] on the filler neck [B].

NOTEWet the cap sealing surfaces with water or coolant toprevent pressure leaks.

•Build up pressure in the system carefully until the pres-sure reaches 123 kPa (1.25 kgf/cm², 17.8 psi).

CAUTION

During pressure testing, do not exceed the pres-sure for which the system is designed. The maxi-mum pressure is 123 kPa (1.25 kgf/cm², 17.8 psi).

•Watch the gauge for at least 6 seconds.If the pressure holds steady, the system is all right.If the pressure drops and no external source is found,check for internal leaks. Droplets in the engine oil indicateinternal leakage. Check the cylinder head gasket and thewater pump.

•Remove the pressure tester, replenish the coolant, andinstall the radiator cap.

Cooling System FlushingOver a period of time, the cooling system accumulates

rust, scale, and lime in the water jacket and radiator. Whenthis accumulation is suspected or observed, flush the cool-ing system. If this accumulation is not removed, it will clogup the water passage and considerable reduce the effi-ciency of the cooling system.

•Drain the cooling system (see Cooling System in the Pe-riodic Maintenance chapter).

• Fill the cooling system with fresh water mixed with a flush-ing compound.

CAUTION

Do not use a flushing compoundwhich is harmful tothe aluminum engine and radiator. Carefully followthe instructions supplied by themanufacturer of thecleaning product.

•Warm up the engine, and run it at normal operating tem-perature for about ten minutes.

• Stop the engine, and drain the cooling system.• Fill the system with fresh water.

•Warm up the engine and drain the system.

•Repeat the previous two steps once more.• Fill the system with a permanent type coolant and bleedthe air from the system (see Cooling System in the Peri-odic Maintenance chapter).

Coolant Reserve Tank Removal/Installation

•The coolant reserve tank is removed and installed dur-ing coolant change (see Cooling System in the PeriodicMaintenance chapter).

4-10 COOLING SYSTEM

Water Pump

Water Pump Removal

•Refer to the Oil Pump Removal in the Engine LubricationSystem chapter.

Water Pump Installation

•Refer to the Oil Pump Installation in the Engine Lubrica-tion System chapter.

Water Pump Inspection

•Check the drainage outlet passage [A] at the bottom ofthe water pump body for coolant leaks.If the mechanical seal is damaged, the coolant leaksthrough the seal and drains through the passage. Re-place the mechanical seal unit.

Water Pump Impeller Disassembly/Assembly

• The sealing seat and rubber seal may be removed easilyby hand.

• Apply coolant around the surfaces of the rubber seal andsealing seat.

• Install the rubber seal [A] and sealing seat [B] into theimpeller by pressing them by hand until the seat stops atthe bottom of the hole.

• Tighten the water pump impeller bolt by special torque.Torque — Water Pump Impeller Bolt: 9.8 N·m (1.0 kgf·m, 87

in·lb)

Water Pump Impeller Inspection

•Visually inspect the water pump impeller [A].If the surface is corroded or if the blades are damaged,replace the impeller.

Water Pump Housing Disassembly

CAUTION

Do not damage the hole wall of the water pumphousing.

• Insert a bar [A] into the pump housing [B], and hammerevenly around the circumference of the mechanical sealbottom [C].

COOLING SYSTEM 4-11

Water Pump

•Take the oil seal [A] out of the housing [B] with a hook [C].

Water Pump Housing Assembly

CAUTION

Do not reuse the mechanical seal and oil seal.

•Apply high temperature grease to the oil seal lips [A].• Press the new oil seal into the housing with a bearingdriver [B] until it stops at the bottom surface [C] of thehousing.

Special Tool — Bearing Driver Set: 57001–1129

CAUTION

Be careful not to damage the sealing surface of themechanical seal.

•Press the newmechanical seal into the housing with bear-ing driver [A] until its flange [B] touches the surface [C] ofthe housing.

Special Tool — Bearing Driver: 57001–382

Mechanical Seal Inspection

•Visually inspect the mechanical seal.If any one of the parts is damaged, replace the mechani-cal seal as a unit.Impeller Sealing Seat Surface [A]Rubber Seal [B]Mechanical Seal [C]

4-12 COOLING SYSTEM

Radiator

Radiator and Radiator Fan Removal

WARNINGThe radiator fan is connected directly to the bat-tery. The radiator fan may start even if the ignitionswitch is off. NEVER TOUCH THE RADIATOR FANUNTIL THE RADIATOR FAN CONNECTOR IS DIS-CONNECTED. TOUCHING THE FAN BEFORE THECONNECTOR IS DISCONNECTED COULD CAUSEINJURY FROM THE FAN BLADES.

•Drain the coolant (see Cooling System in the PeriodicMaintenance chapter).

• Remove:Fuel Tank (see Fuel System (DFI) chapter)Radiator Fan Motor Connector [A]

• Remove:Fan Switch Lead Connector [A]Radiator Lower Bolt [B]Radiator Upper Bolt (left) [C]Left Radiator Hose [D]

• Remove:Radiator Upper Bolt (right) [A]Right Radiator Hose [B]

• Remove the radiator.CAUTION

Do not touch the radiator core. This could damagethe radiator fins, resulting in loss of cooling effi-ciency.

• If necessary, remove:Radiator Fan Mounting Bolts [A]Radiator Fan [B]

COOLING SYSTEM 4-13

Radiator

Radiator and Radiator Fan Installation

• Installation is the reverse of removal.• Install the radiator bracket collars [A] as shown.Rubber Damper [B]30 ∼ 40° [C]Radiator [D]Bracket [E]

• Tighten:Torque — Radiator Lower Bolts [F]: 7.0 N·m (0.70 kgf·m, 61

in·lb)Radiator Upper Bolts [G]: 7.0 N·m (0.70 kgf·m, 61in·lb)

Radiator Inspection

•Check the radiator core.If there are obstructions to air flow, remove them.If the corrugated fins [A] are deformed, carefullystraighten them.If the air passages of the radiator core are blocked morethan 20% by unremovable obstructions or irreparably de-formed fins, replace the radiator with a new one.

CAUTION

When cleaning the radiator with steam cleaner, becareful of the following to prevent radiator damage:Keep the steam gun [A] away more than 0.5 m (1.6ft) [B] from the radiator core.Hold the steam gun perpendicular [C] (not oblique[D]) to the core surface.Run the steam gun, following the core fin direction.

Radiator Cap Inspection

•Remove:Fuel Tank (see Fuel System (DFI) chapter)Radiator Cap

•Check the condition of the bottom [A] and top [B] valveseals and valve spring [C].If any one of them shows visible damage, replace the capwith a new one.

4-14 COOLING SYSTEM

Radiator

• Install the cap [A] on a cooling system pressure tester [B].NOTE

Wet the cap sealing surfaces with water or coolant toprevent pressure leaks.

•Watching the pressure gauge, pump the pressure testerto build up the pressure until the relief valve opens: thegauge needle flicks downward. Stop pumping and mea-sure leak time at once. The relief valve must open withinthe specified range in the table below and the gauge handmust remain within the same range at least 6 seconds.

Radiator Cap Relief Pressure

Standard:93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 14 ∼ 17.8psi)

If the cap can not hold the specified pressure or if it holdstoo much pressure, replace it with a new one.

Radiator Filler Neck Inspection

•Remove the fuel tank (see Fuel System (DFI) chapter).• Remove the radiator cap.• Check the radiator filler neck for signs of damage.• Check the condition of the top and bottom sealing seats[A] in the filler neck. They must be smooth and clean forthe radiator cap to function properly.

COOLING SYSTEM 4-15

Thermostat

Thermostat Removal

•Drain the coolant (see Cooling System in the PeriodicMaintenance chapter).

• Remove:Fuel Tank (see Fuel System (DFI) chapter)Thermostat Bracket Bolt [A]Ground Lead [B]Water Temperature Sensor Connector [C]Three Water Hoses [D]

•Remove the thermostat housing [E].•Remove the screws [A], take off the cap [B], and take outthe thermostat.

Thermostat Installation

• Install the thermostat [A] in the housing so that the airbleeder hole [B] is on top.

• Install a new O-ring into the housing.• Fill the radiator with coolant (see Cooling System in thePeriodic Maintenance chapter).

Thermostat Inspection

•Remove the thermostat, and inspect the thermostat valve[A] at room temperature.If the valve is open, replace the thermostat with a newone.

4-16 COOLING SYSTEM

Thermostat

• To check valve opening temperature, suspend the ther-mostat [A] in a container of water and raise the tempera-ture of the water.The thermostat must be completely submerged and mustnot touch the container sides or bottom. Suspend an ac-curate thermometer [B] in the water so that the heat sen-sitive portions [C] are located in almost the same depth.It must not touch the container, either.If the measurement is out of the specified range, replacethe thermostat with a new one.

Thermostat Valve Opening Temperature58 ∼ 62°C (136 ∼ 144°F)

COOLING SYSTEM 4-17

Hoses and Pipes

Hose Installation

• Install the hoses and pipes, being careful to follow bend-ing direction. Avoid sharp bending, kinking, flattening ortwisting.

•Run the hoses in accordance with the Cable, Wire, andHose Routing section in the Appendix chapter.

• Install the clamp [A] as near as possible to the hose endto clear the raised rib of the fitting. This will prevent thehoses from working loose.The clamp screws should be positioned correctly to pre-vent the clamps from contacting the other parts.

Torque — Radiator HoseClampScrews: 2.0 N·m (0.20 kgf·m,17 in·lb)

Hose Inspection

•Refer to the Cooling System in the Periodic Maintenancechapter.

4-18 COOLING SYSTEM

Radiator Fan Switch, Water Temperature Sensor

CAUTION

The fan switch or the water temperature sensorshould never be allowed to fall on a hard surface.Such a shock to their parts can damage them.

Radiator Fan Switch Removal

•Drain the coolant (see Cooling System in the PeriodicMaintenance chapter).

• Remove:Radiator Fan Switch Lead Connector [A]Radiator Fan Switch [B]

Radiator Fan Switch Installation

• Tighten:Torque — Radiator Fan Switch : 18 N·m (1.8 kgf·m, 13 ft·lb)

• Fill the coolant (see Cooling System in the Periodic Main-tenance chapter).

Radiator Fan Switch Inspection

•Refer to the Electrical System chapter for the RadiatorFan Switch Inspection.

Water Temperature Sensor Removal

•Refer to the Fuel System (DFI) chapter.Water Temperature Sensor [A]

Water Temperature Sensor Inspection

•Refer to the Electrical System chapter for the Water Tem-perature Sensor Inspection.

ENGINE TOP END 5-1

5

Engine Top End

Table of Contents

Exploded View…………………………….. 5-2Specifications ……………………………… 5-6Special Tools and Sealant …………….. 5-8Clean Air System…………………………. 5-10

Air Suction Valve Removal……….. 5-10Air Suction Valve Installation…….. 5-10Air Suction Valve Inspection …….. 5-10Vacuum Switch Valve Removal … 5-10Vacuum Switch Valve Installation 5-10Vacuum Switch Valve Test ……….. 5-11Clean Air System HoseInspection……………………………. 5-11

Cylinder Head Cover ……………………. 5-12Cylinder Head Cover Removal …. 5-12Cylinder Head Cover Installation . 5-12

Camshaft Chain Tensioner ……………. 5-14Camshaft Chain TensionerRemoval ……………………………… 5-14

Camshaft Chain TensionerInstallation …………………………… 5-14

Camshaft, Camshaft Chain …………… 5-15Camshaft Removal …………………. 5-15Camshaft Installation ………………. 5-15Camshaft, Camshaft Cap Wear … 5-16Camshaft Runout ……………………. 5-17Cam Wear……………………………… 5-17Camshaft Chain Removal ………… 5-17

Cylinder Head……………………………… 5-18Cylinder CompressionMeasurement ………………………. 5-18

Cylinder Head Removal …………… 5-19Cylinder Head Installation ………… 5-19

Cylinder Head Warp………………… 5-20Valves ………………………………………… 5-21

Valve Clearance Inspection ……… 5-21Valve Removal ……………………….. 5-21Valve Installation …………………….. 5-21Valve Guide Removal ……………… 5-21Valve Guide Installation …………… 5-22Valve-to-Guide ClearanceMeasurement (WobbleMethod) ………………………………. 5-22

Valve Seat Inspection ……………… 5-23Valve Seat Repair …………………… 5-23

Cylinder, Pistons………………………….. 5-28Cylinder Removal……………………. 5-28Cylinder Installation…………………. 5-28Piston Removal………………………. 5-28Piston Installation……………………. 5-29Cylinder Wear ………………………… 5-30Piston Wear …………………………… 5-30Piston Ring, Piston Ring GrooveWear…………………………………… 5-31

Piston Ring Groove Width………… 5-31Piston Ring Thickness …………….. 5-31Piston Ring End Gap ………………. 5-32

Throttle Body Holder…………………….. 5-33Throttle Body Holder Installation.. 5-33

Muffler………………………………………… 5-34Muffler Body Removal……………… 5-34Exhaust Pipe Removal…………….. 5-34Muffler Body and Exhaust PipeInstallation …………………………… 5-34

5-2 ENGINE TOP END

Exploded View

ENGINE TOP END 5-3

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Air suction valve cover bolts 9.8 1.0 87 in·lb

2 Cylinder head cover bolts 9.8 1.0 87 in·lb S

3 Camshaft cap bolts 12 1.2 104 in·lb S

4 Camshaft chain guide bolts 12 1.2 104 in·lb S

5 Cylinder head bolts (M10 new bolts) 54 5.5 40MO, S(Washer)

5 Cylinder head bolts (M10 used bolts) 49 5.0 36MO, S(Washer)

6 Cylinder head bolts (M6) 12 1.2 104 in·lb S

7 Cylinder head jacket plugs 22 2.2 16 L

8 Throttle body holder bolts 13 1.3 113 in·lb

9 Throttle body assy holder clamp bolts 2.0 0.20 17 in·lb

10 Camshaft sensor bolt 12 1.2 104 in·lb

11 Camshaft sensor rotor bolt 12 1.2 104 in·lb L

12 Front camshaft chain guide bolts (upper) 25 2.5 18

13 Front camshaft chain guide bolts (lower) 12 1.2 104 in·lb

14 Rear camshaft chain guide bolts 25 2.5 18

15 Camshaft chain tensioner mounting bolts 11 1.1 95 in·lb

16 Camshaft chain tensioner cap bolt 28 2.9 21

17 Spark plugs 13 1.3 113 in·lb

EO: Apply engine oil.L: Apply a non-permanent locking agent.M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil.(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)

R: Replacement PartsS: Follow the specific tightening sequence.SS: Apply silicone sealant (Kawasaki Bond: 56019–120).

5-4 ENGINE TOP END

Exploded View

ENGINE TOP END 5-5

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Coolant drain plug (cylinder) 9.8 1.0 87 in·lb

2 Exhaust pipe manifold holder nuts 17 1.7 12

3 Muffler body clamp bolt 17 1.7 12

4 Muffler body mounting bolt 30 3.0 22

5 Crankshaft sensor cover bolts 11 1.1 95 in·lb

6. «1T» marked side faces up.7. «2T» marked side faces up.8. Hollow mark faces forward.

EO: Apply engine oil.R: Replacement Parts

Exhaust System

UK: U.K. Model 78.2: Horsepower 78.2 kW (106.3 ps)

Full: Full Power H: Honeycomb Type Catalyst

5-6 ENGINE TOP END

Specifications

Item Standard Service Limit

Clean Air System:

Vacuum switch valve closing Open → Close – – –

pressure 41 ∼ 49 kPa (310 ∼ 370 mmHg, 6.0 ∼ 7.1psi)

Camshafts:

Cam height:

Exhaust 36.146 ∼ 36.254 mm (1.4231 ∼ 1.4273 in.) 36.05 mm (1.419 in.)

Inlet 36.746 ∼ 36.854 mm (1.4467 ∼ 1.4509 in.) 36.65 mm (1.443 in.)

Camshaft journal, camshaftcap clearance

0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.) 0.16 mm (0.0063 in.)

Camshaft journal diameter 23.950 ∼ 23.972 mm (0.9429 ∼ 0.9438 in.) 23.92 mm (0.942 in.)

Camshaft bearing insidediameter

24.000 ∼ 24.021 mm (0.9449 ∼ 0.9457 in.) 24.08 mm (0.948 in.)

Camshaft runout TIR 0.02 mm (0.0008 in.) or less TIR 0.1 mm (0.004 in.)

Cylinder Head:

Cylinder compression (usable range)

1 110 ∼ 1 590 kPa (11.3 ∼ 16.2 kgf/cm²,161 ∼ 230 psi) @300 r/min (rpm) – – –

Cylinder head warp – – – 0.05 mm (0.002 in.)

Valves:

Valve clearance:

Exhaust 0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.) – – –

Inlet 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.) – – –

Valve head thickness:

Exhaust 1.0 mm (0.039 in.) 0.5 mm (0.020 in.)

Inlet 0.5 mm (0.020 in.) 0.25 mm (0.0098 in.)

Valve stem bend TIR 0.01 mm (0.0004 in.) or lessTIR 0.05 mm(0.002 in.)

Valve stem diameter:

Exhaust 3.955 ∼ 3.970 mm (0.1557 ∼ 0.1563 in.) 3.94 mm (0.155 in.)

Inlet 3.975 ∼ 3.990 mm (0.1565 ∼ 0.1571 in.) 3.96 mm (0.156 in.)

Valve guide inside diameter:

Exhaust 4.000 ∼ 4.012 mm (0.1575 ∼ 0.1580 in.) 4.08 mm (0.161 in.)

Inlet 4.000 ∼ 4.012 mm (0.1575 ∼ 0.1580 in.) 4.08 mm (0.161 in.)

Valve/valve guide clearance

(wobble method):

Exhaust 0.09 ∼ 0.18 mm (0.0035 ∼ 0.0071 in.) 0.40 mm (0.016 in.)

Inlet 0.03 ∼ 0.12 mm (0.0012 ∼ 0.0047 in.) 0.33 mm (0.013 in.)

Valve seat cutting angle 45°, 32°, 60° – – –

Valve seating surface:

Width: Exhaust 0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.) – – –

Inlet 0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.) – – –

Outside diameter:

Exhaust 21.6 ∼ 21.8 mm (0.850 ∼ 0.858 in.) – – –

Inlet 26.4 ∼ 26.6 mm (1.0276 ∼ 1.0472 in.) – – –

ENGINE TOP END 5-7

Specifications

Item Standard Service Limit

Valve spring free length:

Exhaust 40.7 mm (1.602 in.) 38.9 mm (1.531 in.)

Inlet 40.7 mm (1.602 in.) 38.9 mm (1.531 in.)

Cylinder, Pistons:

Cylinder inside diameter: 68.400 ∼ 68.412 mm (2.6929 ∼ 2.6934 in.) 68.50 mm (2.6969 in.)

Piston diameter 68.345 ∼ 68.360 mm (2.6907 ∼ 2.6913 in.) 68.21 mm (2.6854 in.)

Piston/cylinder clearance 0.040 ∼ 0.067 mm (0.0016 ∼ 0.0026 in.) – – –

Piston ring/grooveclearance:

Top 0.04 ∼ 0.08 mm (0.0016 ∼ 0.0031 in.) 0.18 mm (0.0071 in.)

Second 0.02 ∼ 0.06 mm (0.0008 ∼ 0.0024 in.) 0.16 mm (0.0063 in.)

Piston ring groove width:

Top 0.83 ∼ 0.85 mm (0.0327 ∼ 0.0335 in.) 0.93 mm (0.037 in.)

Second 0.81 ∼ 0.83 mm (0.0319 ∼ 0.0327 in.) 0.91 mm (0.036 in.)

Piston ring thickness:

Top 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) 0.70 mm (0.028 in.)

Second 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) 0.70 mm (0.028 in.)

Piston ring end gap:

Top 0.30 ∼ 0.40 mm (0.0118 ∼ 0.0157 in.) 0.7 mm (0.028 in.)

Second 0.45 ∼ 0.55 mm (0.0177 ∼ 0.0217 in.) 0.8 mm (0.031 in.)

5-8 ENGINE TOP END

Special Tools and Sealant

Compression Gauge:57001–221

Valve Spring Compressor Assembly:57001–241

Piston Pin Puller Assembly:57001–910

Valve Seat Cutter, 45° — 24:57001–1113

Valve Seat Cutter, 45° — 27.5:57001–1114

Valve Seat Cutter, 32° — 25:57001–1118

Valve Seat Cutter, 32° — 28:57001–1119

Valve Seat Cutter Holder Bar:57001–1128

Valve Spring Compressor Adapter, 20:57001–1154

Valve Guide Arbor, 4:57001–1273

ENGINE TOP END 5-9

Special Tools and Sealant

Valve Guide Reamer, 4:57001–1274

Valve Seat Cutter Holder, 4:57001–1275

Fork Oil Level Gauge:57001–1290

Compression Gauge Adapter, M10 × 1.0:57001–1317

Valve Seat Cutter, 60° — 25:57001–1328

Valve Seat Cutter, 60° — 27:57001–1409

Spark Plug Wrench (Owner’s Tool):92110–1146

Kawasaki Bond (Silicone Sealant):56019–120

5-10 ENGINE TOP END

Clean Air System

Air Suction Valve Removal

•Remove:Fuel Tank (see Fuel System (DFI) chapter)Connector [A] (from Clamp [B])Air Suction Valve Cover Bolts [C] and ClampAir Suction Valve Cover [D]Air Suction Valve

Air Suction Valve Installation

• Install the air suction valve [A] so that its wider side [B] ofthe reed valve case faces the front.

• Tighten:Torque — Air Suction Valve Cover Bolts: 9.8 N·m (1.0 kgf·m,

87 in·lb)

Air Suction Valve Inspection

•Refer to the Engine Top End in the Periodic Maintenancechapter.

Vacuum Switch Valve Removal

•Remove:Fuel Tank (see Fuel System (DFI) chapter)Vacuum Switch Valve [A]

Vacuum Switch Valve Installation

• Install the vacuum switch valve so that the vacuum fitting[A] faces left side.

• Route the hoses correctly (see Appendix chapter).

ENGINE TOP END 5-11

Clean Air System

Vacuum Switch Valve Test

•Remove:Vacuum Switch Valve (see Vacuum Switch Valve Re-moval)

•Connect a vacuum gauge [A] and syringe [B] or fork oillevel gauge to the vacuum hoses as shown.

Special Tool — Fork Oil Level Gauge: 57001–1290

Air Flow [C]

•Gradually raise the vacuum (lower the pressure) appliedto the vacuum switch valve, and check the valve opera-tion. When the vacuum is low, the vacuum switch valveshould permit air to flow. When the vacuum raises tovalve closing pressure, it should stop air flow.Spring [A]Diaphragm [B]Valve [C]Low Vacuum [D]Secondary Air Flow [E]

If the vacuum switch valve does not operate as described,replace it with a new one.

NOTETo check air flow through the vacuum switch valve, justblow through the air cleaner hose.

Vacuum Switch Valve Closing Pressure (Open→ Close)Standard: 41 ∼ 49 kPa (310 ∼ 370 mmHg, 6.0 ∼ 7.1 psi)

High Vacuum [A]Secondary air cannot flow [B]

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 aircleaner housing, vacuum switch valve, #1 and #4 carbu-retor holders and air suction valve covers.If they are not, correct them. Replace them if they aredamaged.

5-12 ENGINE TOP END

Cylinder Head Cover

Cylinder Head Cover Removal

•Remove:Fuel Tank (see Fuel System (DFI) chapter)Vacuum Switch Valve and HosesStick Coils (see Electrical System chapter)Air Suction Valve Covers [A]

• Remove the cylinder head cover bolts [A] and take off thecover.

Cylinder Head Cover Installation

•Replace the head cover gasket with a new one.• Apply silicone sealant [A] to the cylinder head as shown.Sealant — Kawasaki Bond (Silicone Sealant): 56019-120

• Install:Dowel Pins [A]Plug Hole Gaskets [B]

• Install the washer [A] with the metal side faces upward.

ENGINE TOP END 5-13

Cylinder Head Cover

•Tighten the cover bolts following the specified tighteningsequence.

Torque — Cylinder Head Cover Bolts [B]: 9.8 N·m (1.0 kgf·m,87 in·lb)

• Install the removed parts (see appropriate chapters).

5-14 ENGINE TOP END

Camshaft Chain Tensioner

Camshaft Chain Tensioner Removal

CAUTION

This is a non-return type camshaft chain tensioner.The push rod does not return to its original positiononce it moves out to take up camshaft chain slack.Observe all the rules listed below:When removing the tensioner, do not take out themounting bolts only halfway. Retightening themounting bolts from this position could damagethe tensioner and the camshaft chain. Once thebolts are loosened, the tensioner must be removedand reset as described in «Camshaft Chain Ten-sioner Installation.»Do not turn over the crankshaft while the tensioneris removed. This could upset the camshaft chaintiming, and damage the valves.

•Remove:Fuel Tank (see Fuel System (DFI) chapter)Cap Bolt [A]Washer [B]Spring [C]Rod [D]

• Remove the mounting bolts [E] and take off the camshaftchain tensioner.

Camshaft Chain Tensioner Installation

•Release the stopper [A] and push the push rod [B] intothe tensioner body [C].

• Install the tensioner body so that the stopper faces up-ward.

• Tighten the tensioner mounting bolts [A].Torque — Camshaft Chain Tensioner Mounting Bolts: 11

N·m (1.1 kgf·m, 95 in·lb)

• Install the rod, spring and washer.• Tighten the cap bolt [B].Torque — Camshaft Chain Tensioner Cap Bolt: 28 N·m (2.9

kgf·m, 21 ft·lb)

• Turn the crankshaft 2 turns clockwise to allow the ten-sioner to expand and recheck the camshaft chain timing.

ENGINE TOP END 5-15

Camshaft, Camshaft Chain

Camshaft Removal

•Remove:Cylinder Head Cover (see Cylinder Head Cover Re-moval)Pickup Coil Cover

• Position the crankshaft at #1, 4 piston TDC.TDC mark [A] for #1, 4 PistonsTiming Mark (crankcase halves mating surface) [B]

•Remove:Camshaft Chain Tensioner (see Camshaft Chain Ten-sioner Removal)Camshaft Cap Bolts [A]Chain GuideCamshaft Caps [B]Camshafts [C]

• Stuff a clean cloth into the chain tunnel to keep any partsfrom dropping into the crankcase.

CAUTION

The crankshaft may be turned while the camshaftsare removed. Always pull the chain taut while turn-ing the crankshaft. This avoids kinking the chainon the lower (crankshaft) sprocket. A kinked chaincould damage both the chain and the sprocket.

Camshaft Installation

•Be sure to install the following parts.Plug Hole Gaskets [A]Dowel Pins [B]

• Apply engine oil to all cam parts and journals.

• If a new camshaft is to be used, apply a thin coat of molyb-denum disulfide grease to the cam surfaces.

NOTEThe exhaust camshaft has a 1182 EX mark [A] and theinlet camshaft has a 1182 IN mark [B]. Be careful not tomix up these shafts.

5-16 ENGINE TOP END

Camshaft, Camshaft Chain

•Position the crankshaft at #1, 4 piston TDC.• Pull the tension side (exhaust side) [A] of the chain tautto install the chain.

• Engage the camshaft chain with the camshaft sprocketsso that the timing marks on the sprockets are positionedas shown.The timing marks of #1, 4T must be aligned with the lowersurface of crankcase of rear side [B].The timing marks must be aligned with the cylinder headupper surface [C].EX mark [D]IN mark [E]

• Before installing the camshaft cap and chain guide, installthe camshaft chain tensioner body temporally.

• Install the camshaft cap and chain guide [A].First tighten the camshaft cap and all chain guide boltsevenly to seat the camshaft in place, then tighten all boltsfollowing the specified tightening sequence.

