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Z1000
Motorcycle
Service Manual
This quick reference guide will assist
you in locating a desired topic or pro-
cedure.
•Bend the pages back to match the
black tab of the desired chapter num-
ber with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the spe-
cific topic required.
Quick Reference Guide
General Information 1
j
Periodic Mainte nance 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
Z1000
Motorcycle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Assurance Department/Consumer Products and Machinery
Company/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 t o 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 latest
information 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 may
not depict actual model component parts.
© 2002 Kawasaki Heavy Industries, Ltd. Third Edition (1) : Aug. 25, 2003 (K)
LIST OF ABBREVIATIONS
A ampere(s) lb pound(s)
ABDC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATDC after top dead center
N
newton(s)
BBDC before bottom dead center Pa pascal(s)
BDC
bottom dead center
PS
horsepower
BTDC before top dead center psi pound(s) per square inch
°C degree(s) Celsius r revolution
DC direc
t 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) ohm(s)
L liter(s)
Read OWNER’S MANUAL before operating.
EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emis-
sion (1
) and exhaust emission (2) control systems in compliance with applicable regulations of
the United States Environmental Protection Agency and California Air Resources Board. Addi-
tionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance
with a
pplicable regulations of the California Air Resources Board on vehicles sold in California
only.
1. Crankcase Emission Control System
This s
ystem eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors
are routed through an oil separator to the intake side of the engine. While the engine is operating,
the vapors are drawn into combustion chamber, where they are burned along with the fuel and air
suppl
ied by the fuel injection system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of th
is motorcycle. The fuel, ignition, and exhaust systems of this m otorcycle have been carefully
designed and constructed to ensure an efficient engine w ith low exhaust pollutant levels.
The exhaust system of this model motorcycle manufactured primarily for sale in California includes
acat
alytic converter system.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. In-
ste
ad, fuel vapors are routed into the running engine to be burned, or stored in a canister when
the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is
com
monly referred to as the Act’s "tampering provisions."
"Sec. 203(a) The following acts and the causing thereof are prohibited...
(3)(A) for any person to remove or render inoperative any device or element of design installed
on o
r in a motor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
sal
e and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of r epairing, servicing, selling, leasing, or trading
motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles know-
ing
ly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title follow-
ing its sale and delivery to the ultimate purchaser..."
NOTE
The phrase "remove or render inoperative any device or element of design" has been generally
interpre ted as follows:
1. Tampering does not include the temporary removal or rendering inoperative of de-
vices or elements of design in order to perform maintenance.
2. Tampering could include:
a.Maladjustment of vehicle components such that the emission standards are ex-
ceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or durability of the motorcycle.
c.Addition of components or accessories that result in the vehicle exceeding the stan-
dards.
d.Permanently removing, disconnecting, or rendering inoperative any component or
element of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL
LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL P ENALTIES NOT
EXCEEDING $10,000 PER VIOLATION.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering
inoperative by any person other than for purposes of maintenance, repair, or replacement, of any
device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it i s in use, or (2) the use of the
vehicle after such device or element of design has been removed or rendered inoperative by
any person.
Among those acts presumed to constitute tampering are the acts l isted below:
Replacement of the original exhaust system or muffler with a component not in compliance
with Federal regulations.
Removal of the muffler(s) or any internal portion of the muffler(s).
Removal of the air box or air box cover.
Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such
modifications result in increased noise levels.
Foreword
This manual is designed primarily for use by
tra
ined mechanics in a properly equipped shop.
However, it contains enough detail and basic in-
formation to make it useful to the owner who de-
sir
es to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop proce-
du
res must be understood in order to carry out
maintenance and repair satisfactorily. When-
ever the owner has insufficient experience or
do
ubts his ability to do the work, all adjust-
ments, maintenance, and repair should be car-
ried out only by qualified mechanics.
I
n order to perform the work efficiently and
to avoid costly mistakes, read the text, thor-
oughly familiarize yourself with the procedures
b
efore starting work, and then do the work care-
fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, 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 scheduled
maintenance be performed in accordance with
this service manual. A ny owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your vehicle:
Follow the Periodic M aintenance Chart in the
Service Manual.
Be alert for problems and non-scheduled
maintenance.
Use proper tools and genuine Kawasaki Mo-
torcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki motorcycles are introduced by the
Special Tool Catalog or Manual. Genuine
parts provided as spare parts are listed in the
Parts 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 new
parts installed.
How
to Use This Manual
In preparing this manual, we divided the prod-
uct into its major systems. These systems be-
came the manual’s chapters. All information
for a particular system from adjustment through
disassembly and inspection is located in a sin-
gle chapter.
The Quick Reference Guide shows you all
of the product’s system and assists in locating
their chapters. Each chapter in turn has its own
comprehensive Table of Contents.
The Periodic Maintenance Chart is located in
the Periodic Maintenance chapter. The chart
gives a time schedule f or required maintenance
operations.
If you want spark plug information, for exam-
ple, go to the Periodic Maintenance Chart first.
The chart tells you how frequently to clean and
gap the plug. Next, use the Quick Reference
Guide to locate the Periodic Maintenance chap-
ter. Then, use the Table of Contents on the first
page 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 maintenance
practices.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in per-
sonal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in dam-
age to or destruction of equipment.
This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of informa-
tion.
NOTE
This note symbol indicates points of par-
ticular interest for more efficient and con-
venient operation.
Indicates a procedural step or work to be
done.
Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
also precedes the text of a N OTE.
Indicates a conditional step or what action to
take 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 illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require spec-
ified tightening torque, oil, grease or a locking
agent during assembly.
GENERAL INFORMATION 1-1
1
General Information
Table of Conten ts
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-7
General Specifications............................................................................................................ 1-8
Technical Information Air Inlet System ................................................................................ 1-11
Technical Information New Ignition Interlock Sidestand ...................................................... 1-13
Technical Information Tail/Brake Lights Employing LED ..................................................... 1-14
Technical Information - KLEEN (KAWASAKI LOW EXHAUST EMISSION SYSTEM) ........... 1-16
Unit Conversion Table ............................................................................................................ 1-17
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly opera-
tion on a m otorcycle, read the precautions given below. To facilitate actual operations, notes, illustra-
tions,
photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Espec
ially note the following:
Battery Ground
Before completing any service on the motorcycle, discon-
nect t
he battery wires from the battery to prevent the engine
from accidentally turning over. Disconnect the ground wire
() first and then the positive (+). When completed with the
servi
ce, first connect the positive (+) wire to the positive (+)
terminal of the battery then the negative () wire to the neg-
ative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.
Solvent
Use a high flush point solvent when cleaning parts. High
flush point solvent should be used according to directions
of the solvent manufacturer.
Cleaning vehicle before disassembly
Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into sealed areas during ve-
hicle disassembly can cause excessive wear and decrease
performance of the vehicle.
GENERAL INFORMATION 1-3
Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.
Storage of Removed Parts
After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.
Inspection
Reuse 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 sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is be-
yond its service limit.
Replacement Parts
Replacement Parts must be KAWASAKI genuine or rec-
ommended by KAWASAKI. Gaskets, O rings, Oil seals,
Grease seals, circlips or cotter pins must be replaced with
new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassem-
bly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
1-4 GENERAL INFORMATION
Before Servicing
Tightening Sequence
Bolts, nuts, or screws must be tightened according to the
specif
ied s equence to prevent case warpage or deformation
which can lead to malfunction. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diago
nally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench.
Often, the tightening sequence is followed twice-initial
tightening and final tightening with torque wrench.
Force
Use 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, Oring
Hardening, shrinkage, or damage of both gaskets and
grease seals after disassembly can reduce sealing perfor-
mance. Remove old gaskets and clean the sealing surfaces
thoroughly so that no gasket m aterial or other material re-
mains. Install new gaskets and replace used grease seal
when re-assembling
Liquid Gasket, Locking Agent
For 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 apply
them excessively. Excessive application can clog oil pas-
sages and cause serious damage.
GENERAL INFORMATION 1-5
Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the con-
tact area. Be sure to maintain proper alignment and use
smooth movements when installing.
Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing r ace as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing dam age.
Oil Seal, Grease Seal
Do 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 facing
out. Make sure the seal is aligned properly when installing.
Circlips, Cotter Pins
Replace circlips or cotter pins that were removed with new
ones. Install the circlip with its sharp edge facing outward
and its chamfered side facing i nward to prevent the clip from
being pushed out of its groove when loaded. Take care
not to open the clip excessively when installing to prevent
deformation.
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during i nitial operation. Lubri-
cation points are called out throughout this manual, apply
the specific oil or grease as specified.
1-6 GENERAL INFORMATION
Before Servicing
Direction of Engine Rotation
When rotating the crankshaft by hand, the free play
amount
of rotating direction will affect the adjustment. Ro-
tate the crankshaft to positive direction (clockwise viewed
from output side).
Electrical Wires
A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires m ust be connected to those of the same color.
GENERAL INFORMATION 1-7
Model Identification
ZR1000–A1 Left Side View:
ZR1000–A1 Right Side View:
1-8 GENERAL INFORMATION
General Specifications
Items ZR1000–A1
Dimensions:
Overall length 2 080 mm (81.9 in.)
Overall width 770 mm (30.3 in.)
Overall height 1 055 mm (41.5 in.)
Wheelbase
1 420 mm (55.9 in.)
Road clearance 145 mm (5.7 in.)
Seat height 820 mm (32.3 in.)
Dry mass 198 kg (410.1 lb)
Curb mass:
Front
110 k g (242.6 lb)
Rear 111 kg (244.8 lb)
Fuel tank capacity
18 L (5.0 US gal.)
Performance:
Minimum turning radius
2.8 m (9.2 ft)
Engine:
Type
4-stroke, DOHC, 4-cylinder
Cooling system Liquid-cooled
Bore and stroke
77.2 × 50.9 mm (3.0 × 2.0 in.)
Displacement 953 mL (58.15 cu in.)
Compression ratio
11.2
Maximum horsepower 93.4 kW (127 PS) @10 000 r/min (rpm),
(MY, AU) 90.5 kW (123 PS) @10 000 r/min (rpm)
(HR) 78.2 kW (106 PS) @10 000 r/min (rpm)
(US)---
Maximum torque 95.6 m (9.7 kgf·m, 71 ft·lb) @8 000 r/min (rpm),
(MY, AU) 92.7 N·m (9.4 kgf·m, 68 ft·lb) @8 000 r/min (rpm)
(HR) 86.3 N·m (8.8 kgf·m, 64 ft·lb) @7 500 r/min (rpm)
(US)---
Carburetion system FI (Fuel Injection) Keihin TTK38 × 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 36° BTDC @7 500 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°
GENERAL INFORMATION 1-9
General Specifications
Items ZR1000–A1
Lubrication system
Forced
lubrication (wet sump with cooler)
Engine oil:
Type API S E, SF or SG
API SH or SJ with JASO MA
Viscosity SAE10W-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-s
peed, 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 2.625 (42/16)
Overall drive ratio 4.929 @Top gear
Frame:
Type Tubular, diamond
Caster (rake angle) 24°
Trail 101 mm (4.0 in.)
Front tire: Type Tubeless
Size 120/70 ZR17 M /C ( 58W)
Rear tire: Type Tubeless
Size 190/50 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
138 mm (5.4 in.)
Brake Type: Front Dual discs
Rear
Single disc
Electrical Equip ment:
Battery 12 V 8 Ah
Headlight: Type Semi-sealed beam
Bulb
12 V 55 W × 2/55 W (Hi/Lo)
1-10 GENERAL INFORMATION
General Specifications
Items ZR1000–A1
Tail/brake light 12 V 0.5/3.8 W (LED)
(US, CA, Cal) 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
(US): U.S.A. Model
(CA): Canada Model
(Cal): California Model
(MY): Malaysia Model
(HR): with Honeycomb Catalytic Converter Model (Restricted model)
GENERAL INFORMATION 1-11
Technical Information Air Inlet Sy stem
Subthrottle Control System
The ZR1000–A1 employs large bore throttle bodies to increase power output. However, sudden
changes in throttle opening can cause hesitation and jerky throttle response with a single butterfly
valve in a large bore. Therefore two throttle valves are placed in each inlet tract, the main throttle
valve located closest to the cylinder and a subthrottle valve placed further up the inlet tract. The main
throttle 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 subthrottle
valve automatically adjusts air inlet to more precisely match engine demand, so that when the main
throttle is opened quickly there is no hesitation or jerky response.
The subthrottle valves allow the fuel injection system to provide smooth t hrottle response, similar to
that of a constant velocity carburetor, no m atter how quickly the throttle is opened.
A. Main Throttle Valve
B. Subthrottle Valve
C. Throttle Valve
D. Vacuum Piston
E. Inlet Air
1-12 GENERAL INFORMATION
Technical Information Air Inlet System
Operation
The subthrottle control system consists of the subthrottle valve, subthrottle valve actuator with a
steppi
ng motor built in it, ECU, and subthrottle sensor. The subthrottle valve is built in the each throttle
body.
The subthrottle control system operates on the signal supplied from t he ECU. The open/close oper-
ation o
f the subthrottle valve is performed by the subthrottle actuator which is controlled by the ECU
to change the current direction into the motor of the subthrottle valve actuator.
The s ubthrottle sensor detects the subthrottle valve actuator movement by measuring voltage and
the EC
U determines the subthrottle valve angle based on the operation map.
When turning the ignition switch ON, every time the EC U automatically drives the subthrottle valve
from fully closed position to fully opened position. The ECU memorizes these positions and turns
back t
he subthrottle valve to the original point to confirm the subthrottle valve idling voltage.
A. Su
bthrottle Valves
B. S ubthrottle Valve Actuator
C. S ubthrottle S ensor
D
.
M
ain Throttle Sensor
E. EC
U (Electric Control Unit)
F. Air Cleaner Side
G. Crankshaft Sensor
H
.
S
peed Sensor
GENERAL INFORMATION 1-13
Technical Information New Ignition Interlock Sidestand
Outline
The New Ignition Interlock Sidestand System applied to ZR1000–A1 models t hat cannot function if
gears are engaged and/or the sidestand is not lifted upward even though clutch lever pulled in, which
differs from the traditional one. Refer to the tables below as to the engine starts and/or the driving at
each condition.
New Ignition Interlock Sidestand System
Side 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 Ignitio n Interlock Sidestand System
Side 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 D oesn’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
1-14 GENERAL INFORMATION
Technical Information Tail/Brake Lights Employing LED
Outline
This model employs a tail/brake light containing 21 Light Emitting Diodes (LED). The LED emits
lumino
us beams over a longer life span than those emi tted from a traditional electric heated bulb
(more than 5 times longer), uses lower voltage, expends lower wattage (approx.1/5), and is quicker
responsing.
Due Position of LED Installation
The r
esistors, the diodes, and the Zener diodes are
mounted in the electronic circuits [A] of the LED, which
supplies 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] when
applied the forward voltage and current to the PN junction
diode [C].
GENERAL INFORMATION 1-15
Technical Information Tail/Brake Lights Employing LED
The emitting color differs according to the materials of
semi-conductors.
Materials of Semi-Conductor and Emitting Color
Materials of Semi-Conductor Emitting Color
GaAsP
,
GaAlAs
Red
GaP Gree
n
GaN Blue
Ga: Gallium
As: Arsenic
P: Phosphorus
N: Nitrogen
Al: Aluminum
1-16 GENERAL INFORMATION
Technical Information - KLEEN (K AWASAKI LOW EXHAUST EMISSION SYSTEM)
Since the emission regulations become more severe, Kawasaki has adopted a type of simplified
KLEEN, which have no catalyst protection system, according to each regulation of different countries.
The muf
fler with built-in catalyst has the same durability as the conventional muffller, however, do
not use leaded gasoline and do not coast with the ignition system OFF. Running the engine without
ignition damages catalyst.
Refer t
o 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 Converter
The converter is a three-way catalytic converter, and its surface is covered with alumina upon which
platinum and rhodium are applied, and has a cylindrical metalic honeycomb structure made by bend-
ing 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 surface area
but small size t o react effectively and has low exhaust resistance. In addition, its inherent strength
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 the
converters are installed in the exhaust manifold rear end where the temperature of exhaust gas is
still high. And, the converters will be activated even under low load conditions.
After the exhasut gas is diluted with the secondary air injection, the catalytic converter works well
because of rich oxygen to reduce CO, HC, and NO
x. Accordingly, we can keep the exhaust gas
emission within regulation.
This type of converter works more efficiently as a three-way catalytic converter to reduce CO, HC,
and NO
x than the pipe type catalytic converter because of its more and denser catalysts.
1. M anifold
2. S ilencer
3. H oneycomb Type Catalyst
4. M ark for Manifold
5. M ark for Silencer
GENERAL INFORMATION 1-17
Unit Conversion Table
Prefixes for Units:
Prefix Symbol Power
mega M × 1 000 000
kilo k × 1 000
centi c ×0.01
milli m ×0.001
micro µ × 0.000001
Units of Mass:
kg ×2.205=lb
g × 0.03527 = oz
Units of Volume:
L × 0.2642 = gal (US)
L × 0.2200 =
gal (imp)
L × 1.057 = qt ( US)
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 o f Force:
N × 0.1020 = kg
N × 0.2248 = lb
kg ×9.807=N
kg ×2.205=lb
Units of Length:
km × 0.6214 = mile
m × 3.281 = ft
mm × 0.03937 = in
Units of Torque:
N·m × 0.1020 = kgf·m
N·m × 0.7376 = ft·lb
N·m × 8.851 = in·lb
kgf·m × 9.807 = N·m
kgf·m
× 7.233 =
ft·lb
kgf·m × 86.80 = in·lb
Units of Pressure:
kPa × 0.01020 = kgf/cm²
kPa × 0.1450 = psi
kPa × 0.7501 = cm Hg
kgf/cm²
× 98.07 = kPa
kgf/cm² × 14.22 = psi
cmHg×1.333=kPa
Units of Speed:
km/h × 0.6214 = mph
Units of Power:
kW ×1.360=PS
kW ×1.341=HP
PS × 0.7355 = kW
PS
× 0.9863 = HP
Units of Temperature:
PERIODIC MAINT EN ANCE 2-1
2
Periodic Maintenance
Table of C ontents
Periodic Maintenance Chart .............. 2-2
Torque and Locking Agent................. 2-4
Specifications .................................... 2-9
Special Tools ..................................... 2-11
Periodic Maintenance Procedures..... 2-12
Fuel System (DFI)........................... 2-12
Fuel Hose and Connection
Inspection.................................. 2-12
Throttle Control System
Inspection.................................. 2-13
Idle Speed Inspection .................. 2-14
Idle Speed Adjustment................. 2-14
Engine Vacuum Synchronization
Inspection.................................. 2-15
Air Cleaner Element Cleaning...... 2-19
Evaporative Emission Control
System Inspection (CAL) .......... 2-20
Cooling System............................... 2-21
Radiator Hose and Connection
Inspection.................................. 2-21
Coolant Change ........................... 2-21
Engine Top End .............................. 2-23
Air Suction Valve Inspection ........ 2-23
Valve Clearance Inspection ......... 2-24
Valve Clearance Adjustment........ 2-25
Clutch.............................................. 2-28
Clutch Adjust Inspection .............. 2-28
Engine Lubrication System............. 2-29
Engine Oil C hange....................... 2-29
Oil Filter Change .......................... 2-29
Wheels/Tires................................... 2-30
Tire Inspection ............................. 2-30
Air Pressure
Inspection/Adjustment............... 2-31
Final Drive....................................... 2-31
Drive Chain Slack Inspection ....... 2-31
Drive Chain Slack Adjustment ..... 2-31
Wheel Alignment
Inspection/Adjustment............... 2-32
Drive Chain Wear Inspection ....... 2-32
Drive Chain Lubrication................ 2-33
Brakes............................................. 2-34
Brake Pad Wear Inspection ......... 2-34
Rear Brake Light Switch
Inspection/Adjustment............... 2-34
Caliper Fluid Seal Damage.......... 2-35
Caliper Dust Seal/Friction Boot
Damage..................................... 2-35
Master Cylinder Inspection (Visual
Inspection)................................. 2-36
Level Inspection ........................... 2-37
Brake Fluid Change ..................... 2-37
Brake Line Bleeding..................... 2-39
Brake Hoses and Connections
Inspection.................................. 2-41
Suspension ..................................... 2-42
Front Fork Oil Leak Check ........... 2-42
Rear Shock Absorber Oil Leak
Check . ....................................... 2-42
Swingarm Pivot Lubrication ......... 2-42
Uni-trak Linkage Lubrication ........ 2-42
Steering .......................................... 2-43
Steering Inspection ...................... 2-43
Steering Adjustment..................... 2-43
Stem Bearing Lubrication............. 2-44
Electrical System ............................ 2-44
Spark Plug Cleaning and
Inspection.................................. 2-44
General Lubrication ........................ 2-47
Lubrication ................................... 2-47
Nut, Bolt, and Fastener Tightness .. 2-48
Tightness Inspection .................... 2-48
2-2 PERIODIC MAINTENANCE
Periodic Maintenance Chart
The scheduled maintenance m ust be done in accordance with this chart to keep the motorcycle in
good running condition. The initial maintenance is vitally important and must not be neglected.
FREQUENCY Whichever 1 000 km *ODOMETER
READING
comes (600 mile)
first
6 000 km
(4 000 m ile)
12 000 km
( 7 500 mile)
18 000 km
(12 000 mile)
24 000 km
(15 000 mile)
30 000 km
(20 000 mile)
36 000 km
(24 000 mile)
OPERATION
Every
Spark plug (e) - clean and gap
Valve clearance (e) - inspect
Air suction valve (e) - inspect
Air cleaner element (e) - clean† #
Throttle control system (e) - inspect
Idle speed (e) - inspect
Engine vacuum synchronization (e) -
inspect
Fuel hoses, connections - inspect
Engine oil - change # year
Oil filter - replace
Evaporative emission control system (e)
(CAL) - inspect
Drive chain wear - inspect †#
Brake pad wear - inspect †#
Brake light switch - inspect
Steering - inspect
Rear shock absorber oil leak - inspect
Front fork oil leak - inspect
Tire wear - inspect
Swingarm pivot, Uni-trak linkage -
lubricate
General lubrication - perform
Nut, bolt, and fastener tightness - inspect
Drive chain - lubricate # 600 km
Drive chain slack - inspect †# 1000 km
Brake hoses, c onnections - inspect
Brake fluid level - inspect month
PERIODIC MAINTENANCE 2-3
Periodic Maintenance Chart
FREQUENCY Whichever 1 000 km *ODOMETER
READING
comes (600 m ile)
first 6 000 km
(4 000 mile)
12 000 km
( 7 500 mile)
18 000 km
(12 000 mile)
24 000 km
(15 000 mile)
30 000 km
(20 000 mile)
36 000 km
(24 000 mile)
OPERATION Every
Clutch-adjust
Radiator hoses, connections - inspect
Brake fluid - change
2 years
B
rake master cylinder cup and dust seal
- replace
4 years
Coolant - change 2 years
Caliper piston seal and dust seal -
replace
4 years
Steering stem bearing - lubricate
2 years
# : Service more frequently when operating in severe conditions; dusty, wet, m uddy, high speed,
or frequent starting / stopping.
* : For higher odometer readings, repeat at the frequency i nterval established here.
: Replace, add, adjust, clean, or torque if necessary.
Throttle control system inspection: Inspection of throttle grip play and main throttle bore cleanliness
(CAL): California Model only
(e): Emission R elated Items
2-4 PERIODIC MAINTENANCE
Torque and Locking Agent
The following tables list the tightening torque
for the major fasteners requiring use of a non
-perma
nent locking agent or liquid gasket.
Letter
s used in the “Remarks” column mean:
L: A pply a non-permanent locking agent to
the threads.
G: Apply
grease to the threads.
MO: A pply m olybdenum disulfide grease oil
solution.
EO: Apply
oil to the threads and seating sur-
face.
S: Tighten the fasteners following the speci-
fied
sequence.
SS: Apply silicone sealant.
Si: Apply silicone grease (ex. PBC grease).
R: Rep
lacement parts
AL: Tighten the two clamp bolts alternately
two times to ensure even tightening
tor
que.
The table on the right lists the basic torque
for the bolts and nuts, w hich are determined
by thei
r thread diameter. Use this table for the
bolts and nuts that are not listed in the table
below according to their thread diameter. All of
the ti
ghtening torque values are for use with dry
threads that have been cleaned with solvent.
Basic Torque for General Fasteners
Threads Torque
dia. (mm) N·m kgf·m ft·lb
5 3.4 4.9 0.35 0.50 30 43 in·lb
6 5.9 7.8 0.60 0.80 52 69 in·lb
8 14 19 1.4 1.9 10.0 13.5
10 25 34 2.6 3.5 19.0 25
12 44 61 4.5 6.2 33 45
14 73 98 7.4 10.0 54 72
16 115 155 11.5 16.0 83 115
18 165 225 17.0 23.0 125 165
20 225 325 23 33 165 240
Torque
Fastener
N·m kgf·m ft·lb
Remarks
Fuel S ystem:
Inlet air pressure sensor bolt 12 1.2 104 in·lb
Water temperature sensor 25 2.5 18
Vehicle downsensor bolts 2 0.2 17 in·lb
Cam shaft position sensor bolt
12 1.2 104 in·lb
Cam shaft position sensor rotor bolt 12 1.2 104 in·lb L
Throttle cable plate bolt 6 0.6 52 in·lb
Throttle body cover bolts 7 0.7 61 in·lb
Throttle body assy holder clamp bolts 2 0.2 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 0.2 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 0.7 62 in·lb L
Fuel pump bolts 9.8 1.0 87 in·lb
S, L
Fuel level sensor bolts 6.9 0.7 62 in·lb
Cooling System:
Radiator hose clamp screws 2 0.2 17 in·lb
Thermostat air bleeder bolt 7.8 0.80 69 in·lb
Radiator fan bolts 8.3 0.85 74 in·lb
Water pump impeller bolt 10 1.0 87 in·lb
Water pump cover bolts 11 1.1 95 in·lb
PERIODIC MAINT EN ANCE 2-5
Torque and Locking Agent
Torque
Fastener
N·m kgf·m ft·lb
Remarks
Water p
ump drain bolt
11 1.1 95 in·l
b
Water pipe bolts 11 1.1 95 in·lb in/outlet
Therm
ostat housing ground bolt
7 0.7 61 in·
lb
Thermostat bracket bolt 7 0.7 61 in·lb
Radi
ator upper bolts
7 0.7 61 in
·lb
Radiator lower bolts 7 0.7 61 in·lb
Rad
iator screen bolt
7 0.7 61 i
n·lb
Coolant reserve tank screws 7 0.7 61 in·lb
Radiator fan switch 18 1.
8
13
Water temperature sensor 25 2.5 18
E
ngine Top End:
Air suction valve cover bolts 10 1.0 87 in·lb
Cylinder head cover bolts
10 1.0 87 in·lb
Camshaft cap bolts (L=45 m m) 12 1.2 104 in·lb
Camshaft cap bolts (L=40 m m)
12 1.2 104 in·lb
Cylinder head bolts (M10 new bolts) 54 5.5 40 S, EO
(Washer)
Cylinder head bolts (M10 used bolts) 49 5.0 36 S, EO
(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 holder clamp screws 2.0 0.2 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 cam shaft 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) 10 1.0 87 in·lb
Exhaust pipe manifold holder nuts
17 1.7 12
Muffler body clamp bolts 17 1.7 12
Muffler body mounting bolts
34 3.5 25
Crankshaft sensor cover bolts 11 1.1 95 in·lb
Clutch:
Clutch lever clamp bolts 7.9 0.8 69 ilb S
Clutch cover bolts (L=32 mm)
11 1.1 95 in·lb
Clutch cover bolts (L=45 mm) 11 1.1 95 in·lb
Clutch cover bolts (L=30 mm)
11 1.1 95 in·lb
Clutch cover bolts 11 1.1 95 in·lb
Oil filler plug
1.5 0.15 13 in·lb
Clutch spring bolts 8.8 0.9 78 ilb
Clutch hub nut
135 14 100 R
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
Torque
Fastener
N·m kgf·m ft·lb
Remarks
Engine
Lubrication:
Oil filler plug 1.5 0.15 13 in·lb
Engin
e drain plug
20 2.0 14.5
Oil filter (cartridge type, P/No.16097–1070) 26 2.7 20 R, EO
Oil filter (cartridge type, P/No.16097–0002) 31 3.2 23 R, EO
Oil cooler mounting bolt 76 7.8 56 EO
Oil pan bolts 11 1.1 95 i
n·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
1
3in·lb
Water pump cover bolts 11 1.1 95 in·lb
Impeller bolt 10 1.0 87 in·lb
Coolant drain plug ( water pump) 11 1.1 95 in·lb
Water hose clamp screws 2.0 0.2 17 in·lb
Oil passage plugs 20 2.0 14.5 L
Engine Removal/Installation:
Adjusting collar locknut 49 5.0 36 in·lb S
Engine mounting bolts and nuts 44 4.5 32
S
Front engine bracket bolts 44 4.5 32 S
Rear engine bracket bolts 25 2.5 18
S
Crankshaft/Transmission:
Breather plate bolts 10 1.0 87 in·lb L
Crankcase bolts (M9, L=81 mm) 42 4.3 31 MO,S
Crankcase bolts (M9, L=95 mm)
49 5.0 36
MO,S
Crankcase bolts (M8) 27 2.8 20 S
Crankcase bolts (M7)
20 2.0 14.5
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 4.0 29
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 14.5 L
Crankshaft s ensor 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 0.7 61 in·lb
Tie-rod locknuts 6.9 0.7 61 in·lb
Neutral switch 15 1.5 11
PERIODIC MAINT EN ANCE 2-7
Torque and Locking Agent
Torque
Fastener
N·m kgf·m ft·lb
Remarks
Wheels/Tires:
Front axle clamp bolt 34 3.5 25
Front
axle
127 13 94
Rear axle nut 127 13 94
Fina
l D rive:
Engine sprocket nut 127 13 94 MO
Eng
ine sprocket cover bolts
9.8 1.0 87 i
n·lb
Engine sprocket cover damper bolt 6.9 0.7 61 in·lb L
Re
ar sprocket nuts
59 6.