Torque — Camshaft Cap Bolts (1∼ 16, 19, 20):12 N·m (1.2 kgf·m, 104 in·lb)

Camshaft Chain Guide Bolts (17, 18):12 N·m (1.2 kgf·m, 104 in·lb)

• Tighten the camshaft chain tensioner (see CamshaftChain Tensioner Installation).

• Install the cylinder head cover (see Cylinder Head CoverInstallation).

Camshaft, Camshaft Cap Wear

•Remove:Camshaft Chain GuideCamshaft Cap

•Cut strips of plastigage to journal width. Place a stripon each journal parallel to the camshaft installed in thecorrect position.

•Measure each clearance between the camshaft journaland the camshaft cap using plastigage (press gauge) [A].

• Tighten:Torque — Camshaft Cap Bolts: 12 N·m (1.2 kgf·m, 104 in·lb)

Camshaft Chain Guide Bolts: 12 N·m (1.2 kgf·m,104 in·lb)

NOTEDo not turn the camshaft when the plastigage is be-tween the journal and camshaft cap.

Camshaft Journal, Camshaft Cap ClearanceStandard: 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.)Service Limit: 0.16 mm (0.0063 in.)

ENGINE TOP END 5-17

Camshaft, Camshaft Chain

If any clearance exceeds the service limit, measure thediameter of each camshaft journal with a micrometer.

Camshaft Journal DiameterStandard: 23.950 ∼ 23.972 mm (0.9429 ∼ 0.9438 in.)Service Limit: 23.92 mm (0.942 in.)

If the camshaft journal diameter is less than the servicelimit, replace the camshaft with a new one and measurethe clearance again.If the clearance still remains out of the limit, replace thecylinder head unit.

Camshaft Runout

•Remove the camshaft (see Camshaft Removal).• Set the camshaft in a camshaft alignment jig or on Vblocks.

•Measure runout with a dial gauge at the specified placeas shown.If the runout exceeds the service limit, replace the shaft.

Camshaft RunoutStandard: TIR 0.02 mm (0.0008 in.) or less

Service Limit: TIR 0.1 mm (0.004 in.)

Cam Wear

•Remove the camshaft (see Camshaft Removal).•Measure the height [A] of each cam with a micrometer.If the cams are worn down past the service limit, replacethe camshaft.

Cam HeightInlet

Standard: 36.746 ∼ 36.854 mm (1.4467 ∼ 1.4509in.)

Service Limit: 36.65 mm (1.443 in.)

Exhaust

Standard: 36.146 ∼ 36.254 mm (1.4231 ∼ 1.4273in.)

Service Limit: 36.05 mm (1.419 in.)

Camshaft Chain Removal

•Split the crankcase (see Crankshaft/Transmission chap-ter).

• Remove the camshaft chain [A] from the crankshaftsprocket.

5-18 ENGINE TOP END

Cylinder Head

Cylinder Compression Measurement

NOTEUse the battery which is fully charged.•Warm up the engine thoroughly.

• Stop the engine.• Remove:Seats (see Frame chapter)Fuel Tank (see Fuel System (DFI) chapter)Stick CoilsSpark Plugs

Owner’s Tool — Spark Plug Wrench, 16 mm: 92110–1146

•Attach the compression gauge [A] and adapter [B] firmlyinto the spark plug hole.Using the starter motor, turn the engine over with the throt-tle fully open until the compression gauge stops rising; thecompression is the highest reading obtainable.

Special Tools — Compression Gauge: 57001–221Compression Gauge Adapter, M10 X 1.0:57001–1317

Cylinder CompressionUsable Range : 1 110∼ 1 590 kPa (11.3 ∼ 16.2 kgf/cm²,

161 ∼ 230 psi) @300 r/min (rpm)

•Repeat the measurement for the other cylinders.• Install the spark plugs.Torque — Spark Plugs: 13 N·m (1.3 kgf·m, 113 in·lb)

The following table should be consulted if the obtainable compression reading is not within the us-able range.

Problem Diagnosis Remedy (Action)

Carbon accumulation on piston and incombustion chamber possibly due todamaged valve stem oil seal and/ordamaged piston oil rings (This may beindicated by white exhaust smoke).

Remove the carbon depositsand replace damaged parts ifnecessary.

Cylinder compressionis higher than usablerange

Incorrect cylinder head gasketthickness

Replace the gasket with a standardpart.

Gas leakage around cylinder headReplace damaged check gasketand cylinder head warp.

Bad condition of valve seating Repair if necessary.

Incorrect valve clearance Adjust the valve clearance.

Incorrect piston/cylinder clearance Replace the piston and/or cylinder.

Piston seizureInspect the cylinder andreplace/repair the cylinder and/orpiston as necessary.

Cylinder compressionis lower than usablerange

Bad condition of piston ring and/orpiston ring grooves

Replace the piston and/or thepiston rings.

ENGINE TOP END 5-19

Cylinder Head

Cylinder Head Removal

•Drain the coolant (see Cooling System chapter).

• Remove:Exhaust Pipes (see Exhaust Pipe Removal)Coolant Drain Bolt [A] (cylinder)

•Remove:Cylinder Head Cover (see Cylinder Head Cover Re-moval)Camshaft Position Sensor (see Electrical System chap-ter)Camshafts (see Camshaft Removal)Throttle Body (see Fuel System (DFI) chapter)Water HoseUpper Engine Mounting Bolts (both side) [A]Front Camshaft Chain Guide

•Remove the M6 cylinder head bolts [B], and then the M10cylinder head bolts [A].

• Take off the cylinder head.

Cylinder Head Installation

NOTEThe camshaft cap is machined with the cylinder head,so if a new cylinder head is installed, use the cap thatis supplied with the new head.

• Install a new cylinder head gasket and dowel pins.• Apply molybdenum disulfide oil solution to both sides [A]of the cylinder head bolt washers [B] and the thread ofhead bolts [C].

• Tighten the M10 cylinder head bolts following the tighten-ing sequence [1 ∼ 10].Torque — Cylinder Head Bolts (M10):

First 20 N·m (2.0 kgf·m, 14.5 ft·lb)

Final Used Bolts 49 N·m (5.0 kgf·m, 36 ft·lb)

New Bolts 54 N·m (5.5 kgf·m, 40 ft·lb)

•Tighten the M6 cylinder head bolts [11 ∼ 12].Torque — Cylinder Head Bolts (M6): 12 N·m (1.2 kgf·m, 104

in·lb)

5-20 ENGINE TOP END

Cylinder Head

• Install:Front Camshaft Chain Guide [A]O-ring [B]Collar [C]

• Tighten:Torque — Front Camshaft Chain Guide Bolt (Upper) [D]:

25 N·m (2.5 kgf·m, 18 ft·lb)Front Camshaft Chain Guide Bolt (Lower) [E]:12 N·m (1.2 kgf·m, 104 in·lb)

• Install the removed parts (see appropriate chapters).

Cylinder Head Warp

•Clean the cylinder head.• Lay a straightedge across the lower surface of the cylinderhead at several positions.

• Use a thickness gauge [A] to measure the space betweenthe straightedge [B] and the head.

Cylinder Head WarpStandard: – – –

Service Limit: 0.05 mm (0.002 in.)

If the cylinder head is warped more than the service limit,replace it.If the cylinder head is warped less than the service limit,repair the head by rubbing the lower surface on emerypaper secured to a surface plate (first No. 200, then No.400).

ENGINE TOP END 5-21

Valves

Valve Clearance Inspection

•Refer to the Engine Top End in the Periodic Maintenancechapter.

Valve Removal

•Remove the cylinder head (see Cylinder Head Removal).• Remove the valve lifter and shim.Mark and record the valve lifter and shim locations so theycan be installed in their original positions.

•Using the valve spring compressor assembly, remove thevalve.

Special Tools — Valve Spring Compressor Assembly:57001–241 [A]

Adapter, 20: 57001–1154 [B]

Valve Installation

•Replace the oil seal with a new one.• Apply a thin coat of molybdenum disulfide grease to thevalve stem before valve installation.

• Install the springs so that the closed coil end faces down-wards.Valve Stem [A]Oil Seal [B]Spring Seat [C]Closed Coil End [D]Valve Spring (White) [E]Retainer [F]Split Keepers [G]

Valve Guide Removal

•Remove:Valve (see Valve Removal)Oil SealSpring Seat

•Heat the area around the valve guide to 120 ∼ 150°C (248∼ 302°F), and hammer lightly on the valve guide arbor [A]to remove the guide from the top of the head.

CAUTION

Do not heat the cylinder head with a torch. This willwarp the cylinder head. Soak the cylinder head inoil and heat the oil.

Special Tool — Valve Guide Arbor, 4: 57001–1273

5-22 ENGINE TOP END

Valves

Valve Guide Installation

•Apply oil to the valve guide outer surface before installa-tion.

• Heat the area around the valve guide hole to about 120 ∼150°C (248 ∼ 302°F).• Drive the valve guide in from the top of the head using thevalve guide arbor. The flange stops the guide from goingin too far.

Special Tool — Valve Guide Arbor, 4: 57001–1273

•Wait until the cylinder head cools down and then ream thevalve guide with the valve guide reamer [A] even if the oldguide is reused.Turn the reamer in a clockwise direction until the reamerturns freely in the guide. Never turn the reamer counter-clockwise or it will be dulled.Once the guides are reamed they must be cleaned thor-oughly.

Special Tool — Valve Guide Reamer, 4: 57001–1274

Valve-to-Guide Clearance Measurement (WobbleMethod)If a small bore gauge is not available, inspect the valve

guide wear by measuring the valve to valve guide clearancewith the wobble method as indicated below.

• Insert a new valve [A] into the guide [B] and set a dialgauge against the stem perpendicular to it as close aspossible to the cylinder head mating surface.

•Move the stem back and forth [C] to measure valve/valveguide clearance.

• Repeat the measurement in a direction at a right angle tothe first.If the reading exceeds the service limit, replace the guide.

NOTEThe reading is not actual valve/valve guide clearancebecause the measuring point is above the guide.

Valve/Valve Guide Clearance (Wobble Method)Inlet

Standard: 0.03 ∼ 0.12 mm (0.0012 ∼ 0.0047 in.)Service Limit: 0.33 mm (0.013 in.)

Exhaust

Standard: 0.09 ∼ 0.18 mm (0.0035 ∼ 0.0071 in.)Service Limit: 0.40 mm (0.016 in.)

ENGINE TOP END 5-23

Valves

Valve Seat Inspection

•Remove the valve (see Valve Removal).• Check the valve seating surface [A] between the valve [B]and valve seat [C].Measure the outside diameter [D] of the seating patternon the valve seat.If the outside diameter is too large or too small, repair theseat (see Seat Repair).

Valve Seating Surface Outside DiameterStandard:

Inlet 26.4 ∼ 26.6 mm (1.0276 ∼ 1.0472 in.)Exhaust 21.6 ∼ 21.8 mm (0.850 ∼ 0.858 in.)

Measure the seat width [E] of the portion where there isno build-up carbon (white portion) of the valve seat with avernier caliper.Good [F]If the width is too wide [G], too narrow [H] or uneven [J],repair the seat (see Valve Seat Repair).

Valve Seating Surface WidthStandard:

Inlet 0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.)Exhaust 0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.)

Valve Seat Repair

•Repair the valve seat with the valve seat cutters [A].Special Tools — Valve Seat Cutter Holder, 4: 57001–1275 [B]

Valve Seat Cutter Holder Bar: 57001–1128 [C]

[For Inlet Valve Seat]

Valve Seat Cutter, 45° — 27.5: 57001–1114

Valve Seat Cutter, 32° — 28: 57001–1119

Valve Seat Cutter, 60° — 27: 57001–1409

[For Exhaust Valve Seat]

Valve Seat Cutter, 45° — 24: 57001–1113

Valve Seat Cutter, 32° — 25 : 57001–1118

Valve Seat Cutter, 60° — 25: 57001–1328

If the manufacturer’s instructions are not available, usethe following procedure.

5-24 ENGINE TOP END

Valves

Seat Cutter Operation Care:1. This valve seat cutter is developed to grind the valve forrepair. Therefore the cutter must not be used for otherpurposes than seat repair.

2. Do not drop or shock the valve seat cutter, or the dia-mond particles may fall off.

3. Do not fail to apply engine oil to the valve seat cutterbefore grinding the seat surface. Also wash off groundparticles sticking to the cutter with washing oil.

NOTEDo not use a wire brush to remove the metal particlesfrom the cutter. It will take off the diamond particles.

4. Setting the valve seat cutter holder in position, operatethe cutter in one hand. Do not apply too much force tothe diamond portion.

NOTEPrior to grinding, apply engine oil to the cutter and dur-ing the operation, wash off any ground particles stickingto the cutter with washing oil.

5. After use, wash it with washing oil and apply thin layerof engine oil before storing.

Marks Stamped on the Cutter:Themarks stamped on the back of the cutter [A] represent

the following.60° ……………………… Cutter angle [B]37.5 ………………….. Outer diameter of cutter [C]

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 valveguide.

• Press down lightly on the handle and turn it right or left.Grind the seating surface only until it is smooth.

CAUTION

Do not grind the seat too much. Overgrinding willreduce valve clearance by sinking the valve into thehead. If the valve sinks too far into the head, it willbe impossible to adjust the clearance, and the cylin-der head must be replaced.

ENGINE TOP END 5-25

Valves

•Measure the outside diameter of the seating surface witha vernier caliper.If the outside diameter of the seating surface is too small,repeat the 45° grind until the diameter is within the spec-ified range.Widened Width [A] of engagement by machining with45° cutterGround Volume [B] by 32° cutter32° [C]Correct Width [D]Ground Volume [E] by 60° cutter60° [F]

•Measure the outside diameter of the seating surface witha vernier caliper.If the outside diameter of the seating surface is too small,repeat the 45° grind [A] until the diameter is within thespecified range.Original Seating Surface [B]

NOTERemove all pittings of flaws from 45° ground surface.After grinding with 45° cutter, apply thin coat of machin-ist’s dye to seating surface. This makes seating surfacedistinct and 32° and 60° grinding operation easier.When the valve guide is replaced, be sure to grind with45° cutter for centering and good contact.

If the outside diameter [A] of the seating surface is toolarge, make the 32° grind described below.If the outside diameter of the seating surface is within thespecified range, measure the seat width as described be-low.

•Grind the seat at a 32° angle [B] until the seat O.D. iswithin the specified range.To make the 32° grind, fit a 32° cutter into the holder, andslide it into the valve guide.Turn the holder one turn at a time while pressing downvery lightly. Check the seat after each turn.

CAUTION

The 32° cutter removes material very quickly.Check the seat outside diameter frequently to pre-vent overgrinding.

After making the 32° grind, return to the seat O.D. mea-surement step above.

• To measure the seat width, use a vernier caliper to mea-sure the width of the 45° angle portion of the seat at sev-eral places around the seat.If the seat width is too narrow, repeat the 45° grind untilthe seat is slightly too wide, and then return to the seatO.D. measurement step above.

5-26 ENGINE TOP END

Valves

If the seat width is too wide, make the 60° [A] grind de-scribed below.If the seat width is within the specified range, lap the valveto the seat as described below.

•Grind the seat at a 60° angle until the seat width is withinthe specified range.To make the 60° grind, fit 60° cutter into the holder, andslide it into the valve guide.Turn the holder, while pressing down lightly.After making the 60° grind, return to the seat width mea-surement step above.Correct Width [B]

• Lap the valve to the seat, once the seat width and O.D.are within the ranges specified above.Put a little coarse grinding compound on the face of thevalve in a number of places around the valve head.Spin the valve against the seat until the grinding com-pound produces a smooth, matched surface on both theseat and the valve.Repeat the process with a fine grinding compound.Lapper [A]Valve Seat [B]Valve [C]

• The seating area should be marked about in the middleof the valve face.If the seat area is not in the right place on the valve, checkto be sure the valve is the correct part. If it is, it may havebeen refaced too much; replace it.

• Be sure to remove all grinding compound before assem-bly.

•When the engine is assembled, be sure to adjust the valveclearance (see Engine Top End in the Periodic mainte-nance chapter).

ENGINE TOP END 5-27

Valves

5-28 ENGINE TOP END

Cylinder, Pistons

Cylinder Removal

•Remove:Cylinder Head (see Cylinder Head Removal)Water Hose [A]

• Remove the cylinder [B].

Cylinder Installation

NOTEIf a new cylinder is used, use new piston ring.• Install the dowel pins [A] and new cylinder gasket [B].• Apply engine oil to the cylinder bore.

• The piston ring openings must be positioned as shown inthe figure. The openings of the oil ring steel rails must beabout 30 – 40° of angle from the opening of the top ring.Top Ring [A]Second Ring [B]Oil Ring Steel Rails [C]Oil Ring Expander [D]Hollow [E]30 ∼ 40° [F]

• Position the crankshaft at #2, #3 piston TDC.• Prepare two auxiliary head bolts with their head cut.Install the two cylinder head bolts [A] diagonally in thecrankcase.

• Install the cylinder block [B].Pistons [C]

First insert the #2, #3 pistons, and then rotate the crank-shaft at 90° angle.Insert the piston rings with your thumbs or the thin (–)screwdriver.

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.

ENGINE TOP END 5-29

Cylinder, Pistons

•Remove the piston pins.Special Tool — Piston Pin Puller Assembly: 57001–910 [A]

•Remove the pistons.

•Carefully spread the ring opening with your thumbs andthen push up on the opposite side of the ring [A] to removeit.

• Remove the 3-piece oil ring with your thumbs in the samemanner.

Piston Installation

•Apply molybdenum disulfide oil solution to the oil ring ex-pander, and install the oil ring expander [A] in the bottompiston ring groove so the ends [B] butt together.

• Applymolybdenum disulfide oil solution to the oil ring steelrails, and install the oil ring steel rails, one above the ex-pander and one below it.Spread the rail with your thumbs, but only enough to fitthe rail over the piston.Release the rail into the bottom piston ring groove.

NOTEThe oil ring rails have no “top” or “bottom”.•Do not mix up the top and second ring.• Install the top ring [A] so that the «1T» mark [B] faces up.• Install the second ring [C] so that the «2T» mark [D] facesup.Apply molybdenum disulfide oil solution to the pistonrings.

5-30 ENGINE TOP END

Cylinder, Pistons

NOTEIf a new piston is used, use new piston ring.• Install the piston with its marking hollow facing forward.• Fit a new piston pin snap ring into the side of the pistonso that the ring opening [A] does not coincide with the slit[B] of the piston pin hole.Apply molybdenum disulfide oil solution to the piston pinsand piston journals.When installing the piston pin snap ring, compress it onlyenough to install it and no more.

CAUTION

Do not reuse snap rings, as removal weakens anddeforms them. They could fall out and score thecylinder wall.

• Install the cylinder (see Cylinder Installation).Cylinder Wear

•Since there is a difference in cylinder wear in different di-rections, take a side-to-side and a front-to-back measure-ment at each of the two locations (total of four measure-ments) shown in the figure.If any of the cylinder inside diameter measurements ex-ceeds the service limit, replace the cylinder.10 mm (0.39 in.) [A]60 mm (2.36 in.) [B]

Cylinder Inside DiameterStandard: 68.400 ∼ 68.412 mm (2.6929 ∼ 2.6934 in.)Service Limit: 68.50 mm (2.6969 in.)

Piston Wear

•Measure the outside diameter [A] of each piston 5 mm(0.20 in.) [B] up from the bottom of the piston at a rightangle to the direction of the piston pin.If the measurement is under service limit, replace the pis-ton.

Piston DiameterStandard: 68.345 ∼ 68.360 mm (2.6907 ∼ 2.6913 in.)Service Limit: 68.21 mm (2.6854 in.)

ENGINE TOP END 5-31

Cylinder, Pistons

Piston Ring, Piston Ring Groove Wear

•Check for uneven groove wear by inspecting the ring seat-ing.The rings should fit perfectly parallel to groove surfaces.If not, replace the piston and all the piston rings.

•With the piston rings in their grooves, make several mea-surements with a thickness gauge [A] to determine pistonring/groove clearance.

Piston Ring/Groove ClearanceTop

Standard: 0.04 ∼ 0.08 mm (0.0016 ∼ 0.0031 in.)Service Limit: 0.18 mm (0.0071 in.)

Second

Standard: 0.02 ∼ 0.06 mm (0.0008 ∼ 0.0024 in.)Service Limit: 0.16 mm (0.0063 in.)

Piston Ring Groove Width

•Measure the piston ring groove width.Use a vernier caliper at several points around the piston.Piston Ring Groove WidthTop [A]

Standard: 0.83 ∼ 0.85 mm (0.0327 ∼ 0.0335 in.)Service Limit: 0.93 mm (0.037 in.)

Second [B]

Standard: 0.81 ∼ 0.83 mm (0.0319 ∼ 0.0327 in.)Service Limit: 0.91 mm (0.036 in.)

If the width of any of the two grooves is wider than theservice limit at any point, replace the piston.

Piston Ring Thickness

•Measure the piston ring thickness.Use the micrometer to measure at several points aroundthe ring.

Piston Ring ThicknessTop [A]

Standard: 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.)Service Limit: 0.70 mm (0.028 in.)

Second [B]

Standard: 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.)Service Limit: 0.70 mm (0.028 in.)

If any of the measurements is less than the service limiton either of the rings, replace all the rings.

NOTEWhen using new rings in a used piston, check for un-even groove wear. The rings should fit perfectly parallelto the groove sides. If not, replace the piston.

5-32 ENGINE TOP END

Cylinder, Pistons

Piston Ring End Gap

•Place the piston ring [A] inside the cylinder, using the pis-ton to locate the ring squarely in place. Set it close to thebottom of the cylinder, where cylinder wear is low.

•Measure the gap [B] between the ends of the ring with athickness gauge.

Piston Ring End GapTop

Standard: 0.30 ∼ 0.40 mm (0.0118 ∼ 0.0157 in.)Service Limit: 0.7 mm (0.028 in.)

Second

Standard: 0.45 ∼ 0.55 mm (0.0177 ∼ 0.0217 in.)Service Limit: 0.8 mm (0.031 in.)

If the end gap of either ring is greater than the servicelimit, replace all the rings.

ENGINE TOP END 5-33

Throttle Body Holder

Throttle Body Holder Installation

•Be sure to install the O-rings [A].• Install the clamps [B] as shown and so that its hole fit onthe projection [C] of the holder.

• Tighten:Torque — Throttle Body Holder Bolts [D]:

13 N·m (1.3 kgf·m, 113 in·lb)Throttle Body Assy Holder Clamp Bolts [E]:2.0 N·m (0.20 kgf·m, 17 in·lb)

5-34 ENGINE TOP END

Muffler

WARNINGTo avoid a serious burn, do not remove the mufflerwhen the engine is still hot. Wait until the mufflercool down.

Muffler Body Removal

•Remove:Muffler Body Clamp Bolt [A]Muffler Body Mounting Bolt [B]

• Pull the muffler body backward.

Exhaust Pipe Removal

•Remove:Radiator Lower Bolt (see Cooling System chapter)Muffler Body Clamp Bolt [A]Exhaust Pipe Manifold Holder Nuts [B]Exhaust Pipe [C]Gaskets [D]

Muffler Body and Exhaust Pipe Installation

•Replace the exhaust pipe gaskets [A] and muffler bodyconnection gasket [B] with new ones and install them.Install the muffler body connection gasket until it is bot-tomed so that the chamfer side feces muffler body [C].

• Install:Muffler BodyExhaust Pipe [D]

• Tighten:Torque — Exhaust Pipe Manifold Holder Nuts [E]:

17 N·m (1.7 kgf·m, 12 ft·lb)Muffler Body Mounting Bolt [F]:30 N·m (3.0 kgf·m, 22 ft·lb)

Muffler Body Clamp Bolt [G]:17 N·m (1.7 kgf·m, 12 ft·lb)

ENGINE TOP END 5-35

Muffler

Install the muffler body clamp bolt as shown.Upper Side [H]Outside [I]

• Thoroughly warm up the engine, wait until the enginecools down, and retighten all the bolts and nuts.

CLUTCH 6-1

6

Clutch

Table of Contents

Exploded View………………………………………………………………………………………………………… 6-2Specifications …………………………………………………………………………………………………………. 6-4Special Tool and Sealant ………………………………………………………………………………………….. 6-5Clutch Lever and Cable ……………………………………………………………………………………………. 6-6

Clutch Lever Free Play Inspection ………………………………………………………………………… 6-6Clutch Lever Free Play Adjustment ………………………………………………………………………. 6-6Cable Removal ………………………………………………………………………………………………….. 6-6Cable Installation ……………………………………………………………………………………………….. 6-6Cable Lubrication ……………………………………………………………………………………………….. 6-6Clutch Lever Installation………………………………………………………………………………………. 6-6Clutch Lever Adjustment……………………………………………………………………………………… 6-7

Clutch Cover…………………………………………………………………………………………………………… 6-8Clutch Cover Removal ………………………………………………………………………………………… 6-8Clutch Cover Installation ……………………………………………………………………………………… 6-8Release Shaft Removal ………………………………………………………………………………………. 6-8Release Shaft Installation ……………………………………………………………………………………. 6-8Clutch Cover Disassembly…………………………………………………………………………………… 6-9Clutch Cover Assembly……………………………………………………………………………………….. 6-9

Clutch ……………………………………………………………………………………………………………………. 6-10Clutch Removal………………………………………………………………………………………………….. 6-10Clutch Installation……………………………………………………………………………………………….. 6-10Clutch Plate Assembly Inspection…………………………………………………………………………. 6-12Clutch Plate Assembly Adjustment ……………………………………………………………………….. 6-12Clutch Plate, Wear, Damage Inspection ………………………………………………………………… 6-13Clutch Plate Warp Inspection……………………………………………………………………………….. 6-13Clutch Spring Free Length Measurement ………………………………………………………………. 6-13

6-2 CLUTCH

Exploded View

CLUTCH 6-3

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Clutch lever clamp bolts 7.8 0.80 69 in·lb S

2 Clutch cover mounting bolts 11 1.1 95 in·lb

3 Oil filler plug 1.5 0.15 13 in·lb

4 Clutch spring bolts 8.8 0.90 78 in·lb

5 Clutch hub nut 135 14 100 R

CL: Apply cable lubricant.EO: Apply engine oil.G: Apply grease.M: Apply molybdenum disulfide grease.R: Replacement PartsS: Follow the specific tightening sequence.W: Apply water.

6-4 CLUTCH

Specifications

Item Standard Service Limit

Clutch Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – –

Clutch:

Clutch plate assembly 37.7 ∼ 38.3 mm (1.48 ∼ 1.51 in.) – – –

Friction plate thickness 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) 2.4 mm (0.094 in.)

Friction and steel plate warp 0.2 mm (0.008 in.) or less 0.3 mm (0.012 in.)

Clutch spring free length 80.6 mm (3.17 in.) 76.6 mm (3.02 in.)

CLUTCH 6-5

Special Tool and Sealant

Clutch Holder:57001–1243

Kawasaki Bond (Silicone Sealant):56019–120

6-6 CLUTCH

Clutch Lever and Cable

Clutch Lever Free Play Inspection

•Refer to the Clutch in the Periodic Maintenance chapter.Clutch Lever Free Play Adjustment

•Refer to the Clutch in the Periodic Maintenance chapter.Cable Removal

•Slide the dust cover [A] at the clutch cable lower end outof place.

• Loosen the nuts [B], and slide the lower end of the clutchcable to give the cable plenty of play.

• Screw in the adjuster.• Line up the slots [A] in the clutch lever and adjuster [B],and then free the cable from the lever.

• Free the clutch inner cable tip from the clutch releaselever.

• Push the release lever toward the front of the motorcycleand tape the release lever to the clutch cover to preventthe release shaft from falling out.

• Pull the clutch cable out of the frame.