0
43
Speed sensor bolt 6.9 0.7 61 ilb L
B
rakes:
Bleed valves 7.8 0.80 69 in·lb
Front brake hose joint bracket bolts 6.9 0.7 61
Brake hose banjo bolts 25 2.5 18
Brake lever pivot bolt 1.0 0.10 9in·lb
Brake lever pivot bolt locknut 5.9 0.60 52 in·lb
Front brake reservoir cap screws 1.5 0.15 13 in·lb
Front brake light switch screws 1.2 0.12 11 in·lb
Front master cylinder clamp bolts 8.8 0.9 78 ilb
S
Pad pin bolts (Front caliper) 17 1.7 12
Caliper mounting bolts (Front)
25 2.5 18
Caliper assembly bolts (Front) 22 2.2 16 L
Front brake disc mounting bolts 27 2.8 20 L
Rear brake disc mounting bolts 27 2.8 20 L
Caliper mounting bolts (Rear)
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)
8.8 0.90 78 in·lb AL
Front fork clamp bolts (Upper): ZR1000–A2 13 1.3 113 in·lb
Front fork clamp bolts (Lower)
20 2.0 15 AL
Front fork clamp bolts (Lower): ZR1000–A2 30 3.1 22
Front fork top plugs
35 3.6 26
Piston rod nuts 20 2.0 15
Front fork bottom Allen bolts
20 2.0 15
Front axle clamp bolt 20 2.0 15
Rear shock absorber nuts ( Upper and lower)
34 3.5 25
Swingarm pivot shaft nut 127 13 94
Swingarm pivot shaft locknut
98 10 72
Uni-trak
Rocker arm bolt 34 3.5 25
Tie-rod nuts 59 6.0 43
Steering:
Steering stem head bolt 108 11 80
Steering stem nut
20 2.0 14.5
Handlebar clamp bolts 25 2.5 18 S
2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
Torque
Fastener
N·m kgf·m ft·lb
Remarks
Handle
bar lower clamp nuts
34 3.5 25
Handlebar switch housing screws 3.4 0.35 30 in·lb
Frame
:
Footpeg holder bolts 34 3.5 25
Muffler mounting bolts 29 3.0 22
Side stand bolt 44 4.5 33
Side stand switch bolt 8.8 0.9 78 i
n·lb
Windshield screws 0.35 0.50 0.035 3 4in·lb
0.050
Front fender bolts 3.9 0.4 34.7 in·lb L
Electrical System:
Spark plugs 13 1.3 115 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 s ensor cover bolts 11 1.1 95 in·lb
Crankshaft sensor bolts
5.9 0.6 53 in·lb
Camshaft position sensor bolt 12 1.2 104 in·lb L
Timing rotor bolt 39 4.0 29
Starter m otor mounting bolts 11 1.1 95 in·lb
Switch housing screws
3.4 0.35 30 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 0.7 62 in·lb
Fuel level sensor bolts 6.9 0.7 62 in·lb
Front brake light switch screw 1.2 0.12 11 in·lb
Meter mounting screws 1.2 0.12 11 in·lb
Tail/brake light mounting screws
1.2 0.12 11 in·lb
License plate light mounting screws 1.2 0.12 11 in·lb
Headlight mounting bolts 5.9 0.6 53 in·lb
Starter lockout switch screw - - - L
Starter motor clutch bolts
12 1.2 104 in·lb L
Starter r elay cable terminal bolts 3.9 0.4 35 in·lb L
Regulator/rectifier bolts
6.9 0.7 62 in·lb
Regulator/rectifier bracket bolts 6.9 0.7 62 in·lb
Speed sensor cover bolts
6.9 0.7 62 in·lb L
PERIODIC MAINTENANCE 2-9
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 32.7 ± 1.333 kPa (245 ± 10 mm Hg)
Air cleaner element
Pape
r 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.)
C
lutch:
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
disassembled and dry)
Level Between upper and lower level lines
(after idling or running)
Tires:
Tread depth:
Front
BRIDGESTONE 3.4 mm (0.13 in.) 1 mm (0.04 in.)
1.6 mm (0.063 in.)
(DE, AT, CH)
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.)
2-10 PERIODIC MAINTENANCE
Specif ications
Item Standard Service Limit
Air pressure: (when cold)
Front
Up to 180 kg (396 lb) l oad:
250 kPa (2.5 kgf/cm², 36 psi)
–––
Rear Up to 180 kg (396 lb) load:
290 kPa (2.9 kgf/cm², 41 psi)
–––
Final Drive:
Drivechainslack
20 30 mm (0.8 1.2 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 –––
Bra
ke pad lining thickness:
Front 4 mm (0.16 in.) 1 mm (0.04 in.)
Rear
5 mm (0.20 in.) 1 mm (0.04 in.)
Brake light timing:
Front Pulled ON –––
Rear ON after about 10 mm (0.39 in.) of pedal
travel
–––
Electrical System:
Spark plug gap 0.7 0.8 mm (0.028 0.031 mm) –––
AT: R epublic of Austria
CH: S wiss Confederation
DE: Federal Republic of Germany
PERIODIC MAINTENANCE 2-11
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 (Owners Tool):
92110–1132
2-12 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fuel System (DFI)
Fuel Hose and Connection Inspection
The fuel hoses are designed to be used throughout the
motorcycle’s life without any maintenance, however, if the
motorcycle is not properly handled, the high pressure in-
side the fuel line can cause fuel to leak [A] or the hose
to 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 i f 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 more
than two times, and make sure it is locked and doesn’t
come off. When the hose joint is correctly installed, it
should slide on the delivery pipe about 5 mm (0.20 in.).
If it does not slide, reinstall the hose joint.
WARNING
Make sure the hose joint is installed correctly on the
delivery pipe by sliding the joint, or t he fuel could
leak.
Check that the inlet hose [A] is onto the pipe fully and the
plate clamps [ B] are installed beyond the raised rib [C].
1 2 mm (0.039 0.079 in.) [D]
PERIODIC MAINT EN ANCE 2-13
Periodic Maintenan ce Procedures
Throttle Control System Inspection
Throttle Grip Play Inspection
Check the throttle grip free play [A].
If the free play is incorrect, adjust the throttle cable (see
below).
Throttle Grip Free Play
Standard: 2 3mm(0.08 0.12 in.)
Check that the throttle grip moves smoothly from close to
full open, and the t hrottle closes quickly and completely
in 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. Then
lubricate the throttle cable.
Run the engine at the idle speed, and turn the handlebar
all the way to the right and left to ensure that the idle speed
doesn’t change.
If the idle speed increases, check the throttle grip free play
and the c able routing.
If necessary, adjust the throttle cable as follows.
Loosen the locknut [A] (right-front view).
Turn the adjuster [B ] until the proper amount of free play
can be obtained.
Tighten [C] the locknut against the adjuster securely.
If the throttle grip free play cannot be adjusted with the
adjuster, use the adjusters in the middle of t he throttle
cables.
Loosen the locknut, and screw the adjuster at the upper
end 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 l ocknuts against the adjusters securely.
Front [C]
If the throttle grip free play cannot be adjusted with the
lower adjusters, use the adjuster at the upper end of the
cable again.
2-14 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Throttle Bore Cleaning
Check the throttle bore for cleanliness as follows:
Remove
the throttle body assy (see Fuel System (DFI)
chapter).
Check the main throttle valves and throttle bores [A] for
carbo
n deposits by opening the main valves.
If any carbon accumulates, wipe the carbon off the throt-
tle bores and throttle valves, using a cotton pad [B] pen-
etra
ted with a high-flash point solvent. Be careful not to
remove molybdenum disulfide coat (black) [C] from the
throttle valves and the bores.
Fron
t of Throttle Body [D]
CAUTION
Do not
rub these surfaces hard and do not use a car-
buretor cleaning solution, which dam age molybde-
num disulfide coat; instead, use a high-flash point
clea
ning solution and wipe slowly.
Idle Speed Inspection
Start the engine and warm it up thoroughly.
With the engine idling, turn the handlebar to both sides.
If handlebar movement changes the idle speed, the
throttle cables may be improperly adjusted or incorrectly
routed or damaged. Be sure to correct any of these
conditions before riding (see Cable, Wire, and Hose
Routing section in the Appendix chapter).
WARNING
Operation with improperly adjusted, incorrectly
routed or damaged cables could result in an unsafe
r
iding condition.
Check idle speed.
If the idle speed is out of the specified range, adjust it.
Idle Speed
Standard: 1 100 ± 50 r/min (rpm)
Idle Speed Adjustment
Start the engine and warm it up thoroughly.
Turn the adjusting screw [A] until the idle speed is correct.
Open and close the throttle a few times to make sure that
the idle speed is within the specified range. Readjust if
necessary.
Front [B]
PERIODIC MAINT EN ANCE 2-15
Periodic Maintenan ce Procedures
Engine Vacuum Synchronization Inspection
NOTE
These procedures are explained on the assumption that
the inl
et and exhaust systems of the engine are in good
condition.
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 the
right fitting of each throttle body.
Pull off the vacuum switch valve hose (thick) [A] from the
air cleaner housing [B].
Front [C]
CAUTION
Do not remove the inlet air pressure sensor hoses
on the left fitting of each throttle body.
Connect a commercially available vacuum gauge to these
right fittings of the throttle body as shown.
Connect a highly accurate tachometer to one of the stick
coil primary leads.
Plug:
Vacuum Switch Valve Hose (thick) and its Air Cleaner
Housing Hole
Vacuum Hoses of Throttle Assy (see the next figure)
A. Except California D. Vacuum Switch Valve Hose (small) G. Canister
B. California E. I nlet Air Pressure Sensor Hose H. Vacuum Gauge
C. Front F. S eparator I. Plugs
2-16 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Install t he fuel tank (see Fuel System (DFI) chapter).
Start the engine and warm it up thoroughly.
Check t
he 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 of
the met
er unit.
While idling the engine, inspect the engine vacuum, using
the va
cuum gauge [B].
Front [C]
Engine Vacuum
Standard: 32.7 ± 1.333 k Pa (245 ± 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 #2
throttle valves by using the center adjusting screw [A].
Spe
cial Tool -
Pil
ot 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 the
highest vacuum of #3 and #4 (example 200 mmHg) to
the highest vacuum of #1 and #2 (example 190 mmHg)
by turning the center adjusting screw.
NOTE
After adjustment, the final vacuum measurement be-
tween the highest throttle valves may not be 200 mmH g
(in this example). The goal is to have the highest two
vacuums betw een the left (1 and 2) and right (3 and 4)
banks be t he same.
Open and close the throttle after each m easurement and
adjust the idle speed as necessary.
Once the throttle valves have been synchronized, inspect
the main throttle sensor’s output voltage to ensure proper
operation (procedure is at the end of this section).
PERIODIC MAINT EN ANCE 2-17
Periodic Maintenan ce Procedures
If any one vacuum measurement is out of the standard
measurement after synchronization, adjust the bypass
screws [A].
Front [B]
Special Tool - Pilot Screw Adjuster, C: 57001-1292
Adjust the lowest vacuum between #1 and #2 to the high-
est 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 after each measurement 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 cannot be adjusted within the specification,
remove the bypass screws #1 #4 and clean them.
Turn in the bypass screw and count the number of turns
until it seats fully but not tightly. Record the number of
turns.
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] and
O-ring [D].
Check the bypass screw and its hole for carbon deposits.
If any carbon accumulates, wipe the carbon off the bypass
screw and the hole, using a cotton pad penetrated with a
high-flash point solvent.
Replace the O-ring with a new one.
Check the tapered portion [E] of t he bypass screw for
wear 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 first
turned in. This is to set the screw to its original position.
NOTE
A throttle body has different turns out” of the bypass
screw for each individual unit. When setting the bypass
screw, use the “turns out” determined during disassem-
bly. Use t he 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 of
the main throttle sensor (see Output Voltage Inspection of
Main Throttle Sensor in the Fuel System (DFI) chapter).
Main Throttle Sensor Output Voltage
Connections 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 throttle
input voltage (see Input Voltage Inspection of Main Throt-
tle Sensor in the Fuel System (DFI) chapter).
Remove the vacuum gauge hoses and install the vacuum
hoses and rubber caps on the original position as shown.
A. Except California C. Front F. Separator
B. California D. Vacuum Switch Valve Hose (small) G. Canister
E. Inlet Air Pressure S ensor Hose
PERIODIC MAINT EN ANCE 2-19
Periodic Maintenan ce Procedures
Air Cleaner Element Cleaning
NOTE
In dusty areas, the element should be cleaned more
freque
ntly than the recommended interval.
After riding through rain or on m uddily roads, the ele-
ment should be cleaned immediately.
WARNING
If dirt or dust is allowed to pass through into the
throttle assy, the throttle m ay become stuck, possi-
bly ca
using accident.
CAUTION
If dirt gets through into the engine, excessive en-
gine w
ear and possibly engine damage will occur.
WARNING
Clean the element in a well-ventilated area, and take
care that there are no sparks or flame anywhere
near the working area; this includes any appliance
with a pilot light.
Because of the danger of highly flammable liquids,
do not use gasoline or a low flash-point solvent to
clean the element.
Remove the fuel tank (see Fuel System (DFI) chapter).
Remove the fuel tank bracket [A].
Front [B]
Remove:
Screw [A] and Air Cleaner Duct Holder [B]
Pull it out [C] backwards.
Front [D]
2-20 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Clean the element by tapping it lightly to loosen dust.
Blow away the remaining dust by applying compressed
air [A]
from the outside to the inside (from the clean side
to the dirty side).
Visually inspect the element f or no tears or no breaks and
inspe
ct the sponge gaskets [B] also.
If the element or gasket has any tears or breaks, replace
the element.
Install the element [A] with the flat side [B], facing for-
wards.
Fit the tongue [C] of the air cleaner duct holder into the
slot of the housing the air cleaner duct holder.
Front [D]
Torque - Air Cleaner Duct Holder Screws: 3.8 N·m (0.39
kgf·m, 34 in·lb)
Evaporative Emission Control System Inspection
(CAL)
Inspect the canister as follows:
Remove the rear seat (see Frame chapter).
Remove the band [A] and hoses and take out the canister
[B].
Visually inspect the canister for cracks and other damage.
If the canister has any cracks or bad dam age, replace it
with a new one.
NOTE
The canister is designed to work well through the motor-
cycle’s life without any maintenance if it is used under
normal conditions.
Connect the purge hose (green) [C] and the canister
breather hose (blue) [D] to the canister as shown.
Install the canister with the inlet [E] down and the rear seat
(see Frame chapter).
Front [F]
Check the liquid/vapor separator as follows:
Remove the left frame cover [A].
PERIODIC MAINT EN ANCE 2-21
Periodic Maintenan ce Procedures
Disconnect the hoses from the separator, and remove the
separator [A] from the motorcycle left side.
Front [B]
Visually inspect the separator for cracks and other dam-
age.
If the separator has any cracks or damage, replace i t with
a new one.
To prevent the gasoline from flowing into or out of the
canister, hold the separator perpendicular to the ground.
Check the hoses of the evaporative emission control sys-
tem as follows:
Check that the hoses are securely connected and clips
are beyond the raised rib of the pipe.
Replace any kinked, deteriorated or damaged hoses.
Route the hoses according to Cable, Wire, and Hose
Routing section in the Appendix chapter.
When installing the hoses, avoid sharp bending, kinking,
flattening or twisting, and route these hoses with a mini-
mum of bending so that the emission flow will not be ob-
structed.
Cooling System
Radiator Hose and Connection Inspection
The high pressure inside the radiator hose can cause
coolant to leak [A] or the hose to burst if the line is not
properly maintained. Visually inspect the hoses for signs
of deterioration. Squeeze the hoses. A hose s hould not
be hard and brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.
Check t hat the hoses are securely connected and clamps
are tightened correctly.
Torque - Radiator Hose Clamp Screws: 2 N·m (0.2 kgf·m,
17 in·lb)
Coolant Change
WARNING
To avoid burns, do not remove the radiator cap or
try to change the coolant when the engine is still
hot. Wait until it cools down.
Coolant on tires will make them slippery, and can
cause an accident and injury.
Since coolant is harmful to the human body, do not
use for drinking.
Place a container under the water pump drain bolt [A],
then remove the drain bolt.
Front [B]
2-22 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Remove the fuel tank (see Fuel System (DFI) chapter).
Remove the radiator cap [A] in two steps. First turn the
cap cou
nterclockwise to the first stop. Then push and turn
it further in the same direction and remove the cap.
The c oolant will drain from the radiator and engine.
Front
[B]
Remove :
Left Side Cover (see Frame chapter)
Reserve Tank Screws [A]
Turn over [B] the reserve tank, remove the cap [C], and
pour the coolant into a suitable container.
Install the reserve tank.
Torque - Coolant Reserve Tank Screws: 7 N·m ( 0.7 kgf·m,
61 in·lb)
When filling the coolant, choose a suitable mixture ratio
by referring to the coolant manufacturer’s directions.
CAUTION
Soft or distilled water must be used with the an-
tifreeze in the cooling system.
If hard water is used in the system, it causes scale
accumulation 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)
Tighten the drain bolt.
Torque - Water Pump Drain Bolt: 11 N·m (1.1 kgf·m, 95 in·lb)
Fill the radiator up to the filler neck [A] with coolant.
NOTE
Pour in the coolant slowly so that it can expel the air
from the engine and radiator.
Check the cooling system for leaks.
PERIODIC MAINT EN ANCE 2-23
Periodic Maintenan ce Procedures
Loosen the air bleeder bolt [A] on the thermostat housing.
Front [B]
Replenish the coolant into the radiator until the coolant
begins to flow out the air bleeder bolt hole (that is, all the
remaining air is forced out).
Tap the radiator hoses to force any air bubbles caught
inside.
Fill the radiator up to the filler neck [A] with coolant.
Tighten the air bleeder bolt [B].
Torque - Thermostat Air Bleeder Bolt: 7.8 N·m (0.80 kgf·m,
69 in·lb)
Fill the reserve tank up to the “F” (full) level line [A] with
coolant 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 times
while the engine is cooling down, and replenish as nec-
essary.
If the coolant level is lower than the “L” level line, add
coolant to the “F” level line.
CAUTION
Do not add more coolant above the “F” level line.
Engine Top End
Air Suction Valve Inspection
Remove the air suction valve (see Air Suction Valve Re-
moval in the 5. Engine Top End chapter).
Visually inspect the reeds for cracks, folds, warps, heat
damage or other damage.
If there is any doubt as to the condition of the reeds [A],
replace the air suction valve as an assembly.
Check the reed contact areas [B] of the valve holder for
grooves, scratches, any signs of separation from the
holder or heat dam age.
If there is any doubt as to the condition of the reed contact
areas, replace the air suction valve as an assembly.
If any carbon or other foreign particles have accumulated
between the reed and the reed contact area, wash the
valve assembly clean with a high-flash point solvent.
CAUTION
Do not scrape off the deposits with a scraper as this
could damage the rubber, requiring replacement of
the suction valve assembly.
2-24 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Valve Clearance Inspection
NOTE
Valve clearance must be checked and adjusted when
the engine is cold (at room temperature).
Remove:
Lower Fairings (see Frame chapter)
Pickup Coil Cover
Cylinder Head Cover (see Cylinder Head Cover Re-
moval)
Position the crankshaft at 1,4 piston TDC.
TDC Mark [A] for #1, 4 Pistons
Timi
ng Mark [B]
Using a thickness gauge [A], measure the valve clearance
between the cam and the valve lifter.
Valve Clearance
Standard:
IN:
0.15 0.24 mm (0.0059 0.0094 in.)
EX: 0.22 0.31 mm (0.0087 0.0122 in.)
When positioning #4 piston TDC at the end of the
compression stroke:
Inlet valve clearance of #2 and #4 cylinders
Exhaust valve clearance of #3 and #4 cylinders
Measuring Valve [A]
When positioning #1 piston TDC at the end of the
compression stroke:
Inlet valve clearance of #1 and #3 cylinders
Exhaust valve clearance of #1 and #2 cylinders
Measuring Valve [A]
If the valve clearance is not within the specified range,
first record the clearance, and then adjust it.
PERIODIC MAINT EN ANCE 2-25
Periodic Maintenan ce Procedures
Valve Clearance Adjustment
To change the valve clearance, remove the camshaft
chain tensioner, camshafts and valve lifters. Replace the
shim with one of a different thickness.
NOTE
Mark and record the valve lifter and shim locations so
they c
an be reinstalled in their original positions.
If there is no clearance, select a shim which is several
sizes smaller and then m easure the clearance.
To select a new shim which brings the valve clearance
within the specified range, refer to the Valve Clearance
Adjustment Charts.
Apply a thin coat of molybdenum disulfide grease to the
valve lifters.
Install the camshafts. Be sure to time the camshafts prop-
erly (see Camshaft Installation).
Remeasure any valve clearance that was adjusted.
Readjust if necessary.
CAUTION
Do not put shim stock u nder the shim. This may
cause the shim to pop out at high rpm, causing ex-
tensive engine damage.
Do not grind the shim. This may cause it to fracture,
causing extensive engine damage.
2-26 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE
1. Measure the clearance (when engine is cold).
2. Check present shim size.
3. Match clearance in vertical column with present shim size in horizontal column.
4. Install the shim specified where the lines intersect. This shim will give the proper clearance.
Example: Present shim is 2.95 m m
Measured clearance is 0.45 mm
Replace 2.95 mm shim with 3.20 mm shim.
5. Remeasure the valve clearance and readjust if necessary.
PERIODIC MAINT EN ANCE 2-27
Periodic Maintenan ce Procedures
VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE
1. Measure the clearance (when engine is cold).
2. Check present shim size.
3. Match clearance in vertical column with present shim size in horizontal column.
4. Install the shim specified where the lines intersect. This shim will give the proper clearance.
Example: Present shim is 2.95 mm.
Measured clearance is 0.47 mm.
Replace 2.95 mm shim with 3.15 mm shim.
5. Remeasure the valve clearance and readjust if necessary.
2-28 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Clutch
Clutch Adjust Inspection
Pull the clutch lever just enough to take up the f ree play
[A].
Measure the gap between the lever and the lever holder.
If the gap is too wide, the clutch may not release fully. If
the gap is too narrow, the clutch may not engage fully. In
either case, adjust it.
Clutch Lever Free Play
Standard: 2 3mm(0.08 0.12 in.)
WARNING
To avoid a serious burn, never touch the engine or
exhaust pipe during clutch adjustment.
Turn the adjuster [ A] so that 5 6 mm (0.20 0.24 in.) [B]
of threads are visible.
Slide the dust cover [A] at the clutch cable lower end out
of place.
Loosen both adjusting nuts [B] at the clutch cover as far
as they will go.
Pull the clutch outer cable [C] tight and tighten the adjust-
ing nuts against t he bracket [D].
Slip the rubber dust cover back onto place.
Turn the adjuster at the clutch lever until the free play is
correct.
Push the release lever [A] toward the front of the motor-
cycle until it becomes hard to turn.
At this time, t he release lever should have the proper an-
gle shown.
If the angle is wrong, check the clutch and release parts
for wear.
WARNING
Be sure that the outer cable end at the clutch lever
is fully seated in the adjuster at the clutch lever, or
it could slip into place later, creating enough cable
play to prevent clutch disengagement.
After the adjustment, start the engine and check that the
clutch does not slip and that it releases properly.
PERIODIC MAINT EN ANCE 2-29
Periodic Maintenan ce Procedures
Engine Lubrication System
Engine Oil Change
Sit
uate the motorcycle so that it is vertical after warming
up the engine.
Remove the engine drain plug [A] to drain the oil.
The
oil in the oil f ilter can be drained by removing the filter
(see Oil Filter Change).
Replace the drain plug gasket [B] with a new one if it is
da
maged.
Tighten the drain plug.
Torque - Engine Drain Plug: 20 N·m ( 2.0 kgf·m, 14.5 ft·lb)
Pour in the specified type and amount of oil.
Engine Oil
Grade: API SE, SF or SG
API SH or SJ with JASO MA
Viscosity: SAE 10W–40
Amount:
3.1 L (3.3 US qt) (whe n filter is not removed)
3.3 L (3.5 US qt) (w he n filter is remove d)
3.8 L (4.0 US qt) ( when engine is completely
dry)
NOTE
Depending on the atmospheric temperature of your rid-
ing area, the engine oil viscosity should be changed ac-
cording to the chart.
Oil Filter Change
Drain the engine oil (see Engine Oil Change).
Remove:
Lower Fairing (see Frame chapter)
Remove the oil filter [A] with the oil filter w rench [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 (P/No. 16097–1070): 27 N·m (2.8 kgf·m,
20 ft·lb)
Oil Filter (P/No. 16097–0002): 31 N·m (3.2 kgf·m,
23 ft·lb)
NOTE
Hand tightening of the oil filter can not be allowed since
it does not reach to this tightening torque.
Pour in the specified type and amount of oil (see Engine
Oil Change).
2-30 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Wheels/Tires
Tire Inspection
As the tire tread wears down, the tire becomes more sus-
ceptible to puncture and failure. An accepted estimate is
that 90 % of all tire failures occur during the last 10 % of
tread life (90 % worn). So it is false economy and unsafe to
use the tires until they are bald.
Remove any imbedded stones or other foreign particles
from the tread.
Visually inspect t he tire for cracks and cuts, replacing the
tire in case of damage. Swelling or high spots indicate
internal damage, requiring tire replacement.
Measure the tread depth at the center of the tread with a
depth gauge [A]. Since the tire may wear unevenly, take
measurement at several places.
If any measurement is less than the service limit, replace
the tire.
Tread Depth
Front:
Standard: 3.4 mm (0.13 in.)
Service Limit: 1 mm (0.04 in.)
1.6 mm (0.06 in.) (FG, AR, CH)
Rear:
Standard: 5.8 mm (0.23 in.)
Service Limit: 2 mm (0.08 in.)
(Upto130km/h(80mph))
3 mm (0.12 in.)
(Over 130 km/h (80 mph))
WARNING
To ensure safe handling and stability, use only the
recommended standard tires for replacement, in-
flated to the standard pressure.
NOTE
Most 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 replaced
with a new one.
PERIODIC MAINT EN ANCE 2-31
Periodic Maintenan ce Procedures
Air Pressure Inspection/Adjustment
Remove the air valve cap.
Measure the tire air pressure with an air pressure gauge
[A] when the tires are cold (that is, when the motorcycle
has not been ridden more than a mile during the past 3
hours).
Adjust the tire air pressure according to the specifications
if necessary.
Air Pressure (when cold)
Front 250 kPa (2.5 kgf/cm², 36 psi)
Rear
Up to 180 kg
(396 lb)
290 kPa (2.9 kgf/cm², 41 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)
Final Drive
Drive Chain Slack Inspection
NOTE
Check the slack with the motorcycle setting on its side
stand.
Clean the chain if it is dirty, and lubricate it if it appears
dry.
Check the wheel alignment (see Wheel Alignment Inspec-
tion).
Rotate the rear w heel to find the position where the chain
is tightest.
Measure the vertical movement (chain slack) [A] m idway
between the sprockets.
If the chain slack exceeds the standard, adjust it.
Chain Slack
Standard: 20 30 mm (0.8 1.2 in.)
Drive Chain S lack 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 chain
adjuster [D] evenly.
If the chain is too tight, turn in the left and right chain
adjusters evenly, and kick the wheel forward.
Turn both chain adjusters evenly until the drive chain has
the correct amount of slack. To keep the chain and wheel
properly aligned, the notch [E] on the left wheel alignment
indicator [F] should align with the same swingarm mark or
position [G] that the right indicator notch aligns with.
WARNING
Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
2-32 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Tighten both chain adjuster locknuts securely.
Tighten the axle nut.
Torque - Rear Axle Nut: 127 N·m (13 kgf·m, 94 ft·lb)
Turn the wheel, measure the chain slack again at t he tight-
est position, and readjust if necessary.
Insert a new cotter pin [A].
NOTE
When inserting the cotter pin, if the s lots in the nut do
not align w ith the cotter pin hole in the axle, tighten the
nut clockwise [B] up to next alignment.
It should be within 30 degree.
Loosen once and tighten again when the slot goes past
the nearest hole.
Bend the cotter pin [A] over the nut [B].
WARNING
If the rear axle nut is not securely tightened or the
cotter pin is not installed, an unsafe riding condi-
tion may result.
Wheel Alignment Inspection/Adjustment
Check that the notch [A] on the left alignment indicator [B]
aligns with the same swingarm mark or position [C] that
the right alignment indicator notch aligns with.
If they do not, adjust the chain slack and align the wheel
alignment (see Slack Adjustment).
NOTE
Wheel alignment can be also checked using the
straightedge or string method.
WARNING
Misalignment of the wheel will result in abnormal
wear, and may result in an unsafe riding condition.
Drive Chain Wear Inspection
Remove:
Left Side Muffler Body (see Engine Top End chapter)
Chain Cover Screws [A]
Chain Cover [B]
Mud Guard [C] (see Frame chapter)
PERIODIC MAINT EN ANCE 2-33
Periodic Maintenan ce Procedures
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] of
the chain from the pin center of the 1st pin to the pin center
of the 21st pin. Since the chain may wear unevenly, take
measurements at several places.