Cable Installation

•Run the clutch cable correctly (see Appendix chapter).• Adjust the clutch cable (see Clutch in the Periodic Main-tenance chapter).

Cable Lubrication

•Refer to the General Lubrication in the Periodic Mainte-nance chapter.

Clutch Lever Installation

• Install the clutch lever so that the mating surface [A] of theclutch lever clamp is aligned with the punch mark [B].

• Tighten the upper clamp bolt first, and then the lowerclamp bolt. There will be a gap at the lower part of theclamp after tightening.

Torque — Clutch Lever Clamp Bolts: 7.8 N·m (0.80 kgf·m, 69in·lb)

CLUTCH 6-7

Clutch Lever and Cable

Clutch Lever AdjustmentThe adjuster has 5 positions so that the clutch lever posi-

tion can be adjusted to suit the operator’s hand.

• Push the lever forward and turn the adjuster [A] to alignthe number with the arrow mark [B] on the lever holder.The distance from the grip to the lever is minimum at num-ber 5 and maximum at number 1.

6-8 CLUTCH

Clutch Cover

Clutch Cover Removal

•Remove:Engine Oil (drain, see Engine Lubrication System in thePeriodic Maintenance chapter)Clutch Cable Lower End [A]Clutch Cover Mounting Bolts [B]

• Turn the release lever [A] toward the rear as shown, andremove the clutch cover [B].About 90° [C]

Clutch Cover Installation

•Apply silicone sealant to the area [A] where the matingsurface of the crankcase touches the clutch cover gasket.

Sealant — Kawasaki Bond (Silicone Sealant): 56019–120

•Replace the clutch cover gasket with a new one.• Tighten the clutch cover mounting bolts.Torque — Clutch Cover Mounting Bolts: 11 N·m (1.1 kgf·m,

95 in·lb)

Release Shaft Removal

CAUTION

Do not remove the clutch release lever and shaftassembly unless it is absolutely necessary. If re-moved, the oil seal replacement may be required.

•Remove the clutch cover (see Clutch Cover Removal).• Pull the lever and shaft assembly straight out of the clutchcover.

Release Shaft Installation

•Apply high-temperature grease to the oil seal lips on theupper ridge of the clutch cover.

• Apply oil to the needle bearings in the hole of the clutchcover.

• Apply molybdenum disulfide grease to the pusher-holdingportion [A] on the release shaft.

• Install the washer [B] and spring [C].• Insert the release shaft straight into the upper hole of theclutch cover.

CAUTION

When inserting the release shaft, be careful not toremove the spring of the oil seal.

CLUTCH 6-9

Clutch Cover

•Fit the spring [A] as shown.Viewed from Rear [B]Release Shaft [C]Clutch Cover [D]

Clutch Cover Disassembly

•Remove:Oil Seal [A]Needle Bearings

•Remove:Circlip [A]Oil Level Gauge [B]

Clutch Cover Assembly

•Replace the needle bearings and oil seal with new ones.NOTE

Install the needle bearings so that the manufacture’smark face out.

• Install the needle bearings [A] and oil seal [B] position asshown.Press the bearing until the bottom [C].Press the bearing so that the bearing surface [D] is flushwith the housing end of clutch cover [E].

• Apply water to the rubber of the oil gauge [A] and press itso that the projections [B] face inside.

• Install a new circlip so that the circlip ends [C] do not warpover the projection [D].

6-10 CLUTCH

Clutch

Clutch Removal

•Remove:Engine Oil (drain, see Engine Lubrication System in thePeriodic Maintenance chapter)Clutch Cover (see Clutch Cover Removal)Clutch Spring Bolts [A]Clutch SpringsClutch Spring Plate [B] (with thrust bearing and pusher[C], spring and washer)

• Remove:Friction Plates, Steel PlatesSpring, Spring SeatClutch Hub Nut [A]

Holding the clutch hub [B], remove the nut and washer.Special Tool — Clutch Holder [C]: 57001–1243

•Remove:Clutch HubSpacer

• Using the two 4 mm (0.16 in.) screws [A], pull out thesleeve [B], needle bearing [C] and clutch housing [D].

• Remove the spacer.

Clutch Installation

• Install the following parts on the drive shaft.Spacer [A]Needle Bearing [B]Sleeve [C]Clutch Housing [D]Spacer [E]Clutch Hub [F]Washer [G]Nut [H]

CLUTCH 6-11

Clutch

Install the spacer [A] so that the tapered side [B] facesinward.

Install the washer [A] so that the OUTSIDE mark facesoutward.

Replace the clutch hub nut with a new one.Holding the clutch hub, tighten the clutch hub nut.Special Tool — Clutch Holder: 57001–1243

Torque — Clutch Hub Nut: 135 N·m (14 kgf·m, 100 ft·lb)

• Install the spring seat [A] and spring [B] as shown.Clutch Hub [C]

• Install the friction plates and steel plates, starting with afriction plate and alternating them.

CAUTION

If new dry friction plates and steel plates are in-stalled, apply engine oil to the surfaces of eachplate to avoid clutch plate seizure.

Install the last friction plate [A] fitting the tangs in thegrooves in the housing as shown.

6-12 CLUTCH

Clutch

•Apply molybdenum disulfide grease to the pusher ends[A] and install the bearing [B], pusher [C], spring [D] andwasher [E] in the clutch spring plate [F].Apply engine oil to the needle bearing.• Install the clutch spring plate, springs and spring holders,and tighten the clutch spring bolts.

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 Assembly Inspection

• Inspect the friction plate thickness (see Clutch Plate,Wear, Damage Inspection).

•Measure the length [A] of the clutch plate assembly asshown.Assemble:Clutch Hub [B]Spring Seat [C]Spring [D]Friction Plates [E]Steel Plates [F]Spring Plate [G]Springs [H]Spring Holders [I]Spring Bolts [J]

Torque — Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

Clutch Plate AssemblyStandard: 37.7 ∼ 38.3 mm (1.48 ∼ 1.51 in.)

If the length is not within the specified range, adjust thelength (see Clutch Plate Assembly Adjustment).

Clutch Plate Assembly Adjustment

• Inspect the clutch plate assembly length, and then re-place the steel plate(s) which brings the length within thespecified range.

• Remove:Spring BoltsSpring HoldersSpringsSpring Plate

• Replace the following steel plate(s).Part No. Thickness

13089–1126 1.4 mm (0.055 in.)

13089–013 1.6 mm (0.063 in.) (STD)

13089–1073 2.0 mm (0.079 in.)

NOTEDo not use the steel plate of 1.4 mm (0.055 in.) and 2.0mm (0.079 in.) thickness at the same time.

• Install the removed parts, and inspect the clutch plate as-sembly length.

Torque — Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

CLUTCH 6-13

Clutch

Clutch Plate, Wear, Damage Inspection

•Visually inspect the friction and steel plates for signs ofseizure, overheating (discoloration), or uneven wear.

•Measure the thickness of each friction plate [A] at severalpoints.If any plates show signs of damage, or if they have wornpast the service limit, replace them with new ones.

Friction Plate ThicknessStandard: 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.)Service Limit: 2.4 mm (0.094 in.)

Clutch Plate Warp Inspection

•Place each friction plate or steel plate on a surface plateand measure the gap between the surface plate [A] andeach friction plate or steel plate [B] with a thickness gauge[C]. The gap is the amount of friction or steel plate warp.If any plate is warped over the service limit, replace it witha new one.

Friction and Steel Plate WarpStandard: 0.2 mm (0.008 in.) or less

Service Limit: 0.3 mm (0.012 in.)

Clutch Spring Free Length Measurement

•Measure the free length of the clutch springs [A].If any spring is shorter than the service limit, it must bereplaced.

Clutch Spring Free LengthStandard: 80.6 mm (3.17 in.)

Service Limit: 76.6 mm (3.02 in.)

ENGINE LUBRICATION SYSTEM 7-1

7

Engine Lubrication System

Table of Contents

Exploded View………………………………………………………………………………………………………… 7-2Engine Oil Flow Chart………………………………………………………………………………………………. 7-4Specifications …………………………………………………………………………………………………………. 7-6Special Tools and Sealant ………………………………………………………………………………………… 7-7Engine Oil and Oil Filter……………………………………………………………………………………………. 7-8

Oil Level Inspection…………………………………………………………………………………………….. 7-8Engine Oil Change……………………………………………………………………………………………… 7-8Oil Filter Replacement ………………………………………………………………………………………… 7-8

Oil Pan…………………………………………………………………………………………………………………… 7-9Oil Pan Removal ………………………………………………………………………………………………… 7-9Oil Pan Installation ……………………………………………………………………………………………… 7-9

Oil Pressure Relief Valve………………………………………………………………………………………….. 7-10Oil Pressure Relief Valve Removal ……………………………………………………………………….. 7-10Oil Pressure Relief Valve Installation …………………………………………………………………….. 7-10Oil Pressure Relief Valve Inspection……………………………………………………………………… 7-10

Oil Pump………………………………………………………………………………………………………………… 7-11Oil Pump Removal ……………………………………………………………………………………………… 7-11Oil Pump Installation …………………………………………………………………………………………… 7-11Oil Pump Drive Gear Removal……………………………………………………………………………… 7-12Oil Pump Drive Gear Installation…………………………………………………………………………… 7-12

Oil Pressure Measurement……………………………………………………………………………………….. 7-13Oil Pressure Measurement ………………………………………………………………………………….. 7-13

Oil Pressure Switch …………………………………………………………………………………………………. 7-14Oil Pressure Switch Removal ………………………………………………………………………………. 7-14Oil Pressure Switch Installation ……………………………………………………………………………. 7-14

7-2 ENGINE LUBRICATION SYSTEM

Exploded View

ENGINE LUBRICATION SYSTEM 7-3

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Oil filler plug 1.5 0.15 13 in·lb

2 Engine oil drain bolt 20 2.0 14

3 Oil filter 31 3.2 23 EO, R

4 Holder mounting bolt 76 7.8 56 EO

5 Oil pan bolts 11 1.1 95 in·lb

6 Oil pipe holder bolts 13 1.3 113 in·lb L

7 Oil pressure relief valve 15 1.5 11 L

8 Oil pressure switch 15 1.5 11 SS

9 Oil pressure switch terminal bolt 1.5 0.15 13 in·lb G

10 Water pump cover bolts 11 1.1 95 in·lb

11 Water pump impeller bolt 9.8 1.0 87 in·lb

12 Coolant drain plug (water pump) 11 1.1 95 in·lb

13 Oil passage plugs 20 2.0 14 L

EO: Apply engine oil.G: Apply grease.L: Apply a non-permanent locking agent.

MO: Apply molybdenum disulfide oil.(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)

R: Replacement PartsSS: Apply silicone sealant (Kawasaki Bond: 56019–120).W: Apply water.

7-4 ENGINE LUBRICATION SYSTEM

Engine Oil Flow Chart

ENGINE LUBRICATION SYSTEM 7-5

Engine Oil Flow Chart

1. Camshaft Oil Passage2. Oil Passage Hole in Alternator Rotor Bolt3. Starter Clutch Oil Passage Hole4. Main Oil Passage5. Crankshaft Oil Passage6. Oil Filter7. Oil Pressure Switch8. Oil Pipe9. Oil Pump10. To Drive Shaft11. Oil Pipe12. To Output Shaft13. Drive Shaft Oil Passage Hole14. Output Shaft Oil Passage Hole15. Inlet Camshaft16. Exhaust Camshaft17. To Air Cleaner18. Drive Shaft19. Relief Valve20. Oil Screen21. Engine Oil Drain Bolt22. Output Shaft

7-6 ENGINE LUBRICATION SYSTEM

Specifications

Item Standard

Engine Oil:

Type API SE, SF or SG

API SH or SJ with JASO MA

Viscosity SAE 10W-40

Capacity: 3.1 L (3.3 US gt) (when filter is not removed)

3.3 L (3.5 US gt) (when filter is removed)

3.8 L (4.0 US gt) (when engine is completely dry)

Level Between upper and lower level lines

Oil Pressure Measurement:

Oil pressure @4 000 r/min (rpm),

oil temp. 90°C (194°F) 255 ∼ 314 kPa (2.6 ∼ 3.2 kgf/cm², 37 ∼ 46 psi)

ENGINE LUBRICATION SYSTEM 7-7

Special Tools and Sealant

Oil Pressure Gauge, 10 kgf/cm²:57001–164

Oil Pressure Gauge Adapter, PT3/8:57001–1233

Oil Filter Wrench:57001–1249

Kawasaki Bond (Silicone Sealant):56019–120

7-8 ENGINE LUBRICATION SYSTEM

Engine Oil and Oil Filter

WARNINGMotorcycle operation with insufficient, deteri-orated, or contaminated engine oil will causeaccelerated wear and may result in engine or trans-mission seizure, accident, and injury.

Oil Level Inspection

•Check that the engine oil level is between the upper [A]and lower [B] levels in the gauge.

NOTESituate the motorcycle so that it is perpendicular to theground.If the motorcycle has just been used, wait several min-utes for all the oil to drain down.If the oil has just been changed, start the engine andrun it for several minutes at idle speed. This fills the oilfilter with oil. Stop the engine, then wait several minutesuntil the oil settles.

CAUTION

Racing the engine before the oil reaches every partcan cause engine seizure.If the engine oil gets extremely low or if the oil pumpor oil passages clog up or otherwise do not functionproperly, the oil pressure warning light will light. Ifthis light stays onwhen the engine is running aboveidle speed, stop the engine immediately and find thecause.

Engine Oil Change

•Refer to the Engine Lubrication System in the PeriodicMaintenance chapter.

Oil Filter Replacement

•Refer to the Engine Lubrication System in the PeriodicMaintenance chapter.

ENGINE LUBRICATION SYSTEM 7-9

Oil Pan

Oil Pan Removal

•Remove:Engine Oil (drain, see Engine Lubrication System in thePeriodic Maintenance chapter)Exhaust Pipe Assy and Muffler Body (see Engine TopEnd chapter)Oil Pan Bolts [A]Oil Pan [B]

Oil Pan Installation

•Clean the oil screen [A].• Install the oil screen so that the crankcase rib [B] fits theslot [C] of the oil screen.

• Apply engine oil to the O-rings on the oil pipe.If the oil pressure relief valve was removed, install it.Apply a non-permanent locking agent to the threads ofthe oil pressure relief valve, and tighten it.

CAUTION

Do not apply too much non-permanent lockingagent to the threads. This may block the oil pas-sage.

Torque — Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11ft·lb)

• Install the clamp [A] at an angle of within 45° [B] as shown.•Replace the oil pan gasket with a new one.• Tighten:Torque — Oil Pan Bolts [C]: 11 N·m (1.1 kgf·m, 95 in·lb)

7-10 ENGINE LUBRICATION SYSTEM

Oil Pressure Relief Valve

Oil Pressure Relief Valve Removal

•See Oil Pan Removal.Oil Pressure Relief Valve Installation

•See Oil Pan Installation.Oil Pressure Relief Valve Inspection

•Check to see if the valve [A] slides smoothly when push-ing it in with a wooden or other soft rod, and see if it comesback to its seat by spring [B] pressure.

NOTEInspect the valve in its assembled state. Disassemblyand assembly may change the valve performance.

If any rough spots are found during above inspection,wash the valve clean with a high-flash point solvent andblow out any foreign particles that may be in the valve withcompressed air.

WARNINGClean the oil pressure relief valve in a well-ventilated area, and take care that there is nospark or flame anywhere near the working area.Because of the danger of highly flammable liquids,do not use gasoline or low-flash point solvent.

If cleaning does not solve the problem, replace the oilpressure relief valve as an assembly. The oil pressurerelief valve is precision made with no allowance for re-placement of individual parts.

ENGINE LUBRICATION SYSTEM 7-11

Oil Pump

Oil Pump Removal

•Drain:Coolant (see Cooling System in the Periodic Mainte-nance chapter)Engine Oil (see Engine Lubrication System in the Peri-odic Maintenance chapter)

•Remove:Water Pipe Bolts [A]Water Pipes [B]

•Remove:Water Pump Cover Bolts [A]Clamp [B]Water Pump Cover [C]

•Remove:Impeller Bolt [A]WasherImpeller [B]Water Pump BodyOil Pump CoverOil (Water) Pump ShaftOuter Rotor and Inner Rotor

Oil Pump Installation

• Install the outer rotor [A] into the crankcase.• Install the pin [B], inner rotor [C] and oil (water) pump shaft[D].Turn the pump shaft so that the slot [E] in its shaft fits ontothe projection [F] of the pump drive gear shaft.

• Fit the pin [A] of the oil pump cover [B] into the hole [C] inthe crankcase.

7-12 ENGINE LUBRICATION SYSTEM

Oil Pump

• Install:Pins [A]Water Pump Body [B]

• Install:Impeller [A], Washer and Bolt [B]

• Tighten:Torque — Water Pump Impeller Bolt: 9.8 N·m (1.0 kgf·m, 87

in·lb)

• Install:Pins [C]Water Pump Cover and Bolts

Torque — Water Pump Cover Bolts: 11 N·m (1.1 kgf·m, 95in·lb)

• Install:Water Pipes [A]

• Tighten:Torque — Water Pipe Bolts [B]: 11 N·m (1.1 kgf·m, 95 in·lb)

Oil Pump Drive Gear Removal

•Remove:Clutch (see Clutch chapter)Oil Pan (see Oil Pan Removal)Circlip [A] and WasherOil Pump Drive Gear

Oil Pump Drive Gear Installation

•Apply molybdenum disulfide oil solution to the journal por-tions [A] on the oil pump gear shaft [B].

• Install:Washers [C]

• Install the new circlip [D] into the groove of the oil pumpdrive gear shaft.

ENGINE LUBRICATION SYSTEM 7-13

Oil Pressure Measurement

Oil Pressure Measurement

•Remove the oil passage plug, and attach the adapter [A]and gauge [B] to the plug hole.

Special Tools — Oil Pressure Gauge, 10 kgf/cm²: 57001–164Oil Pressure Gauge Adapter, PT 3/8:57001–1233

•Start the engine and warm up the engine.

•Run the engine at the specified speed, and read the oilpressure gauge.If the oil pressure is much lower than the standard, checkthe oil pump, relief valve, and/or crankshaft bearing insertwear immediately.If the reading is much higher than the standard, check theoil passages for clogging.

Oil PressureStandard: 255 ∼ 314 kPa (2.6 ∼ 3.2 kgf/cm², 37 ∼ 46

psi) @ 4 000 r/min (rpm), oil temp. 90°C(194°F)

•Stop the engine.•Remove the oil pressure gauge and adapter.

WARNINGTake care against burns form hot engine oil thatwill drain through the oil passage when the gaugeadapter is removed.

•Apply a non-permanent locking agent to the oil passageplug, and install it.

Torque — Oil Passage Plug (Right): 20 N·m (2.0 kgf·m, 14ft·lb)

7-14 ENGINE LUBRICATION SYSTEM

Oil Pressure Switch

Oil Pressure Switch Removal

•Remove:Engine Oil (drain, see Engine Lubrication System in thePeriodic Maintenance chapter)Switch Cover [A]Switch Terminal [B]Oil Pressure Switch [C]

Oil Pressure Switch Installation

•Apply silicone sealant to the threads of the oil pressureswitch and tighten it.

Sealant — Kawasaki Bond (Silicone Sealant): 56019–120

Torque — Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb)

• Install the switch lead direction upward.• Tighten the terminal bolt.Torque — Oil Pressure Switch Terminal Bolt: 1.5 N·m (0.15

kgf·m, 13 in·lb)

•Apply grease to the terminal.

ENGINE REMOVAL/INSTALLATION 8-1

8

Engine Removal/Installation

Table of Contents

Exploded View………………………………………………………………………………………………………… 8-2Special Tool ……………………………………………………………………………………………………………. 8-4Engine Removal/Installation……………………………………………………………………………………… 8-5

Engine Removal…………………………………………………………………………………………………. 8-5Engine Installation………………………………………………………………………………………………. 8-7

8-2 ENGINE REMOVAL/INSTALLATION

Exploded View

ENGINE REMOVAL/INSTALLATION 8-3

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Adjusting collar locknut 49 5.0 36 S

2 Upper engine mounting bolts 44 4.5 33 S

3 Rear engine bracket bolts 25 2.5 18 S

4 Front engine bracket bolts 44 4.5 33 S

5 Middle engine mounting nut 44 4.5 33 S

6 Lower engine mounting nut 44 4.5 33 S

7 Engine ground cable terminal bolt 9.8 1.0 87 in·lb

8. Adjusting Collar9. Middle Engine Mounting Bolt10. Lower Engine Mounting BoltS: Follow the specific tightening sequence.

8-4 ENGINE REMOVAL/INSTALLATION

Special Tool

Engine Mount Nut Wrench:57001–1450

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].

WARNINGBe sure to hold the front brake when removing theengine, or the motorcycle may fall over. It couldcause an accident and injury.

CAUTION

Be sure to hold the front brake when removing theengine, or the motorcycle may fall over. The engineor the motorcycle could be damaged.

•Drain:Engine Oil (see Engine Lubrication System in the Peri-odic Maintenance chapter)Coolant (see Cooling System in the Periodic Mainte-nance chapter)

•Remove:Seats (see Frame chapter)Fuel Tank (see Fuel System chapter)Side Covers (see Frame chapter)Frame Covers (see Frame chapter)Clutch Cable Lower End (see Clutch chapter)Exhaust Pipe Assy and Muffler Body (see Engine TopEnd chapter)Throttle Body Assembly (see Fuel System (DFI) chapter)Shift Lever (see Crankshaft/Transmission chapter)

•Remove:Radiator Hose Clamps [A] (Loosen)Radiator Hoses [B]

•Disconnect:Crankshaft Sensor Lead Connector (see Electrical Sys-tem chapter)Stick Coil Harness Connector [C]

• Pull off the connectors from the engine and free the wiringfrom the clamps.

•Remove:Starter Motor Lead (see Electrical System chapter)Alternator Lead Connector (see Electrical System chap-ter)Neutral Switch Lead Connector [A]Side Stand Switch Lead Connector [B]Speed Sensor Connector [C]

•Remove:Left Radiator Hose (see Cooling System chapter)Engine Sprocket (see Final Drive chapter)

8-6 ENGINE REMOVAL/INSTALLATION

Engine Removal/Installation

•Remove:Camshaft Position Sensor Connector [A]Injector Harness Connector [B]

• Remove the vacuum switch valve hose from the aircleaner housing.

• Remove:Breather Hose End [A]Engine Ground Cable Terminal Bolt [B]

• Support the engine with a suitable stand [A].Put a plank [B] onto the suitable stand for engine balance.

• Remove:Right and Left Upper Engine Mounting Bolts [A]Front Engine Bracket Bolts [B]Front Engine Bracket [C]

ENGINE REMOVAL/INSTALLATION 8-7

Engine Removal/Installation

•Remove the middle and lower engine mounting nuts [A]and bolts.

•Remove:Rear Engine Bracket Bolts [B]Rear Engine Bracket [C]

•Using the nut wrench [A], loosen the locknut [B].Special Tool — Engine Mount Nut Wrench: 57001–1450

•Using the Hexagon Wrench, turn the adjusting collar [A]counter clockwise to mark the gap between the engineand frame adjusting collar.

• Remove the drive chain [A] from the output shaft [B].• Using the stand, take out the engine.

Engine Installation

•Support the engine [A] with a suitable stand [B].Put a plank onto the suitable stand for engine balance.

• Screw the adjusting collar fully by hand.• Install the engine ground cable.Torque — Engine Ground Cable Terminal Bolt: 9.8 N·m (1.0

kgf·m, 87 in·lb)

8-8 ENGINE REMOVAL/INSTALLATION

Engine Removal/Installation

• Install the engine mounting bolts and nuts, following thespecified installing sequence.First, hang the drive chain over the output shaft just beforemoving the engine into its final position in the frame.Second, insert the lower engine mounting bolt [A].Third, insert the middle engine mounting bolt [B].Fourth, install the rear engine bracket [C] temporarily.

Fifth, install the left upper engine mounting bolt [A] andtighten it.

Torque — Left Upper Engine Mounting Bolt : 44 N·m (4.5kgf·m, 33 ft·lb)

Sixth, tighten the adjusting collar [A] until the clearancebetween the crankcase [B] and frame bracket [C] cometo 0 mm [D].Seventh, tighten the collar locknut [E].Torque — Adjusting Collar Locknut: 49 N·m (5.0 kgf·m, 36

ft·lb)

Special Tool — Engine Mount Nut Wrench : 57001–1450

Eighth, tighten the rear bracket bolts.Torque — Rear Engine Bracket Bolts: 25 N·m (2.5 kgf·m, 18

ft·lb)

Ninth, tighten securely:Middle Engine Mounting NutLower Engine Mounting Nut

Torque — Engine Mounting Nuts: 44 N·m (4.5 kgf·m, 33 ft·lb)

ENGINE REMOVAL/INSTALLATION 8-9

Engine Removal/Installation

Tenth, temporarily install:Front Engine Bracket [C]Right Upper Engine Mounting Bolt [A]Front Engine Bracket Bolts [B]

Eleventh, tighten the right upper engine mounting bolt.Lastly, tighten the front engine bracket bolts.Torque — Right Upper Engine Mounting Bolt : 44 N·m (4.5

kgf·m, 33 ft·lb)Front Engine Bracket Bolts: 44 N·m (4.5 kgf·m, 33ft·lb)

•Run the leads, cables and hoses correctly (see Cable,Wire and Hose Routing section in Appendix chapter).

• Install the removed parts (see appropriate chapters).• Adjust:Throttle Cables (see Fuel System (DFI) chapter)Choke Cable (see Fuel System (DFI) chapter)Clutch Cable (see Clutch chapter)Drive Chain (see Final Drive chapter)

• Fill the engine with engine oil (see Engine LubricationSystem in the Periodic Maintenance chapter).

• Fill the engine with coolant (see Cooling System in thePeriodic Maintenance chapter).

CRANKSHAFT/TRANSMISSION 9-1

9

Crankshaft/Transmission

Table of Contents

Exploded View…………………………….. 9-2Specifications ……………………………… 9-6Special Tools and Sealant …………….. 9-9Crankcase Splitting………………………. 9-10

Crankcase Splitting …………………. 9-10Crankcase Assembly ………………. 9-10

Crankshaft and Connecting Rods…… 9-13Crankshaft Removal ……………….. 9-13Crankshaft Installation …………….. 9-13Connecting Rod Removal ………… 9-13Connecting Rod Installation ……… 9-13Crankshaft/Connecting RodCleaning ……………………………… 9-16

Connecting Rod Bend……………… 9-17Connecting Rod Twist ……………… 9-17Connecting Rod Big End SideClearance……………………………. 9-17

Connecting Rod Big End BearingInsert/Crankpin Wear ……………. 9-18

Crankshaft Side Clearance ………. 9-19Crankshaft Runout ………………….. 9-20Crankshaft Main BearingInsert/Journal Wear………………. 9-20

Starter Motor Clutch …………………….. 9-22Starter Motor ClutchRemoval/Installation……………… 9-22

Starter Motor Clutch Inspection … 9-22Starter Motor Clutch Disassembly 9-22Starter Motor Clutch Assembly …. 9-22

Transmission ………………………………. 9-23Shift Pedal Removal ……………….. 9-23Shift Pedal Installation …………….. 9-23External Shift MechanismRemoval ……………………………… 9-24

External Shift MechanismInstallation …………………………… 9-25

External Shift MechanismInspection……………………………. 9-25

Transmission Shaft Removal ……. 9-26Transmission Shaft Installation …. 9-26Transmission Shaft Disassembly. 9-26Transmission Shaft Assembly…… 9-27Shift Drum and Fork Removal…… 9-30Shift Drum and Fork Installation… 9-30Shift Drum Disassembly…………… 9-30Shift Drum Assembly ………………. 9-30Shift Fork Bending ………………….. 9-31Shift Fork/Gear Groove Wear …… 9-31Shift Fork Guide Pin/DrumGroove Wear……………………….. 9-31

Gear Dog and Gear Dog HoleDamage………………………………. 9-31

9-2 CRANKSHAFT/TRANSMISSION

Exploded View

CRANKSHAFT/TRANSMISSION 9-3

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Breather plate bolts 9.8 1.0 87 in·lb L

2 Crankcase bolts (M9, L = 81 mm) 42 4.3 31 MO, S

3 Crankcase bolts (M9, L = 95 mm) 42 4.3 31 MO, S

4 Crankcase bolts (M8) 27 2.8 20 S

5 Crankcase bolts (M7) 20 2.0 14 S

6 Crankcase bolts (M6) 12 1.2 104 in·lb S

7 Starter motor clutch bolts 12 1.2 104 in·lb L

8 Oil pipe holder bolts 13 1.3 113 in·lb L

9 Shift drum bearing holder screw 5.4 0.55 48 in·lb L

10 Shift drum bearing holder bolt 13 1.3 113 in·lb L

11 Connecting rod big end nuts see the text ← ← ←12 Crankshaft position rotor bolt 40 4.1 30

13 Oil pressure switch 15 1.5 11 SS

14 Oil pressure switch terminal bolt 1.5 0.15 13 in·lb

15 Oil passage plugs 20 2.0 14 L

16 Crankshaft sensor cover bolts 11 1.1 95 in·lb

17. Do not apply any grease or oil.EO: Apply engine oil.G: Apply grease.L: Apply a non-permanent locking agent.

LG: Apply liquid gasket (Kawasaki Bond: 92104–1066).M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil.(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)

R: Replacement PartsS: Tightening the fasteners following the specified sequence.SS: Apply silicone sealant (Kawasaki Bond: 56019–120).