If any measurements exceed the service limit, replace the
chain. Also, replace the front and rear sprockets when the
drive chain is replaced.
Drive Chain 20-link Length
Standard: 317.5 318.2 mm (12.50 12.53 in.)
Service Limit: 323 mm (12.7 in.)
WARNING
If the drive chain wear exceeds the service limit, re-
place the chain or an unsafe riding condition may
result. A chain that breaks or jumps off the sprock-
ets could snag on the engine sprocket or lock the
rear wheel, severely damaging the motorcycle and
causing it to go out of control.
For safely, use only the standard chain. It is an end-
less type and should not be cut f or installation.
Standard Chain
Make: ENUMA
Type: EK525MVXL2
Link: 112 Links
Drive Chain Lubrication
If a special l ubricant is not available, a heavy oil such as
SAE 90 is preferred to a lighter oil because it will stay on
the chain longer and provide better lubrication.
If the chain appears especially dirty, clean it before lubri-
cation.
CAUTION
The O-rings betw een the side plates seal in the lu-
bricant between the pin and the bushing. To avoid
damaging 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 such as gasoline
or trichloroethylene will cause deterioration and
swelling of the O-ring.
Immediately blow the chain dry with compressed air
after cleaning.
Complete cleaning and drying the chain within 10
minutes.
2-34 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Apply oil to the sides of the rollers so that oil will penetrate
to the rollers and bushings. Apply the oil to the O-rings so
that th
e O-rings will be coated with oil.
Wipe off any excess oil.
Oil Applied Areas [A]
O-ring
[B]
Brakes
Brake Pad Wear Inspection
Check the lining thickness [A] of the pads in each caliper.
If the lining thickness of either pad is less than the service
limit [B], replace both pads in the caliper as a set.
Pad Lining Thickness
Standard:
Front
4 mm (0.16 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 on
after about 10 mm (0.39 in.) of the pedal travel [A].
PERIODIC MAINT EN ANCE 2-35
Periodic Maintenan ce 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.
CAUTIO
N
To avoid damaging the electrical connections in-
side the switch, be sure that the switch body does
not turn during adjustment.
Remove the right side cover (see Frame chapter).
Disconnect the connector [A].
Using a hand tester, i nspect 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 Connec tions:
If the switch has an open or short, replace it with a new
one.
Caliper Fluid Seal Damage
The fluid seals [A] around the piston maintain the proper
pad/disc clearance. If the seals are not satisfactory, pad
wear will increase, and constant pad drag on the disc will
raise brake and brake fluid temperature.
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 pad
wear; (d) the seal is stuck to the piston.
If the fluid seal is replaced, replace the dust seal [B] as
well. Also, replace all seals every other time the pads are
changed.
Caliper Dust Seal/Friction Boot Damage
Check that the dust seals [B] and friction boot [C] are not
cracked, w orn, swollen, or otherwise damaged.
If they show any damage, remove the caliper bracket and
replace them.
2-36 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Master Cylinder Inspection (Visual Inspection)
Disassemble the front and rear master cylinders.
Check t
hat there are no scratches, rust or pitting on the
inner wall [A] of each master cylinder and on the outside
of each piston [B].
If a ma
ster cylinder or piston shows any damage, replace
them.
Inspect the primary cup [C] and secondary cup [D].
If a c
up is worn, damaged softened (rotted), or swollen,
the piston assembly should be replaced to renew the
cups.
If fl
uid 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 t hem.
Check that relief port [ G] and supply port [H] are not
plugged.
If the relief port becomes plugged, the brake pads will
drag on the disc. Blow the ports clean with compressed
air.
Rear Master Cylinder [K ]
PERIODIC MAINT EN ANCE 2-37
Periodic Maintenan ce Procedures
Level Inspection
Check that the brake fluid level in the front brake reservoir
[A] is above the lower level line [B].
NOTE
Hold the reservoir horizontal by turning the handlebar
when checking brake fluid level.
If the fluid level is lower than the lower level line, fill the
reservoir to the upper level l ine [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 l ine, remove
the seats and fill the r eservoir to the upper level line [C].
WARNING
Do not mix two brands of fluid. Change the brake
fluid in the brake line completely if the brake fluid
must be refilled but the type and brand of the brake
fluid that is already in the reservoir are unidentified.
After changing the fluid, use only the same type and
brand of fluid thereafter.
Recommended Di sc Brake Fluid
Grade: DOT4
Follow the procedure below to install the rear brake fluid
reservoir cap correctly.
First, tighten the rear brake fluid reservoir cap [B] clock-
wise [C] by hand until the resistance is felt fully; then,
tighten the cap an additional 1/6 turn [D] while holding the
brake fluid reservoir [A] body.
Brake Fluid Change
NOTE
The procedure to change the front brake fluid is as fol-
lows. Changing the rear brake fluid is the same as for
the front brake.
2-38 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Level the brake fluid reservoir.
Remove the reservoir cap and diaphragm.
Remove
the rubber cap from the bleed valve [A] on the
caliper.
Attach a clear plastic hose [B] to the bleed valve, and run
the ot
her end of the hose i nto a container.
Fill the reservoir with fresh specified brake fluid.
Change the brake fluid:
Repeat this operation until fresh brake fluid comes out
from the plastic hose or t he 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].
NOTE
The fluid level must be checked often during the chang-
ing operation and replenished with fresh brake fluid. If
the fluid in the reservoir runs out any time during the
changing operation, the brakes will need to be bled
since air will have entered the brake line.
Front Brake: Repeat the above steps for the other
caliper.
Rear Brake: Repeat the above steps for the other bleed
valve.
Remove the clear plastic hose.
Install the reservoir cap.
Tighten:
Torque - Front Reservoir Cap Screw: 1.5 N·m (0.15 kgf·m,
13 in·lb)
Follow the procedure below to install the rear brake fluid
reservoir cap correctly.
First, tighten the rear brake fluid reservoir cap [B] clock-
wise [C] by hand until the resistance is felt fully; then,
tighten the cap an additional 1/6 turn [ D] while holding the
brake fluid reservoir [A] body.
Tighten the bleed valve, and install the rubber cap.
Torque - Bleed Valve: 7.8 N·m (0.80 k gf·m, 69 in·lb)
After changing the fluid, check the brake f or good braking
power, no brake drag, and no fluid leakage.
If necessary, bleed the air from the lines.
PERIODIC MAINT EN ANCE 2-39
Periodic Maintenan ce Procedures
Brake Line Bleeding
The brake fluid has a very low compression coefficient so
that almost all the movement of the brake lever or pedal
is transmitted directly to the caliper for braking action. Air,
however, is easily compressed. When air enters the brake
lines, brake lever or pedal movement will be partially used
in compressing the air. This will make the lever or pedal feel
spongy, and there will be a loss in braking power.
WARNING
Be sure to bleed the air from the brake line when-
ever brake lever or pedal action feels soft or
spongy after the brake fluid is changed, or when-
ever a brake line fitting has been loosened for any
reason.
NOTE
The procedure to bleed the front brake line is as follows.
Bleeding the rear brake line is the same as for the front
brake.
Remove the r eservoir cap and diaphragm.
Fill the reservoir with fresh brake fluid to the upper level
lin
einthereservoir.
With the reservoir cap off, slowly pump the brake lever
several times until no air bubbles can be seen rising up
thr
ough the fluid from the holes at the bottom of the reser-
voir.
Bleed the air completely from the master cylinder by this
op
eration.
Remove the rubber cap from the bleed valve on the
caliper.
At
tach a clear plastic hose to the bleed valve, and run the
other end of the hose into a container.
2-40 PERIODIC MAINTENANCE
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 h ose.
1. Pump the brake lever until it becomes hard, and apply
thebrakeandholdit[A].
2. Quick
ly open and close [B] the bleed valve while hold-
ing the brake applied.
3. Release the brake [C].
NOTE
The fluid level must be checked often during the bleed-
ing operation and replenished w ith fresh brake fluid as
necessary. If the fluid in the reservoir runs completely
out any time during bleeding, the bleeding operation
must be done over again from the beginning since air
will 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 other
caliper.
Remove the clear plastic hose.
Install the reservoir cap.
Tighten:
Torque - Front Reservoir Cap Screw: 1.5 N·m (0.15 kgf·m,
13 in·lb)
Follow the procedure below to install the rear brake fluid
reservoir cap correctly.
First, tighten the rear brake fluid reservoir cap [B] clock-
wise [C] by hand until the resistance is felt fully; then,
tighten the cap an additional 1/6 turn [ D] while holding the
brake fluid reservoir [A] body.
Tighten the bleed valve, and install the rubber cap.
Torque - Bleed Valve: 7.8 N·m (0.80 k gf·m, 69 in·lb)
Check the fluid level.
After bleeding is done, check the brake for good braking
power, no brake drag, and no fluid leakage.
PERIODIC MAINT EN ANCE 2-41
Periodic Maintenan ce Procedures
WARNING
When working with the disc brake, observe the pre-
cautions listed below.
1. Never reuse old brake fluid.
2. Do not use fluid from a container that has been left
unsealed or that has been open for a long time.
3. Do not mix two types and brands of fluid for use in
the brake. This lowers the brake fluid boiling point
and could cause the brake to be ineffective. It may
also cause the rubber brake parts to deteriorate.
4. Don’t leave the reservoir cap off for any length of
time to avoid moisture contamination of the fluid.
5. Don’t change the fluid in the rain or when a strong
wind is blowing.
6. Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning of the brake parts. Do not use any other
fluid 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 will
be difficult to wash off completely and will eventually
deteriorate the rubber used in the disc brake.
7. When handling the disc pads or disc, be careful that
no disc brake fluid or any oil gets on them. Clean off
any fluid or oil that inadvertently gets on the pads or
disc with a high-flash point solvent. Do not use one
which will leave an oily residue. Replace the pads
with new ones if they cannot be cleaned satisfacto-
rily.
8. Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely wiped up imme-
diately.
9. If any of the brake line fittings or the bleed valve is
opened at any time, the AIRMUSTBEBLEDFROM
THE 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 to
leak [A] or the hose to burst if the line is not properly main-
tained. Bend and twist the rubber hose while examining
it.
Replace the hose if any cracks [B] or bulges [C] are no-
ticed.
Tighten any loose fittings.
2-42 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Suspension
Front Fork Oil Leak Check
Visually inspect the front forks [A] for oil leakage, scoring
or scratches on the outer surface of the inner tubes.
Replace or repair any defective parts, if necessary.
Rear Shock Absorber Oil Leak Check
Visually inspect the shock absorbers [A] for oil leakage.
If the oil leakage is found on it, replace the shock absorber
with a new one.
Swingarm Pivot Lubrication
The grease nipple [A] is equipped for t he lubrication of
swingarm bearing. Force grease into the nipple until the
grease comes out from right side of the swingarm pivot,
and wipe off any excess of it.
Uni-trak Linkage Lubrication
In order for the tie-rod and rocker arm to function safely
and wear slowly, it should be lubricated in accordance with
the Periodic Maintenance Chart.
For the rocker arm and tie-rod needle bearings, there are
grease nipples [A] on the rocker arm and swingarm for
lubrication. Force grease into the nipples until it comes
out at both sides of the rocker arm and tie-rod, and wipe
off any excess.
PERIODIC MAINT EN ANCE 2-43
Periodic Maintenan ce Procedures
Steering
Steering Inspection
Lif
t the front wheel off the ground using the jack.
Special Tool - Jack: 57001–1238
With the front wheel pointing straight ahead, alternately
tap each end of the handlebar. The front wheel should
swing fully left and right from the force of gravity until the
fork hits the stop.
If the wheel binds or catches before the stop, the steering
is too tight.
Feel for steering l ooseness by pushing and pulling the
forks.
If you feel looseness, the steering is too loose.
NOTE
The 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 properly
lubricated in order for any test to be valid.
Steering Adjustment
Adjust the steering, if necessary.
Remove:
Windshield and Bracket (see Frame chapter)
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 stem
head bolt [B].
Remove the steering stem head [C].
Bend the claw washer tabs [A].
Remove the steering stem locknut [B] and claw washer
[C].
2-44 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Adjust the steering.
Special Tool - Steering Stem Nut Wrench: 57001–1100 [B]
If the steering is too tight, loosen the stem nut [A] a fraction
of a turn.
If the steering is too loose, tighten the stem nut a fraction
of a turn.
NOTE
Turn the stem nut 1/8 turn at time maximum.
Install the claw washer [A] so that its bent side [B] faces
upward, and engage the bent claws with the grooves of
stem locknut [C].
Hand tighten the stem l ocknut until it touches the claw
washer.
Tighten the stem locknut clockwise until the claws are
aligned with the grooves (ranging from 2nd to 4th) of stem
nut [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):
8.8 N·m (0. 90 kgf·m, 78 in·lb)
13 N·m (1.3 kgf·m, 113 in·lb) ZR1000–A2
Check the steering again.
If the steering is still too tight or too loose, repeat the ad-
justment.
Stem Bearing Lubrication
Remove the steering stem.
Using a high flash-point solvent, wash the upper and
lower ball bearings in the cages, and wipe the upper and
lower outer races, which are press-fitted into the frame
head pipe, clean off grease and dirt.
Visually check the outer races and the ball bearings.
Replace the bearing assemblies if they show wear or
damage.
Pack the upper and lower ball bearings [A] in the cages
with grease, and apply a light coat of grease to the upper
and lower outer races.
Install the steering stem, and adjust the steering.
Electrical System
Spark Plug Cleaning and Inspection
Remove:
Fuel Tank (see Fuel System (DFI) chapter)
PERIODIC MAINT EN ANCE 2-45
Periodic Maintenan ce Procedures
Unscrew the thermostat bracket bolt [A].
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] from
the 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 subharness connector [A] from the
bracket.
Remove:
Stick Coil Connector #4 [B] (disconnect)
Stick Coil #4 [C]
Stick Coil Connector #3 [D] (disconnect)
Disconnect:
Water Temperature Sensor Connector [A]
Left Switch Housing Connector [ B]
Pull the main harness [C] upward and remove the stick
coil #3 [D].
Remove the spark plugs using the 16 mm plug wrench
[A].
Owners Tool - Spark Plug Wrench, 16 mm: 92110–1132
2-46 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Clean the spark plug, preferably in a sandblasting device,
and then clean off any abrasive particles. The plug m ay
also be
cleaned using a high-flash point solvent and a wire
brush or other tool.
If the spark plug center electrode [A] and/or side elec-
trode
[B] are corroded or damaged, or if the insulator [C]
is cracked, replace the plug. Use the standard spark plug
or its equivalent.
Meas
ure the gaps [D] with a wire-type thickness gauge.
If the gap is incorrect, carefully bend the side electrode
with a tool to obtain the correct gap.
Spark Plug Gap: 0.7 0.8 mm (0.028 0.031 in.)
In
sertthesparkplugverticallyintotheplugholewiththe
spark plug installed in the plug wrench [A].
Owners Tool - Spark Plug Wrench, 16 mm: 92110–1132
Tighten:
Torque - Spark Plugs: 13 N· m (1.3 k gf·m, 113 in·lb)
Insert the coils as shown being careful of the coil head [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 [B] it
lightly.
Connect and/or install the connectors.
Install:
Fuel Tank (see Fuel System (DFI) chapter)
Thermostat Bracket Bolt (see Cooling System chapter)
PERIODIC MAINT EN ANCE 2-47
Periodic Maintenan ce Procedures
General Lubrication
Lubrication
Bef
ore lubricating each part, clean off any rusty spots with
rust remover and wipe off any grease, oil, dirt, or grime.
Lubricate the points listed below with indicated lubricant.
NOTE
Whenever the vehicle has been operated under
wet or rainy conditions, or especially after using a
high-pressure water spray, perform the general lubri-
cation.
Pivots: Lubricate with Motor Oil
Rear Brake R od Joint
Points: Lubricate with Grease
Throttle and Choke Inner Cable Upper E nds [A]
C
lutch Lever Pivot
Brake Lever Pivot (Apply silicone grease)
Brake Pedal Pivot
S
ide Stand
Tie-Rod Pivots
Rocker Arm Pivots
Sw
ingarm Pivot
Cables: Lubricate with Cable Lubricant
Choke Cable
Throttle Cables
Clutch Cable
Lubricate the cables by seeping the oil between the cable
and housing.
The cable may be lubricated by using a com mercially
available pressure cable lubricator with an aerosol cable
lubricant.
With the cable disconnected at both ends, the cable
should move freely [A] within the cable housing.
If cable movement is not free after lubricating, if the cable
is frayed [B] or if the cable housing is kinked [C], replace
the cable.
2-48 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Nut, Bolt, and Fastener Tightness
Tightness Inspection
Check the tightness of the bolts and nuts listed here. Also,
check to see that each cotter pin is in place and in good
condition.
NOTE
For the engine fasteners, check the tightness of them
when 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 each
fastener, 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 checked
Wheels:
Front Axle
Front Axle Clamp Bolts
Rear Axle Nut
Rear Axle Nut Cotter Pin
Brakes:
Front Master Cylinder Clamp Bolts
Caliper Mounting Bolts
Rear Master Cylinder Mounting Bolts
Brake Lever Pivot Nut
Brake Pedal Bolt
Brake Rod Joint Cotter Pin
Suspension:
Front Fork Clamp Bolts
Front Fender Mounting Bolt
Rear Shock Absorber Mounting Nuts
Swingarm Pivot Shaft Nut
Swingarm Pivot Shaft Lock Nut
Uni-Trak Link Nuts
Steering:
Stem Head Nut
Handlebar Clamp Bolts
Engine:
Throttle Cable Adjuster Locknuts
Engine Mounting Bolts and Nuts
Downtube Bolts
Muffler Mounting Bolts
Exhaust Pipe Holder Nuts
Muffler Connecting Clamp Bolt
Clutch Lever Pivot Nut
Radiator Upper and Lower Bolts
Others:
Sidestand Bolt
Footpeg Stay Bolts
Rear Frame Mounting Bolts
FUEL SYSTEM (DFI) 3-1
3
Fuel System (DFI)
Table of C ontents
Exploded View................................... 3-3
DFI Parts Location............................. 3-8
DFI Wiring Diagram........................... 3-10
Specifications .................................... 3-12
Special Tools ..................................... 3-14
DFI Servicing Precautions................. 3-15
Troubleshooting the DFI System ....... 3-17
Outline ............................................ 3-17
Inquiries to Rider............................. 3-21
DFI System Troubleshooting Guide .. 3-24
Self-Diagnosis ................................... 3-33
Self-diagnosis Outline..................... 3-33
Self-diagnosis Procedures.............. 3-33
Service Code Clearing Procedures 3-34
How to Read Service Codes........... 3-36
How to Erase Service Codes.......... 3-36
Service Code Table......................... 3-37
Backups .......................................... 3-38
Main Throttle Sensor (Service Code
11)................................................... 3-40
Main Throttle Sensor
Removal/Adjustment ................. 3-40
Input Voltage Inspection............... 3-40
Output Voltage Inspection............ 3-41
Resistance Inspection.................. 3-42
Inlet Air Pressure Sensor (Service
Code 12) ......................................... 3-43
Removal....................................... 3-43
Installation.................................... 3-43
Input Voltage Inspection............... 3-43
Output Voltage Inspection............ 3-44
Inlet Air Temperature Sensor (Service
Code 13) ......................................... 3-48
Removal/Installation..................... 3-48
Output Voltage Inspection............ 3-48
Sensor Resistance Inspection ..... 3-49
Water Temperature Sensor (Service
Code 14) ......................................... 3-50
Removal/Installation..................... 3-50
Output Voltage Inspection............ 3-50
Sensor Resistance Inspection ..... 3-51
Atmospheric Pressure Sensor
(Service Code 15)........................... 3-52
Removal....................................... 3-52
Input Voltage Inspection............... 3-52
Output Voltage Inspection............ 3-53
Crankshaft Sensor (Service Code
21)................................................... 3-55
Crankshaft Sensor
Removal/Installation.................. 3-55
Crankshaft Sensor Inspection...... 3-55
Camshaft Position Sensor (Service
Code 23) ......................................... 3-56
Camshaft Position Sensor
Removal/Installation.................. 3-56
Camshaft Position Sensor
Inspection.................................. 3-56
Speed Sensor (Service Code 24, 25) 3-57
Speed Sensor
Removal/Installation.................. 3-57
Speed Sensor Inspection............. 3-57
Input Voltage Inspection............... 3-57
Output Voltage Inspection............ 3-57
Vehicle-down S ensor (Service Code
31)................................................... 3-59
Removal....................................... 3-59
Installation.................................... 3-59
Inspection..................................... 3-59
Subthrottle Sensor (Service Code
32)................................................... 3-62
Subthrottle Sensor
Removal/Adjustment ................. 3-62
Input Voltage Inspection............... 3-62
Output Voltage Inspection............ 3-63
Resistance Inspection.................. 3-64
Stick Coils (#1, #2, #3, #4: Service
Code 51, 52, 53, 54) ....................... 3-65
Removal/Installation..................... 3-65
Input Voltage Inspection............... 3-65
Subthrottle Valve Actuator (Service
Code 62) ......................................... 3-67
Subthrottle Valve Actuator
Removal .................................... 3-67
Audible Inspection........................ 3-67
Visual Inspection.......................... 3-67
Resistance Inspection.................. 3-67
Input Voltage Inspection............... 3-68
FI Indicator LED Light........................ 3-69
LED Light Inspection.................... 3-70
ECU................................................... 3-71
ECU Identification ........................ 3-71
ECU Removal .............................. 3-71
3-2 FUEL SYSTEM (DFI)
ECU Installation ........................... 3-71
ECU Power Supply Inspection..... 3-72
DFI Power Source ............................. 3-74
ECU Fuse Removal ..................... 3-74
ECU Fuse Installation .................. 3-74
ECU Fuse Inspection ................... 3-74
ECU Main Relay Removal ........... 3-74
ECU Main Relay Inspection......... 3-74
Fuel Line............................................ 3-75
Fuel Pressure Inspection ............. 3-75
Fuel Flow Rate Inspection ........... 3-76
Fuel Pump ......................................... 3-78
Fuel Pump Removal .................... 3-78
Fuel Pump Installation ................. 3-78
Operation Inspection.................... 3-79
Operating Voltage Inspection....... 3-79
Pressure Regulator Removal....... 3-80
Pump Screen, Fuel Filter
Cleaning.................................... 3-80
Fuel Pump Relay Removal .......... 3-81
Fuel Pump Relay Inspection ........ 3-81
Fuel Injectors..................................... 3-82
Removal/Installation..................... 3-82
Audible Inspection........................ 3-82
Power Source Voltage Inspection 3-82
Output Voltage Inspection............ 3-83
Injector Signal Test....................... 3-84
Injector Resistance Inspection ..... 3-85
Injector Unit Test .......................... 3-85
Injector Fuel Line Inspection........ 3-85
Throttle Grip and Cables ................... 3-88
Throttle Grip Play
Inspection/Adjustment............... 3-88
Choke Lever O peration................ 3-88
Choke Lever P lay Inspection ....... 3-88
Choke Lever Play Adjustment ...... 3-88
Cable Removal/Installation .......... 3-88
Cable Lubrication and Inspection. 3-88
Throttle Body Assy ............................ 3-89
Idle Speed Inspection/Adjustment 3-89
Throttle Bore Cleaning ................. 3-89
Engine Vacuum Synchronization
Inspection/Adjustment............... 3-89
High Altitude Performance
Adjustment ................................ 3-89
Throttle Body Assy Removal........ 3-89
Throttle Body Assy Installation..... 3-91
Throttle Body Assy Disassembly . 3-92
Throttle Body Assy Assembly ...... 3-93
Air Cleaner......................................... 3-94
Element Rem oval/Installation ...... 3-94
Air Cleaner Oil Draining ............... 3-94
Air Cleaner Housing Removal...... 3-94
Fuel Tank ........................................... 3-95
Fuel Tank Removal ...................... 3-95
Fuel Tank Installation ................... 3-97
Fuel Tank and Cap Inspection ..... 3-98
Fuel Tank Cleaning ...................... 3-98
Evaporative Emission Control
System............................................ 3-99
Parts Removal/Installation ........... 3-99
Canister Installation ..................... 3-99
Hose Inspection ........................... 3-99
Separator Inspection.................... 3-99
Separator Operation Test............. 3-100
FUEL SYSTEM (DFI) 3-3
Exploded View
Clifornia Evaporative Emission Control System
1. Canister
2. Separator
3. Right fitting of throttle body #2
4. Right fitting of throttle body #3
5. Canister purge hose (green)
6. Fuel return hose (left, red)
7. Fuel tank breather hose (right, blue)
8. Separator breather hose (blue)
9. Separator vacuum hose (white)
3-4 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-5
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Throttle cable plate bolt 6 0.6 52 in·lb
2 Throttle body cover bolts 7 0.7 61 in·lb
3 Throttle assy holder clamp bolts 2 0.2 17 ilb
4 Choke link holder screws 2.1 0.21 18 in·lb
5 Delivery pipe screws 3.4 0.35 30 in·lb
6 Bypass screws 0.2 0.02 1. 7 in·lb
7 Fuel pump bolts 9.8 1.0 87 in·lb S, L
8 Fuel level sensor bolts 6.9 0.7 62 in·lb
9. FI indicator LED light
10. Meter unit
11. Throttle cable (accelerator)
12. Throttle cable (decelerator)
13. Choke cable
14. Injector connectors
15. Main throttle sensor connector (grey)
16. Subthrottle sensor connector (black)
17. Subthrottle valve actuator connector
18. Throttle body assy connector
19. Main throttle sensor
20. Subthrottle sensor
21. Injectors
22. Center adjusting screw
CL: Apply cable lubricant.
EO: Apply engine oil to the seals and O-rings.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts.
S: Follow the specified tightening sequence.
3-6 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-7
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Inlet air pressure sensor bolt 12 1.2 104 in·lb
2 Water temperature sensor 25 2.5 18
3 Vehicle downsensor bolts 2 0.2 17 in·lb
4 Camshaft position sensor bolt 12 1.2 104 in·lb
5
Camsh
aft position sensor rotor bolt
12 1.2 104 in·lb L
6 Air cleaner duct holder screws 3.8 0.39 34 ilb
7 Air cleaner housing mounting bolts 9.8 1.0 87 in·lb
8 Air cleaner duct clamp bolts 2 0.2 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 0.7 62 in·lb L
12. Inlet air pressure sensor
13. Stick coils (see Electrical System chapter)
14. ECU
15. Fuel pump relay
16. ECU main relay
17. Atmospheric pressure sensor
18. Crankshaft sensor (see Electrical System chapter)
19. Inlet air temperature sensor
20. Vacuum switch valve (see Engine Top End chapter)
21. Air suction valves
22. Grommet
L: Apply a non-permanent locking agent.
3-8 FUEL SYSTEM (DFI)
DFI Parts Location
DFI: D FI Parts (this chapter) 8. ECU Fuse 15A 19. Turn Signal Relay
F: Front 9. ECU (DFI) 20. Subthrottle Sensor (DFI)
1. Water temperature 10. Stick Coils 21. Main Throttle Sensor (DFI)
Sensor (DFI) 11. Throttle Body Assy 22. Ignition Switch
2. Inlet Air Pressure 12. Self-diagnosis Terminal 23. FI Indicator LED Light (DFI)
Sensor (DFI) 13. Neutral Switch 24. Crankshaft Sensor
3. Injectors (DFI) 14. Vehicle D own Sensor (DFI) 25 Camshaft Position Sensor
4. Fuel Pump (DFI) 15. Atmospheric Pressure 26 Fuel Pump Screen
5. Inlet Air Temperature Sensor (DFI) 27 Return Fuel Check Valve
Sensor (DFI) 16. Delivery Pipe 28 Pressure Regulator
6. Sealed Battery 17. ECU Main Relay 29 Fuel Filter
7. Junction Box 18. Fuel Pump Relay ( DFI)
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 D iagram
Terminal Names
1. Power Supply to Sensors (inlet air pres-
sure, a
tmospheric pressure, and throttle
sensors) from ECU.
2. Main Throttle Sensor Signal
3. Subth
rottle Sensor Signal for ECU
4. Atmospheric Pressure Sensor Signal
5. Water Temperature Sensor Signal (+)
6.7.
8.
9. Camshaft Position Sensor Signal ( +)
10.
11. Cran
kshaft S ensor Signal (+)
12.
13. Power Supply to ECU, Injectors, and Fuel
Pum
p
14. Sensor Ground (inlet air temperature,
water temperature, inlet air pressure, at-
mos
pheric pressure, vehicle-down, and
throttle sensors)
15.
16
.
Ve
hicle-down Sensor Signal
17. Inlet Air Pressure Sensor Signal
18. Inlet Air Temperature Sensor Signal (+)
19
.
20. Speed S ensor S ignal
21.
2
2.
C
amshaft Position Sensor Signal (–)
23.
24. Crankshaft Sensor (–)
2
5.
26. ECU Power Source Circuit Ground to Bat-
tery (–) Terminal
27. Engine
Stop Switch Signal
28. Starter Lockout Switch Signal
29. Electric Starter Button Signal
30. Signa
l For Fuel Pump Relay
31. Subthrottle Valve Actuator Drive Signal
32. Subthrottle Valve Actuator Drive Signal
33.
34. Tachometer Signal
35. Injector #2 Signal
36. Inje
ctor #1 Signal
37. Stick Coil #3 Signal
38. Stick Coil #2 Signal
39. Sti
ck Coil #1 Signal
40. Interlock Circuit Signal
41. Self-diagnosis Signal (generated by
gro
unding this terminal and shown by
FI indicator LED light)
42.