9-4 CRANKSHAFT/TRANSMISSION

Exploded View

CRANKSHAFT/TRANSMISSION 9-5

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Shift pedal mounting bolt 34 3.5 25 L

2 Gear positioning lever bolt 12 1.2 104 in·lb

3 Shift shaft return spring pin 29 3.0 22 L

4 Shift drum cam holder bolt 12 1.2 104 in·lb L

5 Footpeg bracket bolts 34 3.5 25 L

6 Shift lever bolt 6.9 0.70 61 in·lb

7 Tie-rod locknuts 6.9 0.70 61 in·lb

8 Neutral switch 15 1.5 11

EO: Apply engine oil.G: Apply grease.L: Apply a non-permanent locking agent.R: Replacement Parts

9-6 CRANKSHAFT/TRANSMISSION

Specifications

Item Standard Service Limit

Crankshaft, Connecting Rods:

Connecting rod bend – – – TIR 0.2/100 mm

(0.008/3.94 in.)

Connecting rod twist – – – TIR 0.2/100 mm

(0.008/3.94 in.)

Connecting rod big end side clearance 0.13 ∼ 0.38 mm 0.58 mm

(0.0051 ∼ 0.0150 in.) (0.023 in.)

Connecting rod big end bearing insert/crankpin 0.041 ∼ 0.071 mm 0.11 mm

clearance (0.0016 ∼ 0.0028 in.) (0.0043 in.)

Crankpin diameter: 34.984 ∼ 35.000 mm 34.97 mm

(1.3773 ∼ 1.3780 in.) (1.3768 in.)

Marking None 34.984 ∼ 34.992 mm – – –

(1.3773 ∼ 1.3776 in.)34.993 ∼ 35.000 mm – – –

(1.3777 ∼ 1.3780 in.)Connecting rod big end inside diameter: 38.000 ∼ 38.016 mm – – –

(1.4961 ∼ 1.4967 in.)Marking None 38.000 ∼ 38.008 mm – – –

(1.4961 ∼ 1.4964 in.)38.009 ∼ 38.016 mm – – –

(1.4964 ∼ 1.4967 in.)Connecting rod big end bearing insert thickness:

Brown 1.475 ∼ 1.480 mm – – –

(0.05807 ∼ 0.05827 in.)Black 1.480 ∼ 1.485 mm – – –

(0.05827 ∼ 0.05846 in.)Blue 1.485 ∼ 1.490 mm – – –

(0.05846 ∼ 0.05866 in.)Connecting rod big end bearing insert selection:

Con-rod Big End Crankpin Bearing Insert

Bore Diameter Diameter

Marking Marking Size Color Part Number

None Brown 92139–1110

None None Black 92139–1109

None Blue 92139–1108

Connecting Rod Bolt Stretch:

(Usable Range)

New connecting rod 0.24 ∼ 0.36 mm – – –

(0.0094 ∼ 0.0142 in.)Used connecting rod 0.20 ∼ 0.32 mm – – –

(0.0079 ∼ 0.0126 in.)

CRANKSHAFT/TRANSMISSION 9-7

Specifications

Item Standard Service Limit

Crankshaft side clearance 0.05 ∼ 0.20 mm 0.40 mm

(0.0020 ∼ 0.0079 in.) (0.0157 in.)

Crankshaft runout TIR 0.02 mm (0.0008 in.) orless

TIR 0.05 mm(0.0020 in.)

Crankshaft main bearing insert/journal clearance 0.020 ∼ 0.044 mm 0.07 mm

(0.0008 ∼ 0.0017 in.) (0.0028 in.)

Crankshaft main journal diameter: 32.984 ∼ 33.000 mm 32.96 mm

(1.2986 ∼ 1.2992 in.) (1.2976 in.)

Marking None 32.984 ∼ 32.992 mm – – –

(1.2986 ∼ 1.2989 in.)1 32.993 ∼ 33.000 mm – – –

(1.2989 ∼ 1.2992 in.)Crankcase main bearing inside diameter: 36.000 ∼ 36.016 mm – – –

(1.4173 ∼ 1.4179 in.)Marking 36.000 ∼ 36.008 mm – – –

(1.4173 ∼ 1.4176 in.)None 36.009 ∼ 36.016 mm – – –

(1.4177 ∼ 1.4179 in.)Crankshaft main bearing insert thickness:

Brown 1.490 ∼ 1.494 mm – – –

(0.0587 ∼ 0.0588 in.)Black 1.494 ∼ 1.498 mm – – –

(0.0588 ∼ 0.0590 in.)Blue 1.498 ∼ 1.502 mm – – –

(0.0590 ∼ 0.0591 in.)Crankshaft main bearing insert selection:

Crankcase Main Crankshaft Main Bearing Insert*

Bearing Inside Journal Diameter

Diameter Marking Marking Size Color Part Number Journal Nos.

1 Brown 92028–1868 3, 5

92028–1829 1, 2, 4

None 1 Black 92028–1867 3, 5

None 92028–1828 1, 2, 4

None None Blue 92028–1866 3, 5

92028–1827 1, 2, 4

*The bearing inserts for Nos. 1, 2 and 4 journals have an oil groove, respectively.

Transmission:

Shift fork ear thickness 5.9 ∼ 6.0 mm 5.8 mm

(0.232 ∼ 0.236 in.) (0.228 in.)

Gear groove width 6.05 ∼ 6.15 mm 6.25 mm

(0.238 ∼ 0.242 in.) (0.246 in.)

9-8 CRANKSHAFT/TRANSMISSION

Specifications

Item Standard Service Limit

Shift fork guide pin diameter 6.9 ∼ 7.0 mm 6.8 mm

(0.272 ∼ 0.276 in.) (0.268 in.)

Shift drum groove width 7.05 ∼ 7.20 mm 7.3 mm

(0.278 ∼ 0.283 in.) (0.287 in.)

CRANKSHAFT/TRANSMISSION 9-9

Special Tools and Sealant

Bearing Puller:57001–135

Bearing Puller Adapter:57001–317

Kawasaki Bond (Silicone Sealant):56019–120

Kawasaki Bond (Silicone Sealant):92104–1066

9-10 CRANKSHAFT/TRANSMISSION

Crankcase Splitting

Crankcase Splitting

•Remove the engine (see Engine Removal/Installationchapter).

• Set the engine on a clean surface and hold the enginesteady while parts are being removed.

• Remove:Crankshaft Sensor (see Electrical System chapter)Clutch (see Clutch chapter)External Shift Mechanism (see External Shift Mecha-nism Removal)Starter Motor (see Electrical System chapter)Oil Pump (see Engine Lubrication System chapter)Alternator Rotor (see Electrical System chapter)Oil Filter (see Engine Lubrication System chapter)If the crankshaft is to be removed, remove the pistons(see Engine Top End chapter).

• Remove the upper crankcase bolts.First loosen the M6 bolts.M6 Bolts [A]M7 Bolts [B]M8 Bolts [C]

• Remove the oil pan, relief valve, oil screen and oil pipes(see Engine Lubrication System chapter).

• Remove the lower crankcase bolts.First loosen the M7 bolts.M7 Bolts [A]M9 Bolts [B]

• Tap lightly around the crankcase mating surface with aplastic mallet, and split the crankcase. Take care not todamage the crankcase.

Crankcase Assembly

CAUTION

The upper and lower crankcase halves are ma-chined at the factory in the assembled state, so thecrankcase halves must be replaced as a set.

•With a high-flash point solvent, clean off the mating sur-faces of the crankcases halves and wipe dry.

• Using compressed air, blow out the oil passages in thecrankcase halves.

CRANKSHAFT/TRANSMISSION 9-11

Crankcase Splitting

•Apply liquid gasket to the breather plate mating surface[A] 1 to 1.5 mm (0.04 to 0.06 in.) thick, and then installthe breather plate.

Sealant — Three Bond: 1207B

•Apply a non-permanent locking agent to the threads andtighten the bolts [A].

Torque — Breather Plate Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

• Install the breather hose [A].Align the white mark on the hose with the white mark onthe pipe.Install the clamp [B] so that its head faces to right side.Breather Plate [C]

• Install:Crankshaft and Connecting RodsCamshaft Chain [A]Transmission Shafts and GearsDowel Pins [B]Shift DrumShift Forks and Shift Rods

•Before fitting the lower case on the upper case, check thefollowing.Be sure to hang the camshaft chain on the crankshaft.Check to see that the shift drum and transmission gearsare in the neutral position.

9-12 CRANKSHAFT/TRANSMISSION

Crankcase Splitting

•Apply liquid gasket [A] to the mating surface of the lowercrankcase half.

Sealant — Kawasaki Bond (Silicone Sealant): 92104–1066

CAUTION

Do not apply liquid gasket around the crankshaftmain bearing inserts, and oil passage holes.

• Fit the lower crankcase to the upper crankcase.

• Apply molybdenum disulfide oil to the seating surface [A]on the lower crankcase for the M9 bolts [B].Washer [C]

• Tighten the lower crankcase bolts using the followingsteps.Following the sequence numbers on the lower crankcasehalf, tighten the M9 bolts [1 ∼ 6] L= 81 mm (3.19 in.).Torque — Crankcase Bolts (M9): 42 N·m (4.3 kgf·m, 31 ft·lb)

Tighten the M9 bolts [7 ∼ 10] L= 95 mm (3.74 in.) withwashers.

Torque — Crankcase Bolts (M9): 42 N·m (4.3 kgf·m, 31 ft·lb)

Tighten the M7 bolts [A].Torque — Crankcase Bolts (M7): 20 N·m (2.0 kgf·m, 14 ft·lb)

• 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): 20 N·m (2.0 kgf·m, 14 ft·lb)

L= 85 mm (3.35 in.) [B]

L= 50 mm (1.97 in.) [C]

CrankcaseBolts (M6): 12 N·m (1.2 kgf·m, 104 in·lb)

L= 60 mm (2.36 in.) [D]

L= 40 mm (1.57 in.) [E]

L= 90 mm (3.54 in.) [F]

Clamp [G]

• After tightening all crankcase bolts, check the followingitems.Crankshaft and transmission shafts turn freely.While spinning the output shaft, gears shift smoothly fromthe 1st to 6th gear, and 6th to 1st.When the output shaft stays still, the gear can not beshifted to 2nd gear or other higher gear positions.

CRANKSHAFT/TRANSMISSION 9-13

Crankshaft and Connecting Rods

Crankshaft Removal

•Split the crankcase (see Crankcase Splitting).•Remove the crankshaft [A].

Crankshaft Installation

CAUTION

If the crankshaft, bearing inserts, or crankcasehalves are replaced with new ones, select the bear-ing inserts and check clearance with a plastigage(press gauge) before assembling engine to be surethe correct bearing inserts are installed.

•Apply molybdenum disulfide oil solution to the crankshaftmain bearing inserts.

• Install the crankshaft with the camshaft chain [A] hangingon it.

Connecting Rod Removal

•Split the crankcase (see Crankcase Splitting).•Remove the connecting rod nuts [A].•Remove the crankshaft.

NOTEMark and record the locations of the connecting rodsand their big end caps so that they can be reassembledin their original positions.

•Remove the connecting rods from the crankshaft.

CAUTION

Discard the connecting rod bolts. To prevent dam-age to the crankpin surfaces, do not allow the con-necting rod bolts to bump against the crankpins.

Connecting Rod Installation

CAUTION

To minimize vibration, the connecting rods shouldhave the same weight mark.

Big End Cap [A]Connecting Rod [B]Weight Mark, Alphabet [C]Diameter Mark [D]: “ ” or no mark

CAUTION

If the connecting rods, big end bearing inserts, orcrankshaft are replaced with new ones, select thebearing insert and check clearance with a plasti-gage (press gauge) before assembling engine to besure the correct bearing inserts are installed.

9-14 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

•Apply molybdenum disulfide grease [A] to the outer sur-face of the upper insert and the inner surface of the con-necting rod big end.

• Apply molybdenum disulfide oil [B] to the inner surfacesof upper and lower bearing inserts.The molybdenum disulfide oil is a mixture of engine oiland molybdenum disulfide grease with a weight ratio(10:1).Do not apply any grease or oil [C] to the cap inside andcap insert outside.Install the inserts so that their nails [D] are on the sameside and fit them into the recess of the connecting rod andcap.

CAUTION

Wrong application of oil and grease could causebearing damage.

When installing the inserts [A], be careful not to damagethe insert surface with the edge of the connecting rod [B]or the cap [C]. One way to install inserts is as follows:Installation [D] to CapInstallation [E] to Connecting RodPush [F]Spare Dowel Pin [G]Connecting Rod Bolts [H]

• Install the cap on the connecting rod, aligning the weightand diameter marks.

• Remove debris and clean the surface of inserts.• Apply molybdenum disulfide oil [MO] to the threads andseating surfaces of the big end nuts and bolts.

• Install the crankshaft (see Crankshaft Installation).• Install each connecting rod on its original crankpin.The connecting rod big end is bolted using the “plasticregion fastening method”.This method precisely achieves the needed clampingforce without exceeding it unnecessarily, allowing theuse of thinner, lighter bolts further decreasing connectingrod weight.There are two types of the plastic region fastening. One isa bolt length measurement method and other is a rotationangle method. Observe one of the following two, but thebolt length measurement method is preferable becausethis is a more reliable way to tighten the big end nuts.

CAUTION

The connecting rod bolts are designed to stretchwhen tightened. Never reuse the connecting rodbolts. See the table below for correct bolt and nutusage.

CAUTION

Be careful not to overtighten the nuts.The boltsmust be positioned on the seating surfacecorrectly to prevent the bolt heads from hitting thecrankcase.

CRANKSHAFT/TRANSMISSION 9-15

Crankshaft and Connecting Rods

(1) Bolt Length Measurement Method

•Be sure to clean the bolts, nuts, and connecting rodsthoroughly with a high-flash point solvent, because thenew connecting rods, bolts, and nuts are treated with ananti-rust solution.

WARNINGClean the bolts, nuts, and connecting rods in a well-ventilated area, and take care that there is no sparkor flame anywhere near the working area. This in-cludes any appliance with a pilot light. Because ofthe danger of highly flammable liquids, do not usegasoline or low-flash point solvents to clean them.

CAUTION

Immediately dry the bolts and nuts with com-pressed air after cleaning.Clean and dry the bolts and nuts completely.

• Install new bolts in reused connecting rods.•Dent both bolt head and bolt tip with a punch as shown.• Before tightening, use a point micrometer [A] to measurethe length of new connecting rod bolts and record the val-ues to find the bolt stretch.Connecting Rod [B]Mark here with a punch [C].Nuts [D]Fit micrometer pins into punch marks [E].

• Apply a small amount of molybdenum disulfide oil to thefollowing:Threads of Nuts and BoltsSeating Surfaces of Nuts and Con-rods

• Tighten the big end nuts until the bolt elongation reachesthe length specified in the table.

•Check the length [F] of the connecting rod bolts.If the stretch is more than the usable range, the bolt hasstretched too much. An overelongated bolt may break inuse.

Bolt Length Bolt Length

after tightening–

before tightening= Bolt Stretch

Connect-ing RodAssy

Bolt NutUsable Range ofConnecting RodBolt Stretch

Attached tonew con-rodNew

Use the boltsattached tonew con-rod. New

0.24 ∼ 0.36 mm(0.0094 ∼ 0.0142in.)

Used

UsedReplace thebolts with newones. New

0.20 ∼ 0.32 mm(0.0079 ∼ 0.0126in.)

9-16 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

(2) Rotation Angle MethodIf you don’t have a point micrometer, you may tighten thenuts using the “Rotation Angle Method”.

• Be sure to clean the bolts and nuts thoroughly with a high-flash point solvent, because the new bolts and nuts aretreated with an anti-rust solution.

WARNINGClean the bolts and nuts in a well-ventilated area,and take care that there is no spark or flame any-where near the working area. This includes any ap-pliance with a pilot light. Because of the dangeror highly flammable liquids, do not use gasoline orlow-flash point solvents to clean them.

CAUTION

Immediately dry the bolts and nuts with com-pressed air after cleaning.Clean and dry the bolts and nuts completely.

• Install new bolts in reused connecting rods.• Apply a small amount of molybdenum disulfide oil to thefollowing:Threads [A] of Nuts and BoltsSeating Surfaces [B] of Nuts and Con-rods

• First, tighten the nuts to the specified torque. See thetable below.

• Next, tighten the nuts 120° ±5° .Mark [A] the connecting rod big end caps and nuts so thatnuts can be turned 120° [B] properly.Tighten the hexagon nut by 2 corners.

Torque + AngleConnectingRod Assy

Bolt NutN·m (kgf·m, ft·lb)

Attached to 18 (1.8, 13.0)

new con-rod + 120°

20 (2.0, 14.5)New

Use the boltsattached tonew con-rod. New

+ 120°

24 (2.4, 17.4)Used

+ 120°

25 (2.6, 18.8)Used

Replace thebolts with newones New

+ 120°

Crankshaft/Connecting Rod Cleaning

•After removing the connecting rods from the crankshaft,clean them with a high-flash point solvent.

• Blow the crankshaft oil passages with compressed air toremove any foreign particles or residue that may haveaccumulated in the passages.

CRANKSHAFT/TRANSMISSION 9-17

Crankshaft and Connecting Rods

Connecting Rod Bend

•Remove the connecting rod big end bearing inserts, andreinstall the connecting rod big end cap.

• Select an arbor [A] of the same diameter as the connect-ing rod big end, and insert the arbor through the connect-ing rod big end.

• Select an arbor of the same diameter as the piston pinand at least 100 mm (3.94 in.) long, and insert the arbor[B] through the connecting rod small end.

•On a surface plate, set the big-end arbor on V block [C].•With the connecting rod held vertically, use a heightgauge to measure the difference in the height of thearbor above the surface plate over a 100 mm (3.94 in.)length to determine the amount of connecting rod bend.If connecting rod bend exceeds the service limit, the con-necting rod must be replaced.

Connecting Rod BendService Limit: TIR 0.2/100 mm (0.008/3.94 in.)

Connecting Rod Twist

•With the big-end arbor [A] still on V block [C], hold theconnecting rod horizontally and measure the amount thatthe arbor [B] varies from being paralleled with the surfaceplate over a 100 mm (3.94 in.) length of the arbor to de-termine the amount of connecting rod twist.If connecting rod twist exceeds the service limit, the con-necting rod must be replaced.

Connecting Rod TwistService Limit: TIR 0.2/100 mm (0.008/3.94 in.)

Connecting Rod Big End Side Clearance

•Measure connecting rod big end side clearance.Insert a thickness gauge [A] between the big end and ei-ther crank web to determine clearance.

Connecting Rod Big End Side ClearanceStandard: 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.)Service Limit: 0.58 mm (0.023 in.)

If the clearance exceeds the service limit, replace the con-necting rod with new one and then check clearance again.If clearance is too large after connecting rod replacement,the crankshaft also must be replaced.

9-18 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

Connecting Rod Big End Bearing Insert/CrankpinWear

•Measure the bearing insert/crankpin [B] clearance withplastigage [A].

• Tighten the big end nuts to the specified torque (see Con-necting Rod Installation).

NOTEDo not move the connecting rod and crankshaft duringclearance measurement.

CAUTION

After measurement, replace the connecting rodbolts.

ConnectingRodBig EndBearing Insert/Crankpin ClearanceStandard: 0.041 ∼ 0.071 mm (0.0016 ∼ 0.0028 in.)Service Limit: 0.11 mm (0.0043 in.)

If the clearance is within the standard, no bearing replace-ment is required.If the clearance is between 0.072 mm (0.00284 in.) andthe service limit (0.11 mm, 0.0043 in.), replace the bear-ing inserts [A] with inserts painted blue [B]. Check in-sert/crankpin clearance with the plastigage. The clear-ance may exceed the standard slightly, but it must not beless than the minimum in order to avoid bearing seizure.If the clearance exceeds the service limit, measure thediameter of the crankpins.

Crankpin DiameterStandard: 34.984 ∼ 35.000 mm (1.3773 ∼ 1.3780 in.)Service Limit: 34.97 mm (1.3768 in.)

If any crankpin has worn past the service limit, replace thecrankshaft with a new one.If the measured crankpin diameters are not less than theservice limit, but do not coincide with the original diametermarkings on the crankshaft, make new marks on it.

Crankpin Diameter MarksNone 34.984 ∼ 34.992 mm (1.3773 ∼ 1.3776 in.)

34.993 ∼ 35.000 mm (1.3777 ∼ 1.3780 in.)

∆: Crankpin Diameter Marks, » » or no mark.

CRANKSHAFT/TRANSMISSION 9-19

Crankshaft and Connecting Rods

•Measure the connecting rod big end inside diameter, andmark each connecting rod big end in accordance with theinside diameter.

• Tighten the connecting rod big end nuts to the specifiedtorque (see Connecting Rod Installation).

NOTEThe mark already on the big end should almost coincidewith the measurement.

Connecting Rod Big End Inside Diameter MarksNone 38.000 ∼ 38.008 mm (1.4961 ∼ 1.4964 in.)

38.009 ∼ 38.016 mm (1.4964 ∼ 1.4967 in.)

Big End Cap [A]Connecting Rod [B]Weight Mark, Alphabet [C]Diameter Mark (Around Weight Mark) [D]: “ ” or nomark

•Select the proper bearing insert [A] in accordance with thecombination of the connecting rod and crankshaft coding.Size Color [B]

Bearing InsertCon-rod Big EndInside Diameter

Marking

CrankpinDiameterMarking Size Color Part Number

None Brown 92139–1110

None NoneBlack 92139–1109

None Blue 92139–1108

• Install the new inserts in the connecting rod and checkinsert/crankpin clearance with the plastigage.

Crankshaft Side Clearance

• Insert a thickness gauge [A] between the crankcase mainbearing and the crank web at the No. 2 journal [B] todetermine clearance.If the clearance exceeds the service limit, replace thecrankcase halves as a set.

NOTEThe upper and lower crankcase halves are machinedat the factory in the assembled state, so the crankcasehalves must be replaced as a set.

Crankshaft Side ClearanceStandard: 0.05 ∼ 0.20 mm (0.0020 ∼ 0.0079 in.)Service Limit: 0.40 mm (0.0157 in.)

9-20 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

Crankshaft Runout

•Measure the crankshaft runout.If the measurement exceeds the service limit, replace thecrankshaft.

Crankshaft RunoutStandard: TIR 0.02 mm (0.0008 in.) or less

Service Limit: TIR 0.05 mm (0.0020 in.)

Crankshaft Main Bearing Insert/Journal Wear

•Using a plastigage (press gauge) [A], measure the bear-ing insert/journal [B] clearance.

NOTETighten the crankcase bolts to the specified torque (seeCrankcase Assembly).Do not turn the crankshaft during clearance measure-ment.Journal clearance less than 0.025mm (0.00098 in.) cannot bemeasured by plastigage, however, using genuineparts maintains the minimum standard clearance.

Crankshaft Main Bearing Insert/Journal ClearanceStandard: 0.020 ∼ 0.044 mm (0.0008 ∼ 0.0017 in.)Service Limit: 0.07 mm (0.0028 in.)

If the clearance is within the standard, no bearing replace-ment is required.If the clearance is between 0.045 mm (0.0018 in.) and theservice limit (0.07 mm, 0.0028 in.), replace the bearing in-serts [A] with inserts painted blue [B]. Check insert/journalclearance with the plastigage. The clearancemay exceedthe standard slightly, but it must not be less than the min-imum in order to avoid bearing seizure.If the clearance exceeds the service limit, measure thediameter of the crankshaft main journal.

Crankshaft Main Journal DiameterStandard: 32.984 ∼ 33.000 mm (1.2986 ∼ 1.2992 in.)Service Limit: 32.96 mm (1.2976 in.)

If any journal has worn past the service limit, replace thecrankshaft with a new one.If the measured journal diameters are not less than theservice limit, but do not coincide with the original diametermarkings on the crankshaft, make new marks on it.

Crankshaft Main Journal Diameter MarksNone 32.984 ∼ 32.992 mm (1.2986 ∼ 1.2989 in.)1 32.993 ∼ 33.000 mm (1.2989 ∼ 1.2992 in.)

: Crankshaft Main Journal Diameter Marks, «1» or nomark.

CRANKSHAFT/TRANSMISSION 9-21

Crankshaft and Connecting Rods

•Measure the main bearing inside diameter, and mark theupper 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 (seeCrankcase Assembly).

NOTEThe mark already on the upper crankcase half shouldalmost coincide with the measurement.

Crankcase Main Bearing Inside Diameter Marks36.000 ∼ 36.008 mm (1.4173 ∼ 1.4176 in.)

None 36.009 ∼ 36.016 mm (1.4177 ∼ 1.4179 in.)

•Select the proper bearing insert [A] in accordance with thecombination of the crankcase and crankshaft coding.Size Color [B]

Bearing Insert*Crankcase MainBearing InsideDiameter Marking

Crankshaft MainJournal Diameter

Marking Size Color Part Number Journal Nos.

92028–1868 3, 51 Brown

92028–1829 1, 2, 4

None 1 Black 92028–1867 3, 5

None 92028–1828 1, 2, 4

92028–1866 3, 5None None Blue

92028–1827 1, 2, 4

* The bearing inserts for Nos. 1, 2 and 4 journals have an oil groove, respectively.

• Install the new inserts in the crankcase halves and checkinsert/journal clearance with the plastigage.

9-22 CRANKSHAFT/TRANSMISSION

Starter Motor Clutch

Starter Motor Clutch Removal/Installation

•Refer to the Alternator Rotor Removal and Installation inthe Electrical System chapter.

Starter Motor Clutch Inspection

•Remove:Alternator Cover (see Electrical System chapter)Starter Idle Gear

• Turn the starter motor clutch gear [A] by hand. The startermotor clutch gear should turn clockwise [B] freely, butshould not turn counterclockwise [C].If the clutch does not operate as it should or if it makesnoise, go to the next step.

• Remove and disassemble the starter motor clutch, andvisually inspect the clutch parts.If there is any worn or damaged part, replace it.

NOTEExamine the starter motor clutch gear as well. Replaceit if it is worn or damaged.

Starter Motor Clutch Disassembly

•Remove:Alternator Rotor (see Electrical System chapter)Starter Motor Clutch Bolts [A] and Starter Motor Clutch

Starter Motor Clutch Assembly

•Be sure to install the one-way clutch [A] so that its flange[B] fits in the holder recess [C].

• Apply a non-permanent locking agent to the threads ofthe starter motor clutch bolts, and tighten them.

Torque — Starter Motor Clutch Bolts: 12 N·m (1.2 kgf·m, 104in·lb)

CRANKSHAFT/TRANSMISSION 9-23

Transmission

Shift Pedal Removal

•Mark [A] the position of the shift lever [B] on the shift shaftso that it can be installed later in the same position.

•Remove:Shift Lever Bolt [C]Shift Lever

•Remove:Footpeg Bracket Bolts [A]Footpeg Bracket [B]

•Remove the bolt [A], footpeg [B] and shift pedal [C].

Shift Pedal Installation

•Apply grease to the oil seal lip.• Press the oil seals [A] in the shift pedal housing [B] so thatthe oil seal surfaces are flush with the housing end [C] asshown.

• Apply grease to the sliding surfaces [A] on the footpegholder [B].

• Apply a non-permanent locking agent to the shift pedalmounting bolt [C].

• Tighten:Torque — Shift Pedal Mounting Bolt: 34 N·m (3.5 kgf·m, 25

ft·lb)

Footpeg Bracket [D]Shift Pedal [E]Oil Seals [F]

9-24 CRANKSHAFT/TRANSMISSION

Transmission

• Install the footpeg bracket [A].• Tighten:Torque — Footpeg Bracket Bolts [B]: 34 N·m (3.5 kgf·m, 25

ft·lb)

• Install the shift lever [A], aligning the mark (previouslymarked).

• Tighten:Torque — Shift Lever Bolt: 6.9 N·m (0.70 kgf·m, 61 in·lb)

• Install the shift pedal [B] as shown.About 90° [C]

To adjust the pedal position, loosen the front locknut [D](left-hand threads) and rear locknut [E] and then turn thetie-rod [F].

• Tighten:Torque — Tie-rod Locknuts: 6.9 N·m (0.70 kgf·m, 61 in·lb)

External Shift Mechanism Removal

•Remove:Engine Oil (drain, see Engine Lubrication System chap-ter)Shift Pedal (see Shift Pedal Removal)Clutch (see Clutch chapter)Oil Pipe Holder Bolts [A]Oil Pipe Holders [B], Oil Pipe [C] and O-rings

•Remove the shift shaft assembly [A] while pulling the shiftmechanism arm [B] to the direction of the arrow.

CRANKSHAFT/TRANSMISSION 9-25

Transmission

•Remove:Gear Positioning Lever Bolt [A]Gear Positioning Lever [B], Collar and Spring

External Shift Mechanism Installation

• Install the gear positioning lever [A] as shown.Spring [B]Collar [C]Bolt [D]

• Tighten:Torque — Gear Positioning Lever Bolt: 12 N·m (1.2 kgf·m,

104 in·lb)

•Apply grease to the O-rings on the oil pipe ends.• Apply a non-permanent locking agent to the oil pipe holderbolts and tighten them.

Torque — Oil Pipe Holder Bolts: 13 N·m (1.3 kgf·m, 113 in·lb)

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 mechanism arm [D] is damaged in any way,replace the arm.

•Check the return spring pin [A] is not loose.If it is loose, unscrew it, apply a non-permanent lockingagent to the threads, and tighten it.

Torque — Shift Shaft Return Spring Pin: 29 N·m (3.0 kgf·m,22 ft·lb)

•Check the gear positioning lever [B] and its spring forbreaks or distortion.If the lever or spring are damaged in any way, replacethem.

•Visually inspect the shift drum cam [C].If they are badly worn or if they show any damage, replaceit.

9-26 CRANKSHAFT/TRANSMISSION

Transmission

Transmission Shaft Removal

•Split the crankcase (see Crankcase Splitting).• Remove the drive shaft [A] and output shaft [B].

Transmission Shaft Installation

•Check to see that the set pins [A] and set rings [B] are inplace.

• Install the drive shaft and output shaft into the uppercrankcase half.

• Apply engine oil to the bearings.The bearing set pins and rings must match properly withthe holes or grooves in the bearing outer races. Whenthey are properly matched, there is no clearance [A] be-tween the crankcase and the bearing outer races.

• Assemble the crankcase.• Press in the oil seal [A] onto collar [B] so that the surfaceof the oil seal is flush with the counterbore bottom surface[C] of the crankcase.

Transmission Shaft Disassembly

•Remove the transmission shafts (see Transmission ShaftRemoval).

• Remove the circlips, disassemble the transmissionshafts.

• The 5th gear [A] on the output shaft has three steel ballsassembled into it for the positive neutral finder mecha-nism. Remove the 5th gear.Set the output shaft in a vertical position holding the 3rdgear [B].Spin the 5th gear quickly [C] and pull it off upward.

CRANKSHAFT/TRANSMISSION 9-27

Transmission

•Remove the ball bearing [A] from each shafts.

Special Tools — Bearing Puller: 57001–135 [B]Bearing Puller Adapter: 57001–317 [C]

•Discard the bearing.

Transmission Shaft Assembly

•Apply engine oil to the bushings, ball bearings and shafts.• Install the gear bushings [A] on the shaft with their holes[B] aligned.

•Replace any circlips removed with new ones.• Install the circlips [A] so that the opening [B] is alignedwith a spline groove [C].

• The drive shaft gears can be recognized by size: the gearwith the smallest diameter is 1st gear, and the largest oneis 6th gear. Be sure that all parts are put back in the cor-rect sequence and all circlips and washers are properly inplace.

• Install the 3rd/4th gear onto the drive shaft with their oilholes aligned.

• Install the 6th gear bushing onto the drive shaft with theiroil holes aligned.

• The output shaft gears can be recognized by size: thegear with the largest diameter is 1st gear, and the small-est one is 6th gear. Be sure that all parts are put backin the correct sequence and all circlips and washers areproperly in place.

• Install the 5th and 6th gears onto the output shaft withtheir oil holes aligned.

• Install the 3rd/4th gear bushings onto the output shaft withtheir oil holes aligned.

9-28 CRANKSHAFT/TRANSMISSION

Transmission

NOTEWhen the toothed washers [28] [29] are assembled ontothe output shaft, note the following.When the tangs [A] of the toothed washer [29] shall beassembled, they should be installed into the notch [B]of the toothed washer [28] (see Page 9–29).

• Fit the steel balls into the 5th gear holes in the outputshaft, aligning three oil holes [D].5th Gear [A]Output Shaft [B]Steel Balls [C]

CAUTION

Do not apply grease to the balls to hold them inplace. This will cause the positive neutral findermechanism to malfunction.

After assembling the 5th gear with steel balls in place onthe output shaft, check the ball-locking effect that the 5thgear doesn’t come out of the output shaft when moving itup and down by hand.

• Check that each gear spins or slides freely on the trans-mission shafts without binding after assembly.

CRANKSHAFT/TRANSMISSION 9-29

Transmission

1. 1st Gear2. 2nd Gear3. 3rd Gear4. 4th Gear5. 5th Gear6. 6th (Top) Gear7. Toothed Washer, 31 mm (1.22 in.)8. Thrust Washer, 30 mm (1.18 in.)9. Circlip10. Circlip11. Bushing12. Bushing13. Needle Bearing14. Needle Bearing15. Bearing Outer Race16. Steel Ball17. Nut

18. Bushing19. Bushing20. Circlip21. Ball Bearing22. Collar23. Washer24. Toothed Washer25. Oil Seal26. Thrust Washer, 31 mm

(1.22 in.)27. Thrust Washer, 33 mm

(1.30 in.)28. Toothed Washer29. Toothed Washer30. Toothed Washer, 35 mm

(1.38 in.)

9-30 CRANKSHAFT/TRANSMISSION

Transmission

Shift Drum and Fork Removal

•Remove:Lower Crankcase Half (see Crankcase Splitting)Transmission ShaftsExternal Shift Mechanism (see External Shift Mecha-nism Removal)Bolt [A] and Screw [B]Shift Drum Bearing Holder [C]

• Pull out the shift rods [D], and take off the shift forks.• Pull out the shift drum [E].

Shift Drum and Fork Installation

• Install the shift rods [A], noting the groove position. Therods are identical.

• Position the one with shortest ears [B] on the drive shaftand place the pin in the center groove in the shift drum[C].The two forks [D] on the output shaft are identical.• Install the forks so that its “266” and “267” side facesclutch side.

• Apply a non-permanent locking agent to the threads ofthe shift drum bearing holder bolt and screw, and tightenthem.

Torque — Shift DrumBearing Holder Bolt: 13 N·m (1.3 kgf·m,113 in·lb)

Shift Drum Bearing Holder Screw: 5.4 N·m (0.55kgf·m, 48 in·lb)

Shift Drum Disassembly

•Remove the shift drum (see Shift Drum and Fork Re-moval).

•While holding the shift drum with a vise, remove the shiftdrum cam holder bolt.Shift Drum Cam Holder Bolt [A]Dowel Pin [B]

Shift Drum Assembly

•Be sure to install the dowel pin.• Apply a non-permanent locking agent to the threads ofthe shift drum cam holder bolt, and tighten it.

Torque — Shift Drum Cam Holder Bolt: 12 N·m (1.2 kgf·m,104 in·lb)

CRANKSHAFT/TRANSMISSION 9-31

Transmission

Shift Fork Bending

•Visually inspect the shift forks, and replace any fork that isbent. A bent fork could cause difficulty in shifting, or allowthe transmission to jump out of gear when under power.90° [A]

Shift Fork/Gear Groove Wear

•Measure the thickness of the shift fork ears [A], and mea-sure the width [B] of the gear grooves.If the thickness of a shift fork ear is less than the servicelimit, the shift fork must be replaced.

Shift Fork Ear ThicknessStandard: 5.9 ∼ 6.0 mm (0.232 ∼ 0.236 in.)Service Limit: 5.8 mm (0.228 in.)

If the gear groove is worn over the service limit, the gearmust be replaced.

Gear Groove WidthStandard: 6.05 ∼ 6.15 mm (0.238 ∼ 0.242 in.)Service Limit: 6.25 mm (0.246 in.)

Shift Fork Guide Pin/Drum Groove Wear

•Measure the diameter of each shift fork guide pin [A], andmeasure the width [B] of each shift drum groove.If the guide pin on any shift fork is less than the servicelimit, the fork must be replaced.

Shift Fork Guide Pin DiameterStandard: 6.9 ∼ 7.0 mm (0.272 ∼ 0.276 in.)Service Limit: 6.8 mm (0.268 in.)

If any shift drum groove is worn over the service limit, thedrum must be replaced.

Shift Drum Groove WidthStandard: 7.05 ∼ 7.20 mm (0.278 ∼ 0.283 in.)Service Limit: 7.3 mm (0.287 in.)

Gear Dog and Gear Dog Hole Damage

•Visually inspect the gear dogs [A] and gear dog holes [B].Replace any damaged gears or gears with excessivelyworn dogs or dog holes.

WHEELS/TIRES 10-1

10

Wheels/Tires

Table of Contents

Exploded View………………………………………………………………………………………………………… 10-2Specifications …………………………………………………………………………………………………………. 10-4Special Tools ………………………………………………………………………………………………………….. 10-5Wheels (Rims) ………………………………………………………………………………………………………… 10-6

Front Wheel Removal …………………………………………………………………………………………. 10-6Front Wheel Installation ………………………………………………………………………………………. 10-6Rear Wheel Removal………………………………………………………………………………………….. 10-7Rear Wheel Installation……………………………………………………………………………………….. 10-8Wheel Inspection ……………………………………………………………………………………………….. 10-9Axle Inspection…………………………………………………………………………………………………… 10-10Balance Inspection……………………………………………………………………………………………… 10-10Balance Adjustment ……………………………………………………………………………………………. 10-10Balance Weight Removal…………………………………………………………………………………….. 10-10Balance Weight Installation………………………………………………………………………………….. 10-11

Tires………………………………………………………………………………………………………………………. 10-12Air Pressure Inspection……………………………………………………………………………………….. 10-12Tire Inspection …………………………………………………………………………………………………… 10-12Tire Removal……………………………………………………………………………………………………… 10-12Tire Installation…………………………………………………………………………………………………… 10-12Tire Repair ………………………………………………………………………………………………………… 10-14

Hub Bearing……………………………………………………………………………………………………………. 10-15Hub Bearing Removal…………………………………………………………………………………………. 10-15Hub Bearing Installation………………………………………………………………………………………. 10-15Hub Bearing Inspection……………………………………………………………………………………….. 10-15

10-2 WHEELS/TIRES

Exploded View

WHEELS/TIRES 10-3

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Front axle clamp bolt 34 3.5 25

2 Front axle 108 11 80

3 Rear axle nut 108 11 80

G: Apply grease.R: Replacement Parts

WL: Apply soap and water solution or rubber lubricant.

10-4 WHEELS/TIRES

Specifications

Item Standard Service Limit

Wheels (Rims):

Rim runout: Axial – – – TIR 0.5 mm

(0.020 in.)

Radial – – – TIR 0.8 mm

(0.031 in.)

Axle runout/ TIR 0.05 mm (0.0020 in.) or less TIR 0.2 mm

100 mm (3.94 in.) (0.008 in.)

Wheel balance 10 g (0.35 oz.) or less – – –

Balance weights 10 g (0.35 oz.), 20 g (0.71 oz.), 30 g (1.06 oz.) – – –

Tires: Front 250 kPa – – –

Air pressure: (2.5 kgf/cm², 36 psi)

(when cold) RearUp to 180 kg (397 lb) load:

290 kPa – – –

(2.9 kgf/cm², 42 psi)

Tread depth: Front BRIDGESTONE 3.4 mm 1 mm

(0.13 in.) (0.04 in.)

1.6 mm

(0.06 in.)

(AT, CH, DE)

Rear BRIDGESTONE 5.8 mm Up to 130 km/h

(0.23 in.) (80 mph): 2 mm

(0.08 in.)

Over 130 km/h

(80 mph) : 3 mm

(0.12 in.)

Standard tires: Make, Type Size

Front BRIDGESTONE, BATTLAX BT-019F RADIAL E 120/70 ZR17

M/C (58 W)

Rear BRIDGESTONE, BATTLAX BT-012R RADIAL E 180/55 ZR17

M/C (73 W)

WARNINGUse the same manufacturer’s tires on both front and rear wheels.

AT: Republic of AustriaCH: Swiss ConfederationDE: Federal Republic of Germany

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

10-6 WHEELS/TIRES

Wheels (Rims)

Front Wheel Removal

•Remove:Brake Caliper Mounting Bolts [A]

• Loosen the front axle clamp bolt [A].• Remove the front axle [B].

• Raise the front wheel off the ground.Special Tool — Jack: 57001–1238

•Pull out the axle to the right and drop the front wheel outof the forks.

CAUTION

Do not lay the wheel down on one of the discs. Thiscan damage or warp the disc. Place blocks un-der the wheel so that the disc does not touch theground.

Front Wheel Installation

NOTEThe direction of the wheel rotation [A] is shown by anarrow [B] on the wheel spoke.

•Check the wheel rotation mark on the front wheel andinstall it.

• Fit the collars [A] on the both sides of the hub.

WHEELS/TIRES 10-7

Wheels (Rims)

•Tighten the front axle.Torque — Front Axle: 108 N·m (11 kgf·m, 80 ft·lb)

•Before tightening the clamp bolt on the right front fork leg,pump the front fork up and down 4 or 5 times to allow theright front fork leg to seat on the front axle.

NOTEPut a block in front of the front wheel to stop moving.

•Tighten the axle clamp bolt [A].Torque — Front Axle Clamp Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb)

• Install the front brake calipers (see Brakes chapter).• Check the front brake effectiveness (see Brakes chapter).

WARNINGDo not attempt to drive the motorcycle until a fullbrake lever is obtained by pumping the brake leveruntil the pads are against the disc. The brake willnot function on the first application of the lever ifthis is not done.

Rear Wheel Removal

•Using the stand [A], raise the rear wheel off the ground.

•Remove:Cotter Pin [A]Axle Nut [B]Axle [C]

10-8 WHEELS/TIRES

Wheels (Rims)

•Remove:Caliper Mounting Bolts [A]Caliper [B]

• Remove the drive chain [A] from the rear sprocket towardthe left.

•Move the rear wheel back and remove the wheel from therear caliper.

• Remove the rear wheel.CAUTION

Do not lay the wheel on the ground with the discfacing down. This can damage or warp the disc.Place blocks under the wheel so that the disc doesnot touch the ground.

Rear Wheel Installation

• Install the caliper bracket [A] onto the swingarm stop [B].• Engage the drive chain with the rear sprocket.• Insert the axle from the right side of the wheel, and tightenthe axle nut.

Torque — Rear Axle Nut: 108 N·m (11 kgf·m, 80 ft·lb)

• Insert a new cotter pin [A].NOTE

When inserting the cotter pin, if the slots in the nut donot align with the cotter pin hole in the axle, tighten thenut clockwise [B] up to next alignment.It should be within 30 degree.Loosen once and tighten again when the slot goes pastthe nearest hole.

WHEELS/TIRES 10-9

Wheels (Rims)

•Bend the cotter pin [A] over the nut.WARNING

If the rear axle nut is not securely tightened or thecotter pin is not installed, an unsafe riding condi-tion may result.

•Adjust the drive chain slack after installation (see FinalDrive chapter).

• Check the rear brake effectiveness.WARNING

Do not attempt to drive the motorcycle until a fullbrake pedal is obtained by pumping the brake pedaluntil the pads are against the disc. The brake willnot function on the first application of the pedal ifthis is not done.

Wheel Inspection

•Raise the front/rear wheel off the ground.Special Tool — Jack: 57001–1238

•Spin the wheel lightly, and check for roughness or binding.If roughness or binding is found, replace the hub bearings.

• Inspect the wheel for small cracks, dents, bending, orwarp.If there is any damage to the wheel, replace the wheel.

• Remove the wheel, and support it without the tire by theaxle.

•Measure the rim runout, radial [A] and axial [B], with a dialgauge.If rim runout exceeds the service limit, check the hub bear-ings.If the problem is not due to the bearings, replace thewheel.

Rim RunoutService Limit: Axial TIR 0.5 mm (0.020 in.)

Radial TIR 0.8 mm (0.031 in.)

WARNINGNever attempt to repair a damaged wheel. If thereis any damage besides wheel bearings, the wheelmust be replaced to insure safe operational condi-tion.

10-10 WHEELS/TIRES

Wheels (Rims)

Axle Inspection

•Remove the front and rear axles.• Visually inspect the front and rear axle for damages.If the axle is damaged or bent, replace it.

• Place the axle in V blocks that are 100 mm (3.94 in.) [A]apart, and set a dial gauge [B] on the axle at a pointhalfway between the blocks. Turn [C] the axle to mea-sure the runout. The difference between the highest andlowest dial readings is the amount of runout.If axle runout exceeds the service limit, replace the axle.

Axle Runout/100 mm (3.94 in.)Standard: TIR 0.05 mm (0.0020 in.) or less

Service Limit: TIR 0.2 mm (0.008 in.)

Balance Inspection

•Remove the wheel.• Support the wheel so that it can be spun freely.• Spin the wheel lightly, and mark [A] the wheel at the topwhen the wheel stops.Repeat this procedure several times. If the wheel stopsof its own accord in various positions, it is well balanced.If the wheel always stops in one position, adjust the wheelbalance.

Balance Adjustment

• If the wheel always stops in one position, provisionallyattach a balance weight [A] on the rim at themarking usingadhesive tape.

• Rotate the wheel 1/4 turn [B], and see whether or not thewheel stops in this position. If it does, the correct balanceweight is being used.If the wheel rotates and the weight goes up, replace theweight with the next heavier size. If the wheel rotates andthe weight goes down, replace the weight with the nextlighter size. Repeat these steps until the wheel remainsat rest after being rotated 1/4 turn.

• Rotate the wheel another 1/4 turn and then another 1/4turn to see if the wheel is correctly balanced.

• Repeat the entire procedure as many times as necessaryto achieve correct wheel balance.

• Permanently install the balance weight.Balance Weight Removal

• Insert a standard screwdrivers [A] [B] between the rib [C]and the weight [D] as shown.

• Pry the weight with two screwdrivers and remove the bal-ance weight.

WHEELS/TIRES 10-11

Wheels (Rims)

CAUTION

When removing the balance weight, do not touchthe brake disc. The disc could be damaged.Do not tap the screwdrivers. The rim could be dam-aged.

Balance Weight Installation

•Check if the weight portion has any play on the clip.If it does, discard it.

WARNINGIf the balance weight has any play on the rim, theclip of the weight have been stretched. Replace theloose balance weight.Do not reuse used balance weight.Unbalanced wheels can create an unsafe ridingcondition.

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.)

NOTEBalance weights are available from Kawasaki dealers in10, 20, and 30 grams (0.35, 0.71, and 1.06 oz.) sizes.An imbalance of less than 10 grams (0.35 oz.) will notusually affect running stability.Do not use four or more balance weight (more than 90gram, 3.17 oz.). If the wheel requires an excess bal-ance weight, disassemble the wheel to find the cause.

•Slip the balance weight [A] onto the rib [B] by pushing orlightly hammering [C] the clip [D].Left Side [E]Right Side [F]

CAUTION

When installing the balance weight, do not touchthe brake disc. The disc could be damaged.

•Check that the weight [A] and clip [B] are fully seated onthe rim [C] and that the clip is hooked over the rib [D].Left Side [E]Right Side [F]

WARNINGIf the balance weight has any play on the rim, theclip of the weight has been stretched. Replace theloose balance weight.Do not reuse balance weight.Unbalanced wheels can create an unsafe ridingcondition.

10-12 WHEELS/TIRES

Tires

Air Pressure Inspection

•Refer to the Air Pressure Inspection in the Periodic Main-tenance chapter.

Tire Inspection

•Refer to the Tire Wear Inspection in the Periodic Mainte-nance chapter.

Tire Removal

•Remove:Wheel (see Front Wheel Removal, Rear Wheel Re-moval)Disc(s)Valve Core (let out the air)

• To maintain wheel balance, mark the valve stem positionon the tire with chalk so that the tire can be reinstalled inthe same position.Chalk Mark or Yellow Mark [A]Air Valve [B]Align [C]

• Lubricate the tire beads and rim flanges on both sides witha soap and water solution or rubber lubricant. This helpsthe tire beads slip off the rim flanges.

CAUTION

Never lubricate with engine oil or petroleum distil-lates because they will deteriorate the tire.

•Remove the tire from the rim using a suitable commer-cially available tire changer.

NOTEThe tires cannot be removed with hand tools becausethey fit the rims too tightly.

Tire Installation

WARNINGUse the samemanufacturer’s tires on both front andrear wheels.

• Inspect the rim and tire, and replace them if necessary.• Clean the sealing surfaces of the rim and tire, and smooththe sealing surfaces of the rim with a fine emery cloth ifnecessary.

• Remove the air valve and discard it.CAUTION

Replace the air valve whenever the tire is replaced.Do not reuse the air valve.

WHEELS/TIRES 10-13

Tires

• Install a new valve in the rim.Remove the valve cap, lubricate the stem seal with a soapand water solution or rubber lubricant, and pull [B] thevalve stem [A] through the rim from the inside out until itsnaps into place.

CAUTION

Do not use engine oil or petroleum distillates to lu-bricate the stem because they will deteriorate therubber.

•Apply a soap and water solution, or rubber lubricant to therim flange and tire beads.

The air valve is shown in the figure.Valve Cap [A]Valve Core [B]Stem Seal [C]Valve Stem [D]Valve Seat [E]Valve Opened [F]

•Check the tire rotation mark on the front and rear tires andinstall them on the rim accordingly.Tire Rotation Mark [A]Rotation Direction [B]

• Position the tire on the rim so that the valve [A] align withthe tire balance mark [B] (the chalk mark made duringremoval, or the yellow paint mark on a new tire).

• Install the tire bead over the rim using a suitable commer-cially available tire changer.

• Lubricate the tire beads and rim flanges with a soap andwater solution or rubber lubricant to help seat the tirebeads in the sealing surfaces of the rim while inflating thetire.

•Center the rim in the tire beads, and inflate the tire withcompressed air until the tire beads seat in the sealingsurfaces.

WARNINGBe sure to install the valve core whenever inflatingthe tire, and do not inflate the tire to more than 400kPa (4.0 kgf/cm², 57 psi). Overinflation can explodethe tire with possibility of injury and loss of life.

10-14 WHEELS/TIRES

Tires

•Check to see that the rim lines [A] on both sides of the tiresidewalls 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 inflate the tire again.• After the tire beads seat in the rim flanges, check for airleakage.Inflate the tire slightly above standard inflation.Use a soap and water solution or submerge the tire, andcheck for bubbles that would indicate leakage.

• Adjust the air pressure to the specified pressure (see TireInspection).

• Install the brake disc(s) so that the marked side faces out(see Brakes chapter).

• Adjust the wheel balance (see Balance Adjustment).• Install the air valve cap.Tire RepairCurrently two types of repair for tubeless tires have come

into wide use. One type is called a temporary (external) re-pair which can be carried out without removing the tire fromthe rim, and the other type is called permanent (internal)repair which requires tire removal. It is generally under-stood that higher running durability is obtained by perma-nent (internal) repairs than by temporary (external) ones.Also, permanent (internal) repairs have the advantage ofpermitting a thorough examination for secondary damagenot visible from external inspection of the tire. For thesereasons, Kawasaki does not recommend temporary (exter-nal) repair. Only appropriate permanent (internal) repairsare recommended. Repair methods may vary slightly frommake to make. Follow the repair methods indicated by themanufacturer of the repair tools and materials so that saferesults can be obtained.

WHEELS/TIRES 10-15

Hub Bearing

Hub Bearing Removal

•Remove the wheel, and take out the following.CollarsCoupling (out of rear hub)Grease SealsCirclip

•Use the bearing remover to remove the hub bearings [A].CAUTION

Do not lay the wheel on the ground with the discfacing down. This can damage or warp the disc.Please blocks under the wheel so that the disc doesnot touch the ground.

Special Tools — Bearing Remover Head, 20 × 22:57001–1293 [C]

Bearing Remover Shaft, 13: 57001–1377[B]

Hub Bearing Installation

•Before installing the wheel bearings, blow any dirt or for-eign particles out of the hub with compressed air to pre-vent contamination of the bearings.

•Replace the bearings with new ones.NOTE

Install the bearings so that the marked side faces out.• Install the bearings by using the bearing driver set whichdoes not contact the bearing inner race.

• Press in each bearing [A] right until they are bottomed.Special Tool — Bearing Driver Set: 57001–1129 [B]

•Replace the circlip with a new one.•Replace the grease seals with new ones.• Press in the grease seals [A] so that the seal surface flush[B] with the end of the hole.Apply high temperature grease to the grease seal lips.Special Tool — Bearing Driver Set: 57001–1129 [C]

Hub Bearing InspectionSince the hub bearings are made to extremely close tol-

erances, the clearance can not normally be measured.

NOTEDo not remove any bearings for inspection. If any bear-ings are removed, they will need to be replaced withnew ones.

•Turn each bearing in the hub back and forth [A] whilechecking for plays, roughness, or binding.If bearing play, roughness, or binding is found, replacethe bearing.

• Examine the bearing seal [B] for tears or leakage.If the seal is torn or is leaking, replace the bearing.