43
.
Ba
ttery Power ON-OFF Signal
44. Subthrottle Valve Actuator Drive Signal
45. Subthrottle Valve Actuator Drive Signal
46
.
47. FI Indicator LED Light Signal
48. Injector #4 Signal
4
9.
I
njector #3 Signal
50. DFI System Ground
51. Ignition System Ground
5
2.
S
tick Coil #4 Signal
Part Name
A. ECU (Electronic Control Unit)
B. Crankshaft Sensor
C. Inlet Air Pressure Sensor
D. Water Temperature Sensor
E. Atmospheric Pressure Sensor
F. Inlet Air Temperature Sensor
G. Camshaft Position Sensor
H. Speed Sensor
I. Main Throttle Sensor
J. Subthrottle Sensor
K. Injectors #1, #2, #3, #4
L. Subthrottle Valve Actuator
M. Stick Coils #1, #2, #3, #4
N. Engine Stop Switch
O. Joint Connector D
P. see Electrical System chapter
Q. Ground Terminal
R. Ground Terminal
S. ECU Main Relay
T. Ignition Switch
U. FI Indicator LED Light
V. Tachometer
W. Speedometer
X. Ignition Fuse 10A
Y. Junction Box
Z. Fuel Pump Relay (for fuel pump and in-
jectors)
a. ECU Fuse 15A
b. Vehicle-down Sensor
d. Starter Relay
e. Joint Connector D
f. Sealed Battery
g. Fuel Pump
h. Self-diagnosis Terminal
j. Joint Connector B
k. Main F use 30A
m. Throttle B ody Assy Connector
n: Connector Locks
p: ECU C onnector
3-12 FUEL SYSTEM (DFI)
Specif ications
Item Standard
Digital Fuel Injection System
Idle Speed 1 100 ± 50 r/min (rpm)
Throttle Assy:
Type Four b
arrel type
Bore 38 mm (1.5 in.)
ECU ( Electronic Control Unit):
Make Denso
Typ
e
Digital m emory type, with built in IC igniter, sealed with resin
Usable engine speed 100 11 160 r/min (rpm)
Fuel Pressure (high pressure l ine):
Right after Ignition switch ON 310 kPa (3.2 kgf/cm², 46 psi) with fuel pump running
After 3 sec from Ignition switch
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 pum p running
F
uel Pump:
Type In-tank friction pump
Discharge
67 mL (2.3 US oz) or more for 3 seconds
Fuel Injectors:
Type INP–250
Nozzle type One spray type with 4 holes
Resistance
about 11.7 12.3 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 leads
Output voltage at idle throttle 0.99 1.03 V DC between Y/W and BR/BK leads
opening
Output voltage at full throttle 4.19 4.39 V DC between Y/W and BR/BK leads
opening
Resistance 4 6k
Inlet Air Pressure Sensor or
Atmospheric Pressure Sensor:
Input voltage
4.75 5.25 V DC between BL and BR/BK leads
Output 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 k at 20°C (68°F)
0.24 0.43 k 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 S witch ON
Output voltage at sensor about 0.05 0.07 V DC at I gnition Switch ON and 0 km/h
Vehicle-down S ensor:
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 7 or more: 3.7 4.4 V
with sensor arrow mark pointed up: 0.4 1.4 V
Subthrottle Sensor: Non-adjustable and non-removal
Input Voltage
4.75
5.25 V DC between BR and BR/BK leads
Output voltage at idle throttle 0.48 0.52 V DC between BR and BR/BK leads
opening
Output voltage at full throttle 3.6 3.8 V DC between BR and BR/BK leads
opening
Resistance 4 6k
Su
bthrottle Valve Actuator:
Resistance about 5 7k
Input voltage
a
bout 8.5 10.5 V DC
Throttle G rip 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
Carburetor Drain Plug Wrench, Hex 3:
57001–1269
Fork Oil Level Gauge:
57001–1290
Hand Tester:
57001–1394
Throttle Sensor Setting Adapter:
5
7001–1400
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):
5
6019–120
FUEL SYSTEM (DFI) 3-15
DFI Servicing Precautions
There are a number of important precautions that should
be followed servicing the DFI system.
This DFI system is designed to be used with a 12 V sealed
battery as its power source. Do not use any other battery
except for a 12 V sealed battery as a power source.
Do not reverse the battery cable connections. This will
damage t he ECU.
To prevent dam age to the DFI parts, do not disconnect the
battery cables or any other electrical connections when
the ignition switch is on or while the engine is running.
Take care not to short the leads that are directly con-
nected to the battery positive (+) terminal to the chassis
ground.
When charging, remove the battery from the motorcycle.
This is to prevent ECU damage by excessive voltage.
Do not turn the ignition switch ON while any of the DFI
electrical connectors are disconnected. The ECU memo-
rizes service codes.
Do not spray water on the electrical parts, DFI parts, con-
nectors, leads, and wiring. Never water a vehicle with
connectors unplugged because seals don’t work and ter-
minals could corrode.
If a transceiver is installed on the motorcycle, make sure
that the operation of the DFI system is not influenced by
electric wave radiated from the antenna. Check operation
of the system with the engine at idle. Locate the antenna
as far as possible away from the ECU .
When any fuel hose is disconnected, do not turn on the
ignition switch. Otherwise, the fuel pump will operate and
fuel will spout from the fuel hose.
Do not operate the fuel pump if the pump is completely
dry. 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 out
by residual pressure in the fuel line. Cover the hose joint
with a piece of clean cloth to prevent fuel spillage.
To prevent corrosion and deposits in the fuel system, do
not add to fuel any fuel antifreeze chemicals.
Whenever the DFI electrical connections are to be discon-
nected, first turn off the ignition switch. Conversely, make
sure that all the DFI electrical connections are firmly re-
connected before starting the engine.
Whenever the DFI electrical connections are to be dis-
connected, first turn off the ignition switch, and disconnect
the battery (–) terminal. Do not pull the lead, only the con-
nector. Conversely, make sure that all the DFI electrical
connections are firmly r econnected before starting the en-
gine.
When disconnecting the vehicle-down sensor connector,
raise the lock of the connector. Push the lock of the other
connectors.
3-16 FUEL SYSTEM (DFI)
DFI Servicing Precautions
To maintain the correct fuel/air mixture (F/A), there must
be no inlet air leaks in the DFI system. Be sure to install
the oil
filler plug [A] after filling the engine oil.
Clutch Cover [B]
Front [C]
Torque - Oil Filler Plug: 1.5 N·m (0.15 kgf·m, 13 in·lb)
FUEL SYSTEM (DFI) 3-17
Troubleshooting the DFI System
Outline
When an abnormality in the system occurs, the FI indica-
tor
LED (Light Emitting Diode) light goes on to alert the rider
on the meter panel. In addition, the condition of the problem
is stored in the m emory of the ECU (electronic control unit).
Wit
h t he engine stopped and turned in the self-diagnosis
mode, the service code [A] is indicated by the number of
times the FI indicator LED light blinks.
Wh
en due to a malfunction, the FI indicator LED light re-
mains lit, ask the rider about the conditions [B] under which
the problem occurred and try to determine the cause [C].
Fi
rst, conduct a self-diagnosis inspection and then a non
-self-diagnosis inspection. The non–self–diagnosis items
are not indicated by the FI indicator LED light. Don’t rely
s
olely on the DFI self-diagnosis function, use common
sense.
Even when the DFI system is operating normally, the FI
indicator LED light [A] may light up under strong electrical
interference. No repair needed. Turn the ignition 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 erased
to preserve the problem history, and the LED light can dis-
play the codes in the self-diagnosis mode. The problem
history 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 and
ignition system. The FI indicator LED light blinks but the
fault code cannot be displayed. The ignition switch is left
ON. If the starter button is pushed, the electric starter turns
but the engine doesn’t start. To start the engine again, raise
the motorcycle, turn the ignition switch OFF, and then ON.
The vehicle-down sensor is turned ON and the LED light
goes OFF.
3-18 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
The DFI part connectors [A] have seals [B], including the
ECU.
Join th
e connector and insert the needle adapters (special
tool) [C] inside the seal [B] from behind the connector until
the adapter reaches the terminal.
Special Tool - Needle Adapter Set: 57001–1457
CAUTION
Insert the needle adapter straight along the terminal
in the connector to prevent short-circuit between
terminals.
Make sure that measuring points are correct i n the con-
nector, noting the position of the lock [D] and the lead
color before measurement. Do not reverse connections
of 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 switch O N and measure the voltage with
the connector joined.
CAUTION
Incorrect, reverse connection or short circuit by
needle adapters could damage the DFI or electrical
system 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)
- Seals of Connector
Always check battery condition before replacing the DFI
parts. A fully charged battery is a must for conducting
accurate tests of the DFI system.
Trouble may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the problem. If the problem was caused by
some other item or items, they too must be repaired or
replaced, 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 cause
reappearance of problems and unstable operation of the
DFI 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 it
is damaged, replace it. Connect the connectors securely.
Check the wiring for continuity.
Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
Connect the hand tester between the ends of the leads.
Set the tester to the × 1 range, and read the tester.
If the tester does not read 0 , the lead is defective. R e-
place the lead or the main harness or the sub harness.
If both ends of a harness [A] are far apart, ground [B] the
one 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 harness
is open, repair or replace the harness.
When checking a harness [A] for short circuit, open one
end [B] and check the continuity between the other end
[C] and ground [D]. If there is continuity, the harness has
a 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, the
DFI parts are the next likely suspects. Check the part,
starting with input and output voltages. However, there is
no 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, and
DFI parts, replace the ECU.
Lead Color Codes:
BK: Black
G: Green
P: Pink
BL: B lue GY: Gray PU: Purple
BR: Brown LB: Light blue R: Red
CH: C hocolate 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 is
voltage Check Method and the other is Resistance Check
Method
.
(Voltage Check Method)
This method is conducted by measuring the input voltage
[B] to
a sensor [A] first, and then the output voltage [C]
from the sensor.
Sometimes this method can detect a fault of the ECU.
Refer
to each sensor inspection section for detail in this
chapter.
Use a fully charged battery and a digital meter [D] which
can b
e read two decimal places voltage or resistance.
(Resistance Check Method)
This method is simple. No need for a fully charged battery
and the needle adapter. Just do the following especially
when a sensor [A] is suspect.
Turn the ignition switch OFF and disconnect the connec-
tors.
Inspect the sensor resistance, using a digital meter (see
each sensor inspection in this chapter).
Inspect the wiring and connectors [B] for continuity, using
the hand tester [C] (analog tester) rather than a digital
meter.
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 this
chapter). If the ground and power supply are good, the
ECU is suspect. Replace the ECU.
FUEL SYSTEM (DFI) 3-21
Troubleshooting the DFI System
DFI Diagnosis Flow Chart
Inquiries to Rider
Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms
the rider has encountered.
Try to find out exactly what problem occurred under exactly what 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 will
help 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 Sheet
Rider name: Registration No. (license plate No.): Year of initial registration:
Model: Engine No.: Frame No.:
Date problem occurred: Mileage:
Environment when problem occurred.
Weather fine, cloudy, rain, snow, always, other:
Temperature hot, warm, cold, very cold, always
Problem chronic, often, once
frequency
Road street, highway, mountain road ( uphill, downhill), bumpy, pebble
Altitude normal, high (about 1 000 m (3 281 ft) or more)
Motorcycle conditions when problem occurred.
FI indicator light up immediately after ignition switch O N, and goes off after 1 2 seconds
LED light (normal)
lights blinks immediately after ignition switch ON, and stays on (DFI problem)
lights up immediately after ignition switch 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 rotating
difficulty 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 engine
flooding)
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)
b ackfiring
a f terfiring
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
NOTE
This is not an exhaustive list, giving every possible cause for each problem listed. It is meant
simply
as a rough guide to assist the troubleshooting for some of the more common difficulties.
The ECU may be involved in the DFI electrical and ignition system troubles. If these parts and
circuits checked out good, be sure to check the ECU for ground and power supply. If the ground
and po
wer supply are checked good, replace the ECU.
Engine Doesn’t Start, Starting Difficulty
Sympt
oms or possible Causes
Actio
ns (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 v oltage 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 30A or ignition fuse blown Inspect and replace (see chapter 16).
St
arter motor rotating but engine doesn’t
turn 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 maladjusted
Clean spark plugs and adjust plug gap (see
chapter 2).
Starting technique faulty
When flooded, don’t crank engine with throttle
fully opened.
No spark or spark weak :
FUEL SYSTEM (DFI) 3-25
DFI System Troubleshooting Guide
Symptoms or possible Causes Actions (chapter)
Ignition and engine stop switches not ON Turn both switches ON .
Clutch lever not pulled in and gear not in neutral
wheth
er sidestand up or not
Pull the lever in and shift the gear in neutral.
Though clutch lever pulled in, sidestand up and
gear not in neutral
Pull the lever in and shift the gear in neutral.
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 maladjusted
Clean spark plug and adjust plug gap (see chapter
2).
Spar
k plug cap trouble
Insp
ect 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 switch
trouble
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 30A or ignition fuse blown Inspect and replace (see chapter 16).
F
uel/air mixture incorrect :
Air cleaner clogged, poorly sealed or missing
Clean or reinstall (see chapter 3).
Leak from oil filler cap, crankcase breather hose
or air cleaner drain hose
Inspect and repair or replace (see chapter 3).
Water or foreign matter in fuel
Change fuel. Inspect and clean fuel system (see
chapter 3).
Fuel pressure regulator trouble
Inspect fuel pressure and replace fuel pump (see
chapter 3).
Main throttle sensor trouble Inspect (see chapter 3).
Fuel pressure may be l ow 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).
Cylinder, piston worn Inspect and replace (see chapter 5).
Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapter 5).
3-26 FUEL SYSTEM (DFI)
DFI System Troubleshooting Guide
Symptoms or possible Causes Actions (chapter)
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).
Valvespringbrokenorweak Inspect and replace (see chapter 5).
Valve not seating properly (valve bent, worn or
carbon accumulating on seating surface)
Insp
ect and repair or replace (see chapter 5).
Poor Running at Low Speed
Symptoms or Possible Causes Actions (chapter)
Spark weak :
Battery voltage low Inspect and charge (see chapter 16).
Spark plug dirty, broken or gap maladjusted
Clean spark plugs and adjust plug gap (see
chapter 2).
Spark plug cap trouble Inspect t he 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 clogged
Inspect fuel pressure and replace fuel pump (see
chapter 3).
Fuel line clogged Inspect and repair (see chapter 3).
Inlet air pressure sensor trouble Inspect (see 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).
Inlet air temperature sensor trouble Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
FUEL SYSTEM (DFI) 3-27
DFI System Troubleshooting Guide
Symptoms or Possible Causes Actions (chapter)
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 s ensor trouble Inspect (see chapter 3).
Fuel pressure too low or too high
Insp
ect (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 trouble
Inspect fuel pressure and replace fuel pump (see
chapter 3).
Crankshaft sensor trouble Inspect (see chapter 16).
St
ick coil trouble
In
spect (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 c hapter 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 or
carbon 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 sensor
hose
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).
Main throttle sensor trouble Inspect (see chapter 3).
3-28 FUEL SYSTEM (DFI)
DFI System Troubleshooting Guide
Symptoms or Possible Causes Actions (chapter)
Subthrottle sensor trouble Inspect (see chapter 3).
Subthrottle valve actuator trouble Inspect (see chapter 3).
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).
Loos
e terminal of battery (–) lead or engine
ground lead
Inspect and repair (see chapter 16).
Delay of ignition timing
Inspect 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).
Wa
ter or foreign matter in fuel
Change fuel. Inspect and clean fuel system (see
chapter 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 maladjusted
Clean spark plugs and adjust plug gap (see
chapter 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 pressure
Fuel pressure regulator trouble (Inspect and
replace fuel pum p) or kinked fuel line (Inspect and
repair 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 maladjusted
Clean spark plugs and adjust plug gap (see
chapter 2).
Too lo
w fuel pressure
Inspe
ct (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
In
spect (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 switch trouble Inspect and repair or replace (see chapter 16).
Fuel injector trouble Inspect (see chapter 3).
Loose terminal of battery (–) lead or ECU
ground lead
Inspect and repair (see chapter 16).
Carbon accumulating on valve seating surface Repair (see chapter 5).
Engine overheating
(see Overheating of Troubleshooting Guide, see
chapter 17)
Other :
Engine oil viscosity too high Change (see chapter 2).
Drive train trouble
Inspect drive chain (see chapter 2) and sprocket
(see chapter 11).
Brake dragging
Inspect caliper fluid seal damage or clogging
of master cylinder relief and supply ports (see
chapter 12).
Clutch slipping Inspect friction plates for wear (see chapter 6).
Engine overheating
(see Overheating of Troubleshooting Guide, see
chapter 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 recovery
Check 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 maladjusted
Clean spark plug and adjust plug gap (see chapter
2).
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 fuel
Change fuel. Inspect and clean fuel system (see
chapter 3).
Throttle body assy loose Reinstall ( see chapter 3).
Throttle body assy O-ring damaged Replace (see chapter 3).
Fuel tank air vent obstructed
In
spect and repair (see chapter 3).
Fuel line clogged
Inspect and repair (see chapter 3).
Fuel pump operates intermittently and often
ECU fuse blows.
Pump bearings may wear. Replace the pump (see
chapter 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 sensor
hose
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).
Valvespringbrokenorweak Inspect and replace (see chapter 5).
Valve not seating properly (valve bent , worn or
carbon 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 (U se the gasoline
recommended in the O wners Manual)
Change fuel (see chapter 3).
Spark
plug incorrect
Repla
ce 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 open
Inspect throttle cable and lever linkage (see
chapter 3).
Brake dragging
Inspect caliper fluid seal damage or clogging
of master cylinder relief and supply ports (see
chapter 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 in
chapter 17).
Engine oil level too high Repair (see chapter 7).
Engine oil viscosity too high Change (see chapter 3).
Drive train trouble
Inspect 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 muffler
overheating (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).
Toohighfuelpressure 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 Outline
The self-diagnosis system has three modes and can be
switch
ed to another mode by grounding the self-diagnosis
terminal.
User Mode:
The ECU notifies the rider of troubles in DFI system and
ignition system by lighting the FI indicator when DFI system
and ignition system parts are faulty, and initiates fail-safe
function. In case of serious troubles, the ECU stops the
injection/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 system
has 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 system
had in the past.
Self-diagno sis Procedures
When a problem occurs with the DFI system and ignition
system, the DFI indicator LED light [A] goes on.
NOTE
Use a fully charged battery when conducting
self-diagnosis. Otherwise, the LED light blinks very
slowly or doesn’t blink.
Keep the self-diagnosis terminal grounded during self
-diagnosis, with an auxiliary lead.
Remove the rear and front seats (see Frame chapter).
Ground [A] the self-diagnossis terminal [B] (yellow lead)
to the battery (–) terminal [C] or battery (–) lead connector,
using a wire.
Front [D]
Turn on the ignition switch.
Connect an auxiliary lead [E] t o the self-diagnosis terminal
[G] for grounding.
To enter the self-diagnosis dealer mode 1, ground [A] the
self-diagnosis indicator terminal to the battery (–) terminal
for more than 2 seconds [C], and then keep it grounded
continuously [D].
Count the blinks of the LED light to read the service code.
Keep the auxiliary lead ground until you finish reading the
service code.
3-34 FUEL SYSTEM (DFI)
Self-Diagnosis
To enter the self-diagnosis dealer mode 2, open [B] and
ground [A] the lead more than five times [F] within 2 sec-
onds [C
] after the lead is first grounded, and then keep it
grounded continuously [D] for more than 2 seconds.
Count the blinks of the LED light to read the service code.
Keep t
he auxiliary lead ground until you finish reading the
service code.
NOTE
To enter the dealer mode 2 from the dealer mode 1, turn
off the ignition switch once.
Service Code Clearing Procedures
Enter the self-diagnosis dealer mode 2 ( see Self- diagno-
sis Procedures).
NOTE
Make sure to keep the grounding until the following
opening and grounding starts.
Pull the clutch lever in more than 5 seconds, and then
release it.
Repeat opening [B] and grounding [A] the lead
(self-diagnosis terminal) more than five times [F] within 2
seconds [C] after the lead is grounded, and then keep it
grounded continuously [D] for more than 2 seconds.
FUEL SYSTEM (DFI) 3-35
Self-Diagnosis
3-36 FUEL SYSTEM (DFI)
Self-Diagnosis
HowtoReadServiceCodes
Service codes are shown by a series of long and short blinks of the FI indicator LED light as shown
below.
Read 10th digit and unit digit as the FI indicator LED light blinks.
When there are a number of problems, all the service codes can be stored and the display will
begin starting from the lowest number service code in the numerical order. Then after completing
all codes, the display i s repeated until the self-diagnosis indicator terminal is open.
If there is no problem, no c ode and unlight.
For example, if two problems occurred in the order of 21, 12, the service codes are displayed from
the lowest number in the order listed.
(12 21) (12 21) · · · (repeated)
If the problem is with the following parts, the ECU cannot mem orize these problems, the FI indicator
LED light doesn’t go on, and no service codes can be displayed.
FI Indicator LED Light
Fuel Pump
Fuel Pump Relay
DFI Main Relay
ECU Power Source Wiring and Ground Wiring (see ECU Inspection in this chapter)
Fuel Injectors
How to Erase Service Codes
Even if the ignition switch is turned OFF, the battery or the ECU are disconnected or the problem is
solved, all service codes remain in the ECU.
Refer to the S ervice Code Clearing Procedure for the service code erasure.
FUEL SYSTEM (DFI) 3-37
Self-Diagnosis
ServiceCodeTable
Servic
e
Code
FI Indicator LED Light Problems
11 Main throttle sensor malfunction, wiring open or short
12
Inlet air pressure sensor malfunction, wiring open or
short
13
Inlet air temperature sensor malfunction, wiring open
or short
14
Water temperature sensor malfunction, wiring open
or sh
ort
15
Atmospheric pressure sensor malfunction, wiring
open or short
21 Crankshaft sensor malfunction, wiring open or short
23
Camshaft position sensor m alfunction, wiring open
or short
24
and
25
+
Speed sensor m alfunction, wiring open or short
First 24 is displayed and then 25, repeatedly
31
Vehicle-down sensor, malfunction, wiring open or
short
32 Subthrottle sensor malfunction, wiring open or short
51
St
ick (Ignition) coil #1 malfunction, wiring open or
short
52
Stick (Ignition) coil #2 malfunction, wiring open or
short
53
Stick (Ignition) coil #3 malfunction, wiring open or
short
54
Stick (Ignition) coil #4 malfunction, wiring open or
short
62
Subthrottle valve actuator malfunction, wiring open
or short
Notes:
The ECU may be involved in these problems. If all the parts and circuits checked out good, be sure
to 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 electronical parts of the DFI system has no fault, and the
mechanical parts of the DFI system and the engine are suspect.
3-38 FUEL SYSTEM (DFI)
Self-Diagnosis
Backu ps
The ECU takes the following measures to prevent engine dam age when the DFI or the ignition
system parts have troubles.
Service
Codes
Parts
Output Signal Usable
Range or Criteria
Backups by ECU
11
Main
Throttle
Sensor
Main Throttle Sensor
Output Voltage
0.2 4.8 V
If the main throttle sensor system fails (the signal
is out of the usable range, wiring short or open),
the ECU locks ignition timing into the ignition
timing at closed throttle position and sets the DFI
in the D-J method.
Also, the main throttle sensor system and inlet air
pressure fails, the ECU locks ignition timing into
the ignition timing at closed throttle position and
sets the DFI in the α-N method.
12
Inlet Air
Pressure
Sensor
Inlet Air Pressure
(absolute)
Pv = 100 mmHg 900
mmHg
If the inlet air pressure sensor system fails (the
signal Pv is out of the usable range, wiring short
or open), the ECU sets the DFI in the α -N
method.
13
Inlet Air
Tempera-
ture Sensor
Inlet Air Temperature
Ta = 47°C + 178°C
If t
he inlet air temperature sensor fails (the signal
is out of the usable range, wiring short or open),
the ECU sets Ta at 40°C.
14
Water Tem-
perature
Sensor
Water Tem perature
Tw = 30C° + 120°C
If the water temperature sensor system fails (the
signal is out of the usable range, wiring short or
open), the ECU sets Tw at 80°C.
15
Atmo-
spheric
Pressure
Sensor
Absolute Atmospheric
Pressure
Pa = 100 mmHg 900
mmHg
If the atmospheric pressure sensor system fails
(the signal is out of the usable r ange, wiring short
or open), the ECU sets Pa at 760 mmHg (the
standard atmospheric pressure).
21
Crankshaft
Sensor
Crankshaft sensor must
send 23 signals (output
signal) to the ECU at the
one cranking.
If crankshaft sensor generates other than 23
signals, the engine stops by itself.
23
Camshaft
Position
Sensor
Cam sensor must send
one signal (output signal)
to the ECU at the two
cranking
If the camshaft position sensor system fails
(the signal is m issing, wiring short or open), the
ECU continues to ignite cylinders in the sam e
sequence following the last good signal.
24
and
25
Speed
Sensor
Speed sensor must send
4 signals (output signal)
to the ECU at the one
rotation of the engine
sprocket.
The gear position is
decided by the signal of
the speed sensor.
If the speed sensor system fails (no signal, wiring
short or open), the speedometer shows 0, and
the ECU sets the top (6) gear position.
31
Vehicle
-down
Sensor
Vehicle-down Sensor
Output 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.
32
Subthrottle
sensor
Subthrottle Sensor
Output Voltage
0.15 4.85 V
If the subthrottle sensor system fails (the signal
is out of the usable range, wiring short or open),
the actuator locks sub throttle valve at full open
position.
FUEL SYSTEM (DFI) 3-39
Self-Diagnosis
Service
Codes
Parts
Output Signal Usable
Range or Criteria
Backups by ECU
51
Stick Coil
#1 (Ignition
Coil)*
The stick coil primary
winding must send
signals (output voltage)
continuously to the ECU.
If the ignition primary winding #1 has failures (no
signal, wiring short or open), the ECU shuts off
the injector #1 to stop fuel to the cylinder #1,
though the engine keeps running.
52
Stick Coil
#2 (Ignition
Coil)*
The stick coil primary
winding must send
signals (output voltage)
continuously to the ECU.
If the
ignition primary winding #2 has failures (no
signal, wiring short or open), the ECU shuts off
the injector #2 to stop fuel to the cylinder #2,
thou
gh the engine keeps running.
53
Stick Coil
#3 (Ignition
Coil)*
The stick coil primary
winding must send
signals (output voltage)
continuously to the ECU.
If the ignition primary winding #3 has failures (no
signal, wiring short or open), the ECU shuts off
the injector #3 to stop fuel to the cylinder #3,
though the engine keeps running.
54
Stick Coil
#4 (Ignition
Coi
l) *
The stick coil primary
winding must send
signals (output voltage)
continuously to the ECU.
If the ignition primary winding #4 has failures (no
signal, wiring short or open), the ECU shuts off
the injector #4 to stop fuel to the cylinder #4,
though the engine keeps running.
62
Subthrottle
Valve
Actuator
The
actuator operates
open and close of the
subthrottle valve by the
pu
lse signal from the
ECU.
If the subthrottle valve actuator fails (the signal is
out of the usable range, w iring short or open), the
ECU 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 l ow speed, the ECU
determines the injection quantity by calculating from the throttle vacuum (inlet air pressure sensor
output voltage) and engine speed (crankshaft sensor output voltage). This method is called D-J
method (low-speed mode). As the engine speed increases, and the engine load turns middle to
heavy, the ECU determines the injection quantity by calculating from the throttle opening (throttle
sensor output voltage) and the engine speed. This method is called α N method (high-speed
mode).
(*) 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 at
the fac
tory.
Never drop the sensor, especially on a hard surface.
Such a shock to the sensor can damage it.
Main Throttle S ensor Connector (gray) [B]
Input Voltage Inspection
NOTE
Be sure the battery is fully charged.
Turn the i gnition switch OFF.
Disconnect the main throttle sensor (gray) [A] and con-
ne
ct the harness adapter [B] between these connectors.
Connect a digital m eter to the harness adapter lead.
Special Tool - Throttle Sensor Harness Adapter :
57001–1538
Measure the sensor input voltage with the engine stopped
and with the connector joined.
Turn the ignition switch ON.
Main Throttle Sensor Input Voltage
Connections to Adapter
Meter (+) R (sensor BL) lead
Meter (–) BK (sensor BR/BK) lead
Standard : 4.75 5.25 V DC
Turn the i gnition switch OFF.
If the input voltage is normal, check the sensor output
voltage.
If the input voltage is less than the standard, remove the
ECU and check the wiring between these connectors.
Disconnect the ECU and sensor connectors.
Wiring Conne ction
ECU 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 and
power supply (see ECU section).
FUEL SYSTEM (DFI) 3-41
Main Thrott le Sensor (Service Code 11)
Output Voltage Inspection
Measure the output voltage at the main throttle sensor
in the same way as input voltage inspection, Note the
following.
Disconnect the main throttle sensor (gray) [A] and con-
nect the harness adapter [B] 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 Speed
Standard: 1 100 ± 50 r/min (rpm)
If the idle speed is out of the specified r ange, adjust it
(see Idle Speed Inspection in the Periodic Maintenance
chapter).
Turn off the ignition switch.
Measure the output voltage of the sensor with the engine
stopped, and with the connector joined.
Turn the ignition switch ON.
Main Throttle Sensor Output Voltage
Connections 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 the
main throttle sensor resistance.
If the output voltage is normal, check the wiring for conti-
nuity.
Wiring Connection
ECU 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 and
power supply (see ECU section).
3-42 FUEL SYSTEM (DFI)
Main Throttle Sensor (Service Code 11)
Resistance Inspection
Turn the i gnition switch OFF.
Discon
nect the main throttle sensor connector.
Connect a digital meter [A] to the main throttle sensor
connector [B].
Measu
re the main throttle sensor resistance.
Main Throttle Sensor Re sis tance
Conne
ctions:
BL lea
d[C]←→ BR/BK lead [D]
Standard: 4 6k
If the reading is out of the range, replace the throttle body
assy.
If the reading is within the range, but the problem still
exists, replace the ECU (see this chapter).
A. ECU
I. Main Throttle Sensor
m. 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 dam age it.
Removal
Remove:
Fuel T
ank (see Fuel System chapter)
Water Temperature Sensor Connector [A]
Inlet Air Pressure Sensor Bolt [B]
Raise
the inlet air pressure sensor [C] and disconnect the
inlet air pressure sensor connector and the vacuum hose
[D].
Front
[E]
Installation
NOTE
The inlet air pressure sensor is the same part as the at-
mospheric sensor except that the sensor has a vacuum
hose and different wiring.
I
nstall:
Vacuum Hose
Inlet Air Pressure Sensor
Torque - Inlet Air P ressure S ensor Bolt: 12 N·m (1.2 kgf·m,
104 in·lb)
Input Voltage Inspection
NOTE
Be sure the battery is fully charged.
The inspection is the same as “ Input Voltage Inspection”
of the m ain throttle sensor or the atmospheric pressure
sensor.
Turn the ignition switch OFF.
Remove the ECU (see this chapter). Do not disconnect
the ECU connectors.
Connect a digital voltmeter [A] to the connector [B] with
the needle adapter set.
Special Tool - Needle Adapter Set: 57001–1457
Measure the input voltage with the engine stopped, and
with the connectors joined.
Turn the ignition switch ON.
Inlet Air Pressure Sensor Input Voltage
Connections 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 the
ECU and check the wiring between these connectors.
If the wiring is good, check the ECU for its ground and
power supply (see ECU section).
3-44 FUEL SYSTEM (DFI)
Inlet Air Pressure Sensor (Service Code 12)
Output Voltage Inspection
NOTE
The output voltage changes according to the local at-
mospheric pressure.
Measure the output voltage at the ECU in the same way
as input voltage inspection. Note the following.
Inlet Air Pressure Sensor Output Voltage
Connections to ECU
Meter
(+) Y/BL lead (terminal 17)
Meter (–) BR/BK lead (terminal 14)
Usable Range:
3.74 4.26 V DC at the standard
atmospheric pressure (101.32 kPa,
76 cmHg abs.)
Turn the i gnition switch OFF.
If the output voltage is within the usable range, check the
ECU for its ground, and power supply (see this chapter).
If the output voltage is out of the usable range, remove
the fuel tank and check t he wiring. If the output voltage is
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 sec-
tion).
Remove the i nlet air pressure sensor [A] and disconnect
the 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: 57001–1290
Sensor Harness Adapter: 57001–1561
Inlet Air Pressure Sensor Output Voltage
Connection to Adapter
Meter (+) BL (sensor Y/BL) lea d
Meter (–) Y/W (sensor BR/BK) lead
FUEL SYSTEM (DFI) 3-45
Inlet Air Pressure Sensor (Service Code 12)
Turn the ignition switch ON.
Measure the inlet air pressure sensor output voltage from
various vacuum readings, while pulling the 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 Sensor
Pl : Local Atmospheric Pressure (absolute) m easured by
a barometer
Pv : Vacuum Pressure (absolute) to Sensor
Vv : Sensor Output Voltage (v)
then
Pv = Pl P
g
For example, suppose the following data is obtained:
Pg = 8 cmHg (vacuum gauge reading)
Pl = 70 cmHg (barometer reading)
Vv = 3.2 V (digital volt meter reading)
then
Pv=70–8=62cmHg(abs)
Plot this Pv (62 cmHg) at a point [1] on the chart and draw a
vertical line through the point. Then, you can get the usable
range [2] of the sensor output voltage.
Usable range = 3.04 3.49 V
Plot Vv (3.2 V) on the vertical l ine. Point [3].
Results: In the chart, Vv is within the usable range and
the sensor is normal.
3-46 FUEL SYSTEM (DFI)
Inlet Air Pressure Sensor (Service Code 12)
Pv = 24 55 cmHg
FUEL SYSTEM (DFI) 3-47
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
TO: Throttle Full Open
Pv: Throttle Vacuum Pressure (absolute) ST: Standard of Sensor O utput Voltage (v)
Ps: Standard Atmospheric Pressure (abso-
lute)
UR: Usable Range of Sensor Output Voltage (v)
A. ECU
C. Inlet Air Pressure Sensor
3-48 FUEL SYSTEM (DFI)
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).
Discon
nect the connector [A] from the i nlet air tempera-
ture sensor.
Pull out [B] the inlet air temperature sensor.
Put th
e inlet air temperature sensor into the grommet.
Front [C]
Output Voltage Inspection
NOTE
Be sure the battery is fully charged.
The output voltage changes according to the inlet air
temperature.
Remove the ECU (see this chapter). Do not disconnect
the ECU connectors.
Co
nnect a digital voltmeter to the ECU connector, using
needle adapter set.
Special Tool - Needle Adapter Set: 57001–1457
Measure the sensor output voltage with the engine
stopped and the connector joined.
Turn the ignition switch ON.
Inlet Air Temperature Sensor Output Voltage
Connections to ECU Connector
Meter (+) Y lead (terminal 18)
Meter (–) BR/BK lead (terminal 14)
Standard:
about 2.25 2.50 V at inlet air temperature
20°C (68°F)
Turn the i gnition switch OFF.
If the output voltage is out of the standard, remove the
fuel tank and check the wiring. And if the output voltage
is 4.8 V, the ECU is normal.
If the output voltage is within the standard, check the ECU
for its ground, and power supply (see ECU section in this
chapter).
If the wiring is good, check the sensor resistance.
Remove the needle adapter set, and apply silicone
sealant to the seals of the connector for waterproofing.
Silicone Sealant (Kawasaki Bond: 56019–120)
- Seals of ECU Connectors
FUEL SYSTEM (DFI) 3-49
Inlet Air Temperature Sensor (Service Code 13)
Sensor Resistance Inspection
Remove the inlet air temperature sensor (see this sec-
tion).
Suspend the sensor [A] in a container of machine oil so
that the heat-sensitive portion is submerged.
Suspend a thermometer [B] with the heat-sensitive por-
tion [C] located in almost the same depth with the sensor.
NOTE
The sensor and thermometer must not touch the con-
taine
r side or bottom.
Place t he container over a source of heat and gradually
raise the temperature of the oil while stirring the oil gently
for even temperature.
Using a digital meter, measure the internal resistance
of the sensor across the terminals at the temperatures
shown in the table.
Inlet A ir Temperature Sensor Resistance
Standard: 1.6 3.7 k at 20°C (68°F)
0.24 0.43 k at 80°C (176°F)
If the measurement is out of the range, replace the sensor.
If the measurement is within the specified, replace the
ECU.
A. ECU
F. Inlet Air Temperature Sensor
3-50 FUEL SYSTEM (DFI)
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 t
he coolant about 200 mL (6.76 US oz).
Disconnect the sensor connector, and unscrew the water
temperature sensor [A].
Front
[B]
Torque - Water Temperature Sensor: 25 N·m (2.5 kgf·m, 18
ft·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
NOTE
Be sure the battery is fully charged.
Remove the ECU (see this chapter). Do not disconnect
the 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 engine
stopped and the connector joined.
Turn the ignition switch ON.
Water Temperature Sensor Output Voltage
Connections 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)
NOTE
The output voltage changes according to the coolant
temperature in the engine.
Turn the i gnition switch OFF.
If the output voltage is within the standard, check the ECU
for its ground, and power supply ( see this chapter).
If the output voltage is out of the standard, remove the
fuel tank and check the wiring. And if the output voltage
is 4.8 V, the ECU is normal.
If the wiring i s good, check the water temperature sensor
resistance.
Remove the needle adapter set, and apply silicone
sealant to the seals of the connector for waterproofing.
Silicone Sealant (Kawasaki Bond: 56019–120)
- Seals of ECU Connectors
FUEL SYSTEM (DFI) 3-51
Water Temperature Sensor (Service Code 14)
A. ECU
D. Water Temperature Sensor
V. Coolant Temperature Gauge in Tachometer
Sensor Resistance Inspection
Remove the water temperature sensor (see this section).
Refer to the Electrical System chapter for water temper-
ature sensor inspection.
3-52 FUEL SYSTEM (DFI)
Atmospheric Pressure Sensor (Service Code 15)
CAUTION
Never drop the sensor, especially on a hard surface.
Such a shock to the sensor can damage it.
NOTE
The atmospheric pressure sensor is the same part as
the inl
et air pressure sensor except that the inlet air
pressure sensor has the vacuum hose and different
wiring.
Removal
Turn the ignition switch off.
Remove the seat cover (see Frame chapter).
Remove the atmospheric pressure sensor [A] from the
rubber damper in the frame.
Disconnect the sensor connector.
Front [B]
Input Voltage Inspection
NOTE
Be 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 i gnition switch OFF.
Remove the ECU (see this chapter). Do not disconnect
the ECU connectors.
Connect a digital voltmeter [A] to the connector [B], with
the needle adapter set.
Special Tool - Needle Adapter Set: 57001–1457
Measure the input voltage with the engine stopped, and
with the connectors joined.
Turn the ignition switch ON.
Atmospheric Pressure Sensor Input Voltage
Connections 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 of input voltage is less than the standard
range, remove the ECU and check the wiring between
these connections.
If the wiring is good, check the ECU for its ground and
power supply (see ECU section).
FUEL SYSTEM (DFI) 3-53
Atmospheric Pressure Sensor (Service Code 15)
Output Voltage Inspection
Measure the output voltage at the ECU in the sam e way
as input voltage inspection. Note the following.
Digital Meter [A]
ECU Connector [B]
Atmospheric Pressure S ensor Output Voltage
Connections to ECU
Meter (+) G/W lead (terminal 4)
Meter (–) BR/BK lead (terminal 14)
Usable Range:
3.74 4.26 V DC at the standard
atmospheric pressure (101.32 kPa,
76 cmHg abs.)
NOTE
The 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 the
ECU f or its ground, and power supply (see this chapter).
If the output voltage is out of the standard, remove the
seat cover and check the wiring. And if the output voltage
is 4.8 V, the EC U 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 sec-
tion).
Determine the local altitude (elevation).
If you know the local atmospheric pressure using a
barometer, substitute the atmospheric pressure for Pv
(throttle vacuum) in the vacuum sensor chart (see inlet
air pressure sensor section in this chapter).
Get the usable range of the atmospheric pressure sensor
output voltage in the same way as Output Voltage Inspec-
tion of the inlet air pressure sensor and check if Va (output
voltage) is within the usable range or not.
If you know the local altitude, use the following chart.
For example:
Suppose the local altitude is 1 300 m (4 265 ft) and the
sensor output voltage Va is 3.3 V.
Plot this H (1 300 m, 4 265 ft) at a point [1] on the fol-
lowing chart and draw a vertical line through the point.
Then, you can get the usable range [2] of the sensor out-
put 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.
3-54 FUEL SYSTEM (DFI)
Atmospheric Pressure Sensor (Service Code 15)
Va: A tmospheric Pressure Sensor Output
Voltage (v)
ST: Standard of Sensor Output Voltage (v)
UR: Usable Range of Sensor Output Voltage (v)
H: A ltitude (m or feet)
A. ECU
E. A tmospheric Pressure Sensor
FUEL SYSTEM (DFI) 3-55
Crankshaft Sensor (S ervice Code 21)
Start the engine and switch the diagnosis mode to Dealer
1 mode to know all the problem that the DFI system has at
the time of self-diagnosis. If the engine cannot be started,
the self-diagnosis system does not detect dynamic condi-
tion of 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 D FI
system had in both static and dynamic conditions.
Crankshaft Sensor Rem oval/Installation
See the Ignition System section in the Electrical System
chapter.
Crankshaft Sensor Inspection
The crankshaft sensor has no power source, and when
the engine stops, t he crankshaft sensor generates no sig-
nals.
Crank the engine and measure the peak voltage of the
crankshaft sensor (see Electrical System chapter) in or-
der to check the sensor.
Check the wiring for continuity, using the following dia-
gram.
A. ECU
B. Crankshaft Sensor
3-56 FUEL SYSTEM (DFI)
Camshaft Po sition Sensor (Service Code 23)
Start the engine and switch the diagnosis mode to Dealer
1 mode to know all the problem that the DFI system has at
the tim
e 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 off
the ig
nition switch and turn it on again to enter the Dealer 2
mode. In this mode, the system tells all the troubles which
the DFI system had in both static and dynamic conditions.
Camshaft Position Sensor Removal/Installation
The camshaft position sensor detects the position of the
camshaft, and distinguishes the cylinder.
See the Ignition system section in the Electric System
chapter.
Camshaft Position Sensor Inspection
The camshaft position sensor has no power source, and
when the engine stops, the camshaft position sensor gen-
erates no signal.
Crank the engine and measure the peak voltage of the
camshaft position sensor (see Electrical System chapter)
in order to check the sensor.
Check the wiring for continuity, using the following dia-
gram.
A. ECU
G. Camshaft Position Sensor
FUEL SYSTEM (DFI) 3-57
Speed Sensor (Service Code 24, 25)
Speed Sensor Removal/Installation
See the Switches and Sensors section in the Electrical
System chapter.
Speed Sensor Inspection
See the Switches and Sensors section in the Electrical
System chapter.
Input Voltage Inspection
NOTE
B
e sure the battery is fully charged.
Turn the ignition switch OFF.
Disconnect the speed sensor connector [A] under the left
side of the air cleaner housing and connect the harness
adapter [B] between the harness connector and speed
sensor connector.
Engine Sprocket Cover [C]
Connect a digital meter to the harness adapter leads.
Special Tool - Throttle Sensor Setting Adapter:
57001-1400
Measure the sensor input voltage with the engine
stopped, and with the connector joined.
Turn the ignition switch ON.
Speed Sensor Input Voltage
Connection to Adapter
Meter (+) BL (sensor P) lead [C]
Meter () BK/BL (sensor BK) lead [D]
Standard: About 9 11 V DC a t Ignition switch ON
If the reading is out of the range, check the wiring (see
wiring diagram in this section), and meter (see Electrical
System 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 Input
Voltage Inspection).
NOTE
Be sure the battery is fully charged.
Turn the ignition switch OFF.
3-58 FUEL SYSTEM (DFI)
Speed Sensor (Service Code 24, 25)
Disconnect the speed sensor connector [A] and connect
the harness adapter [B] between the harness connector
and spe
ed 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 engine
stopped, and with the connector joined.
Turn the ignition switch ON.
Speed Sensor Output Voltage at Sensor
Connections to Adapter
Meter (+) Y/W (sensor Y) lead [C]
Meter (–) BK/BL (sensor BK) lead [D]
Stan
dard:
Abou
t0.05 0.07 V DC
NOTE
If you rotate the engine sprocket, t he output voltage will
be increased.
If the reading is out of the range, check the speed sensor
operation (see Electrical System chapter) and the wiring
to ECU (see wiring diagram in this section).
If the reading, speed sensor operation and wiring are
good, check the E CU for its ground, and power supply
(see ECU section).
A. E CU W. Speedometer Unit H. Speed Sensor
FUEL SYSTEM (DFI) 3-59
Vehicle-down Sensor (Service Code 3 1)
Removal
CAUTION
Never drop the down-sensor, especially on a hard
surface. Such a shock to the sensor can damage it.
Remove:
Connection and Vehicle-down Sensor [A]
Bolts and Washers [B]
Front [C]
Installation
The UP mark [ A] of the sensor should face upward.
Torque - Vehicle-down Sensor Bolts: 2 N·m (0.2 kgf·m, 17
in·lb)
WARNING
Incorrect installation of the vehicle-down sensor
could cause sudden loss of engine power. The
rider could lose balance during certain riding situ-
ations like leaning over in a turn w ith t he potential
for an accident resulting in injury or death. Ensure
that the down sensor is held in place by the sensor
brackets.
Inspection
NOTE
Be sure the battery is fully charged.
Connect a digital volt m eter [A] to the connector of the
vehicle-down sensor [B] with the needle adapter set [C].
Vehicle-down S ensor Power Source Voltage
Connections to Sensor
Meter (+) W/Y lead [D]
Meter (–) BK/Y lead [E]
Turn the ignition switch ON, and measure the power
source voltage with the connector joined.
Power Source Voltage at Sensor
Standard: 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 A
Wiring for Vehicle-down Sensor Power Source (see next
diagram)
If the power source is normal, check the output voltage.
3-60 FUEL SYSTEM (DFI)
Vehicle-down Sensor (Service Code 31)
Turn the i gnition switch OFF.
Remove the sensor.
Connec
t a digital volt meter [A] to the connector with nee-
dle adapter set [B].
Special Tool - Needle Adapter Set: 57001–1457
Vehicle-down Sensor Output Voltage
Connections to Sensor
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 hold
the sensor almost vertical with the arrow mark pointed up,
and measure the output voltage.
Output Voltage at Sensor
Standard: with sensor tilted 60 70° or more right or
left: 3.7 4.4 V
with sensor arrow ma rk pointed up: 0.4
1.4 V
NOTE
If you need to test again, turn the ignition switch OFF,
and then ON.
Turn the i gnition switch OFF.
Remove the needle adapter set, and apply silicone
sealant 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 and
power supply (see ECU section).
If the output voltage is out of the specified, replace the
vehicle-down sensor.
FUEL SYSTEM (DFI) 3-61
Vehicle-down Sensor (Service Code 3 1)
A. ECU
S. ECU M ain Relay
T. Igniti o n S witc h
a. ECU Fuse 15A
b. Vehicle-down Sensor
d. Starter Relay
f. Sealed Battery
j. Joint Connector B
k. Main Fuse 30 A
3-62 FUEL SYSTEM (DFI)
Subthrottle Sensor (Service Code 32)
Subthrottle Sensor Removal/Adjustment
CAUTION
Do not remove or adjust the subthrottle sensor [A]
since it has been adjusted and set with precision at
the fac
tory.
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
NOTE
Be sure the battery is fully charged.
Turn the i gnition switch OFF.
Disconnect the subthrottle sensor (black) [A] and connect
th
e harness adapter [B] between these connectors.
Connect a digital m eter to the harness adapter lead.
Special Tool - Throttle Sensor Harness Adapter :
57001–1538
Measure the sensor input voltage with the engine stopped
and with the connector joined.
Turn the ignition switch ON.
Subthrottle Sensor Input Voltage
Connections to Adapter
Meter (+) R (sensor BL) lead
Meter (–) BK (sensor BR/BK) lead
Standard : 4 .75 5.25 V DC
Turn the i gnition switch OFF.
If the input voltage is normal, check the sensor output
voltage.
If the input voltage is less than the standard, remove the
ECU and check the wiring between these connectors.
Disconnect the ECU and sensor connectors.
Wiring Conne ction
ECU 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 and
power supply (see ECU section).
FUEL SYSTEM (DFI) 3-63
Subthrottle Sensor (Service Code 32)
Output Voltage Inspection
Remove the throttle body assy (see Throttle Body Assy
Removal).
Measure the output voltage at the subthrottle sensor in
the same way as input voltage inspection. Note the fol-
lowing.
Disconnect the 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 engine
stopped, and with the connector joined.
Turn the ignition switch ON.
Measure the output voltage when the subthrottle valve is
fully opened or completely closed by hand.
Main Throttle Sensor Output Voltage
Connections 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 the
subthrottle sensor resistance.
If the output voltage is normal, check the wiring for conti-
nuity.
Wiring Connection
ECU Conne ctor [A] ←→
Subthrottle S ensor Connector [B]
BR lead (ECU terminal 3)
BR/BK lead (ECU terminal 14)
If the wiring is good, check the ECU for its ground and
power supply (see ECU section).
3-64 FUEL SYSTEM (DFI)
Subthrottle Sensor (Service Code 32)
Resistance Inspection
Turn the i gnition switch OFF.
Discon
nect the subthrottle sensor connector.
Connect a digital meter [A] to the subthrottle sensor con-
nector [B].
Measu
re the subthrottle sensor resistance.
Throttle Sensor Resistance
Connections: BL lead [C] ←→ BR/BK lead [D]
Standard: 4 6k
If the reading is out of the range, replace the throttle body
assy.
If the reading is within the range, but the problem still
exists, replace the ECU (see this chapter).
A. E CU L. S ubthrottle Valve Actuator
J. S ubthrottle Sensor m. Throttle Body Assy Connector
FUEL SYSTEM (DFI) 3-65
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 t he stick coil can damage it.
See Ignition System section in the Electrical System
chapter.
Input Voltage Inspection
NOT
E
Be sure the battery is fully charged.
Turn the ignition switch OFF.
Remove the ECU (see this chapter). Do not disconnect
the ECU connector.
Connect a digital voltmeter [A] as shown, with the needle
adapter set [B].
Measure the input voltage to each primary winding of the
stick coils with the engine stopped, and with the connec-
tors joined.
Turn the ignition switch ON.
Stick Coil Input Voltage at ECU
Connections 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 ECU
Standard: Battery Voltage (12.6 V or more)
If the reading is out of the standard, check the wiring (see
next wiring diagram).
If the reading is good, the input voltage is normal. Crank
the engine, and check the peak voltage of the stick coils
(see Electrical System chapter) in order to check the pri-
mary coils.
3-66 FUEL SYSTEM (DFI)
Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54)
A. ECU
M. St
ick Coils
N. E ngine Stop Switch
T. Ignition Switch
X. Ignition Fuse 10 A
Y. J u
nction Box
d. S tarter Relay
e. Joint Connector D
f. Sealed Battery
k. M a
in Fuse 30 A
FUEL SYSTEM (DFI) 3-67
Subthrottle Valve Actuator (Service Code 62)
Subthrottle Valve Actuator Removal
CAUTION
Do not remove the subthrottle valve actuator [A]
since it has been adjusted and set with precision
at the factory.
Never drop the actuator , especially on a hard sur-
face. Such a shock to the actuator can damage it.
Audible Inspection
NOTE
Be sure the battery is fully charged.
Turn the ignition switch ON and ensure t hat the actuator
valves open and close ( make light sounds) several times
within seconds, and then close at the idle throttle opening
position.
Turn the ignition switch OFF.
If the actuator does not work as described above, do the
visual inspection.
Visual Inspection
Remove the throttle body assy (see Throttle Body Assy
Removal).
Turn the ignition switch ON.
Check to see that all the subthrottle valves [A] open and
close smoothly.
If the subthrottle valves do not operate, check the actuator
internal resistance (see Resistance I nspection).
Resistance Inspection
Turn the ignition switch OFF.
Remove the throttle body assy (see Throttle Body Assy
Removal).
Disconnect the subthrottle valve actuator connector [A].
Connect a digital meter to the subthrottle valve actuator
connector [A].
Measure the subthrottle valve actuator resistance.
Subthrottle Valve Actuator Resistance
Connections: BK/BL lead [1] ←→ P/BL lead [2]
G lead [3] ←→ W/BL lead [4]
Standard: About 5 7k
Special Tool - Hand Tester : 57001–1394
If the r eading is out of the range, replace the actuator
along with the throttle body assy.
If the reading is within the range, check the input voltage
(see Input Voltage Inspection).
3-68 FUEL SYSTEM (DFI)
Subthrottle Valve Actuator (Service Code 62)
Input Voltage Inspection
NOTE
Be sure the battery is fully charged.
Turn the i gnition switch OFF.
Remove the t hrottle body assy (see Throttle Body Assy
Removal).
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 Adapter
Type: KEK-54–9–B
Brand: KOWA SEIKI
Speci
al Tool -
Needl
e Adapter Set: 57001–1457
Subthrottle Valve Actuator Input Voltage
Connections to Harness Connector
(I) Meter (+) BK/BL lead [1]
Meter (–) P/BL lead [2]
(II) Meter (+) Glead[3]
Meter (–) W/BL lead [4]
Measure the actuator input voltage with the engine
stopped, and with the connector joined.
Turn the ignition switch ON.
Input Voltage at Actuator
Standard: about 8.5 10.5 V DC
If the r eading is within the standard but the actuator
doesn’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 and
power supply (see ECU section).
A. ECU L. Subthrottle Valve Actuator
J. Subthrottle Sensor m. Throttle Body Assy Connector
FUEL SYSTEM (DFI) 3-69
FI Indicator LED Light
Inspection Flow Chart
3-70 FUEL SYSTEM (DFI)
FI Indicator LED Light
LED Light Inspection
Remove the meter unit (see Electrical System chapter).
Using t
wo auxiliary leads, supply battery power to the FI
indicator LED light [A].
12 V Battery [B]
FI Indicator LED Light Check
Connector: M eter Connector [C] (disconnected)
Connection: BR/W Lead Terminal [1] of the Meter
Battery (+) Terminal
BR/RLeadTerminal[6]oftheMeter
Battery (–) Terminal
Criterion: The LE
D light should light.
If the LED light does not go on, replace t he meter unit.
A. ECU
T. Ignition Switch
U. FI Indicator LED Light
X. Ignition Fuse 10 A
Y. Junction Box
d. S tarter Relay
e. Joint Connector D
f. Sealed Battery
k. M ain Fuse 30 A
FUEL SYSTEM (DFI) 3-71
ECU
CAUTION
Never drop the ECU, especially on a hard surface.
Such a shock to th e ECU can dam age it.
ECU Identification
Most countries have their own regulations, so each ECU
has d
ifferent characteristic. So, do not confuse ECU’s
with each other and use only the ECU’s for your country.
Otherwise, the motorcycle could not clear the regulation.
ECU Identification
Models Type [A] Part No. [B]
CA and US TBCF25
21175–0007
EUR TBCF19 2117
5–1097
AU and M Y
TBCF27
21175–0006
CA: Canadian Model
US: United States of America Model
EUR: European Model
AU: Australian Model
MY: Malaysian Model
ECU Removal
Remove:
Front and Rear Seats (see Frame chapter)
Regulator/rectifier [A]
Front [B]
Take the ECU [A] out along with the harness.
Disconnect the ECU lead connectors [B].
Front [C]
ECU Installation
Connect the ECU connectors, noting the length of the
locks.
Longer Lock [A]
Shorter Lock [B]
ECU [C]
3-72 FUEL SYSTEM (DFI)
ECU
If the rubber protector [A] is removed, install it.
ECU [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 off
with compressed air.
Replace the main harness if the terminals of the main
harness connectors are cracked, bent, or otherwise dam-
aged.
Replace the ECU if the terminals of the ECU connectors
are cracked, bent, or otherwise damaged.
With the ECU connectors [A] connected, check the fol-
lowing ground lead for continuity with the ignition Switch
OFF, using a tester and needle adapter set.
ECU Grounding Inspection
26, 50, or 51 (BK/Y)
Terminal
←→
Battery (–) Terminal: 0
Engine Ground
←→
Battery (–) Terminal: 0
If no continuity, check the connector, the engine ground
lead, or main harness, and repair or replace them if nec-
essary.
Battery [B]
Teste r [C]
Special Tool - Needle Adapter Set: 57001–1457
FUEL SYSTEM (DFI) 3-73
ECU
Check the ECU power source voltage with a digital meter
[A].
Position the terminal in accordance w ith terminal numbers
of ECU connectors [B] in this chapter figure.
Battery [C]
ECU Power Source Inspection
Meter between Terminal 13 (W/Y) and
Connections: Battery (–) Terminal
between Terminal 43 (W/BK) and
Battery (–) Terminal
Ignition switch
OFF:
Terminal 13 (W/Y) : 0 V,
Terminal 43 (W/BK) : 12.6 V or more
Ignition switch
ON:
Both: Battery Voltage (12.6 V or
more)
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 W iring (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.
ECU Power Source Circuit
A. ECU
S. ECU M ain Relay
T. Igniti o n S witc h
a. ECU Fuse 15 A
d. Starter Relay
e. Joint Connector C
f. Sealed Battery
j. Joint Connector B
k. Main Fuse 30 A
3-74 FUEL SYSTEM (DFI)
DFI Power Source
ECU Fuse Removal
Refer to the Electrical System chapter for the ECU fuse
remova
l.
ECU Fuse Installation
If a fuse fails during operation, inspect the DFI system to
determine the cause, and then replace i t with a new fuse
of proper amperage.
Refer to the Electrical System chapter for the ECU fuse
installation.
ECU Fuse Inspection
R
efer to the Electrical System chapter for the ECU Fuse
Inspection.
ECU Main Relay Removal
CAUTION
Never drop the r elay, 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 the
storage compartment and disconnect the connector.
Front [B]
ECU Main R elay Inspection
Remove the ECU main relay (see above).
Connect the hand tester [A] and one 12 V battery [B] to
the relay connector [C] as shown.
Special Tool - Hand Tester: 57001–1394
Relay Coil Terminals [1] and [2]
Relay Switch Terminals [3] and [4]
Testing Relay
Tester range:
1 range
Criteria: When battery is connected 0
When battery is disconnected →∞Ω
If the relay does not work as specified, replace the relay.
FUEL SYSTEM (DFI) 3-75
Fuel Line
Fuel Pressure Inspection
NOTE
This inspection can determine which trouble t he DFI
system
has, mechanical or electrical trouble.