FINAL DRIVE 11-1

11

Final Drive

Table of Contents

Exploded View………………………………………………………………………………………………………… 11-2Specifications …………………………………………………………………………………………………………. 11-4Special Tools ………………………………………………………………………………………………………….. 11-5Drive Chain…………………………………………………………………………………………………………….. 11-6

Drive Chain Slack Inspection ……………………………………………………………………………….. 11-6Drive Chain Slack Adjustment ……………………………………………………………………………… 11-6Drive Chain Wear Inspection ……………………………………………………………………………….. 11-6Drive Chain Lubrication……………………………………………………………………………………….. 11-6Drive Chain Removal ………………………………………………………………………………………….. 11-6Drive Chain Installation ……………………………………………………………………………………….. 11-6Drive Chain Replacement ……………………………………………………………………………………. 11-7

Sprocket, Coupling ………………………………………………………………………………………………….. 11-10Engine Sprocket Removal …………………………………………………………………………………… 11-10Engine Sprocket Installation ………………………………………………………………………………… 11-10Rear Sprocket Removal………………………………………………………………………………………. 11-11Rear Sprocket Installation……………………………………………………………………………………. 11-11Coupling Bearing Removal ………………………………………………………………………………….. 11-11Coupling Bearing Installation ……………………………………………………………………………….. 11-11Coupling Installation……………………………………………………………………………………………. 11-12Coupling Bearing Inspection ………………………………………………………………………………… 11-12Coupling Bearing Lubrication……………………………………………………………………………….. 11-12Coupling Damper Inspection………………………………………………………………………………… 11-12Sprocket Wear Inspection……………………………………………………………………………………. 11-13Rear Sprocket Warp Inspection ……………………………………………………………………………. 11-13

11-2 FINAL DRIVE

Exploded View

FINAL DRIVE 11-3

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Engine sprocket cover bolts 9.8 1.0 87 in·lb

2 Engine sprocket nut 125 13 92 MO

3 Rear sprocket nuts 59 6.0 43

4 Speed sensor cover bolts 6.9 0.70 61 in·lb L

5 Speed sensor bolt 6.9 0.70 61 in·lb L

6 Rear axle nut 108 11 80

G: Apply grease.HO: Apply heavy oil.L: Apply a non-permanent locking agent.

MO: Apply molybdenum disulfide oil.R: Replacement Parts

11-4 FINAL DRIVE

Specifications

Item Standard Service Limit

Drive Chain:

Chain slack 25 ∼ 35 mm (1.0 ∼ 1.4 in.) – – –

20-link length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.)

Standard chain

Make ENUMA – – –

Type EK520MVXL – – –

Link 112 links – – –

Sprockets:

Rear sprocket warp 0.4 mm (0.016 in.) or less 0.5 mm (0.020 in.)

FINAL DRIVE 11-5

Special Tools

Bearing Driver Set:57001–1129

Jack:57001–1238

11-6 FINAL DRIVE

Drive Chain

Drive Chain Slack Inspection

•Refer to the Drive Chain Slack Inspection in the PeriodicMaintenance chapter.

Drive Chain Slack Adjustment

•Refer to the Drive Chain Slack Adjustment in the PeriodicMaintenance chapter.

Drive Chain Wear Inspection

•Refer to the Drive Chain Wear Inspection in the PeriodicMaintenance chapter.

Drive Chain Lubrication

•Refer to the Drive Chain Lubrication in the Periodic Main-tenance chapter.

Drive Chain Removal

•Remove:Rear Wheel (see Wheels/Tires chapter)Chain Cover Screws [A]Chain Cover [B]Mud Guard [C] (see Frame chapter)Swingarm (see Suspension chapter)Engine Sprocket Cover (see this chapter)

• Disengage the drive chain [A] from the engine sprocket[B], and take it off the chassis.

Drive Chain Installation

•Engage the drive chain to the engine sprocket.• Install:Swingarm (see Suspension chapter)Rear Wheel (see Wheels/Tires chapter)Engine Sprocket Cover (see this chapter)Mud Guard (see Frame chapter)Chain Cover

• Adjust the chain slack after installing the chain (see DriveChain Slack Adjustment).

FINAL DRIVE 11-7

Drive Chain

Drive Chain Replacement

•Remove:Chain Cover (see Drive Chain Removal)Engine Sprocket Cover (see Engine Sprocket Removal)

EK JOINT TOOL #50Body [A]Handlebar [B]Cutting & Riveting Pin [C]For Cutting [D]For Riveting [E]Plate Holder (A) [F]Plate Holder (B) [G]Gauge [H]

•Grind [A] pin head to make it flat.• Set cutting & riveting pin [B] as shown.

• Screw pin holder until it touches chain pin.• Be sure that cutting pin hits center of chain pin.

• Screw handlebar [A] into body.• Turn pin holder with wrench [B] clockwise to extract chainpin.

11-8 FINAL DRIVE

Drive Chain

•Replace the link pin, link plate and grease seals.• Apply grease to the link pins [A] and grease seals [B] [C].• Engage the drive chain on the engine and rear sprockets.• Insert the link pins in the drive chain ends.• Install the grease seals [C].• Install the link plate so that the mark [D] faces out.• Push link plate by hand or plier to fix it.• In case of O-ring chain, be sure to set O-rings correctly.

• Set plate holder (A) [A] and plate holder (B) [B] on thebody.

• Fit plate holder (A) to link plate.• Turn pin holder by hand until plate holder (B) touches theother link plate.

• Turn pin holder by wrench clockwise until two pins of linkcome into groove of plate holder (A).

• Take off plate holder.

• Set plate holder (B) [A] and cutting & riveting pin [B] asshown.

FINAL DRIVE 11-9

Drive Chain

•Turn pin holder until riveting pin touches link pin.

• Turn wrench clockwise until tip of riveting pin hits of linkpin.

•Rivet it.• Some work for the other link pin.

• After staking, check the staked area of the link pin forcracks.

•Measure the outside diameter [A] of the link pin and linkplates width [B].

Link Pin Outside DiameterStandard: 5.6 ∼ 6.0 mm (0.22 ∼ 0.24 in.)

Link Plates Outside WidthStandard: 17.45 ∼ 17.60 mm (0.687 ∼ 0.693 in.)

If the reading exceeds the specified length, cut and rejointhe chain again.

•Check:Movement of the RollersChain Slack

11-10 FINAL DRIVE

Sprocket, Coupling

Engine Sprocket Removal

•Remove:Speed Sensor Connector [A]Engine Sprocket Cover Bolts [B]Engine Sprocket Cover [C] with Speed Sensor

• Flatten out the bended washer [A].• Remove the engine sprocket nut [B] and washer.

NOTEWhen loosening the engine sprocket nut, hold the rearbrake on.

•Using the jack, raise the rear wheel off the ground.Special Tool — Jack : 57001–1238

• Loosen the drive chain (see Slack Adjustment).• Remove the drive chain from the rear sprocket toward theright.

• Disengage the drive chain [A] from the engine sprocket[B].

• Pull the engine sprocket off the output shaft [C].

Engine Sprocket Installation

•Replace the sprocket washer and axle cotter pin.• Install the engine sprocket so that “OUTSIDE” letters [A]face outward.

• Apply molybdenum disulfide oil to the threads of the out-put shaft and the seating surface of the engine sprocketnut.

• After torquing the engine sprocket nut, bend the one sideof the washer over the nut.

NOTETighten the nut while applying the rear brake.• Tighten:Torque — Engine Sprocket Nut: 125 N·m (13 kgf·m, 92 ft·lb)

Engine Sprocket Cover Bolts: 9.8 N·m (1.0 kgf·m,87 in·lb)

•Adjust the drive chain slack after installing the sprocket(see Drive Chain Slack Adjustment in the Periodic Main-tenance chapter).

FINAL DRIVE 11-11

Sprocket, Coupling

Rear Sprocket Removal

•Remove the rear wheel (see Wheels/Tires chapter).CAUTION

Do not lay the wheel on the ground with the discfacing down. This can damage or warp the disc.Place blocks under the wheel so that the disc doesnot touch the ground.

•Remove the rear sprocket nuts [A].•Remove the rear sprocket [B].Rear Sprocket Installation

• Install the sprocket facing the tooth number marking [A]outward.

• Tighten the rear sprocket nuts.Torque — Rear Sprocket Nuts: 59 N·m (6.0 kgf·m, 43 ft·lb)

• Install the rear wheel (see Wheels/Tires chapter).

Coupling Bearing Removal

•Remove:CouplingGrease SealCirclip [A]

•Remove the bearing [A] by tapping from the wheel side.Special Tool — Bearing Driver Set: 57001–1129 [B]

Coupling Bearing Installation

•Replace the bearing with a new one.• Press in the bearing [A] until it is bottomed.Special Tool — Bearing Driver Set: 57001–1129 [B]

•Pack the bearing with high temperature grease.•Replace the circlip with a new one.

11-12 FINAL DRIVE

Sprocket, Coupling

•Replace the grease seal with a new one.• Press in the grease seal so that the seal surface is flushwith the end of the hole.Apply high temperature grease to the grease seal lips.Special Tool — Bearing Driver Set: 57001–1129

Coupling Installation

•Grease the following and install the coupling.Coupling Grease Seal [A]Coupling Internal Surface [B]Ball Bearing [C]

Coupling Bearing InspectionSince the coupling bearing is made to extremely close

tolerances, the clearance can not normally be measured.

NOTEIt is not necessary to remove the coupling bearing forinspection. If the bearing is removed, it will need to bereplaced with a new one.

•Spin [A] it by hand to check its condition.If it is noisy, does not spin smoothly, or has any roughspots, it must be replaced.

Coupling Bearing Lubrication

•Pack the bearing with good quality bearing grease. Turnthe bearing around by hand a few times to make sure thegrease is distributed uniformly inside the bearing.

Coupling Damper Inspection

•Remove the rear wheel coupling, and inspect the rubberdampers [A].

• Replace the damper if it appears damaged or deterio-rated.

FINAL DRIVE 11-13

Sprocket, Coupling

Sprocket Wear Inspection

•Visually inspect the engine and rear sprocket teeth forwear and damage.If the teeth are worn as illustrated, replace the sprocket,and inspect the drive chain wear (see Drive Chain WearInspection).Worn Tooth (Engine Sprocket) [A]Worn Tooth (Rear Sprocket) [B]Direction of Rotation [C]

NOTEIf a sprocket requires replacement, the chain is proba-bly worn also. When replacing a sprocket, inspect thechain.

Rear Sprocket Warp Inspection

•Raise the rear wheel off the ground (see Wheels/Tireschapter) so that it will turn freely.

• Set a dial gauge [A] against the rear sprocket [B] near theteeth as shown, and rotate [C] the rear wheel to measurethe sprocket runout (warp). The difference between thehighest and lowest dial gauge readings is the amount ofrunout (warp).If the runout exceeds the service limit, replace the rearsprocket.

Rear Sprocket WarpStandard: 0.4 mm (0.016 in.) or less

Service Limit: 0.5 mm (0.020 in.)

BRAKES 12-1

12

Brakes

Table of Contents

Exploded View…………………………….. 12-2Specifications ……………………………… 12-6Special Tool ………………………………… 12-7Brake Lever, Brake Pedal……………… 12-8

Brake Lever Position Adjustment. 12-8Brake Pedal Position Inspection .. 12-8Brake Pedal Position Adjustment. 12-8

Calipers ……………………………………… 12-9Front Caliper Removal …………….. 12-9Rear Caliper Removal……………… 12-9Caliper Installation ………………….. 12-9Front Caliper Disassembly……….. 12-10Front Caliper Assembly……………. 12-10Rear Caliper Disassembly ……….. 12-11Rear Caliper Assembly ……………. 12-12Caliper Fluid Seal Damage………. 12-12Caliper Dust Seal/Friction BootDamage………………………………. 12-12

Caliper Piston and CylinderDamage………………………………. 12-13

Caliper Holder Shaft Wear ……….. 12-13Brake Pads…………………………………. 12-14

Front Brake Pad Removal………… 12-14Front Brake Pad Installation……… 12-14Rear Brake Pad Removal ………… 12-14Rear Brake Pad Installation ……… 12-14

Brake Pad Wear Inspection ……… 12-14Master Cylinder …………………………… 12-15

Front Master Cylinder Removal … 12-15Front Master Cylinder Installation 12-15Rear Master Cylinder Removal…. 12-16Rear Master Cylinder Installation. 12-16Front Master CylinderDisassembly………………………… 12-16

Rear Master CylinderDisassembly………………………… 12-17

Master Cylinder Assembly ……….. 12-17Master Cylinder Inspection (VisualInspection)…………………………… 12-17

Brake Disc ………………………………….. 12-18Brake Disc Removal ……………….. 12-18Brake Disc Installation …………….. 12-18Brake Disc Wear …………………….. 12-18Brake Disc Warp …………………….. 12-18

Brake Fluid …………………………………. 12-19Brake Fluid Level Inspection…….. 12-19Brake Fluid Change ………………… 12-19Brake Line Bleeding………………… 12-19

Brake Hose…………………………………. 12-20Brake Hose Removal/Installation. 12-20Brake Hose Inspection…………….. 12-20

12-2 BRAKES

Exploded View

BRAKES 12-3

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Front caliper mounting bolts 34 3.5 25

2 Brake hose banjo bolts 25 2.5 18

3 Bleed valve 7.8 0.80 69 in·lb

4 Brake lever pivot bolt 1.0 0.10 9 in·lb Si

5 Brake lever pivot bolt locknut 5.9 0.60 52 in·lb

6 Front brake disc mounting bolts 27 2.8 20 L

7 Front brake light switch screws 1.0 0.10 9 in·lb

8 Front brake reservoir cap screws 1.0 0.10 9 in·lb

9 Front master cylinder clamp bolts 8.8 0.90 78 in·lb S

B: Apply brake fluid.L: Apply a non-permanent locking agent.R: Replacement PartsS: Follow the specific tightening sequence.Si: Apply silicone grease (ex. PBC grease).

12-4 BRAKES

Exploded View

BRAKES 12-5

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Rear master cylinder push rod locknut 18 1.8 13

2 Rear caliper mounting bolts 25 2.5 18

3 Brake hose banjo bolts 25 2.5 18

4 Bleed valve 7.8 0.80 69 in·lb

5 Rear master cylinder mounting bolts 25 2.5 18

6 Rear brake disc mounting bolts 27 2.8 20 L

B: Apply brake fluid.G: Apply grease.L: Apply a non-permanent locking agent.R: Replacement PartsSi: Apply silicone grease (ex. PBC grease).

12-6 BRAKES

Specifications

Item Standard Service Limit

Brake Lever, Brake Pedal:

Brake lever position 5-way adjustable (to suit rider) – – –

Brake lever free play Non-adjustable – – –

Pedal free play Non-adjustable – – –

Pedal position About 47 mm (1.85 in.) below footpeg top – – –

Brake Fluid:

Grade DOT4 – – –

Brake Pads:

Lining thickness:

Front 4.5 mm (0.18 in.) 1 mm (0.04 in.)

Rear 5 mm (0.20 in.) 1 mm (0.04 in.)

Brake Discs:

Thickness:

Front 4.3 ∼ 4.5 mm (0.17 ∼ 0.18 in.) 4.0 mm (0.16 in.)

Rear 4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.) 4.5 mm (0.18 in.)

Runout Not more than 0.2 mm (0.008 in.) 0.3 mm (0.012 in.)

BRAKES 12-7

Special Tool

Jack:57001–1238

12-8 BRAKES

Brake Lever, Brake Pedal

Brake Lever Position AdjustmentThe 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 alignthe number with the arrow mark [B] on the lever holder.The distance from the grip to the lever is minimum at num-ber 5 and maximum at number 1.

Brake Pedal Position Inspection

•Check that the brake pedal [A] is in the correct position.Footpeg [B]

Pedal PositionStandard: About 47 mm (1.85 in.) [C] below top of

footpeg

If it is incorrect, adjust the brake pedal position.

Brake Pedal Position Adjustment

NOTEUsually it is not necessary to adjust the pedal position,but always adjust it when the push rod locknut has beenloosened.

•Remove the bolts [A] and remove the guard bracket [B].

• Loosen the locknut [A] and turn the push rod with the hexhead [B] to achieve the correct pedal position.If the length [C] shown is 70 ±1 mm (2.76 ±0.04 in.), thepedal position will be within the standard range.

• Tighten:Torque — Rear Master Cylinder Push Rod Locknut:

18 N·m (1.8 kgf·m, 13 ft·lb)

•Check the brake light switch operation (see Brakes in thePeriodic Maintenance chapter).

BRAKES 12-9

Calipers

Front Caliper Removal

•Loosen the banjo bolt [A] at the brake hose lower end,and tighten it loosely.

•Unscrew the caliper mounting bolts [B], and detach thecaliper [C] from the disc.

•Unscrew the banjo bolt and remove the brake hoses [D]from the caliper (see Brake Hose Removal/Installation).

CAUTION

Immediately wash away any brake fluid that spills.

NOTEAfter the caliper removal, if compressed air will not beavailable for disassembling the caliper, remove the pis-ton before detaching the brake hose (see Front CaliperDisassembly).

Rear Caliper Removal

•Loosen the banjo bolt [A] at the brake hose lower end,and tighten it loosely.

•Unscrew the caliper mounting bolts [B], and detach thecaliper [C] from the disc.

•Unscrew the banjo bolt and remove the brake hose [D]from the caliper (see Brake Hose Removal/Installation).

CAUTION

Immediately wash away any brake fluid that spills.

NOTEAfter the caliper removal, if compressed air will not beavailable for disassembling the caliper, remove the pis-ton before detaching the brake hose (see Rear CaliperDisassembly).

Caliper Installation

• Install the caliper and brake hose lower end.Replace the washers on each side of hose fitting with newones.

• Tighten:Torque — Caliper Mounting Bolts (Front): 34 N·m (3.5 kgf·m,

25 ft·lb)Caliper Mounting Bolts (Rear): 25 N·m (2.5 kgf·m,18 ft·lb)

Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

•Check the fluid level in the brake reservoirs.• Bleed the brake line (see Bleeding the Brake Line).•Check the brake for good braking power, no brake drag,and no fluid leakage.

WARNINGDo not attempt to drive the motorcycle until a fullbrake lever or pedal is obtained by pumping thebrake lever or pedal until the pads are against thedisc. The brakes will not function on the first appli-cation of the lever or pedal if this is not done.

12-10 BRAKES

Calipers

Front Caliper Disassembly

•Remove:Front Caliper (see Caliper Removal)Brake Pads and Springs (see Brake Pad Removal)

• Using compressed air, remove the pistons.Cover the piston area with a clean, thick cloth [A].Blow compressed air [B] into the hole for the banjo bolt toremove the piston.

WARNINGTo avoid serious injury, never place your fingers orpalm in front of the piston. If you apply compressedair into the caliper, the piston may crush your handor fingers.

Pull out the pistons by hand.• Remove the dust seals [A] and fluid seals [B].• Remove the bleed valve [C] and rubber cap [D].

NOTEIf compressed air is not available, with the brake hosestill attached, apply the brake lever to remove the pis-ton. The remaining process is as described above.

Front Caliper Assembly

•Clean the caliper parts except for the pads.CAUTION

For cleaning the parts, use only disc brake fluid,isopropyl alcohol, or ethyl alcohol.

• Install the bleed valve and rubber cap.Torque — Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

BRAKES 12-11

Calipers

•Replace the fluid seals [A] with new ones.Apply brake fluid to the fluid seals, and install them intothe cylinders by hand.

•Replace the dust seals [B] with new ones if they are dam-aged.Apply brake fluid to the dust seals, and install them intothe cylinders by hand.

• Apply brake fluid to the outside of the pistons, and pushthem into each cylinder by hand.

•Check the shaft rubber friction boot [A] and the dust cover[B] replace them with new ones if they are damaged.

• Apply a thin coat of PBC (Poly Butyl Cuprysil) grease tothe caliper holder shafts [C] and holder holes [D] (PBC isa special high temperature, water-resistance grease).

• Install the anti-rattle spring [A].• Install the pads (see Front Brake Pad Installation).•Wipe up any spilled brake fluid on the caliper with wetcloth.

Rear Caliper Disassembly

•Remove the rear caliper.•Remove the pads and anti-rattle spring (see Rear BrakePad Removal).

• Using compressed air, remove the piston.Cover the piston area with a clean, thick cloth [B].Blow compressed air [A] into the hole for the banjo bolt toremove the piston.

WARNINGTo avoid serious injury, never place your fingers orpalm inside the caliper opening. If you apply com-pressed air into the caliper, the piston may crushyour hand or fingers.

•Remove the dust seal and fluid seal.• Remove the bleed valve and rubber cap.

NOTEIf compressed air is not available, with the brake hosestill attached, apply the brake pedal to remove the pis-ton. The remaining process is as described above.

12-12 BRAKES

Calipers

Rear Caliper Assembly

•Clean the caliper parts except for the pads.CAUTION

For cleaning the parts, use only disc brake fluid,isopropyl alcohol, or ethyl alcohol.

• Install the bleed valve and rubber cap.Torque — Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

•Replace the fluid seal [A] with a new one.Apply brake fluid to the fluid seal, and install it into thecylinder by hand.

• Replace the dust seal [B] with a new one if it is damaged.Apply brake fluid to the dust seal, and install it into thecylinder by hand.

• Apply brake fluid to the outside of the piston, and push itinto the cylinder by hand.

• Replace the shaft rubber friction boot [A] and dust cover[B] if they are damaged.

• Apply a thin coat of PBC (Poly Butyl Cuprysil) grease tothe caliper holder shafts [C] and holder holes [D] (PBC isa special high temperature, water-resistance grease).

• Install the anti-rattle spring [A] in the caliper as shown.• Install the pads (see Rear Brake Pad Installation).•Wipe up any spilled brake fluid on the caliper with wetcloth.

Caliper Fluid Seal Damage

•Refer to the Brakes in the Periodic Maintenance chapter.Caliper Dust Seal/Friction Boot Damage

•Refer to the Brakes in the Periodic Maintenance chapter.

BRAKES 12-13

Calipers

Caliper Piston and Cylinder Damage

•Visually inspect the piston [E] and cylinder surfaces.Replace the caliper if the cylinder and piston are badlyscores or rusty.Fluid Seal [A]Dust Seal [B]Rubber Boot [C]Front Caliper [J]Rear Caliper [K]

Caliper Holder Shaft WearThe caliper bodymust slide smoothly on the caliper holder

shaft [F]. If the body does not slide smoothly, one pad willwear more than the other, pad wear will increase, and con-stant drag on the disc will raise brake and brake fluid tem-perature.

•Check to see that the caliper holder shaft are not badlyworn or stepped, and that the rubber friction boots [D] arenot damaged.If the rubber friction boot is damaged, replace the rubberfriction boot. To replace the friction boot, remove the padsand the caliper bracket.If the caliper holder shaft is damage, replace the caliperbracket.

12-14 BRAKES

Brake Pads

Front Brake Pad Removal

•Remove the caliper from the disc.

• Draw out the holder shaft pin [A], and take off the holdershaft [B].

• Remove the pad [C] on the piston side.• Push the holder [D] towards the piston, and remove thepad of the other side [E] from the holder shaft [F].

Front Brake Pad Installation

•Push the caliper pistons in by hand as far as they will go.• Install the anti-rattle spring in its correct position.• Install the pad on the piston side first, then install the otherpad on the holder.

• Install the caliper (see Caliper Installation).WARNING

Do not attempt to drive the motorcycle until a fullbrake lever is obtained by pumping the brake leveruntil the pads are against the disc. The brake willnot function on the first application of the lever ifthis is not done.

Rear Brake Pad Removal

•Remove the caliper with the hose installed.• Draw out the holder shaft pin [A], and take off the holdershaft [B].

• Remove the pad [C] on the piston side.• Push the holder [D] towards the piston, and remove thepad of the other side [E] from the holder shaft [F].

Rear Brake Pad Installation

•Push the caliper piston in by hand as far as it will go.• Install the anti-rattle spring in its correct position.• Install the pad on the piston side first, then install the otherpad on the holder.

• Install the caliper (see Caliper Installation).WARNING

Do not attempt to drive the motorcycle until a fullbrake pedal is obtained by pumping the brake pedaluntil the pads are against the disc. The brake willnot function on the first application of the pedal ifthis is not done.

Brake Pad Wear Inspection

•Refer to the Brakes in the Periodic Maintenance chapter.

BRAKES 12-15

Master Cylinder

Front Master Cylinder Removal

•Disconnect the front brake light switch connectors [A].•Remove the banjo bolt [B] to disconnect the brake hosefrom themaster cylinder [C] (see Brake Hose Removal/In-stallation).

•Unscrew the clamp bolts [A], and take off the master cylin-der as an assembly with the reservoir, brake lever, andbrake switch installed.

Front Master Cylinder Installation

• Install the front master cylinder so that the punch mark [A]of the handlebar is aligned with the mating surface [B] ofthe master cylinder clamp to level the reservoir.

• The master cylinder clamp must be installed with the ar-row mark [A] upward.

• Tighten the upper clamp bolt [B] first, and then the lowerclamp bolt [C]. There will be a gap at the lower part of theclamp after tightening.

Torque — Front Master Cylinder Clamp Bolts: 8.8 N·m (0.90kgf·m, 78 in·lb)

•Replace the washers on each side of the hose fitting withnew ones.

• Tighten the brake hose banjo bolt.Torque — Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

•Bleed the brake line (see Brake Line Bleeding in the Pe-riodic Maintenance chapter).

• Check the brake for good braking power, no brake drag,and no fluid leakage.

12-16 BRAKES

Master Cylinder

Rear Master Cylinder Removal

•Unscrew the brake hose banjo bolt [A] on themaster cylin-der (see Brake Hose Removal/Installation).

• Pull off the reservoir hose lower end [B], and drain thebrake fluid into a container.

• Loosen the master cylinder mounting bolts [C] lightly.• Remove the cotter pin [D].

NOTEPull off the joint pin while pressing down the brakepedal.

•Unscrew the master cylinder mounting bolts, and removethe master cylinder.

Rear Master Cylinder Installation

•Replace the cotter pin [A] with a new one.• Replace the washers on each side of hose fitting with newones.

• Tighten the following bolts.Torque — Rear Master Cylinder Mounting Bolts: 25 N·m (2.5

kgf·m, 18 ft·lb)Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

•Bleed the brake line (see Brakes in the Periodic Mainte-nance chapter).

• Check the brake for good braking power, no brake drag,and no fluid leakage.

Front Master Cylinder Disassembly

•Remove the frontmaster cylinder (see Front Master Cylin-der Removal).

• Remove the reservoir cap and diaphragm, and pour thebrake fluid into a container.

• Unscrew the locknut and pivot bolt, and remove the brakelever.

• Pull the dust cover [A] out of place, and remove the circlip[B].

• Pull out the piston [C], secondary cup [D], primary cup [E],and return spring [F].

CAUTION

Do not remove the secondary cup from the pistonsince removal will damage it.

BRAKES 12-17

Master Cylinder

Rear Master Cylinder Disassembly

NOTEDo not remove the push rod clevis for master cylinderdisassembly since removal requires brake position ad-justment.

•Remove the rear master cylinder (see Rear Master Cylin-der Removal).

• Slide the dust cover on the push rod out of place, andremove the circlip.

• Pull out the push rod with the piston stop.• Take off the piston [A], secondary cup [B], primary cup [C],and return spring [D].

CAUTION

Do not remove the secondary cup from the pistonsince removal will damage it.

Master Cylinder Assembly

•Before assembly, clean all parts including the mastercylinder with brake fluid or alcohol.

CAUTION

Except for the disc pads and disc, use only discbrake fluid, isopropyl alcohol, or ethyl alcohol forcleaning of the brake parts. Do not use any otherfluid for cleaning these parts, Gasoline, engine oil,or any other petroleum distillate will cause deterio-ration of the rubber parts. Oil spilled on any part willbe difficult to wash off completely, and will eventu-ally deteriorate the rubber used in the disc brake.

•Apply brake fluid to the removed parts and to the innerwall of the cylinder.

• Take care not to scratch the piston or the inner wall of thecylinder.