It is preferable to measure the fuel pressure while run-
ning the motorcycle just when trouble occurred in order
to kno
w 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 pum p outlet
pipe and the delivery pipe.
Remove the fuel pump outlet hose [A].
Front [B]
WARNING
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
When the fuel hose is disconnected, fuel spills out
from the hose and the pipe because of residual
pressure. Cover the hose connection with a piece
of clean cloth to prevent fuel spillage.
Install the fuel pressure gauge adapter [A] between the
fuel pum p outlet pipe [B] and the delivery pipe [C].
Connect the pressure gauge [D] to the fuel pressure
gauge adapter (right side view).
Special Tools - Oil Pressure Gauge: 57001–125
Fuel Pressure Gauge Adapter: 57001–1417
WARNING
Do not try to start the engine w ith the fuel hoses
disconnected.
Temporarily, install the fuel tank [E]
Clamps [F]
Turn the ignition switch ON. The fuel pump will turn for 3
seconds, and then stop.
CAUTION
Do not drive the fuel pump without the fuel in the
fuel tank.
Measure the fuel pressure with the engine stopped.
Fuel Pressure
Right after Ignition switch ON, with pump running:
Standard: 310 kPa (3.2 kgf/cm², 44 psi)
After 3 seconds from Ignition switch ON,
with pump stopped:
Standard: 290 kPa (3.0 kgf/cm², 43 psi) ,
residual fuel pressure)
The system should hold the residual
pressure about 30 seconds.
3-76 FUEL SYSTEM (DFI)
Fuel Line
Start the engine, and let it idle.
Measure the fuel pressure with the engine idling.
Fuel Pressure (idling)
Standard: 310 kPa (3.2 kgf/cm², 46 psi)
NOTE
The gauge needle will fluctuate. Read the pressure at
the average of the maximum and minimum indications.
If the fuel pressure is normal, the fuel circulation system
(fuel pump, pressure regulator, and oil passage) is no
faults. Check the DFI electronic control system ( injectors,
sensors, crankshaft sensor, and ECU).
If the fuel pressure is much lower than specified, check
the following:
Fuel Pump Inlet Hose Clogging
Fuel Line Leakage
Fuel Pum p 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, check
the following:
Delivery Pipe Clogging
Injector Clogging
Remove the fuel pressure gauge and adapter.
Install the fuel tank (see Fuel Tank Installation).
Fuel Flow Rate Inspection
NOTE
Be sure the battery is fully charged.
WARNING
Gasoline is extremely flammable and can be explo-
sive under certain conditions. Make sure the area
is well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch O FF.
Be prepared for fuel spillage; any spilled fuel must
be 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).
FUEL SYSTEM (DFI) 3-77
Fuel Line
Open the fuel tank cap [A] to lower the pressure in the
tank.
Front [B]
Be sure to place a piece of cloth around the fuel pump
outlet hose.
Remove the fuel pump outlet hose [A] from the fuel pump
[B] and the delivery pipe [C] (see Fuel Pump Removal).
Front [D]
WARNING
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
When the fuel hose is disconnected, fuel spills out
from the hose and the pipe because of residual
pressure. Cover the hose connection with a piece
of 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 measuring
cylinder [C].
Front [D]
WARNING
Wipe off spilled out fuel immediately.
Be sure to hold the measuring cylinder vertical.
Temporarily instal the fuel tank and close the fuel tank
cap.
With the engine stopped, turn the ignition switch ON. The
fuel pump should operate for 3 seconds, and then should
stop. Repeat this several times until the plastic hose is
filled with fuel.
CAUTION
Do not drive the fuel pump without the fuel in the
fuel tank.
Measure the discharge for 3 seconds with the plastic hose
filled with fuel.
Repeat this operation several times.
Amount of Fuel Flow
Standard: 67 mL (2.3 US oz) or more for 3 seconds
If the f uel flow is much less than the specified, check the
battery condition (see Electrical System chapter). If the
battery 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.
3-78 FUEL SYSTEM (DFI)
Fuel Pump
Fuel Pump Removal
CAUTION
Never drop the fuel pump, especially on a hard sur-
face. Such a shock to the pump can damage it.
WARNING
Gasoline is extremely flammable and can be explo-
sive under certain conditions. Make sure the area
is well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch OFF.
Disconnect the battery (–) terminal.
To make fuel spillage minimum, draw the fuel out
from the fuel tank when the engine is cold. Be
prepared for fuel spillage; any spilled fuel must be
completely wiped up immediately.
Draw the f uel out from the f uel tank with a commercially
available electric pump.
Remove the fuel tank (see Fuel Tank Removal).
Be careful of f uel spillage from the f uel tank since fuel still
remains i n t he fuel tank and fuel pump. Plug the fuel pipe
of the fuel tank.
Turn the fuel tank upside down.
Remove the fuel pump inlet hose [A].
Unscrew t he fuel pump bolts [B], and take out the fuel
pump [C] and gasket.
Discard the fuel pump gasket.
CAUTION
Do not pull the leads of the fuel pump. If they are
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.
FUEL SYSTEM (DFI) 3-79
Fuel Pump
Replace the fuel pump gasket [A] with a new one.
Check that the fuel pump (–) terminal [A] and band [B] are
in place.
Front [C]
Apply a non-permanent locking agent to the threads of
the fuel pump bolts.
Tighten the fuel pump bolts to a snug fit, following the
tightening sequence shown.
Following the tightening sequence, tighten the fuel pump
bolts 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 the
order shown.
Operation Inspection
NOTE
Be sure the battery is fully charged.
Just listen to the pump sound in the fuel tank to confirm
pump operation.
Turn the ignition switch ON and make sure t hat the fuel
pump operates (make light sounds) for 3 seconds, and
then stops.
Turn the ignition switch OFF.
If the pump does not work as described above, inspect
the operating voltage.
Operating Voltage Inspection
NOTE
Be sure the battery is fully charged.
Turn the ignition switch OFF.
Remove the fuel tank bolt and lift up the fuel tank.
3-80 FUEL SYSTEM (DFI)
Fuel Pump
Connect the hand tester (25 V DC) to the fuel pump con-
nector [A] with needle adapter set.
Front [
B]
Special Tools - Hand Tester: 57001–1394
Needle Adapter Set: 57001–1457
Measure the operating voltage with the engine stopped,
and with the connector joined.
Turn the ignition switch ON.
The tester needle should indicate battery voltage for 3
seconds, and then 0 V.
Pump Operating Voltage at Pump
Connections to Pump Connectors
Teste
r(+) Y/R Lead
Tester (–) BK/W Lead
Operating Voltage at Pump Connector
Standard: Battery Voltage (12.6 V or more) for 3
seconds, and then 0 V.
If the reading stays on battery voltage, and never shows
0 V. Check the ECU and fuel pump relay.
If the voltage is in specification, but the pump doesn’t
work, replace the pump.
If there is still no battery voltage, check the pump relay
(see this chapter).
Pressure Regulator Removal
The pressure regulator [A] i s built into the fuel pump [B]
and cannot be removed.
Pump Screen, Fuel Filter Cleaning
The pump screen [A] and fuel filter [B] are built into the
pump and cannot be cleaned or checked.
If the pump screen or fuel filter is suspected of clogging
or being damaged, replace it with the fuel pump as a set.
FUEL SYSTEM (DFI) 3-81
Fuel Pump
Fuel Pump Relay Removal
CAUTION
Never drop the relay, especially on a hard surface.
Such a shock to the relay can dam age it.
Remove the seat cover (see Frame chapter).
Remove the fuel pump relay [A] from the tongue of the
storage compartment.
Disconnect the connector.
Front [B]
Fuel Pump Relay Inspection
Remove the f uel pump relay (see above).
Connect the hand tester [A] and one 12 V battery [B] to
the relay connector [C] as shown.
Special Tool - Hand Tester: 57001–1394
Relay Coil Terminals [1] and [2]
Relay Switch Terminals [3] and [4]
Tes
ting Relay
Tester range:
1 r
ange
Cri
teria:
Whe
n battery is connected 0
Whe
n battery is disconnected →∞
If the relay does not work as specified, replace the relay.
A. ECU
N. Engine Stop Switch
T. Igniti o n S witc h
X. Ignition Fuse 10 A
Y. Junction Box
Z. Fuel Pump Relay (for fuel
pump and injectors)
d. Starter Relay
f. Sealed Battery
g. Fuel Pump
j. Joint Connector B
k. Main Fuse 30A
3-82 FUEL SYSTEM (DFI)
Fuel Injectors
Removal/Installation
Refer to t he Throttle Body Assy Disassembly/Assembly.
Audible Inspection
Start the engine.
Apply the tip of a screwdriver [A] to the injector [C]. Put
the grip end onto your ear, and listen whether the injector
is clicking or not.
A sound scope [B] can also be used.
Do the same for the other injectors.
If all the injectors click at a regular intervals, the injectors
are good. The trouble may be related to the fuel line,
requiring fuel pressure inspection (see Fuel Line section
in this chapter).
The click interval becomes shorter as the engine speed
rises.
If any injector(s) doesn’t click, the DFI circuit or the injector
is suspect. Perform “Power Source Voltage Inspection”,
first.
Power Source Voltage Inspection
Remove the ECU (see ECU section). Do not disconnect
the 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 engine
stopped, and with the connector joined.
Turn the ignition switch ON.
Injector Power Source Voltage at ECU
Connections: 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 30A (see Electrical System chapter)
Fuel P ump Relay (see DFI Power Source section)
Power Source Wiring (see Wiring diagram below)
To check the W/R leads between the injector connector
and the fuel pump relay, remove the fuel tank (see Fuel
Tank Removal) and the seat cover (see Frame chapter).
If the power source voltage is normal, check the output
voltage of the injectors.
FUEL SYSTEM (DFI) 3-83
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].
Speci
al Tool -
Needl
e Adapter Set: 57001–1457
Injector Output Voltage
Connections 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 Inje ctor Connector
Standard: Battery Voltage (12.6 V or more)
If the output voltage is normal, perform “Injector Signal
Test .
If the output voltage is out of the standard, turn the ignition
switch OFF, remove the fuel tank, and check the injector
wiring for continuity.
Injector Wiring Inspection
ECU 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 connector
for waterproofing.
3-84 FUEL SYSTEM (DFI)
Fuel Injectors
Injector Signal Test
Prepare two test light sets with male terminals as shown.
Rating
of Bulb [A]: 12 V × 3 3.4 W
Terminal Width [B]: 1.8 mm (0.071 in.)
Terminal Thickness [C]: 0.8 mm (0.031 in.)
CAUTION
Do not use larger terminals than specified above. A
larger
terminal could damage the injector main har-
ness connector (female), leading to harness repair
or replacement.
Be sure
to connect bulbs in series. The bulb w orks
as a current limiter to protect the solenoid in the
injector from excessive current.
Remove the f uel t ank.
Remove connectors for injector [A].
Connect each test light set [B] to the injector subharness
connector [C].
Turn the ignition switch ON.
While cranking the engine with the starter motor, watch
the test lights.
If the test lights flicker at regular intervals, the injector
circuit in the ECU, and the wiring are good. Perform the
“Injector Resistance Inspection”.
Injector signals can be also confirmed by connecting the
hand tester 10 V AC) instead of the test light set to
the injector main harness (female) connector. Crank the
engine with the starter motor, and check to see if the hand
oscillates at regular intervals.
Special Tool - Hand Tester: 57001–1394
If the test light doesn’t flicker (or the tester needle doesn’t
oscillates), check the wiring and connectors again. If the
wiring is good, check the injector voltage. If the wiring is
good, inspect the ECU for its ground and power supply
(see ECU section).
FUEL SYSTEM (DFI) 3-85
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].
Front [C]
Special Tool - Hand Tester: 57001–1394
Injector Resistance
Connections 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 @20°C (68°F)
If the reading is out of the range, perform the “Injector Unit
Test .
If the reading is normal, perform the Injector Unit Test”
for confirmation.
Injector Unit Test
Use t wo leads [A] and the same t est light set [B] as in
“Injector Signal Test”.
Rating of Bulb [C]: 12 V × (3 3.4) W
12 V Battery [D]
CAUTION
Be sure to connect the bulb in series. The bulb
works as a current limiter to protect the solenoid
in 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 s hould click.
If the i njector does not click, replace the injector.
If the injector clicks, check the wiring again. If the wiring
is good, replace the injector (may be clogged) or ECU.
Injector Fuel Line Inspection
While pinching the fuel pump outlet hose joint locks [C]
with fingers, pull the joint out along the delivery pipe (see
Fuel Tank Removal).
Cloth [A]
Pump Outlet Hose Joint [B]
Front [D]
3-86 FUEL SYSTEM (DFI)
Fuel Injectors
Check the injector fuel line for leakage as follows:
Connect a commercially available vacuum/pressure
pump [A
] to the nipple of the delivery pipe [B] with a
high-pressure fuel hose [C] (both ends connected with
the clamps [D]) as shown.
Torque - Fuel Hose Clamp Screws: 1.5 N· m (0.15 kgf·m, 13
in·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 reaches
the maximum pressure.
Injector Fuel Line Maximum Pressure
Standard: 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 in
the 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).
FUEL SYSTEM (DFI) 3-87
Fuel Injectors
A. ECU
K. Fuel Injectors
N. Engine Stop Switch
T. Igniti o n S witc h
X. Ignition Fuse 10 A
Y. Junction Box
Z. Fuel Pump Relay (for fuel
pump an i njectors)
d. Starter Relay
e. Joint Connector C
f. Sealed Battery
j. Joint Connector B
k. Main Fuse 30 A
3-88 FUEL SYSTEM (DFI)
Throttle Grip and Cables
Throttle Grip Pla y Inspe ction/Adjustment
Refer to the Throttle Control System Inspection in the Pe-
riodic
Maintenance chapter.
Choke Lever Operation
Do not use the choke lever except when the engine has a
starting difficulty like i n cold weather (10 °C, 50 °F or be-
low) or at high altitude. The DFI system has an automatic
choke system, using a water temperature sensor, and an
atmospheric pressure sensor, which provide startability.
NOTE
Pull [A] the choke lever fully w hen using. The choke
doesn’t work with the lever k nob halfway.
Front [B]
When flooded, do not crank the engine with the throt-
tl
e fully opened like a carburetor. This promotes engine
flooding because more fuel is supplied automatically by
the DFI system.
Choke Lever Play Inspection
Push the choke lever [A] fully and ensure by your finger
that the choke cam [B] has the specified play.
Choke Lever Free Play
Standard: 0 0.5 mm (0 0.02 in.)
Pull [C] the choke lever fully and ensure that the choke
cam turns the choke link [D].
Front [E]
If the free play is incorrect, adjust the choke cable.
Choke Lever Play Adjustment
Remove the fuel tank (see this chapter).
Loosen the locknut [A], and turn the adjuster [B] until the
cable has the proper amount of free play.
Tighten the locknut against the adjuster securely.
Front [C]
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.
FUEL SYSTEM (DFI) 3-89
Throttle Body Assy
Idle Speed Inspection/Adjustment
Refer to the Idle Speed Inspection in the Periodic Main-
tenance chapter .
Throttle Bore Cleaning
Refer to the Throttle Control System Inspection in the Pe-
riodic Maintenance chapter.
Engine Vacuum Synchronization
Inspection/Adjustment
Refer to the Engine Vacuum Synchronization Inspection
in the Periodic M aintenance chapter.
High Altitude Performance Adjustment
Any modification is not necessary in this model since the
atmospheric pressure sensor senses atmospheric pres-
sure change due to high altitude and the ECU compen-
sates the change.
Throttle Body Assy Removal
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn t he ignition
switch OFF. Disconnect the battery (–) cable ter-
minal. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
Be prepared for fuel spillage: any spilled fuel must
be completely wiped up immediately.
Remove:
Fuel Tank (see Fuel Tank Removal)
Vacuum Switch Valve Vacuum Hose [A] (from air cleaner
housing [B])
Front [C]
Remove the vacuum hoses from the positions [A] shown.
Front [B]
3-90 FUEL SYSTEM (DFI)
Throttle Body Assy
Loosen:
Throttle Assy Holder Clamp Bolts [A]
Air Cle
aner Duct Clamp Bolts [B]
Special Tool - Ca rburetor Drain Plug Wrench, Hex 3:
57001–1269
Remove:
Right and Left Side Covers (see Frame chapter)
Coolant Reserve Tank (see Coolant Change in the Peri-
odic Maintenance chapter)
Starter Relay, Junction Box (right)
Crankcase Breather Hose
Right and Left Air Cleaner Housing Mounting Bolts [A]
Front [B]
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] left and remove it.
Loosen the locknut and screw in the throttle cable adjuster
fully t o give the cables plenty of play.
Remove the right handlebar switch housing and take out
the accelerator cable upper end [A] and the decelerator
cable upper end [B].
Front [C]
FUEL SYSTEM (DFI) 3-91
Throttle Body Assy
Remove the bolt [A] and the throttle cable plate [B] from
the throttle body front side.
Remove the throttle cable lower ends from the throttle
pulley.
Remove:
Choke Cable Upper End (From choke lever)
Choke Cable Lower End [A]
Throttle Body #2 [B]
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 wear
and possible engine damage will occur.
Throttle Body Assy Installation
Install the holder clamp bolts [A] in the direction shown
with each bolt heads, facing outwards.
Cylinder Head [B]
Tighten:
Torque - Throttle Body Assy Holder Clamp Bol ts: 2 N·m
(0.2 kgf·m, 17 in·lb)
Tighten:
Torque - Air Cleaner Duct Cl amp Bolts [A]: 2 N·m (0.2
kgf·m, 17 in·lb)
Run the vacuum hoses as shown in the Cable, Wire, and
Hose Routing section of the Appendix chapter.
Fit the accelerator cable end [A] and the decelerator cable
end [B] into the throttle pulley (front view).
Tighten the throttle plate bolt (see Throttle Body A ssy Re-
moval).
Check fuel leakage from the throttle body assy.
WARNING
Fuel spilled from the carburetors is hazardous.
3-92 FUEL SYSTEM (DFI)
Throttle Body Assy
Apply a thin coating of grease to the throttle cable upper
ends.
Instal
l the upper ends of the throttle cables in the grip (see
Throttle Body Assy Removal).
Fit the projection [A] of the right switch housing into the
hole [
B] of the handlebar (front view).
Turn the throttle grip and make sure that the throttle valves
move smoothly and return by spring force.
Chec
k the throttle grip free play (see Throttle Grip Free
Play Inspection).
WARNING
Operation with an incorrectly routed cable could re-
sult in an unsafe riding condition.
Adjust:
Throttle Gr ip Free P lay
Choke Lever Free Play
Idle Speed
Throttle Body Assy Disassembly
CAUTION
Do not remove, disassemble or adjust the main
throttle sensor [A], subthrottle sensor [B], sub-
throttle valve actuator [C], t hrottle link mechanism
[D] and throttle body assy [E], because they are
adjusted or set at the manufacturer. Adjustment
of these parts could result in poor performance,
requiring replacement of the throttle body assy.
Remove the t hrottle body assy (see Throttle Body Assy
Removal).
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 a
hard surface. Such a shock to the body assy can
damage it.
Push the lock and disconnect the injector connectors [A].
Remove:
Screws [B]
Delivery Pipe [C] along with harness [D] and injectors
If necessary, cut straps and take the harness off the de-
livery pipe.
FUEL SYSTEM (DFI) 3-93
Throttle Body Assy
CAUTION
Never drop the i njector, especially on a hard sur-
face. Such a shock to the injector can damage it.
Pull out [A] the injectors along with the delivery pipe [B].
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 Assembly
Replace the O-rings [ A] of injectors and the seals [B] with
the new ones.
Before assembling, blow away dirt or dust from the throttle
body 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 whether
the injectors turn smoothly or not.
Install the injectors along with the delivery pipe assy i nto
the throttle bodies [E].
Torque - Delivery Pipe Screws: 3.4 N·m (0.35 kgf·m, 30
in·lb)
Connect all the connectors [A], including the subthrot-
tle valve actuator connector [C] and bind the leads with
straps [B].
Insert the each hoses onto the throttle body fittings.
Install the throttle body assy (see Throttle Body Assy In-
stallation).
3-94 FUEL SYSTEM (DFI)
Air Cleaner
Element Removal/Installation
Refer to the Air Cleaner Element Cleaning in the Periodic
Mainte
nance chapter.
Air Cleaner Oil Draining
A drain hose is connected to the bottom of t he 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 the
plug [B] from the drain hose and drain it.
Front [C]
WARNING
Be sure to reinstall the plug in the drain hose after
draining. Oil on tires will make them slippery and
can cause an accident and injury.
Air Cleaner Housing Removal
Remove the engine (see Engine Removal/Installation
chapter).
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 it
from the right side of the frame.
FUEL SYSTEM (DFI) 3-95
Fuel Tank
Fuel Tank Removal
WARNING
Gasoline is extremely flammable and can be explo-
sive under certain conditions. Make sure the area
is well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the i gnition switch OFF.
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
Remove:
Rear and Front Seats ( see Frame chapter)
California Fuel Return Hose (left, red) [A]
California Fuel Tank Breather Hose (right, blue) [B]
Fuel Tank Bolt [C]
Drain Hose [D]
Disconnect the battery (–) terminal.
Turn
both ignition switch, and engine stop switch O FF.
Wait until the engine cools dow n.
Open the fuel tank cap [A] to lower the pressure in the
tan
k.
Front [B]
During tank removal, keep the tank cap open to release
pre
ssure in the tank. This makes fuel spillage less.
Draw the fuel out from the fuel tank with a com mercially
available pump [A].
Use a soft plastic hose [B] as a pump inlet hose in order
to insert the hose smoothly.
Put the hose through the fill opening [C] into the tank and
draw the fuel out.
Front [D]
WARNING
The fuel could not be removed completely from the
fuel tank. Be careful for remained fuel spillage.
Raise the fuel tank and disconnect the fuel pump lead
connector [A] and fuel level sensor lead connector [B].
Front [C]
3-96 FUEL SYSTEM (DFI)
Fuel Tank
Be sure to place a piece of cloth [A] around the fuel hose
pump outlet joint [B].
While p
inching the hose joint locks [C] with fingers, pull
the joint out along the delivery pipe.
Front [D]
WARNING
Be prep
ared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
When the f uel hose is disconnected, fuel spills out
from t
he hose and the pipe because of residual
pressure. Cover the hose connection w ith a piece
of clean cloth to prevent fuel spillage.
Close the fuel tank cap.
Remov
e the fuel tank, and place it on a flat surface.
Do not remove the pump inlet hose [A].
For California Model, note the following:
CAUTION
For California model, if gasoline, solvent, water or
any other liquid enters the canister, the canisters
vapor absorbing capacity is greatly reduced. If the
canister does become contaminated, replace it with
a new one.
Be sure to plug the evaporative fuel return hose to prevent
fuel spilling before fuel tank removal.
WARNING
For California model, be careful not to spill the
gasoline through the return hose. Spilled f uel is
hazardous.
If liquid or gasoline flows into the breather hose, remove
the hose and blow it clean with compressed air (California
model).
Be careful of f uel spillage from the f uel tank since fuel still
remains in the fuel tank and fuel pump.
WARNING
Store the fuel tank in an area which i s well
-ventilated and free from any source of flame
or sparks. Do not smoke in this area. Place the
fuel tank on a flat surface and plug the fuel pipes
to prevent fuel leakage.
FUEL SYSTEM (DFI) 3-97
Fuel Tank
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 and
the f uel tank.
Front [B]
Check that the dampers [A] are in place on the fuel tank
as well.
Front [B]
If the dampers are damaged or deteriorated, replace
them.
If the dampers are damaged or deteriorated, replace
them.
For California Model, note the following:
To prevent the gasoline from flowing into or out of the
canister, hold the separator perpendicular to the ground.
Connect the hoses according to the diagram of the sys-
tem (see Cable, Wire, and Hose Routing section in the
Appendix chapter). Make sure they do not get pinched or
kinked.
Route hoses with a minimum of bending so that the air or
vapor will not be obstructed.
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 m ore
than two times and make sure it is locked and doesn’t
come off. When the hose joint is correctly i nstalled, it
should slide on the delivery pipe about 5 mm (0.2 in.).
WARNING
Make sure the hose joint is installed correctly on the
delivery pipe by sliding the joint, or the fuel could
leak.
If it does not slide, reinstall the hose joint.
Connect the fuel pum p and the fuel level sensor connec-
tors and the battery (–) lead terminal.
3-98 FUEL SYSTEM (DFI)
Fuel Tank
Fuel Tank and Cap Inspection
Visually inspect the gasket [A] on the tank cap f or any
damage
.
Replace the gasket if it is damaged.
Check to see if the w ater drain pipe [B] and fuel breather
pipe [
C] in the tank are not clogged. Check the tank cap
breather also.
If they are clogged, remove the tank and drain it, and then
blow
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 and
clogging of the labyrinth in the cap.
Fuel Tank Cleaning
WARNING
Clean the tank in a well-ventilated area, and take
care that there are no sparks or flame anyw here
near the working area. Because of the danger or
highly flammable liquids, do not use gasoline or
low-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 (see
Fuel Pump section in this chapter).
Pour some high flash-point solvent into the fuel tank and
shake 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).
FUEL SYSTEM (DFI) 3-99
Evaporative Emission Control System
Parts Removal/Installation
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn t he ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
CAUTION
If gasoline, solvent, w ater or any other liquid enters
the canister, the canister’s vapor absorbing capac-
ity is greatly reduced. If the canister does become
contaminated, replace it with a new one.
To prevent the gasoline from flowing into or out of the
canister, hold the separator perpendicular to the ground.
Be sure to plug the return hose to prevent fuel spilling
before fuel tank removal.
If liquid or gasoline flows into the breather hose, remove
the hose and blow it clean with compressed air.
Connect the hoses according to the diagram of the sys-
tem (see Cable, Wire, and Hose Routing section in the
Appendix chapter). Make sure they do not get pinched or
kinked.
Route hoses with a minimum of bending so that the air or
vapor will not be obstructed.
Canister Installation
Refer t o the Evaporative Emission Control S ystem In-
spection in the P eriodic Maintenance chapter.
Hose Inspection
Refer t o the Evaporative Emission Control S ystem In-
spection in the P eriodic Maintenance chapter.
Separator Inspection
Refer t o the Evaporative Emission Control S ystem In-
spection in the P eriodic Maintenance chapter.
3-100 FUEL SYSTEM (DFI)
Evaporative Emission Control System
Separator Operation Test
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch
OFF. Do not smoke. M ake sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light
.
Conne
ct the hoses to the separator, and install the sepa-
rator on the motorcycle.
Disconnect the breather hose from the separator, and in-
ject
about 20 mL of gasoline [A] into the separator [B]
through the hose fitting.
Disconnect the evaporative fuel return hose [C] from the
fuel
tank [D].
Run the open end of the return hose into the container
and hold it level with the tank top [E].
Sta
rt the engine, and let it idle.
If the gasoline in the separator comes out of the hose, the
separator works well. If it does not, replace the separator
wi
th a new one.
COOLING SYSTEM 4-1
4
Cooling System
Table of C ontents
Exploded View........................................................................................................................ 4-2
Coolant Flow Chart................................................................................................................. 4-4
Specifications ......................................................................................................................... 4-6
Special Tool ............................................................................................................................ 4-7
Coolant ................................................................................................................................... 4-8
Coolant Deterioration Inspection....................................................................................... 4-8
Coolant Level Inspection................................................................................................... 4-8
Coolant Draining ............................................................................................................... 4-8
Coolant Filling ................................................................................................................... 4-8
Pressure Testing ............................................................................................................... 4-9
Cooling System Flushing .................................................................................................. 4-9
Coolant Reserve Tank Removal/Installation ..................................................................... 4-9
Water Pump............................................................................................................................ 4-10
Water Pump Removal ....................................................................................................... 4-10
Water Pump Installation.................................................................................................... 4-10
Water Pump Inspection..................................................................................................... 4-10
Mechanical Seal Replacement ......................................................................................... 4-10
Radiator .................................................................................................................................. 4-12
Radiator Removal ............................................................................................................. 4-12
Radiator Inspection ........................................................................................................... 4-13
Radiator Cap Inspection ................................................................................................... 4-13
Radiator Filler Neck Inspection ......................................................................................... 4-14
Thermostat ............................................................................................................................. 4-15
Thermostat Removal......................................................................................................... 4-15
Thermostat Installation...................................................................................................... 4-15
Thermostat Inspection ...................................................................................................... 4-15
Hose and Pipes ...................................................................................................................... 4-17
Hose Installation ............................................................................................................... 4-17
Hose Inspection ................................................................................................................ 4-17
Radiator Fan Switch, Water Temperature Sensor .................................................................. 4-18
Radiator Fan Switch Removal .......................................................................................... 4-18
Radiator Fan Switch Installation ....................................................................................... 4-18
Radiator Fan Switch Inspection ........................................................................................ 4-18
Water Temperature Sensor Removal................................................................................ 4-18
Water Temperature Sensor Inspection ............................................................................. 4-18
4-2 COOLING SYSTEM
Exploded View
COOLING SYSTEM 4-3
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Radiator hose clamp screws 2 0.2 17 in·lb
2 Thermostat air bleeder bolt 7.8 0.80 69 in·lb
3 Radiator fan bolts 8.3 0.85 74 in·lb
4 Water pump impeller b olt 9.8 1.0 87 in·lb
5 Water pump cover bolts 11 1.1 95 in·lb
6 Water pump drain bolt 11 1.1 95 in·lb
7 Water pipe bolts 11 1.1 95 in·lb in/outlet
8 Thermostat housing ground bolt 7 0.7 61 in·lb
9 Thermostat bracket bolt 7 0.7 61 ilb
10 Radiator upper bolts 7 0.7 61 in·lb
11 Radiator lower bolts 7 0.7 61 in·lb
12 Radiator screen bolt 7 0.7 61 in·lb
13 Coolant reserve tank screws 7 0.7 61 ilb
14 Radiator fan switch 18 1.8 13
15 Water temperature sensor 25 2.5 18
16. Oil cooler
17. Thermostat
18. To cylinder head
19. To cylinder
20. Mechanical seal
21. Oil pump rotor
G: Apply grease.