• Apply silicone grease (ex. PBC grease).Brake Lever Pivot BoltBrake Lever Pivot ContactPush Rod ContactDust Covers

• Tighten:Torque — Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 9

in·lb)Brake Lever Pivot Bolt Locknut: 5.9 N·m (0.60kgf·m, 52 in·lb)

Master Cylinder Inspection (Visual Inspection)

•Refer to the Brakes in the Periodic Maintenance chapter.

12-18 BRAKES

Brake Disc

Brake Disc Removal

•Remove the wheel (see Wheels/Tires chapter).• Unscrew the mounting bolts, and take off the disc.Brake Disc Installation

• Install the brake disc on the wheel so that the marked side[A] faces out.

• Apply a non-permanent locking agent to the threads ofthe front and rear brake disc mounting bolts [B].

• Tighten:Torque — Brake Disc Mounting Bolts: 27 N·m (2.8 kgf·m, 20

ft·lb)

Brake Disc Wear

•Measure the thickness of each disc [A] at the point whereit has worn the most.If the disk has worn past the service limit, replace it.Measuring Area [B]

Front Disc ThicknessStandard: 4.3 ∼ 4.5 mm (0.17 ∼ 0.18 in.)Service Limit: 4.0 mm (0.16 in.)

Rear Disc ThicknessStandard: 4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.)Service Limit: 4.5 mm (0.18 in.)

Brake Disc Warp

• Jack up the motorcycle so that the wheel is off the ground(see Wheels/Tires chapter).

Special Tool — Jack: 57001–1238

For front disc inspection, turn the handlebar fully to oneside.

• Set up a dial gauge against the disc [A] as shown andmeasure disc runout, while turning [B] the wheel by hand.If runout exceeds the service limit, replace the disc.

Disc RunoutStandard: Not more than 0.2 mm (0.008 in.)

Service Limit: 0.3 mm (0.012 in.)

Special Tool — Jack: 57001–1238

BRAKES 12-19

Brake Fluid

Brake Fluid Level Inspection

•Refer to the Brakes in the Periodic Maintenance chapter.Brake Fluid Change

•Refer to the Brakes in the Periodic Maintenance chapter.Brake Line Bleeding

•Refer to the Brakes in the Periodic Maintenance chapter.

12-20 BRAKES

Brake Hose

Brake Hose Removal/Installation

CAUTION

Brake fluid quickly ruins painted or plastic sur-faces; any spilled fluid should be completely wipedup immediately with wet cloth.

•When removing the brake hose, take care not to spill thebrake fluid on the painted or plastic parts.

•When removing the brake hose, temporarily secure theend of the brake hose to some high place to keep fluidloss to a minimum.

• There are washers on each side of the brake hose fitting.Replace them with new ones when installing.

•When installing the hoses, avoid sharp bending, kinking,flattening or twisting, and route the hoses according toCable, Wire and Hose Routing section in General Infor-mation chapter.

• Tighten:Torque — Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18

ft·lb)

•Bleed the brake line after installing the brake hose (seeBrakes in the Periodic Maintenance chapter).

Brake Hose Inspection

•Refer to the Brakes in the Periodic Maintenance chapter.

SUSPENSION 13-1

13

Suspension

Table of Contents

Exploded View………………………………………………………………………………………………………… 13-2Specifications …………………………………………………………………………………………………………. 13-6Special Tools ………………………………………………………………………………………………………….. 13-7Front Fork ………………………………………………………………………………………………………………. 13-8

Front Fork Removal ……………………………………………………………………………………………. 13-8Front Fork Installation …………………………………………………………………………………………. 13-8Front Fork Oil Change ………………………………………………………………………………………… 13-8Front Fork Disassembly ………………………………………………………………………………………. 13-9Front Fork Assembly…………………………………………………………………………………………… 13-11Inner Tube/Outer Tube Inspection ………………………………………………………………………… 13-12Dust Seal Inspection …………………………………………………………………………………………… 13-12Fork Spring Inspection ………………………………………………………………………………………… 13-12

Rear Shock Absorber ………………………………………………………………………………………………. 13-13Rebound Damping Force Adjustment……………………………………………………………………. 13-13Spring Preload Adjustment ………………………………………………………………………………….. 13-13Rear Shock Absorber Removal ……………………………………………………………………………. 13-13Rear Shock Absorber Installation …………………………………………………………………………. 13-14Rear Shock Absorber Inspection ………………………………………………………………………….. 13-14

Swingarm……………………………………………………………………………………………………………….. 13-15Swingarm Removal…………………………………………………………………………………………….. 13-15Swingarm Installation………………………………………………………………………………………….. 13-16Swingarm Bearing Removal ………………………………………………………………………………… 13-16Swingarm Bearing Installation ……………………………………………………………………………… 13-17Swingarm Bearing, Sleeve Inspection …………………………………………………………………… 13-17Chain Guide Inspection……………………………………………………………………………………….. 13-17

Tie-rod, Rocker Arm ………………………………………………………………………………………………… 13-18Tie-rod Removal ………………………………………………………………………………………………… 13-18Tie-rod Installation ……………………………………………………………………………………………… 13-18Rocker Arm Removal………………………………………………………………………………………….. 13-18Rocker Arm Installation……………………………………………………………………………………….. 13-18Rocker Arm/Tie-rod Bearing, Sleeve Inspection……………………………………………………… 13-19

13-2 SUSPENSION

Exploded View

SUSPENSION 13-3

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Front fork clamp bolts (Upper) 20 2.0 14

2 Front fork clamp bolts (Lower) 20 2.0 14 AL

3 Front fork top plugs 25 2.5 18

4 Front fork bottom Allen bolts 30 3.1 22 L

5 Front axle clamp bolt 34 3.5 25

6. Right fork leg7. Left fork legAL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.L: Apply a non-permanent locking agent.R: Replacement Parts

13-4 SUSPENSION

Exploded View

SUSPENSION 13-5

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Rear shock absorber nuts (upper and lower) 34 3.5 25

2 Swingarm pivot shaft nut 108 11 80

3 Swingarm pivot shaft locknut 98 10 72

4 Rocker arm nut 34 3.5 25

5 Tie-rod bolts 59 6.0 43

13-6 SUSPENSION

Specifications

Item Standard

Front Fork (per one unit):

Fork inner tube outside diameter 41 mm (1.61 in.)

Air Pressure Atmospheric pressure (Non-adjustable)

Fork spring setting Non-adjustable

Damper setting Non-adjustable

Fork oil viscosity KAYABA KHL34-G10

Fork oil capacity 452 ±4 mL (15.28 ±0.135 US oz.) (completely dry)

approx. 385 mL (13.01 US oz.) (when changing oil)

Fork oil level 115 ±2 mm (4.53 ±0.08 in.) below from inner tube topwith fully compressed, without fork spring

Fork spring free length 277.2 mm (10.91 in.) (Service limit 272 mm (10.71 in.))

Rear Shock Absorber:

Rebound damping force Number 2 (Adjustable Range: Number 1 ∼ 4)Spring preload 4th position (Adjustable Range: 1st ∼ 7th position)Gas pressure 980 kPa (10 kgf/cm², 142 psi, Non-adjustable)

SUSPENSION 13-7

Special Tools

Fork Cylinder Holder Handle:57001–183

Fork Cylinder Holder Adapter:57001–1057

Oil Seal & Bearing Remover:57001–1058

Bearing Driver Set:57001–1129

Jack:57001–1238

Fork Oil Seal Driver:57001–1288

Fork Oil Level Gauge:57001–1290

Hook Wrench:57001–1539

Swingarm pivot Nut Wrench:57001–1541

13-8 SUSPENSION

Front Fork

Front Fork Removal

•Remove:Front Wheel (see Tires/Wheels chapter)Front Fender (see Frame chapter)Fairing (see Frame chapter)Loosen the handlebar bolt, upper fork clamp bolt and forktop plug before-hand if the fork leg is to be disassembled.

NOTELoosen the top plug after loosening the upper forkclamp bolt.

• Loosen the upper fork clamp bolt and lower fork clampbolts [A].

•With a twisting motion, work the fork leg down and out.Front Fork Installation

• Install the fork with the upper end of the inner tube flush[A] against the top surface of the stem head [B].

• Tighten:Torque — Front Fork Clamp Bolts (Lower): 20 N·m (2.0

kgf·m, 14 ft·lb)Front Fork Top Plug: 25 N·m (2.5 kgf·m, 18 ft·lb)

NOTETighten the top plug before tightening the upper forkclamp bolt.Tighten the two clamp bolts alternately two times to en-sure even tightening torque.

• Tighten:Torque — Front Fork Clamp Bolt (Upper): 20 N·m (2.0 kgf·m,

14 ft·lb)

• Install the removed parts (see appropriate chapters).Front Fork Oil Change

•Remove the front fork (see Front Fork Removal).• Remove:Top Plug [A]Collar [B]Fork Spring Seat [C]Fork Spring [D]

• Compress [B] the fork [A] upside down to draw out the oilinto the suitable container [C].

• Pour in the specified amount of oil.Fork Oil Viscosity: KAYABA KHL34–G10

Capacity (when changingoil):

385 mL (13.01 US oz.)

NOTEMove the outer tube up and down a few times to removethe air that is trapped in the fork oil in order to stabilizethe oil level.

SUSPENSION 13-9

Front Fork

•Hold the outer tube vertically in a vise and compress thefork completely.

•Wait until the oil level stabilizes.•Use the fork oil level gauge [A] to measure the distancebetween the top of the inner tube to the oil level.

Special Tool — Fork Oil Level Gauge: 57001–1290

Set the oil level gauge stopper [B] so that the distance [C]from the bottom of the stopper to the lower end of the pipeis the standard oil level distance.A correct measurement can not be obtained unless thelevel gauge pipe is placed in the center of the inner tube.

Oil Level (fully compressed, without spring)Standard: 115 ±2 mm (4.53 ±0.08 in.)

Place the stopper of the level gauge at the top [E] of theinner tube [D] and pull the handle slowly to draw out theexcess oil from fork into the gauge, thus attaining the stan-dard level.If not oil is drawn out, there is not enough oil in the fork.Pour in some more oil and measure again.

•Repeat the same procedure for adjusting the other fork.• Install the fork spring [A], fork spring seat [B] and collar[C].

• Inspect the top plug O-ring and replace it with a new one.• Install the front fork (see Front Fork Installation).

Front Fork Disassembly

•Remove the front fork (see Front Fork Removal).• Remove the top plug [A] with O-ring, take out the collar[B], spring seat [C], and spring [D].

•Drain the fork oil (see Fork Oil Change).

•Remove the Allen bolt [C] from the bottom of the fork.Special Tools — Fork Cylinder Holder Handle: 57001-183 [D]

Fork Cylinder Holder Adapter: 57001-1057[E]

NOTEHold the outer tube in a vise [A], stop the cylinder unit[B] from turning by using the special tools, and unscrewthe Allen bolt.

13-10 SUSPENSION

Front Fork

•Remove the cylinder unit [A], washer, and the spring [B]from the inner tube.

• Remove the following from the top of the outer tube:Dust Seal [A]Retaining Ring [B]

• Separate the inner tube [A] from the outer tube [B].NOTE

From the compressed state, firmly pull down the outertube a few times towards the direction of elongation.

•Remove the following from the inner tube:Guide Bushing (inner) [A]Guide Bushing (outer) [B]Washer [C]Oil Seal [D]

• Remove the cylinder base [A] from the bottom of the outertube.

SUSPENSION 13-11

Front Fork

Front Fork Assembly

•Check the top plug O-ring and replace it with a new one.•Replace the following parts with new ones:Retaining Ring [A]Dust Seal [B]Oil Seal [C]Inner Guide Bushing [D]Outer Guide Bushing [E]Fork Bottom Allen Bolt Gasket [F]

• Install the guide bushing on the end of the inner tube.• Insert the cylinder unit and the spring into the inner tube,and install the cylinder base [B] onto the cylinder end [A]that protrudes from the bottom.Install the cylinder base starting with its stepped end.• Insert the inner tube, cylinder unit, washer, spring, andcylinder base as a set into the outer tube.

• Install the guide bushing into the outer tube.• After installing the washer, install the oil seal [A] by usingthe fork oil seal driver [B].

Special Tool — Fork Oil Seal Driver: 57001-1288

Apply high-temperature grease to the oil seal lips.• Install the retaining ring into the outer tube.• Install the dust seal by hand.• Apply non-permanent locking agent to the threads of thebottom Allen bolt [C].

• Hold the front fork horizontally in a vise [A].•Hold the cylinder unit [B] with the special tools and tightenthe bottom Allen bolt to secure the cylinder in place.

Torque — Front Fork Bottom Allen Bolt: 30 N·m (3.1 kgf·m,22 ft·lb)

Special Tools — Fork Cylinder Holder Handle: 57001-183 [D]Fork Cylinder Holder Adapter: 57001-1057[E]

•Pour in the specified type of oil (see Front Fork OilChange).

13-12 SUSPENSION

Front Fork

Inner Tube/Outer Tube Inspection

•Visually inspect the inner tube [A] and repair any nicks orrust by using an oil stone.If the damage is not repairable, replace the inner tube.Since damage to the inner tube damages the oil seal slip,replace the oil seal whenever the inner tube is repaired orreplaced.

CAUTION

If the inner tube is badly nicked or bent, replaceit. Excessive bending, followed by subsequentstraightening, can weaken the inner tube.

•Place the inner tube in the outer tube [B] and pump themback and forth manually to check for smooth operation.If themovement is not smooth, replace both the inner tubeand the outer tube.

WARNINGReplace the inner and outer tubes with new ones ifthey are bent because it is dangerous to use themby repairing them.Make sure to inspect the inner and outer tubes ofthe other side.

Dust Seal Inspection

• Inspect the dust seal [A] for any signs of deterioration ordamage.Replace it if necessary.

Fork Spring Inspection

•Measure the free length [B] of the fork spring [A].If the measured length is shorter than the service limit, thespring must be replaced. If the free length of the replace-ment spring and that of the remaining spring vary greatly,the remaining spring should also be replaced in order tokeep the fork legs balanced to ensure stability.

Fork Spring Free LengthStandard: 277.2 mm (10.91 in.)Service Limit: 272 mm (10.71 in.)

SUSPENSION 13-13

Rear Shock Absorber

Rebound Damping Force Adjustment

•Turn the damper adjuster [A] to adjust the rebound damp-ing.Align the numbered mark [B] of the adjuster.The standard adjuster setting for average-build rider of68 kg (150 Ib) with no passenger and no accessories isposition «2».If the damper’s effectiveness is not suited to the operatingconditions, adjust it to an appropriate position by referringto the table below.

Rebound Damping Adjustment

AdjusterPosition

DampingForce

ShockAbsorberHardness

LoadRoad

ConditionsDrivingSpeed

1 Weak Soft Light Good Street

2 ↑ ↑ ↑ ↑ ↑3 ↓ ↓ ↓ ↓ ↓4 Strong Hard Heavy Bad Highway

Spring Preload Adjustment

•Remove the mud guard (see Frame chapter).• Using the hook wrench [A], turn the adjusting nut [B] toadjust the spring preload.The standard adjuster setting for average-build rider of 68kg (150 Ib) with no passenger and no accessories is 4thposition.

Spring Preload SettingStandard Position: 4th positionAdjustable Range: 1st to 7th position

• If the compression of the spring is not suited to the op-erating conditions, adjust it to an appropriate position byreferring to the table below.

Spring Preload Adjustment

AdjusterPosition

DampingForce

ShockAbsorberHardness

LoadRoad

ConditionsDrivingSpeed

1st Weak Soft Light Good Low

↑ ↑ ↑ ↑ ↑ ↑↓ ↓ ↓ ↓ ↓ ↓7th Strong Hard Heavy Bad Highway

Rear Shock Absorber Removal

•Using the jack, raise the rear wheel off the ground.Special Tool — Jack: 57001–1238

•Squeeze the brake lever slowly and hold it with a band[A].

WARNINGBe sure to hold the front brake when removing theshock absorber, or the motorcycle may tall over. Itcould cause an accident and injury.

13-14 SUSPENSION

Rear Shock Absorber

•Remove:Lower Shock Absorber Nut [A]Lower Shock Absorber Bolt [B]

• Remove:Upper Shock Absorber Nut [A]Upper Shock Absorber Bolt [B]

• Remove the shock absorber [A] from upside.

Rear Shock Absorber Installation

• Tighten:Torque — Rear Shock Absorber Nuts: 34 N·m (3.5 kgf·m, 25

ft·lb)

Rear Shock Absorber Inspection

•Remove the rear shock absorber.• Visually inspect the following items.Smooth StrokeOil LeakageCrack or DentIf there is any damage to the rear shock absorber, replaceit.

• Visually inspect the rubber bushing.If it show any signs of damage, replace it.

SUSPENSION 13-15

Swingarm

Swingarm Removal

•Raise the rear wheel off the ground with jack.Special Tool — Jack: 57001–1238

•Remove:Chain Cover (see Final Drive chapter)Mud Guard (see Frame chapter)Brake Hose Clamp [A]Rear Wheel (see Wheels/Tires chapter)

Lower Shock Absorber Nut and Bolt [A]Upper Tie-rod Nut and Bolt [B]

•Remove the both frame cover (see Frame chapter).• Unscrew the swingarm pivot locknut [A], using the nutwrench [B].

Special Tool — Swingarm Pivot Nut Wrench: 57001–1541

•Unscrew the swingarm pivot nut [A] and loosen theswingarm pivot shaft [B].

• Pull off the pivot shaft and remove the swingarm.

13-16 SUSPENSION

Swingarm

Swingarm InstallationPlace the collar [A] on the stopper [B] inside the frame [C].• Insert the pivot shaft into the frame from the right side.• Tighten the pivot shaft so that the clearance [D] betweenthe collar and the frame come to zero mm.

• Tighten:Torque — Swingarm Pivot Shaft Nut: 108 N·m (11 kgf·m, 80

ft·lb)

• Tighten the pivot locknut, using the socket wrench.Special Tool — Swingarm Pivot Nut Wrench: 57001–1541

Torque — Swingarm Pivot Shaft Locknut: 98 N·m (10 kgf·m,72 ft·lb)

• Install the removed parts (see appropriate chapters).Swingarm Bearing Removal

•Remove:SwingarmCollar [A]Grease Seals [B]Sleeve [C]Circlip (right side) [D]

• Remove the ball bearing and needle bearings.Special Tool — Oil Seal & Bearing Remover: 57001–1058

[A]

SUSPENSION 13-17

Swingarm

Swingarm Bearing Installation

• Install the needle bearings so that the manufacturer’smarks face in.

• Install the ball bearing so that the manufacturer’s marksfaces out.

Special Tool — Bearing Driver Set: 57001–1129 [A]

Swingarm Bearing, Sleeve Inspection

CAUTION

Do not remove the bearings for inspection. Removemay damage them.

• Inspect the needle bearings [A] and ball bearing [B] in-stalled in the swingarm.The rollers and ball in bearing normally wear very little,and wear is difficult to measure. Instead of measuring,visually inspect the bearing for abrasion, discoloration, orother damage.If the needle bearings, ball bearing, and sleeve show anysings of abnormal wear, discoloration, or damage. re-place them as a set.

Chain Guide Inspection

•Visually inspect the chain guide [A].Replace the chain guide if it shows any signs of abnormalwear or damage.

13-18 SUSPENSION

Tie-rod, Rocker Arm

Tie-rod Removal

•Remove the side stand (see Frame chapter).• Using the jack, raise the rear wheel off the ground.Special Tool — Jack: 57001–1238

•Squeeze the brake lever slowly and hold it with a band[A].

• Remove:Lower Rear Shock Absorber Bolt and Nut [A]Upper and Lower Tie-rod Nuts and Bolts [B]Tie-rods [C]

Tie-rod Installation

• Install the tie-rods so that the marked side faces the boltsand nuts.

• Tighten:Torque — Tie-rod Nuts: 59 N·m (6.0 kgf·m, 43 ft·lb)

Rear Shock Absorber Nut: 34 N·m (3.5 kgf·m, 25ft·lb)

Rocker Arm Removal

•Using the jack, raise the rear wheel off the ground.Special Tool — Jack: 57001–1238

•Squeeze the brake lever slowly and hold it with a band.• Remove:Lower Rear Shock Absorber Nut and Bolt [A]Lower Tie-rod Nut and Bolt [B]Rocker Arm Nut [C] and BoltRocker Arm [D]

Rocker Arm Installation

• Tighten:Torque — Rocker Arm Nut: 34 N·m (3.5 kgf·m, 25 ft·lb)

Tie-rod Nut: 59 N·m (6.0 kgf·m, 43 ft·lb)Rear Shock Absorber Nut: 34 N·m (3.5 kgf·m, 25ft·lb)

SUSPENSION 13-19

Tie-rod, Rocker Arm

Rocker Arm/Tie-rod Bearing, Sleeve Inspection

•Visually inspect the rocker arm/tie-rod sleeves and needlebearings.

• The rollers in a needle bearing normally wear very little,and wear is difficult to measure. Instead of measuring,inspect the bearing for abrasion, color change, or otherdamage.If there is any doubt as to the condition of any of the nee-dle bearings or sleeve, replace the sleeve, and needlebearings as a set.

STEERING 14-1

14

Steering

Table of Contents

Exploded View………………………………………………………………………………………………………… 14-2Special Tools ………………………………………………………………………………………………………….. 14-4Steering …………………………………………………………………………………………………………………. 14-5

Steering Inspection …………………………………………………………………………………………….. 14-5Steering Adjustment……………………………………………………………………………………………. 14-5

Steering Stem…………………………………………………………………………………………………………. 14-6Stem, Stem Bearing Removal………………………………………………………………………………. 14-6Stem, Stem Bearing Installation……………………………………………………………………………. 14-7Stem Bearing Lubrication…………………………………………………………………………………….. 14-8Steering Stem Warp……………………………………………………………………………………………. 14-8

Handlebar ………………………………………………………………………………………………………………. 14-9Handlebar Removal ……………………………………………………………………………………………. 14-9Handlebar Installation …………………………………………………………………………………………. 14-9

14-2 STEERING

Exploded View

STEERING 14-3

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Steering stem nut 27 2.8 20

2 Steering stem head bolt 108 11 80

3 Front fork clamp bolts (Upper) 20 2.0 14

4 Front fork clamp bolts (Lower) 20 2.0 14 AL

5 Handlebar clamp bolts 25 2.5 18 S

6 Handlebar lower clamp nuts 34 3.5 25

7 Switch housing screws 3.5 0.36 31 in·lb

8. Steering stem head bolt plugAD: Apply adhesive.AL: Tighten the two clamp bolts alternately two times to ensure even tighten torque.G: Apply grease.L: Apply a non-permanent locking agent.R: Replacement PartsS: Follow the specific tightening sequence.

14-4 STEERING

Special Tools

Steering Stem Nut Wrench:57001–1100

Bearing Driver Set:57001–1129

Jack:57001–1238

Steering Stem Bearing Driver:57001–1344

Steering Stem Bearing Driver Adapter:57001–1345

STEERING 14-5

Steering

Steering Inspection

•Refer to the Steering in the Periodic Maintenance chapter.Steering Adjustment

•Refer to the Steering in the Periodic Maintenance chapter.

14-6 STEERING

Steering Stem

Stem, Stem Bearing Removal

•Remove:Inner Cover (see Frame chapter)Fairing and Bracket (see Frame chapter)Front Wheel (see Wheels/Tires chapter)Handlebar (see Handlebar Removal)Steering Stem Head Bolt PlugSteering Stem Head Bolt [A] and WasherFront Fork Clamp Bolts (Lower) (Loosen)Steering Stem Head

•Remove the brake hose clamp bolt [A] and take the hose[B] off the steering stem [C].

• Remove the front fork (see Suspension chapter).

• Bend the claw washer tabs [A].• Pushing up the stem base, and remove the steering stemlocknut [B] and claw washer [C].Stem Cap [D]

• Remove the steering stem nut [A].

Special Tool — Steering Stem Nut Wrench: 57001–1100 [B]

•Remove the stem cap.

• Remove the upper stem bearing inner race.

• To remove the bearing outer races [C] pressed into thehead pipe [B], insert a bar [A] into the recesses of headpipe, and applying it to both recess alternately hammer itto drive the race out.

NOTEIf either steering stem bearing is damaged, it is recom-mended that both the upper and lower bearings (includ-ing outer races) should be replaced with new ones.

•Remove the lower bearing inner race which is pressedonto the steering stem with a suitable commercially avail-able chisel.

STEERING 14-7

Steering Stem

Stem, Stem Bearing Installation

•Replace the bearing outer races with new ones.• Apply grease to the outer races, and drive them into thehead pipe at the same time.

Special Tool — Bearing Driver Set: 57001–1129 [A]

•Replace the bearing inner races and oil seal with newones.

• Apply grease to the oil seal.• Drive the lower ball bearing inner race applied the greaseonto the stem.

Special Tools — Steering Stem Bearing Driver: 57001–1344[A]

Steering Stem Bearing Driver Adapter:57001–1345 [B]

•Apply grease the lower ball bearing [A] and install it ontothe stem.

•Apply grease to the upper ball bearing [B] and inner race[C].

• Install the stem [A] through the head pipe and install theball bearing [B] and inner race [C] on it.

• Install the stem cap [D] and steering stem nut [E].

• Settle the inner races in place as follows:Tighten the steering stem nut with 39 N·m (4.0 kgf·m, 29ft·lb) of torque first, and loosen it a fraction of a turn untilit turns lightly. Afterward tighten it again with specifiedtorque using a stem nut wrench [A] in the direction shown.Check that there is no play and the steering stem turnssmoothly without rattles. If not, the steering stem bearingsmay be damaged.

Special Tool — Steering Stem Nut Wrench: 57001–1100

Torque — Steering Stem Nut: 27 N·m (2.8 kgf·m, 20 ft·lb)

14-8 STEERING

Steering Stem

• Install the claw washer [A] so that its bent side [B] facesupward, and engage the bent claws with the grooves ofstem locknut [C].

• Hand tighten the stem locknut until it touches the clawwasher.

• Tighten the stem locknut clockwise until the claws arealigned with the grooves (ranging from 2nd to 4th) of stemnut [D], and bend the 2 claws downward [E].

• Install the stem head.

• Install the washer, and tighten the stem head bolt withspecified torque.

• Install the steering stem head bolt plug.

• Install the front fork (see Suspension chapter).NOTE

Tighten the fork upper clamp bolts first, next the stemhead nut, last the fork lower clamp bolts.Tighten the two clamp bolts alternately two times to en-sure even tightening torque.

Torque — Steering Stem Head Bolt : 108 N·m (11 kgf·m, 80ft·lb)

Front Fork Clamp Bolts (Upper) :20 N·m (2.0 kgf·m, 14 ft·lb)

Front Fork Clamp Bolts (Lower) :20 N·m (2.0 kgf·m, 14 ft·lb)

WARNINGDo not impede the handlebar turning by routing thecables, harnesses and hoses improperly (see Ap-pendix chapter).

• Install the removed parts (see appropriate chapters).Stem Bearing Lubrication

•Refer to the Steering in the Periodic Maintenance chapter.Steering Stem Warp

•Whenever the steering stem is removed, or if the steeringcannot be adjusted for smooth action, check the steeringstem for straightness.If the steering stem [A] is bent, replace the steering stem.

STEERING 14-9

Handlebar

Handlebar Removal

•Remove:Handlebar Holder PlugsClutch Lever Assembly [A]Left Handlebar Switch Housing [B]Front Brake Master Cylinder [C]Right Handlebar Switch Housing [D]Handlebar Holder Bolts [E]

•Remove the handlebar holder [F] and then pull out thehandlebar.

•Remove the cotter pins [A].•Remove the mounting nuts [B], washers and handlebarlower clamps [C].