4-4 COOLING SYSTEM
Coolant Flow Chart
COOLING SYSTEM 4-5
Coolant Flow Chart
1. Drain Bolt
2. Water Pump
3. Cylinder Jacket
4. Cylinder Head Jacket
5. Thermostat Housing
6. Thermostat Air Bleeder
Bolt
7. Radiator Cap
8. Radiator
9. Oil Filter
10. Outlet Hose
11. Inlet Hose
12. Oil Cooler
13. Reserve Tank
14. Reserve Tank Hose
15. Reserve Tank Overflow
Hose
16. Radiator Fan
17. Water Temperature Sen-
sor
18. Radiator Fan Switch
19. Hot Coolant
20. Cold Coolant
21. Front
Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion.
When the engine starts, the w ater pump turns and the coolant circulates.
Th
e 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 less than 55 ° (131 °F), the thermostat closes so that the coolant flow
i
s restricted through the air bleeder hole, causing the engine to warm up more quickly. When coolant
temperature is more than 58 62 °C (136 144 °F), the thermostat opens and the coolant flows.
When the coolant temperature goes up beyond 93 103 °C (199 217 °F), the radiator fan switch
c
onducts to operate the radiator fan. The radiator fan draws air t hrough the radiator core when there
is not sufficient air flow such as at l ow speeds. This increases up the cooling action of the radiator.
When the temperature is below 85 100 °C (185 212 °F), the fan switch opens and the radiator fan
s
tops.
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.
T
he 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 the
water jacket expands. The excess coolant flows t hrough the radiator cap and hose to the reserve tank
to be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator and
the 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, 13.5
17.8 psi), the pressure valve opens and releases the pressure to the reserve tank. As soon as
pressure escapes, the valve closes, and keeps the pressure at 93 123 kPa (0.95 1.25 kgf/cm²,
13.5 17.8 psi). When the engine cools down, another small valve (vacuum valve) in the cap opens.
As the coolant cools, the coolant contracts to form a vacuum in the system. The vacuum valve opens
and allows the coolant from the reserve tank to enter the radiator.
4-6 COOLING SYSTEM
Specif ications
Item Standard
Coolant provided when shipping:
Type (recommended) Permanent type of antifreeze (soft water and ethylene
glycol plus corrosion and rust inhibitor chemicals for
aluminum engines and radiators)
Color Green
Mixed ratio
Soft water 50%, coolant 50%
Freezing 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, 13.5 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 Tool
Bearing Driver Set:
57001–1129
Bearing Driver:
57001–382
Kawasaki Bond (Silicone Sealant):
56019–120
4-8 COOLING SYSTEM
Coolant
Coolant Deterioration Inspection
Remove the left side cover (see Frame chapter).
Visual
ly inspect the coolant [A] in the reserve tank.
Front [B]
If whitish cotton-like wafts are observed, aluminum parts
in the
cooling system are corroded. If the coolant is
brown, iron or steel parts are rusting. In either case, flush
thecoolingsystem.
If the
coolant gives off an abnormal sm ell, check for a
cooling system leak. It may be caused by exhaust gas
leaking into the cooling system.
Coolant Level Inspection
NOTE
Check the level when the engine is cold (room or ambi-
ent temperature).
Check the coolant level in the reserve tank [A] with the
motorcycle held perpendicular (Do not use the 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
Front [D]
CAUTION
For refilling, add the specified mixture of coolant
an
d soft water. Adding water alone dilutes the
coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum en-
g
ine parts. In an emergency, soft water alone can
be added. But the diluted coolant must be returned
to the correct mixture ratio within a few days.
I
f coolant must be added often or the reservoir tank
has run completely dry, there is probably leakage in
the cooling system. Check the system for leaks.
C
oolant ruins painted surfaces. Immediately wash
away any coolant that spills on the frame, engine,
wheels or other painted parts.
Coolant Draining
Refer to the Coolant Change in the Periodic Maintenance
chapter.
Coolant Filling
Refer to the Coolant Change in the Periodic Maintenance
chapter.
COOLING SYSTEM 4-9
Coolant
Pressure Testing
Remove the fuel tank (see Fuel System (DFI) chapter).
Remove the r adiator cap, and install a cooling system
pressure tester [A] on the filler neck [B].
NOTE
Wet the cap sealing surfaces with water or coolant to
preve
nt 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 indicate
internal leakage. Check t he cylinder head gasket and the
water pump.
Remove the pressure tester, replenish the coolant, and
install the radiator cap.
Cooling System Flushing
Over a period of time, the cooling system accumulates
rust, scale, and lime in the water jacket and radiator. When
this accumulation is suspected or observed, flush the cool-
ing system. If this accumulation is not removed, it will clog
up the water passage and considerable reduce the effi-
ciency of the cooling system.
Drain the cooling system (see Coolant Change in the P e-
riodic Maintenance chapter).
Fill the cooling system with fresh water mixed with a flush-
ing compound.
CAUTION
Do not use a flushing compound which is harmful to
the aluminum engine and radiator. Carefully follow
the instructions supplied by the manufacturer of the
cleaning 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 bleed
the air from the system (see Coolant Change in the Peri-
odic Maintenance chapter).
Coolant Reserve Tank Removal/Installation
The coolant reserve tank is removed and installed dur-
ing coolant change (see Coolant Change in the Periodic
Maintenance chapter).
4-10 COOLING SYSTEM
Water Pump
Water Pump Removal
Refer to Oil Pump Removal in the Engine Lubrication Sys-
tem cha
pter.
Water Pump [A]
Front [B]
Water Pump Installation
Refer to Oil Pump Installation in the Engine Lubrication
System chapter.
Water Pump Inspection
Check the drainage outlet passage [A] at the bottom of
the water pump body for coolant leaks.
If the mechanical seal is damaged, the coolant leaks
through the seal and drains through the passage. Re-
place the mechanical seal in the water pump body (see
this section).
Front [B]
Visually inspect the water pump impeller [A].
If the surface is corroded or if the blades are damaged,
replace the impeller.
Water Pump Body [B]
Mechanical Seal Replacement
Remove the water pump body [A] (see Oil Pump Removal
in the Engine Lubrication System chapter).
Insert a metal rod [B] into the w ater pump body and
tap evenly around the mechanical seal [C] until the seal
comes off.
Replace the mechanical seal with a new one.
Using a thin-bladed screwdriver, pry out the oil seal [D].
COOLING SYSTEM 4-11
Water Pump
Be sure to replace the mechanical seal, oil seal, and O
-ring with new ones because these parts will be damaged
by removal.
Apply plenty of high temperature grease to the oil s eal
lips.
Apply oil to the outer circumference of the oil seal.
Press the oil seal [A] into the water pump body [B] with
the bearing driver [C] so that the spring side [D] of the
seal lips is toward the inside of the water pump body.
Press the oil seal until it bottoms out.
Special Tool - Bearing Driver Set: 57001–1129
NOTE
Since the replacement mechanical seal has an adhe-
sive coated body, do not apply a liquid gasket to the
exterior surface of the body.
Press t he flange [A] of the mechanical s eal, using a collar
[B] and a bearing driver [C] until the seal flange touches
th
e step.
Collar Inside Dia. :
26.5 mm (1.043 in.) 28 mm (1.102 in.)
Collar Outside Dia. :
31.7 mm (1.248 in.) or more
Special Tool - Bearing Driver Set: 57001–1129
Clean both sliding surfaces of a new mechanical seal with
a high-flash point solvent (e.g. ethyl alcohol), and apply a
little coolant to the sliding surface to give the mechanical
seal initial lubrication.
Apply coolant to the surface of the rubber seal [A] and
sealing seat [B], and press [C] the rubber seal and sealing
seat into the impeller by hand until the seat bottoms out.
Torque - Water Pump Impeller Bolt: 9.8 N·m (1.0 kgf·m, 87
in·lb)
4-12 COOLING SYSTEM
Radiator
Radiator Removal
WARNING
The radiator fan is connected directly to the bat-
tery. The radiator fan may start even if the ignition
switch is off. NEVER TOUCH T HE RADIATOR FAN
UNTIL THE RADIATOR FAN CONNECTOR IS DIS-
CONNECTED. TOUCHING THE FAN BEFORE THE
CONNECTOR IS DISCONNECTED COULD CAUSE
INJURY FROM THE FAN BLADES.
Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).
Remove:
Right Radiator Cover [A] and Screws [B]
Lower Bolt [C]
Bolt and Bracket [D] (from cylinder)
Right Radiator Upper Bolt [E]
Left Radiator Cover
Front [F]
Remove:
Right R adiator Hose [A] and Oil Cooler Hose [B]
Remove:
Fuel Tank (see Fuel System (DFI) chapter)
Radiator Fan Motor Connector [A] (BL/W, BK/Y leads)
Front [B]
Remove:
Fan Switch Lead Connector [A]
Left Radiator Hose [B]
Horn and Connectors [C]
Left Radiator Upper Bolt [D]
Remove the radiator.
CAUTION
Do not touch the radiator core. This could damage
the radiator fins, resulting in loss of cooling effi-
ciency.
COOLING SYSTEM 4-13
Radiator
If necessary, remove:
Radiator Fan Mounting Bolts [A]
Radiator Fan [B]
Radiator Inspection
Check the radiator core.
If there are obstructions to air flow, remove them.
If the corrugated fins [A] are deformed, carefully
straighten them.
If the air passages of the radiator core are blocked more
than 20 % by unremovable obstructions or irreparably de-
formed fins, replace the radiator with a new one.
CAUTION
When cleaning the radiator with steam cleaner, be
careful of the following to prevent r adiator damage:
Keep the steam gun [A] away more than 0.5 m (1.6
ft) [B] from the radiator core.
Hold the steam gun perpendicular [C] (not oblique
[D]) to the core surface.
Run 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 valve seal [A] and top
[B] valve seals and valve spring [C].
If any one of them shows visible damage, replace the cap
with 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 to
prevent pressure leaks.
Watching the pressure gauge, pump the pressure tester
to build up the pressure until the relief valve opens: the
gauge needle flicks downward. Stop pumping and mea-
sure leak time at once. The relief valve must open within
the specified range in the table below and the gauge hand
must remain within the same range at least 6 seconds.
Radiator Cap Relief Pressure
Standard: 93 123 kPa
(0.95 1.25 kgf/cm², 13.5 17.8 psi)
If the cap cannot hold the specified pressure or if it holds
too 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 for
the radiator cap to function properly.
Front [B]
COOLING SYSTEM 4-15
Thermostat
Thermostat Removal
Remove:
Coolant : Drain about 200 mL
Fuel Tank (see Fuel System (DFI) chapter)
Thermostat Bracket Bolt [A]
Water Temperature Sensor Connector [B]
Three Water Hoses [C]
Remove the thermostat housing [D].
Front [E]
Remove the screws [A], take off the cap [B], and take out
the thermostat.
Thermostat Installation
Install the thermostat [A] in the housing so that the air
bleeder hole [B] is on top.
Install a new O-ring into the housing.
Fill the radiator with coolant (see Coolant Change in the
Periodic 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 new
one.
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 therm ostat must be completely submerged and must
not touch the container sides or bottom. Suspend an ac-
curat
e 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 th
e measurement is out of the specified range, replace
the thermostat with a new one.
Thermostat Valve Opening Temperature
58 62°C (136 144°F)
COOLING SYSTEM 4-17
Hose and Pipes
Hose Installation
Install the hoses and pipes, being careful to follow bend-
ing direction. Avoid sharp bending, kinking, flattening or
twisting.
Run the hoses in accordance w ith the Cable, Wire, and
Hose Routing section in the Appendix chapter.
Wet the internal diameter of both ends of the water hose
with water or c oolant and install the hose onto the pipe.
Install the clamp [A] as near as possible to the hose end
to clear the raised rib of the fitting. This will prevent the
hoses from working loose.
The clamp screws should be positioned correctly to pre-
vent the clamps from contacting the other parts.
Torque - Hose Clamp Screws: 2.0 m (0.2 kgf·m, 1 7 in·lb)
Hose Inspection
Refer to t he Cooling System in the Periodic M aintenance
chapter.
4-18 COOLING SYSTEM
Radiator Fan Switch, Water Temperature Sensor
CAUTION
The fan switch or the w ater temperature sensor
should never be allowed to fall on a hard surface.
Such a shock to their parts can damage them.
Radiator Fan Switch Removal
Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).
Remove the screws [A] and take off t he left radiator cover
[B].
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 and bleed the air from cooling system (see
Coolant Change in the Periodic Maintenance chapter ).
Radiator Fan Switch Inspection
Refer to the Electrical System chapter for its inspections.
Water Temperature Sensor Removal
Refer to the Fuel System (DFI) chapter.
Water Temperature Sensor [A]
Front [B]
Water Temperature Sensor Inspection
Refer t o the Electrical System chapter for the water Tem-
perature Sensor Inspection.
ENGINE TOP E ND 5-1
5
Engine Top End
Table of C ontents
Exploded View................................... 5-2
Specifications .................................... 5-6
Special Tools and Sealant ................. 5-8
Clean Air System............................... 5-10
Air Suction Valve Removal........... 5-10
Air Suction Valve Installation........ 5-10
Air Suction Valve Inspection ........ 5-10
Vacuum Switch Valve Removal ... 5-10
Vacuum Switch Valve Installation 5-10
Vacuum Switch Valve Test ........... 5-11
Clean Air System Hose
Inspection.................................. 5-11
Cylinder Head Cover ......................... 5-12
Cylinder Head Cover Removal .... 5-12
Cylinder Head Cover Installation . 5-12
Camshaft Chain Tensioner ................ 5-14
Camshaft Chain Tensioner
Removal.................................... 5-14
Camshaft Chain Tensioner
Installation................................. 5-14
Camshaft, Camshaft Chain ............... 5-15
Camshaft Removal ...................... 5-15
Camshaft Installation ................... 5-15
Camshaft, Camshaft Cap Wear ... 5-17
Camshaft Runout......................... 5-17
Cam Wear.................................... 5-17
Camshaft Chain Removal............ 5-18
Cylinder Head.................................... 5-19
Cylinder Compression
Measurement ............................ 5-19
Cylinder Head Removal............... 5-20
Cylinder Head Installation ............ 5-20
Cylinder Head Warp..................... 5-21
Valves ................................................ 5-22
Valve Clearance Inspection ......... 5-22
Valve Clearance Adjustment........ 5-22
Valve Removal ............................. 5-22
Valve Installation .......................... 5-22
Valve Guide Removal .................. 5-22
Valve Guide Installation ............... 5-23
Valve-to-Guide Clearance
Measurement (Wobble
Method)..................................... 5-23
Valve Seat Inspection .................. 5-24
Valve Seat Repair ........................ 5-24
Cylinder, Pistons................................ 5-29
Cylinder R emoval......................... 5-29
Cylinder Installation...................... 5-29
Piston Removal............................ 5-29
Piston Installation......................... 5-30
Cylinder Wear .............................. 5-31
Piston Wear ................................. 5-31
Piston R ing, Piston Ring Groove
Wear.......................................... 5-31
Piston Ring Groove W idth............ 5-32
Piston Ring Thickness ................. 5-32
Piston Ring End Gap ................... 5-32
Throttle Body Holder.......................... 5-33
Throttle Body Holder Installation.. 5-33
Muffler................................................ 5-34
Muffler Body Removal.................. 5-34
Exhaust Pipe R emoval................. 5-34
Muffler Body and Exhaust Pipe
Installation ................................. 5-34
5-2 ENGINE TOP END
Exploded View
ENGINE TOP E ND 5-3
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Air suction valve cover bolts 10 1.0 87 in·lb
2 Cylinder head cover bolts 10 1.0 87 in·lb
3 Camshaft cap bolts (L=45 mm) 12 1.2 104 in·lb
4 Camshaft cap bolts (L=40 mm) 12 1.2 104 in·lb
5
Cylin
der head bolts (M10 new bolts)
54 5.5 40
MO, S
(Washer)
5 Cylinder head bolts (M10 used bolts) 49 5.0 36 MO, 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 holder clamp screws 2.0 0.2 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
18: Closed coil end faces downward.
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 Parts
S: Follow the specific tightening sequence.
SS: Apply silicone sealant (Kawasaki Bond: 56019–120).
CAL: California model
5-4 ENGINE TOP END
Exploded View
ENGINE TOP E ND 5-5
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Coolant Drain Plug (Cylinder) 10 1.0 87 in·lb
2 Exhaust pipe manifold holder nuts 17 1.7 12
3 Muffler body clamp bolts 17 1.7 12
4 Muffler body mounting bolts and nuts 34 35 25
5
Crank
shaft sensor cover bolts
11 1.1 95 in·lb
6: "R" marked side faces up.
7. "RN" 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: H oneycomb Type Catalyst
[A] Manifold Mark Position
The silencer mark position is outside of the
lower silencer.
5-6 ENGINE TOP END
Specif ications
Item Standard Service L imit
Clean Air System:
Vacuum switch valve closing Open Close
pressure: 45 53 kPa ---
(340 400 mmHg, 6.5 7.7 psi)
Camshafts:
Cam height: Exhaust 36.146 36.254 mm 36.05 mm
(1.4231 1.4273 in.) (1.419 in.)
Inlet 36.746 36.854 mm 36.65 mm
(1.4467 1.4509 in.) (1.443 in.)
Camshaft journal, camshaft cap
clearance
0.028 0.071 mm 0.16 mm
(0.0011 0.0028 in.) (0.0063 in.)
Camshaft journal diameter 23.950 23.972 mm 23.92 mm
(0.9429 0.9438 in.) (0.942 in.)
Camshaft bearing inside diameter 24.000 24.021 mm 24.08 mm
(0.9449 0.9457 in.) (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)
1070 1 620 kPa (10.9 16.5 kgf/cm², ---
155 235 psi) @320 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 0.8 mm (0.031 in.) 0.4 mm
(0.016 in.)
Inlet 0.5 mm (0.020 in.) 0.25 m m
(0.0098 in.)
Valve stem bend TIR 0.01 mm (0.0004 in.) or less TIR 0.05 mm
(0.02 in.)
Valve stem diameter: Exhaust 4.455 4.470 mm 4.44 mm
(0.1754 0.1760 in.) (0.175 in.)
Inlet 4.475 4.490 mm 4.46 mm
(0.1762 0.1768 in.) (0.176 in.)
Valve guide inside
diameter:
Exhaust
4.500 4.512 mm 4.58 mm
(0.1772 0.1776 in.) (0.180 in.)
Inlet 4.500 4.512 mm 4.58 mm
(0.1772 0.1776 in.) (0.180 in.)
ENGINE TOP END 5-7
Specifications
Item Standard Service Limit
Valve/valve guide clearance
(wobble method): Exhaust 0.09 0.18 mm 0.40 mm
(0.0035 0.0071 in.) (0.016 in.)
Inlet 0.03 0.12 m m 0.33 mm
(0.0012 0.0047 in.) (0.013 in.)
Valve seat cutting angle
45°, 3
2°, 60°
---
Valve seating surface:
Width: Exhaust 0.8 1.2 mm (0.031 0.047 in.) ---
Inlet 0.5 1.0 mm (0.020 0.039 in.) ---
Outside diameter: Exhaust 25.2 25.4 mm (0.992 1.000 in.) ---
Inlet 29.4 29.6 mm (1.1575 1.1654 in.) ---
Valve spring f ree length: Exhaust 39.0 mm (1.535 in.) 37.4 mm
(1.472 in.)
Inlet 39.0 mm (1.535 in.) 37.4 mm
(1.472 in.)
Cylinder, Piston:
Cylinder inside diameter 77.194 77.206 mm 77.30 mm
(3.0391 3.0396 in.) (3.0433 in.)
Piston diameter 77.174 77.184 mm 77.02 mm
(3.0383 3.0389 in.) (3.0323 in.)
Piston/cylinder
clearance
0.010 0.037 mm ---
(0.0004 0.0015 in.)
Piston ring/groove
clearance:
Top
0.04 0.08 mm 0.18 mm
(0.0016 0.0031 in.) (0.0071 in.)
Second 0.03 0.07 m m 0.17 mm
(0.0012 0.0028 in.) (0.0067 in.)
Piston ring groove width: Top 0.83 0.85 mm 0.93 mm
(0.0327 0.0335 in.) (0.037 in.)
Second 0.82 0.84 m m 0.92 mm
(0.0323 0.0331 in.) (0.036 in.)
Piston ring thickness: Top 0.77 0.79 mm 0.70 mm
(0.0303 0.0311 in.) (0.028 in.)
Second 0.77 0.79 m m 0.70 mm
(0.0303 0.0311 in.) (0.028 in.)
Piston ring end gap: Top 0.20 0.30 mm 0.6 mm
(0.0079 0.0118 in.) (0.024 in.)
Second 0.35 0.50 m m 0.8 mm
(0.0138 0.0197 in.) (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° - 27.5:
57001–1114
Valve Seat Cutter, 45° - 32:
57
001–1115
Valve Seat Cutter, 32° - 28:
57001–1119
Valve Seat Cutter, 32° - 30:
57001–1120
Valve Seat Cutter, 60° - 30:
57001–1123
Valve Seat Cutter Holder Bar:
57001–1128
Valve S pring Compressor Adapter, 20:
57
001–1154
ENGINE TOP E ND 5-9
Special Tools and Sealant
Valve Spring Compressor Adapter, 22:
57001–1202
Spark Plug Wrench, Hex 16:
57001–1262
Fork Oil Level Gauge:
57001–1290
Compression Gauge Adapter, M10 × 1.0:
57001–1317
Valve Guide Arbor, 4.5:
57
001–1331
Valve Seat Cutter Holder, 4.5:
57001–1330
Valve Guide Reamer, 4.5:
57001–1333
Valve Seat Cutter, 60° - 33:
57001–1334
Kawasaki Bond (Silicone Sealant):
56019–120
5-10 ENGINE TOP END
Clean A i r System
Air Suction Valve R emoval
Remove:
Fuel Ta
nk (see Fuel System (DFI) chapter)
Connector [A] (from Clamp [B])
Air Suction Valve Cover Bolts [C] and Clamp
Air Suc
tion Valve Cover [D]
Air Suction Valve
Air Suction Valve Installation
Install the air suction valve [A] so that its wider side [B] of
the 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 Maintenance
chapter.
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:
Fuel Tank (see Fuel System (DFI) chapter)
Vacuum Switch Valve
Connect a vacuum gauge [A] and syringe [B] or fork oil
level gauge to the vacuum hoses as shown.
Special Tool - F ork Oil Level Gauge: 57001–1290
Air Fl ow [C]
Gradually raise the vacuum (lower the pressure) applied
to the vacuum switch valve, and check the valve opera-
tion. When the vacuum is low, the vacuum switch valve
should permit air to flow. When the vacuum raises to
valve 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.
NOTE
To check air flow through the vacuum switch valve, just
blow through the air cleaner hose.
Vacuum Switch Valve Closing Pressure (Open Close)
Standard: 45 53 kPa (340 400 mmHg, 6.5 7.7 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 air
cleaner 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 are
damaged.
5-12 ENGINE TOP END
Cylinder Head Cover
Cylinder Head Cover Removal
Remove:
Fuel Ta
nk (see Fuel System (DFI) chapter)
Vacuum Switch Valve and Hoses
Stick Coils (see Electrical System chapter)
Air Suc
tion Valve Covers [A]
Remove the cylinder head cover bolts [A] and take off the
cover.
Cylinder Head Cover Installation
Replace the head cover gasket with a new one if dam-
aged.
Apply silicone sealant [A] to t he cylinder head as shown.
Sealant - Kawasaki Bond (Silicone Sealant): 56019–120
Install:
Dowel Pins [A]
Plug Hole Gaskets [B]
ENGINE TOP END 5-13
Cylinder Head Cover
Install the w asher [A] with the metal side faces upward.
Tighten:
Torque
-
Cylind
er Head Cover Bolts [B]: 10 N·m (1.0 kgf·m,
87 in·lb)
5-14 ENGINE TOP END
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
CAUTION
This is a non-return type camshaft chain tensioner.
The push rod does not return to its original position
once it
moves out to take up camshaft chain slack.
Observe all the rules listed below:
When removing the tensioner, do not take out the
mounti
ng bolts only halfway. Retightening the
mounting bolts from this position could damage
the tensioner and the camshaft chain. Once the
bolts
are loosened, the tensioner must be removed
and reset as described in "Camshaft Chain Ten-
sioner Installation."
Do not
turn over the crankshaft while the tensioner
is removed. This could upset the cam shaft chain
timing, and damage the valves.
Remove:
Fuel Tank (see Fuel System (DFI) chapter)
Cap Bolt [A]
Washer [B]
Spring [C]
Rod [D]
Remove the m ounting bolts [E] and take off the camshaft
chain tensioner.
Camshaft Chain Tensioner Installation
Release the stopper [A] and push the push rod [B] into
the tensioner body [C].
Install the tensioner body so that the stopper faces up-
ward.
Tighten the tensioner m ounting bolts [A].
Torque - Camshaft Chain Tensioner M ounting Bolts: 11
N·m (1.1 kgf·m, 95 i n· lb)
Install t he 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:
Fuel Tank (see Fuel System (DFI) chapter)
Stick Coils (see Electrical System)
Cylinder Head Cover (see Cylinder Head Cover Re-
moval)
Pickup Coil Cover
Position the crankshaft at #1, 4 piston TDC.
[A] TDC mark for #1, 4 Pistons
[B] Timing Mark (crankcase halves mating surface)
Remove:
Camshaft Chain Tensioner (see Camshaft Chain Ten-
sioner Removal)
Camshaft Cap Bolts [D]
Chain Guide [A]
Camshaft Caps [B]
Camshafts [C]
Stuff a clean cloth into the chain tunnel to keep any parts
from dropping into the crankcase.
CAUTION
The crankshaft may be turned while the camshafts
are removed. Always pull the chain taut while turn-
ing the crankshaft. This avoids kinking the chain
on the lower (crankshaft) sprocket. A kinked chain
could damage both the chain and the sprocket.
Camshaft Installation
Be sure to install the following parts.
Plug Hole Gaskets [A]
Dowel P ins [B]
5-16 ENGINE TOP END
Camshaft, Camshaft Chain
Apply engine oil to all cam parts and journals.
If a new camshaft is to be used, apply a thin coat of molyb-
denum d
isulfide grease to the cam surfaces.
NOTE
The exhaust camshaft has a 030 EX mark [A] and the
inlet camshaft has a 030 IN mark [B]. Be careful not to
mix up these shafts.
Position the crankshaft at #1, 4 piston TDC .
Pull the tension side (exhaust side) [A] of the chain taut
to install the chain.
Engage the camshaft chain with the camshaft sprockets
so that the timing m arks on the sprockets are positioned
as shown.
The timing marks of #1, 4T must be aligned with the lower
surface of crankcase of rear side [B].
The timing marks must be aligned with the cylinder head
upper surface [ C].
[D] EX mark
[E] IN mark
Before installing the camshaft cap and chain guide, install
the camshaft chain tensioner body temporally.
Install the camshaft cap and chain guide [A].
First tighten the camshaft cap and all chain guide bolts
evenly to seat the camshaft i n place, then tighten all bolts
following the specified t ightening sequence.
Torque - Camshaft Cap Bolts: 12 N·m (1.2 kgf·m, 104 in·lb)
Camshaft Ch ain Guide Bolts: 12 N·m (1.2 kgf·m,
104 in·lb)
Tighten the camshaft chain tensioner (see Camshaft
Chain Tensioner Installation).
Install the cylinder head cover (see Cylinder Head Cover
Installation).
ENGINE TOP END 5-17
Camshaft, Camshaft Chain
Camshaft, Camshaft Cap Wear
Remove:
Camshaft Chain Guide
Camshaft Cap
Cut strips of plastigage to journal width. Place a strip
on each journal parallel to the camshaft installed in the
correct position.
Measure each clearance between the camshaft journal
and the camshaft cap using plastigage (press gauge) [A].
Tighten:
Torque - Camshaft Cap Bolts: 12 N·m (1.2 k gf·m, 104 in·lb)
Camsh
aft Chain Guide Bolts: 12 N·m (1.2 kgf·m,
104 in·lb)
NOTE
Do not turn the camshaft when the plastigage is be-
tween the journal and camshaft cap.
Camshaft Journal, Camshaft Cap Clearance
Standard: 0.028 0.071 mm (0.0011 0.0028 in.)
Service Limit: 0.16 mm (0.0063 in.)
If any clearance exceeds the service limit, measure the
diameter of each camshaft journal with a micrometer.
Camshaft Journal Diameter
Standard: 23.950 23.972 mm (0.9429 0.9438 in.)
Service Limit: 23.92 mm (0.942 in.)
If the camshaft journal diameter is less than the service
limit, replace the camshaft with a new one and measure
the clearance again.
If the clearance still remains out of the limit, replace the
cylinder head unit.
Camshaft Runout
Remove the camshaft.
Set the camshaft in a camshaft alignment jig or on V
blocks.
Measure runout with a dial gauge at the specified place
as shown.
If the runout exceeds the service limit, replace the shaft.