Handlebar Installation

• Install the handlebar lower clamps [A], noting the letters“L” [B] and “R” [C].

• Tighten:Torque — Handlebar Lower Clamp Nuts: 34 N·m (3.5 kgf·m,

25 ft·lb)

•Align the punch mark [A] on the handlebar and the corneredge [B] on the lower clamp.

• Tighten the front clamp bolts first, and then the rear clampbolts. There will be a gap [A] at the rear part of the clampafter tightening.

Torque — Handlebar Clamp Bolts: 25 N·m (2.5 kgf·m, 18ft·lb)

• Install the removed parts (see appropriate chapters).

FRAME 15-1

15

Frame

Table of Contents

Exploded View………………………………………………………………………………………………………… 15-2Seats …………………………………………………………………………………………………………………….. 15-7

Rear Seat Removal…………………………………………………………………………………………….. 15-7Rear Seat Installation………………………………………………………………………………………….. 15-7Front Seat Removal ……………………………………………………………………………………………. 15-7Front Seat Installation …………………………………………………………………………………………. 15-7

Side Covers ……………………………………………………………………………………………………………. 15-8Side Cover Removal …………………………………………………………………………………………… 15-8Side Cover Installation ………………………………………………………………………………………… 15-8

Fairings………………………………………………………………………………………………………………….. 15-9Inner Cover Removal ………………………………………………………………………………………….. 15-9Inner Cover Installation……………………………………………………………………………………….. 15-9Fairing Removal…………………………………………………………………………………………………. 15-9Fairing Installation………………………………………………………………………………………………. 15-9Fairing Bracket Removal……………………………………………………………………………………… 15-9

Seat Covers……………………………………………………………………………………………………………. 15-10Seat Cover Removal…………………………………………………………………………………………… 15-10Seat Cover Installation………………………………………………………………………………………… 15-10

Mud Guard……………………………………………………………………………………………………………… 15-11Mud Guard Removal…………………………………………………………………………………………… 15-11Mud Guard Installation………………………………………………………………………………………… 15-11

Fenders …………………………………………………………………………………………………………………. 15-12Front Fender Removal ………………………………………………………………………………………… 15-12Front Fender Installation ……………………………………………………………………………………… 15-12Rear Fender Rear Removal…………………………………………………………………………………. 15-12Rear Fender Rear Installation………………………………………………………………………………. 15-13

Frame Cover…………………………………………………………………………………………………………… 15-14Frame Cover Removal………………………………………………………………………………………… 15-14

Battery Case…………………………………………………………………………………………………………… 15-15Battery Case Removal ………………………………………………………………………………………… 15-15Battery Case Installation ……………………………………………………………………………………… 15-15

Side Stand……………………………………………………………………………………………………………… 15-16Side Stand Removal …………………………………………………………………………………………… 15-16Side Stand Installation ………………………………………………………………………………………… 15-16

Rear View Mirrors……………………………………………………………………………………………………. 15-17Rear View Mirrors Removal …………………………………………………………………………………. 15-17Rear View Mirrors Installation ………………………………………………………………………………. 15-17

Frame ……………………………………………………………………………………………………………………. 15-18Frame Inspection ……………………………………………………………………………………………….. 15-18

15-2 FRAME

Exploded View

FRAME 15-3

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Footpeg bracket bolts 34 3.5 25 L

2 Side stand bracket bolts 49 5.0 36

3 Side stand bolt 44 4.5 33

4 Side stand switch bolt 8.8 0.90 78 in·lb

G: Apply grease.L: Apply a non-permanent locking agent.

15-4 FRAME

Exploded View

FRAME 15-5

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Front fender bracket bolts 8.8 0.90 78 in·lb L

2 Front fender bolts 3.9 0.40 35 in·lb

15-6 FRAME

Exploded View

FRAME 15-7

Seats

Rear Seat Removal

• Insert the ignition switch key into the seat lock [A], turningthe key clockwise, pulling up on the rear of the seat [B],and pulling the seat backward.

Rear Seat Installation

•Slip the rear seat hooks [A] into the hollow-cubic bracket[B] on the frame.

• Insert the seat latch [C] into the latch hole [D].• Push down the rear part of the seat until the lock clicks.

Front Seat Removal

•Remove:Rear Seat (see Rear Seat Removal)Mounting Bolt [A]Seat Bracket [B]

•Remove the front seat [C] by pulling the rear of it up andbackward.

Front Seat Installation

•Slip the front seat hook [A] under the brace [B] on the fueltank bracket.

15-8 FRAME

Side Covers

Side Cover Removal

•Remove the bolt [A].• Pull the side cover [B] evenly outward to clear the stop-pers.

Side Cover Installation

• Insert the tabs [A] into the holes [B].• Install the bolt.

FRAME 15-9

Fairings

Inner Cover Removal

•Remove:Inner Cover Screws [A] and WashersInner Cover [B]

Inner Cover Installation

•Fit the projection [A] on the inner cover [B] into the hole[C] in the fairing.

• Install the washers and inner cover screws.

Fairing Removal

•Remove:Fairing Mounting Bolts [A] (both side)Headlight Connectors

Fairing Installation

• Install the headlight connectors.• Fit the projections [A] on the fairing bracket into the holes[B] in the fairing.

• Tighten the fairing mounting bolts.

Fairing Bracket Removal

•Remove:Fairing (see Fairing Removal)Meter Unit (see Electrical System chapter)Turn Signal Light Nuts [A] and LightsRubber Cover [B]Clamps [C]Bolts [D]Fairing Bracket [E]

15-10 FRAME

Seat Covers

Seat Cover Removal

•Remove:SeatsScrews [A]

• Push the central pin, and then remove the quick rivets [A].

• Pull the front portions [A] of the seat cover outside [B],and then remove the seat cover backward.

Seat Cover Installation

• Installation is reverse of removal.• Put the projections [A] into the grommets [B] on the frame.

FRAME 15-11

Mud Guard

Mud Guard Removal

•Remove:Chain Cover (see Final Drive chapter)Bolt [A]Clamp [B]

• Lift up the mud guard [A], and then pull it out backward.

Mud Guard Installation

•Put the projections [A] into the grommets [B].

15-12 FRAME

Fenders

Front Fender Removal

•Remove:Front Wheel (see Wheels/Tires chapter)Brake Hose ClampsFront Reflector Bolts [A]Bolts [B] (both side)

• Remove the front fender [C].

Front Fender Installation

•Apply a non-permanent locking agent to the threads ofthe bracket bolts.

• Tighten:Torque — Front Fender Bracket Bolts: 8.8 N·m (0.90 kgf·m,

78 in·lb)Front Fender Bolts: 3.9 N·m (0.40 kgf·m, 35 in·lb)

• Install the brake hose clamps to the front fender holes.• Install the front wheel (see Wheels/Tires chapter).Rear Fender Rear Removal

•Remove:SeatsSeat CoverDiodes [A] (pull out)Stop and Turn Signal Light Lead Connectors [B]Seat Lock Mounting Bolts [C]Rear Fender Assy Bolts [D]

• Remove:Screws [A] and WashersTail-Lamp Assembly [B]

• Remove:Bolts [A]Storage Compartment [B]

FRAME 15-13

Fenders

•Remove:Quick Rivets [A]Rear Fender Rear [B]

Rear Fender Rear Installation

•Put the projection [A] into the hole [B].

• Put the projections [A] into the holes [B].• Installation is reverse of removal.

15-14 FRAME

Frame Cover

Frame Cover Removal

•Remove:Bolts [A]Frame Cover [B] (both side)

FRAME 15-15

Battery Case

Battery Case Removal

•Remove:SeatsSeat CoverRear Fender AssySide CoversBatteryReserver Tank Screws

•Pull out the battery case [A] backward.

Battery Case Installation

•Put the battery case attachments [A] at the projections [B]on the frame.

15-16 FRAME

Side Stand

Side Stand Removal

•Raise the rear wheel off the ground with the stand.• Remove:Side Stand Switch Bolt [A]Side Stand Switch [B]Spring [C]

Side Stand Nut [D]Side Stand Bolt [E]Side Stand [F]

Side Stand Installation

•Apply grease to the sliding area [B] of the side stand [A].• Tighten the bolt and lock them with the nut.

Torque — Side Stand Bolt: 44 N·m (4.5 kgf·m, 33 ft·lb)

•Hook the spring• Install the side stand switch.Apply a non-permanent locking agent to the thread of theswitch bolt.

Torque — Side Stand Switch Bolt: 8.8 N·m (0.90 kgf·m, 78in·lb)

FRAME 15-17

Rear View Mirrors

Rear View Mirrors Removal

•Loosen the lower hexagonal area [A] for tightening to re-move the rear view mirror from the holder.

CAUTION

Do not force to tighten and/or loosen the upperhexagonal area (Adapter) [B] with a pair of span-ners. Disassembly of this area is Not Available.Non-permanent locking agent [D] is already appliedto the threads of this inner area. Forcible loosen-ing may damage the adapter and/or the turningmechanism of the stay [C].

Rear View Mirrors Installation

•Screw the mounting area of the right rear view mirror intothe holder all the way, and tighten the lower hexagonalarea for tightening securely.Lower Hexagonal Area for Tightening [A]Upper Hexagonal Area (Adapter) [B]Rear View Mirror (Right) [C]

• Turn the stay [A] to assure the safe conditions of the rearwith the operator sat on the motorcycle.

• Adjust the rear view mirror slightly with its mirror [B].Installation and adjustment of the left side are commonwith those of the right side. Follow the procedure speci-fied at the right side.

15-18 FRAME

Frame

Frame Inspection

•Visually inspect the frame for cracks, dents, bending, orwarp.If there is any damage to the frame, replace it.

WARNINGA repaired frame may fail in use, possibly causingan accident. If the frame is bent, dented, cracked,or warped, replace it.

ELECTRICAL SYSTEM 16-1

16

Electrical System

Table of Contents

Parts Location…………………………………………………………………………………………………………. 16-3Exploded View………………………………………………………………………………………………………… 16-4Specifications …………………………………………………………………………………………………………. 16-10Special Tools and Sealant ………………………………………………………………………………………… 16-11Wiring Diagram (Canada)…………………………………………………………………………………………. 16-12Wiring Diagram (Australia) ……………………………………………………………………………………….. 16-14Wiring Diagram (Other than Canada, Australia and Malaysia)……………………………………….. 16-16Wiring Diagram (Malaysia) ……………………………………………………………………………………….. 16-18Precautions…………………………………………………………………………………………………………….. 16-20Electrical Wiring………………………………………………………………………………………………………. 16-22

Wiring Inspection ……………………………………………………………………………………………….. 16-22Battery …………………………………………………………………………………………………………………… 16-23

Battery Removal ………………………………………………………………………………………………… 16-23Battery Installation ……………………………………………………………………………………………… 16-23Electrolyte Filling………………………………………………………………………………………………… 16-23Initial Charge……………………………………………………………………………………………………… 16-25Precautions ……………………………………………………………………………………………………….. 16-26Interchange ……………………………………………………………………………………………………….. 16-27Charging Condition Inspection……………………………………………………………………………… 16-27Refreshing Charge……………………………………………………………………………………………… 16-27

Charging System…………………………………………………………………………………………………….. 16-29Alternator Cover Removal……………………………………………………………………………………. 16-29Alternator Cover Installation…………………………………………………………………………………. 16-29Stator Coil Removal ……………………………………………………………………………………………. 16-29Stator Coil Installation …………………………………………………………………………………………. 16-30Alternator Rotor Removal ……………………………………………………………………………………. 16-30Alternator Rotor Installation …………………………………………………………………………………. 16-30Alternator Inspection …………………………………………………………………………………………… 16-32Regulator/Rectifier Inspection………………………………………………………………………………. 16-33Charging Voltage Inspection………………………………………………………………………………… 16-35

Ignition System……………………………………………………………………………………………………….. 16-37Crankshaft Sensor Removal ………………………………………………………………………………… 16-37Crankshaft Sensor Installation ……………………………………………………………………………… 16-38Crankshaft Sensor Inspection………………………………………………………………………………. 16-39Crankshaft Sensor Peak Voltage Inspection…………………………………………………………… 16-39Timing Rotor Removal ………………………………………………………………………………………… 16-40Timing Rotor Installation ……………………………………………………………………………………… 16-40Camshaft Position Sensor Removal ……………………………………………………………………… 16-40Camshaft Position Sensor Installation …………………………………………………………………… 16-40Camshaft Position Sensor Inspection ……………………………………………………………………. 16-41Camshaft Position Sensor Peak Voltage Inspection………………………………………………… 16-41Stick Coil (Ignition Coil together with Spark Plug Cap) Removal……………………………….. 16-42Stick Coil (Ignition Coil together with Spark Plug Cap) Installation…………………………….. 16-42Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection……………………………… 16-43Stick Coil Primary Peak Voltage …………………………………………………………………………… 16-43Spark Plug Removal …………………………………………………………………………………………… 16-44

16-2 ELECTRICAL SYSTEM

Spark Plug Installation ………………………………………………………………………………………… 16-44Spark Plug Inspection …………………………………………………………………………………………. 16-44Spark Plug Gap Inspection ………………………………………………………………………………….. 16-44Interlock Operation Inspection ……………………………………………………………………………… 16-45IC Igniter Inspection ……………………………………………………………………………………………. 16-46

Electric Starter System…………………………………………………………………………………………….. 16-49Starter Motor Removal………………………………………………………………………………………… 16-49Starter Motor Installation……………………………………………………………………………………… 16-49Starter Motor Disassembly…………………………………………………………………………………… 16-49Starter Motor Assembly ………………………………………………………………………………………. 16-50Brush Inspection ………………………………………………………………………………………………… 16-51Commutator Cleaning and Inspection……………………………………………………………………. 16-51Armature Inspection……………………………………………………………………………………………. 16-51Brush Lead Inspection ………………………………………………………………………………………… 16-52Brush Plate and Terminal Bolt Inspection ………………………………………………………………. 16-52Starter Relay Inspection………………………………………………………………………………………. 16-52

Lighting System………………………………………………………………………………………………………. 16-54Headlight Beam Horizontal Adjustment …………………………………………………………………. 16-54Headlight Beam Vertical Adjustment……………………………………………………………………… 16-54Headlight Bulb Replacement ……………………………………………………………………………….. 16-54Headlight Removal/Installation …………………………………………………………………………….. 16-55City Light Bulb Replacement (European Model)……………………………………………………… 16-56Turn Signal Light Bulb Replacement …………………………………………………………………….. 16-58Turn Signal Relay Inspection ……………………………………………………………………………….. 16-60Tail/Brake Light (LED) Removal……………………………………………………………………………. 16-60Tail/Brake Light (LED) Installation…………………………………………………………………………. 16-61

Radiator Fan System……………………………………………………………………………………………….. 16-62Fan System Circuit Inspection ……………………………………………………………………………… 16-62Fan Motor Inspection ………………………………………………………………………………………….. 16-62

Meter, Gauge, Indicator Unit……………………………………………………………………………………… 16-64Meter Unit Removal ……………………………………………………………………………………………. 16-64Meter, Gauge Disassembly………………………………………………………………………………….. 16-64Electronic Combination Meter Unit Inspection ………………………………………………………… 16-65

Switches and Sensors ……………………………………………………………………………………………… 16-74Brake Light Timing Inspection………………………………………………………………………………. 16-74Brake Light Timing Adjustment …………………………………………………………………………….. 16-74Switch Inspection ……………………………………………………………………………………………….. 16-74Radiator Fan Switch Inspection ……………………………………………………………………………. 16-74Water Temperature Sensor Inspection ………………………………………………………………….. 16-75Speed Sensor Inspection…………………………………………………………………………………….. 16-76Fuel Level Sensor Inspection……………………………………………………………………………….. 16-78Fuel Reserve Switch Inspection……………………………………………………………………………. 16-78Diode (Rectifier) Inspection………………………………………………………………………………….. 16-79

Junction Box…………………………………………………………………………………………………………… 16-80Junction Box Fuse Circuit Inspection…………………………………………………………………….. 16-80Starter Circuit/Headlight Relay Inspection ……………………………………………………………… 16-81Diode Circuit Inspection ………………………………………………………………………………………. 16-82

Fuse………………………………………………………………………………………………………………………. 16-8330 A Main Fuse Removal…………………………………………………………………………………….. 16-83Junction Box Fuse Removal ………………………………………………………………………………… 16-83Fuse Installation…………………………………………………………………………………………………. 16-8315 A ECU Fuse Removal…………………………………………………………………………………….. 16-83Fuse Inspection………………………………………………………………………………………………….. 16-84

ELECTRICAL SYSTEM 16-3

Parts Location

1. Starter Lockout Switch2. Camshaft Position Sen-sor

3. Radiator Fan Switch4. Starter Motor5. Alternator6. Speed Sensor7. Neutral Switch8. Side Stand Switch

9. Water Temperature Sen-sor

10. Battery11. Junction Box12. Front Brake Light Switch13. Stick Coils14. Crankshaft Sensor15. Rear Brake Light Switch16. Starter Relay and Main

Fuse

17. ECU Fuse18. Turn Signal Relay19. Diode (Rectifier)20. ECU (Electronic Control

Unit)21. Oil Pressure Switch22. Radiator Fan

16-4 ELECTRICAL SYSTEM

Exploded View

ELECTRICAL SYSTEM 16-5

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Meter mounting screws 1.2 0.12 10 in·lb

2 Tail/brake light mounting screws 1.2 0.12 10 in·lb

3 License plate light mounting screws 1.2 0.12 10 in·lb

4 Front brake light switch screw 1.0 0.10 9 in·lb

5 Starter locknut switch screws – – – L

6 Left switch housing screws 3.5 0.36 31 in·lb

7 Right switch housing screws 3.5 0.36 31 in·lb

8 Headlight mounting bolts 5.9 0.60 52 in·lb

9. Tail/brake lights (LED)10. Vibration Resistance Bulb11. Install the rear brake spring as shown.

Longer Side [A]L: Apply a non–permanent locking agent.

AU: AustraliaCA: CanadaEUR: European Community

16-6 ELECTRICAL SYSTEM

Exploded View

ELECTRICAL SYSTEM 16-7

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Water temperature sensor 25 2.5 18 SS

2 Spark plugs 13 1.3 113 in·lb

3 Alternator lead holding plate bolt 11 1.1 95 in·lb L

4 Starter motor mounting bolts 11 1.1 95 in·lb

5 Stator coil bolts 11 1.1 95 in·lb

6 Alternator rotor bolt 110 11 81

7 Starter motor clutch bolts 12 1.2 104 in·lb L

8 Alternator cover bolts 11 1.1 95 in·lb

9 Crankshaft sensor bolts 5.9 0.60 52 in·lb

10 Crankshaft sensor cover bolts 11 1.1 95 in·lb

11 Timing rotor bolt 39 4.0 29

12 Camshaft position sensor bolt 12 1.2 104 in·lb L

13 Radiator fan switch 18 1.8 13

14 Starter relay cable terminal bolts 3.9 0.40 35 in·lb L

15 Oil pressure switch terminal bolt 1.5 0.15 13 in·lb G

16 Oil pressure switch 15 1.5 11 SS

17. Radiator fan18. Crankshaft sensor19. Camshaft position sensor20. Starter relay/main fuse21. Stick coils22. Ignition switchG: Apply grease.L: Apply a non-permanent locking agent.M: Apply molybdenum disulfide grease.SS: Apply silicone sealant.

16-8 ELECTRICAL SYSTEM

Exploded View

ELECTRICAL SYSTEM 16-9

Exploded View

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

1 Regulator/rectifier bolts 6.9 0.70 61 in·lb

2 Fuel level sensor bolts 6.9 0.70 61 in·lb

3 Side stand switch bolt 8.8 0.90 78 in·lb L

4 Neutral switch 15 1.5 11

5 Speed sensor bolt 6.9 0.70 61 in·lb L

6 Speed sensor cover bolts 6.9 0.70 61 in·lb L

7 Regulator/rectifier bracket bolts 6.9 0.70 61 in·lb

8 Engine ground cable terminal bolt 9.8 1.0 87 in·lb

9. Turn signal relay10. Junction box11. ECU (Electrical Unit Control)12. 15 A ECU fuse13. Fuel reserve switch14. Diode (Rectifier)15. Speed sensor16. Regulator/rectifier17. Battery 12 V 8 AhL: Apply a non-permanent locking agent.

16-10 ELECTRICAL SYSTEM

Specifications

Item Standard

Battery:

Type Sealed Battery

Capacity 12 V 8 Ah

Voltage 12.6 V or more

Charging System:

Type Three-phase AC

Alternator output voltage 42 V or more

Stator coil resistance 0.3 ∼ 0.4 ΩCharging voltage 14.7 ±0.5 V

(regulator/rectifier output voltage)

Ignition System:

Crankshaft sensor resistance 376 ∼ 564 ΩCrankshaft sensor peak voltage 1.9 V or more

Camshaft Position Sensor resistance 400 ∼ 460 ΩCamshaft Position Sensor peak voltage 0.2 V or more

Interlock Operation Voltage 4 V or more

Stick coil:

Primary winding resistance 1.04 ∼ 1.56 ΩSecondary winding resistance 10.8 ∼ 16.2 kΩPrimary peak voltage 88 V or more

Spark plug:

Spark plug gap 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)Electric Starter System:

Starter motor:

Brush length 12 mm (0.47 in.) (Service limit: 8.5 mm, 0.33 in.)

Commutator diameter 28 mm (1.10 in.) (Service limit: 27 mm, 1.06 in.)

Switch and Sensor:

Rear brake light switch timing ON after about 10 mm pedal travel

Engine oil pressure switch connections When engine is stopped: ON

When engine is running: OFF

Fan switch connections

Rising temperature From OFF to ON @ 93 ∼ 103°C (199 ∼ 217°F)

Falling temperatureFan stops with the temperature 3 ~ 8°C (38 ∼ 46°F)lower than the operation temperature range.

ON: Less than 0.5 ΩOFF: More than 10 MΩ

Water temperature sensor resistance in the text

Fuel level sensor resistance:

Fuel position 4 ~ 10 ΩEmpty position 90 ~ 100 Ω

ELECTRICAL SYSTEM 16-11

Special Tools and Sealant

Rotor Puller, M16/M18/M20/M22 × 1.5 :57001–1216

Flywheel & Pulley Holder :57001–1343

Hand Tester :57001–1394

Flywheel Puller, M38 × 1.5 :57001–1405

Lead Wire-Peak Voltage Adapter :57001–1449

Needle Adapter :57001–1457

Harness Adapter :57001–1542

Rotor Holder :57001–1543

Spark Plug Wrench (Owner’s Tool) :92110–1146

Kawasaki Bond (Silicone Sealant) :56019–120

16-12 ELECTRICAL SYSTEM

Wiring Diagram (Canada)

ELECTRICAL SYSTEM 16-13

Wiring Diagram (Canada)

16-14 ELECTRICAL SYSTEM

Wiring Diagram (Australia)

ELECTRICAL SYSTEM 16-15

Wiring Diagram (Australia)

16-16 ELECTRICAL SYSTEM

Wiring Diagram (Other than Canada, Australia and Malaysia)

ELECTRICAL SYSTEM 16-17

Wiring Diagram (Other than Canada, Australia and Malaysia)

16-18 ELECTRICAL SYSTEM

Wiring Diagram (Malaysia)

ELECTRICAL SYSTEM 16-19

Wiring Diagram (Malaysia)

16-20 ELECTRICAL SYSTEM

Precautions

There are a number of important precautions that aremusts when servicing electrical systems. Learn and ob-serve all the rules below.Do not reverse the battery lead connections. This willburn out the diodes on the electrical parts.Always check battery condition before condemning otherparts of an electrical system. A fully charged battery is amust for conducting accurate electrical system tests.The electrical parts should never be struck sharply, aswith a hammer, or allowed to fall on a hard surface. Sucha shock to the parts can damage them.To prevent damage to electrical parts, do not disconnectthe battery leads or any other electrical connections whenthe ignition switch is on, or while the engine is running.Because of the large amount of current, never keep thestarter button pushed when the starter motor will not turnover, or the current may burn out the starter motor wind-ings.Take care not to short the leads that are directly con-nected to the battery positive (+) terminal to the chassisground.Troubles may involve one or in some cases all items.Never replace a defective part without determining whatCAUSED the failure. If the failure was caused by someother item or items, they must be repaired or replaced, orthe new replacement will soon fail again.Make sure all connectors in the circuit are clean and tight,and examine wires for signs of burning, fraying, etc. Poorwires and bad connections will affect electrical system op-eration.Measure coil and winding resistance when the part is cold(at room temperature).Color Codes:

BK Black G Green P Pink

BL Blue GY Gray PU Purple

BR Brown LB Light blue R Red

CH Chocolate LG Light green W White

DG Dark green O Orange Y Yellow

Electrical ConnectorsFemale Connectors [A]

ELECTRICAL SYSTEM 16-21

Precautions

Male Connectors [B]

16-22 ELECTRICAL SYSTEM

Electrical Wiring

Wiring Inspection

•Visually inspect the wiring for signs of burning, fraying,etc.If any wiring is poor, replace the damaged wiring.

• Pull each connector [A] apart and inspect it for corrosion,dirt, and damage.If the connector is corroded or dirty, clean it carefully. If itis damaged, replace it.

• Check the wiring for continuity.Use the wiring diagram to find the ends of the lead whichis suspected of being a problem.Connect the hand tester between the ends of the leads.Special Tool — Hand Tester: 57001–1394

Set the tester to the × 1 Ω range, and read the tester.If the tester does not read 0 Ω, the lead is defective. Re-place the lead or the wiring harness [B], [C], [D], [E] ifnecessary.

ELECTRICAL SYSTEM 16-23

Battery

Battery Removal

CAUTION

Do not disconnect the battery cables or any otherelectrical connections when the ignition switch isON, as this could damage the ECU (Electronic Con-trol Unit).Never reverse the connections of the battery, thiscould damage the ECU.

•Remove:Seats (see Frame Chapter)

•Disconnect the negative (–) cable [A].• Slide out the positive (+) terminal cap [B] and then discon-nect the positive (+) cable.

CAUTION

Be sure to disconnect the negative (–) cable first.

•Remove the battery.Battery Installation

•Apply a light coat of grease on the terminals to preventcorrosion.

• Install the positive (+) cable [A] first.• Cover the (+) terminal with the cap [B].• Install the negative (–) cable [C].

Electrolyte Filling

•Make sure that the model name [A] of the electrolyte con-tainer matches the model name [B] of the battery. Thesenames must be the same.

Battery Model Name for ZR750–J1 : YTX9–BS

CAUTION

Be sure to use the electrolyte container with thesame model name as the battery since the elec-trolyte volume and specific gravity vary with thebattery type. This is to prevent overfilling of theelectrolyte, shorting the battery life, and deteriora-tion of the battery performance.

16-24 ELECTRICAL SYSTEM

Battery

CAUTION

Do not remove the aluminum seal sheet [A] sealingthe filler ports [B] until just before use.

•Check to see that there is no peeling, tears or holes in theseal sheet on the top of the battery.

• Place the battery on a level surface.• Remove the seal sheet.

NOTEA battery whose seal sheet has any peeling, tears orholes, requires a refreshing charge (initial charge).

• Take the electrolyte container out of the vinyl bag.• Detach the seal cap [A] from the container.

NOTEDo not discard the seal cap because it is used as thebattery plugs later.Do not peel back or pierce the seals [B] on the container.

•Place the electrolyte container upside down aligning thesix seals with the six battery filler ports.

• Push the container down strongly enough to break theseals. Now the electrolyte should start to flow into thebattery.

NOTEDo not tilt the container as the electrolyte flow may beinterrupted.

•Make sure air bubbles [A] are coming up from all six fillerports.Leave the container this way for 5 minutes or longer.

NOTEIf no air bubbles are coming up from a filler port, tap[B] the bottom of the bottle two or three times. Neverremove the container from the battery.