Camshaft Runout
Standard: TIR 0.02 mm (0.0008 in.) or less
Service Limit: TIR 0.1 mm (0.004 in.)
Cam Wear
Remove the camshaft.
Measure the height [A] of each cam with a micrometer.
If the cams are worn down past the service limit, replace
the camshaft.
Cam Height
Inlet Exhaust
Standard:
36.746 36.854 mm 36.146 36.254 mm
(1.4467 1.4509 in.) (1.4231 1.4273 in.)
Service
Limit:
36.65 mm 36.05 mm
(1.443 in.) (1.419 in.)
5-18 ENGINE TOP END
Camshaft, Camshaft Chain
Camshaft Chain Removal
Split the crankcase (see Crankshaft/Transmission chap-
ter).
Remove the camshaft chain [A] from the crankshaft
sprocket.
ENGINE TOP END 5-19
Cylinder Head
Cylinder Compression Measurement
NOTE
Use the battery which is fully charged.
Warm up the engine thoroughly.
Stop the engine.
Remove:
Seats (see Frame chapter)
Fuel Tank (see Fuel System (DFI) chapter)
Stick Coils
Spark Plugs
Owners Tool - Spark Plug Wrench, Hex 16
Attach the compression gauge [A] and adapter [B] firmly
into
the spark plug hole.
Using the starter motor, turn the engine over with the throt-
tle fully open until the compression gauge stops rising; the
com
pression is the highest reading obtainable.
Special Tools - Compression Gauge: 57001–221
Compression Gauge Adapter, M10 × 1.0:
57001–1317
Cylinder Compression
Usable Range :
1070 1620 kPa (10.9 16.5 kgf/cm²,
155 235 psi) @ 320 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)
Cylinder compression
is higher than usable
range
Carbon accumulation on piston and in
combustion chamber possibly due to
damaged valve stem oil seal and/or
damaged piston oil rings (This may be
indicated by white exhaust smoke).
Remove the carbon deposits
and replace damaged parts if
necessary.
Incorrect cylinder head gasket
thickness.
Replace the gasket with a standard
part.
Cylinder compression
is lower than usable
range
Gas leakage around cylinder head
Replace damaged check gasket
and 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 seizure. Inspect the cylinder and
replace/repair the cylinder and/or
piston as necessary.
Bad condition of piston ring and/or
piston ring grooves
Replace the piston and/or the
piston rings.
5-20 ENGINE TOP END
Cylinder Head
Cylinder Head R emoval
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) c hapter)
Water Hose [A]
Bracket Bolt [B]
Engine Bracket [C]
Cam Chain Guide
Remove the M6 cylinder head bolts [B], and then the M 10
cylinder head bolts [A].
T
ake off the cylinder head.
Cylinder Head Installation
NOTE
The camshaft cap is machined with the cylinder head,
so if a new cylinder head is installed, use the cap that
is 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 t hread of
head 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)
ENGINE TOP END 5-21
Cylinder Head
Install:
Front Camshaft Chain Guide [A]
O-ring [B]
Collar [C]
Tighten:
Torque
-
Front C
amshaft 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:
Rear Camshaft Chain Guide [F]
Tighten:
Torque - Rear Camshaft Chain Guide Bolt [G]:
25 N·m (2.5 kgf·m, 18 ft·lb)
Install the camshafts (see Camshaft Installation).
Cylinder Head Warp
Clean the cylinder head.
Lay a straightedge across the lower surface of the cylinder
head at several positions.
Use a thickness gauge [A] to measure the space between
the straightedge [B] and the head.
Cylinder Head Warp
Standard:
---
Service Limi t: 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 emery
paper secured to a surface plate (first No. 200, then No.
400).
5-22 ENGINE TOP END
Valves
Valve Clearance Inspection
Refer to the Engine Top End in the Periodic Maintenance
chapte
r.
Valve Clearance Adjustment
Refer to the Engine Top End in the Periodic Maintenance
chapter.
Valve Removal
R
emove the cylinder head (see Cylinder Head Removal).
Remove the valve lifter and shim.
Mark and record the valve lifter and shim locations so they
c
an be installed in their original positions.
Using the valve spring compressor assembly, remove t he
valve.
Special Tools - Valve Spring Compressor Assembly:
57001–241 [A]
Adapter,
22: 57001–1202 [B]
Valve Installatio n
Replace the oil seal with a new one.
Apply a thin coat of molybdenum disulfide grease to the
valve stem before valve installation.
Install the springs so that the closed coil end faces down-
wards.
[A] Valve Stem
[B] Oil Seal
[C] Spring Seat
[D] Closed Coil End
[E] Valve Spring (Yellow)
[F] Retainer
[G] Split K eepers
Valve Guide Removal
Remove:
Valve (see Valve Removal)
Oil Seal
Spring 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 will
warp the cylinder head. Soak the cylinder head in
oil and heat the oil.
Special Tool - Valve Guide Arbor, 4.5: 57001–1331
ENGINE TOP END 5-23
Valves
Valve Guide Installation
Apply oil to the valve guide outer surface before i nstalla-
tion.
Heat the area around the valve guide hole to about 120
150 °C (248 302 °F).
Drive the valve guide in from the t op of the head using the
valve guide arbor. The flange stops the guide from going
in too far.
Spec
ial Tool -
Valv
e G uide A rbor,
4.5: 57001–1331
Wait until the cylinder head cools down and then ream the
valve guide with the valve guide reamer [A] even if the old
guide is reused.
Turn the reamer in a clockwise direction until the reamer
turns 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, 4.5: 57001–1333
V
alve-to-Guide Clearance Measurement (Wobble
Method)
If a small bore gauge is not available, inspect the valve
g
uide wear by measuring the valve to valve guide clearance
with the wobble method as indicated below.
Insert a new valve [A] into the guide [B] and set a dial
gauge against the stem perpendicular to it as close as
possible to the cylinder head mating surface.
Move the stem back and forth [C] to measure valve/valve
guide clearance.
Repeat the measurement in a direction at a right angle to
the first.
If the reading exceeds the service limit, replace the guide.
NOTE
The reading is not actual valve/valve guide clearance
because the measuring point is above the guide.
Valve/Valve Guide Clearance (Wobble Method)
Inlet Exhaust
Standard:
0.03 0.12 mm 0.09 0.18 mm
(0.0012 0.0047 in.) (0.0035 0.0071 in.)
Service
0.33 mm 0.40 mm
Limit:
(0.013 in.) (0.016 in.)
5-24 ENGINE TOP END
Valves
Valve Seat Inspection
Remove the valve (see Valve Removal).
Check t
he valve seating surface [A] between the valve [B]
and valve seat [C].
Measure the outside diameter [D] of the seating pattern
on the
valve seat.
If the outside diam eter is too large or too small, repair t he
seat (see Seat Repair).
Valve Seating Surface Outside Diameter
Standard:
Inle
t
29.4 29.6 mm ( 1.1575 1.1654 in.)
Exhaust
25.2 25.4 mm (0.992 1.000 in.)
Measure the seat width [E] of the portion where there is
no build-up carbon (white portion) of the valve seat with a
vernier 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 Width
Standard:
Inlet
0.5 1.0 mm (0.020 0.039 in.)
Exhaust
0.8 1.2 mm (0.031 0.047 in.)
Valve Seat Repair
Repair the valve seat with the valve seat cutters [A].
Special Tools - Valve Seat C utter Holder, 4.5: 57001–1330[B]
Valve Seat Cutter Holder Bar: 57001–1128[C]
[For Inlet Valve Seat]
Valve Seat Cutter, 45° -
32: 57001–1115
Valve Seat Cutter, 32° -
30: 57001–1120
Valve Seat Cutter, 60° -
33: 57001–1334
[For Exhaust Valve Seat]
Valve Seat Cutter, 45° -
27.5: 57001–1114
Valve Seat Cutter, 32° -
28 : 57001–1119
Valve Seat Cutter, 60° -
30: 57001–1123
If the manufacturers instructions are not available, use
the following procedure.
ENGINE TOP END 5-25
Valves
Seat Cutter Operation Care:
1. This valve seat cutter is developed to grind t he valve for
repair. Therefore the cutter must not be used for other
purposes than seat repair.
2. Do not drop or shock the valve seat cutter, or the dia-
mond particles may fall off.
3. Do not fail to apply engine oil to the valve seat cutter
before grinding the seat surface. Also wash off ground
particles sticking to the cutter with washing oil.
NOTE
Do not use a wire brush to remove the metal particles
from the cutter. It will take off the diamond particles.
4. Setting the valve seat cutter holder in position, operate
the cutter in one hand. Do not apply too much force to
the diamond portion.
NOTE
Prior to grinding, apply engine oil to the cutter and dur-
ing the operation, wash off any ground particles sticking
to the cutter with washing oil.
5. After use, wash it with washing oil and apply thin layer
of engine oil before storing.
Marks Stamped on the Cutter:
The marks 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 valve
guide.
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 m uch. Overgrinding will
reduce valve clearance by sinking the valve into the
head. If the valve sinks too far into the head, it will
be impossible to adjust the clearance, and the cylin-
der head must be replaced.
5-26 ENGINE TOP END
Valves
Measure the outside diameter of the seating surface with
a vernier caliper.
If the o
utside diameter of the seating surface is too small,
repeat the 45° grind until the diameter is within the spec-
ified range.
Widen
ed Width [A] of engagement by machining with
45° cutter
Ground Volume [B] by 32° cutter
32° [C
]
Correct Width [D]
Ground Volume [E] by 60° cutter
60° [F]
Measure the outside diameter of the seating surface with
a vernier caliper.
If the outside diameter of the seating surface is too small,
repeat the 45° grind [A] until the diameter i s within the
specified range.
Original Seating Surface [B]
NOTE
Remove all pittings of flaws from 45° ground surface.
After grinding with 45° cutter, apply t hin coat of machin-
ist’s dye to seating surface. This makes seating surface
distinct and 32° and 60° grinding operation easier.
When the valve guide is replaced, be sure to grind with
45° cutter for centering and good contact.
If the outside diameter [A] of the seating surface is too
large, m ake the 32° grind described below.
If the outside diameter of the seating surface is w ithin the
specified range, measure the seat width as described be-
low.
Grind the seat at a 32° angle [B] until the seat O.D. is
within the specified range.
To make the 32° grind, fit a 32° cutter into the holder, and
slide it into the valve guide.
Turn the holder one turn at a time while pressing down
very 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 w idth is too narrow, repeat the 45° grind until
the seat is slightly too wide, and then return to the seat
O.D. measurement step above.
ENGINE TOP END 5-27
Valves
If the seat width is too wide, make the 60° [A] grind de-
scribed below.
If the seat width is within the specified range, lap the valve
to the seat as described below.
Grind the seat at a 60° angle until the seat width is within
the specified range.
To m ake the 60° grind, fit 60° cutter into the holder, and
slide 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 the
valve 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 the
seat and the valve.
Repeat the process with a fine grinding compound.
[A] Lapper
[B] Valve Seat
[C] Valve
The seating area should be marked about in the middle
of the valve face.
If the seat area is not in the right place on the valve, check
to be sure the valve is the correct part. If it is, it may have
been 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 valve
clearance ( see Valve Clearance Adjustment section of the
Periodic maintenance chapter).
5-28 ENGINE TOP END
Valves
ENGINE TOP END 5-29
Cylinder, Pistons
Cylinder Removal
Remove:
Cylinder Head (see Cylinder Head Removal)
Water Hose [A]
Remove the cylinder [B].
Cylinder Installation
NOTE
If a new cylinder is used, use new piston ring.
Install the pins [A] and new cylinder gasket [B].
Apply engine oil to the cylinder bore.
The piston ring openings must be positioned as shown in
the figure. The openings of the oil ring steel rails must be
about 30 40° of angle from the opening of the t op ring.
[A] Top Ring
[B] Second Ring
[C] Oil Ring Steel Rails
[D] Oil Ring Expander
[E] Hollow
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 the
crankcase.
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.
5-30 ENGINE TOP END
Cylinder, Pistons
Remove the piston pins.
Special Tool - Piston Pin Puller Assembly: 57001–910 [A]
Remove the pistons.
Carefully spread the ring opening with your thumbs and
then push up on the opposite side of the ring [A] to remove
it.
Remove the 3-piece oil ring with your thumbs in the same
manner.
Piston Installation
Apply m olybdenum disulfide oil solution to the oil ring ex-
pander, and install the oil ring expander [A] in the bottom
piston ring groove so the ends [B] butt together.
Apply molybdenum disulfide oil solution to the oil ring steel
rails, 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 fit
the rail over the piston.
Release the rail into the bottom piston ring groove.
NOTE
The 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 "R" mark [B] faces up.
Install the second ring [C] so that the " RN" mark [D] faces
up.
Apply molybdenum disulfide oil solution to the piston
rings.
ENGINE TOP END 5-31
Cylinder, Pistons
NOTE
If a new piston is used, use new piston ring.
Install the piston with its hollow facing forward.
Fit a n
ew piston pin snap ring into the side of the piston
so that the ring opening [A] does not coincide with t he slit
[B] of the piston pin hole.
Apply
molybdenum disulfide oil solution to the piston pins
and piston journals.
When installing the piston pin snap ring, compress it only
enou
gh to install it and no more.
CAUTION
Do not
reuse snap rings, as removal weakens and
deforms them.
They could fall out and score the cylinder 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 t he cylinder.
[A] 1 0 mm (0.39 in.)
[B] 6 0 mm (2.36 in.)
Cylinder Inside Diameter
Standard: 77.194 77.206 mm (3.0391 3.0396 in.)
S
ervice Limit:
7
7.30 mm (3.0433 in.)
Piston Wear
Measure the outside diameter [A] of each piston 5 m m
(0.20 in.) [B] up from the bottom of the piston at a right
angle to the direction of the piston pin.
If the measurement is under service limit, replace the pis-
ton.
Piston Diameter
Standard: 77.174 77.184 mm (3.0383 3.0389 in.)
Service Limit: 77.02 mm (3.0323 in.)
PistonRing,PistonRingGrooveWear
Check for uneven groove wear by inspecting the ring seat-
ing.
The rings should fit perfectly parallel t o groove surfaces.
If not, replace the piston and all the piston rings.
With the piston r ings in their grooves, make several m ea-
surements with a thickness gauge [A] to determine piston
ring/groove clearance.
Piston Ring/Groov e Clearance
Standard Service Limit
Top 0.04 0.08 mm 0.18 mm
(0.0016 0.0031 in.) (0.0071 in.)
Second 0.03 0.07 mm 0.17 mm
(0.0012 0.0028 in.) (0.0067 in.)
5-32 ENGINE TOP END
Cylinder, Pistons
Piston Ring Groove Width
Measure the piston ring groove width.
Use a ve
rnier caliper at several points around the piston.
Piston Ring Groove Width
Standard Service Limit
Top [A] 0.83 0.85 mm 0.93 mm
(0.0327 0.0335 in.) (0.037 in.)
Second [B]
0.82 0.84 mm 0.92 mm
(0.0323 0.0331 in.) (0.036 in.)
If the width of any of the two grooves is wider than the
service limit at any point, replace the piston.
Piston Ring Thickness
Measure the piston ring thickness.
Use the m icrometer to measure at several points around
the ring.
Piston Ring Thickness
Standard Service Limit
Top [A] 0.77 0.79 mm 0.70 mm
(0.0303 0.0311 in.) (0.028 in.)
Second [B]
0.77 0.79 mm 0.70 mm
(0.0303 0.0311 in.) (0.028 in.)
If any of the measurements is less than the service limit
on either of the rings, replace all the rings.
NOTE
When using new rings in a used piston, check for un-
even groove wear. The rings should fit perfectly parallel
to the groove sides. If not, replace the piston.
Piston Ring End Gap
Place the piston ring [A] inside the cylinder, using the pis-
ton to locate the ring squarely in place. Set it close to the
bottom of the cylinder, where cylinder wear is low.
Measure the gap [B] between the ends of the ring with a
thickness gauge.
Piston Ring End Gap
Standard Service Limit
Top 0.20 0.30 mm 0.6 mm
(0.0079 0.0118 in.) (0.024 in.)
Second 0.35 0.50 mm 0.8 mm
(0.0138 0.0197 in.) (0.031 in.)
If the end gap of either ring is greater than the service
limit, 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 on
the projection [C] of the holder.
Tighten:
Torqu
e-
Throt
tle Body Holde r Bolts [D]: 12 N·m (1.2 kgf·m,
104 in·lb)
Throttle Body Holder Cl amp Screws [E]: 2.0 N·m
(0.2 k
gf·m, 17 in·lb)
5-34 ENGINE TOP END
Muffler
WARNING
To avoid a serious burn, do not rem ove the mufflers
when the engine is still hot. Wait until the mufflers
cool down.
Muffler Body Removal
Remove:
Muffler Body Clamp Bolts [A]
Muffler Body Mounting Bolts [B]
Muffler Body [C]
Exhaust Pipe Removal
Remove:
Muffler Body Clamp Bolts [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 body
connection 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 Body
Exhaust Pipe [ D]
Install the muffler body until it is bottomed [E].
Install:
Dampers [F]
Washer [G]
Tighten:
Torque - Exhaust Pipe Manifold Holder Nuts [H]: 17 N·m
(1.7 kgf·m, 12 ft·lb)
Muffler Body Mounting Bolts [I] and Nuts [J]: 34
N·m (3.5 kgf·m, 25 ft·lb)
Muffler Body Clamp Bolts [K]: 17 N·m (1.7 kgf·m,
12 ft·lb)
ENGINE TOP END 5-35
Muffler
Install the muffler body clamp bolts as shown.
[L] Upper Side
[M] Inside
[N] Connection Part Detail
Thoroughly warm up the engine, wait until the engine
cools down, and retighten all the bolts and nuts.
CLUTCH 6-1
6
Clutch
Table of C ontents
Exploded View........................................................................................................................ 6-2
Specifications ......................................................................................................................... 6-4
Special Tools and Sealant ...................................................................................................... 6-5
Clutch Lever and Cable.......................................................................................................... 6-6
Clutch Lever Free Play Inspection .................................................................................... 6-6
Clutch Lever Free Play Adjustment .................................................................................. 6-6
Cable Removal ................................................................................................................. 6-6
Cable Installation .............................................................................................................. 6-6
Cable Lubrication.............................................................................................................. 6-6
Clutch Lever Installation.................................................................................................... 6-6
Clutch Cover........................................................................................................................... 6-7
Clutch Cover Removal ...................................................................................................... 6-7
Clutch Cover Installation . .................................................................................................. 6-7
Release Shaft Removal .................................................................................................... 6-7
Release Shaft Installation ................................................................................................. 6-7
Clutch Cover Disassembly................................................................................................ 6-8
Clutch Cover Assembly..................................................................................................... 6-8
Clutch ..................................................................................................................................... 6-9
Clutch Removal................................................................................................................. 6-9
Clutch Installation..............................................................................................................6-9
Clutch Plate Assembly Inspection..................................................................................... 6-11
Clutch Plate Assembly Adjustment ................................................................................... 6-12
Clutch Plate, Wear, Damage Inspection ........................................................................... 6-12
Clutch Plate Warp Inspection............................................................................................ 6-12
Clutch Spring Free Length M easurement ......................................................................... 6-12
6-2 CLUTCH
Exploded View
CLUTCH 6-3
Exploded View
Torque
No. Fastener
N·m kgf·m ft·lb
Remarks
1 Clutch lever clamp bolts 7.9 0.8 69 in·lb S
2 Clutch cover bolts (L = 32 mm) 11 1.1 95 in·lb
3
Clutch cover bolts (L = 45 mm)
11 1.1 95 in·lb
4 Clutch cover bolts (L = 30 mm) 11 1.1 95 in·lb
5 Clutch cover bolts 11 1.1 95 in·lb
6 Oil filler plug 1.5 0.15 13 in·lb
7 Clutch spring bolts 8.8 0.9 78 in·lb
8
Clutc
h hub nut
135 14 100 R
CL: Apply cable lubricant.
EO: Apply engine oil.
G: Apply grease.
M: Apply molybdenum disulfide grease.
R: Replacement Parts
S: Follow the specific tightening sequence.
W: Apply water.
6-4 CLUTCH
Specif ications
Item Standard Service Limit
Clutch Lever Free Play 2 3 m m (0.08 0.12 in.)
---
Clutch:
Clutch plate assembly 48.4 49.0 mm ( 1.91 1.93 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 75.42 mm (2.97 in.) 71.8 mm (2.83 in.)
CLUTCH 6-5
Special Tools and Sealant
Inside Circlip Pliers:
57001–143
Clutch Holder:
57001–1243
Kawasaki Bond (Silicone Sealant):
56019–120
6-6 CLUTCH
Clutch Lever and Cable
Clut ch Lever Free Play Inspection
Refer to the Clutch Adjust Inspection in the Periodic Main-
tenanc
e chapter.
Clutch Lever Free Play Adjustment
Refer to the Clutch Adjust Inspection in the Periodic Main-
tenance chapter.
Cable Removal
S
lide the dust cover [A] at the clutch cable lower end out
of place.
Loosen the nuts [B], and slide the lower end of the clutch
c
able 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 release
lever.
Push the release lever toward the front of the motorcycle
and tape the release lever to the c lutch cover to prevent
the 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 the
clutch lever clamp is aligned with the punch mark [B].
Tighten the upper clamp bolt first, and then the lower
clamp bolt. There will be a gap at the lower part of the
clamp after tightening.
Torque - Clutch Lever Holder Bolts: 7.8 N·m (0.80 kgf·m, 69
in·lb)
CLUTCH 6-7
Clutch C o ver
Clutch Cover Removal
Remove:
Engine Oil (drain, see Engine Oil Change section in the
Periodic Maintenance chapter)
Clutch Cable Lower End [A]
Clutch Cover Mounting Bolts [B]
Clutch Cable Bracket [C]
Turn the release lever [A] toward the rear as shown, and
remove the clutch cover [B].
[C] about 90°
Clutch Cover Installation
Apply silicone sealant to the area [A] where the mating
surface of the crankcase touches the clutch cover gasket.
Sealant - Kawasaki Bond (Silicone Sealant): 56019–120
Replace the cover gasket with a new one.
Tighten the cover bolts.
Torque - Clutch Cover Bolts: 11 N·m (1.1 kgf·m, 95 in·lb)
Release Shaft Removal
CAUTION
Do not remove the clutch release lever and shaft
assembly 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 [A] and shaft assembly out of the clutch
cover.
Release Shaft Installation
Apply high-temperature grease to the oil seal lips on the
upper ridge of the clutch cover.
Apply oil to the needle bearings in the hole of the clutch
cover.
Apply molybdenum disulfide grease to the pusher-holding
portion [A] on the release shaft.
Install t he washer [B] and spring [C].
Insert the release shaft straight into the upper hole of the
clutch cover.
CAUTION
When inserting the release shaft, be careful not to
remove the spring of the oil seal.
6-8 CLUTCH
Clutch Cover
Fit the spring [A] as shown.
[B] Viewed from Rear
[C] Rel
ease Shaft
[D] Clutch Cover
Clutch Cover Disassembly
Remove:
Oil Seal [A]
Needle Bearings
Remove:
Circlip [A]
Special Tool - Inside Circlip Pliers [B]: 57001–143
Remove:
Oil Level G auge [C]
Clutch Cover Assembly
Replace the needle bearings and oil seal with new ones.
NOTE
Install the needle bearings so that the manufacture’s
mark face out.
Install the needle bearings [A] and oil seal [B] position as
shown.
[C] Press the bearing until the bottom.
[D] Press the bearing so that the bearing surface is flush
with the housing end of clutch cover [E ].
Apply water to the rubber of the oil gauge [A] and press it
so that the projections [B] f ace inside.
Install a new circlip so that the circlip ends [C] do not wrap
over the projection [D].
CLUTCH 6-9
Clutch
Clutch Removal
Remove:
Engine Oil (drain, see Engine Oil Change section in the
Periodic Maintenance chapter)
Clutch C over (see Clutch Cover Removal)
Clutch Spring Bolts [A]
Clutch Springs
Clutch Spring Plate [B] (with thrust bearing and pusher
[C])
Remove:
Friction Plates, Steel Plates
Spring, Spring Seat
Clutch Hub Nut [A]
Holding the clutch hub [B], remove the nut.
Special Tool - Clutch Holder [C]: 57001–1243
Remove:
Clutch Hub
Spcer
Using the two 4 mm (0.16 in.) bolts [A], pull out the sleeve
[B], needle bearing [C] and clutch housing [D].
Remove the spacer.
Clutch Installation
Install the following parts on the drive shaft.
[A] Spacer
[B] S leeve
[C] Needle Bearing
[D] Clutch Housing
[E] Spacer
[F] Clutch Hub
[G] Washer
[H] Nut
6-10 CLUTCH
Clutch
Install the spacer [A] so t hat the tapered side [B] f aces
inward.
Install the washer [A] so that the OUT SIDE mark faces
outward.
Replace the clutch hub nut with a new one.
Holding the clutch hub, tighten the clutch hub nut.
Special Tool - Clutch Holder: 57001–1243
Torque - Clutch Hub Nut: 135 N· m (14 kgf·m, 100 ft·lb)
Install t he spring seat [A] and spring [B] as shown.
[C] Clutch Hub
Install the friction plates and steel plates, starting with a
friction plate and alternating them.
CAUTION
If new dry friction plates and steel plates are in-
stalled, apply engine oil to the surfaces of each
plate to avoid clutch plate seizure.
Install the last friction plate [A] fitting the tangs in the
grooves in the housing as shown.
CLUTCH 6-11
Clutch
Apply molybdenum disulfide grease to the pusher ends
[A] and install the pusher [B].
Apply engine oil t o the needle bearing [C] and install it.
Install the washer [D].
Align the mark [A] of the clutch spring plate [B] with the
groove [C] of the clutch hub.
Install the clutch spring plate and spring, and tighten the
clutch spring bolts.
Torque - Clutch Spring Bolts: 8.8 N·m (0.9 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 as
shown.
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 (0.9 kgf·m, 78 in·lb)
Clutch Plate Assembly
Standard: 48.4 49.0 mm (1.91 1.93 in.)
If the length is not within the specified range, adjust the
length (see Clutch Plate Assembly Adjustment).
6-12 CLUTCH
Clutch
Clutch Plate Assembly Adjustment
Inspect the clutch plate assembly length, and then re-
place t
he steel plate(s) which brings the length within the
specified range.
Remove:
Sprin
gBolts
Spring Holders
Springs
Spring
Plate
Replace the following steel plate(s).
Part No. Thickness
13089–1073
2.0 mm (0.08 in.)
13089–1084
2.3 mm (0.09 in.) (STD)
13089–1115
2.6 mm (0.10 in.)
NOTE
Do not use the steel plate of 2.0 mm (0.08 in.) and 2.6
mm (0.10 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 (0.9 kgf·m, 78 in·lb)
Clutch Plate, Wear, Damage Inspection
Visually inspect the friction and steel plates for signs of
seizure, overheating (discoloration), or uneven wear.
Measure t he thickness of each friction plate [A] at several
points.
If any plates show signs of damage, or if they have worn
past the service limit, replace them with new ones.
Friction Plate Thickness
Standard: 2.72 2.88 mm (0.107 0.113 in.)
Service Limit: 2.4 mm (0.094 in.)
Clut ch Plate Warp Inspection
Place each friction plate or steel plate on a surface plate
and measure the gap between the surface plate [A] and
each 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 with
a new one.
Friction and Steel Plate Warp
Standard: 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 be
replaced.
Clutch Spring Free Length
Standard: 75.42 mm (2.97 in.)
Service Limit: 71.8 mm (2.83 in.)
ENGINE LUBRICATION SYSTEM 7-1
7
Engine Lubrication S ystem
Table of C ontents
Exploded View........................................................................................................................ 7-2
Engine Oil Flow Chart............................................................................................................. 7-4
Specifications ......................................................................................................................... 7-6
Special Tools and Sealant ...................................................................................................... 7-7
Engine Oil and Oil Filter.......................................................................................................... 7-8
Oil Level Inspection........................................................................................................... 7-8
Engine Oil C hange............................................................................................................ 7-8
Oil Filter Replacement ...................................................................................................... 7-8
Oil Pan.................................................................................................................................... 7-9
Oil Pan Removal . .............................................................................................................. 7-9
Oil Pan Installation ............................................................................................................ 7-9
Oil Pressure Relief Valve........................................................................................................ 7-10
Oil Pressure Relief Valve Removal ................................................................................... 7-10
Oil Pressure Relief Valve I nstallation ................................................................................ 7-10
Oil Pressure Relief Valve I nspection................................................................................. 7-10
Oil Pump................................................................................................................................. 7-11
Oil Pump Removal ............................................................................................................ 7-11
Oil Pump Installation ......................................................................................................... 7-11
Oil Pump Drive Gear Removal.......................................................................................... 7-13
Oil Pump Drive Gear Installation....................................................................................... 7-13
Oil Cooler................................................................................................................................ 7-14
Oil Cooler Removal........................................................................................................... 7-14
Oil Cooler Installation........................................................................................................ 7-14
Oil Pressure Measurement..................................................................................................... 7-15
Oil Pressure Measurement ............................................................................................... 7-15
Oil Pressure Switch ................................................................................................................ 7-16
Oil Pressure Switch Removal ........................................................................................... 7-16
Oil Pressure Switch Installation ........................................................................................ 7-16
7-2 ENGINE LUBRICATION SYSTEM
Exploded View
ENGINE LUBR ICATION S YSTEM 7-3
Exploded View
Torque
No. Fastener
N·m kgf·m ft·lb
Remarks
1 Oil f iller plug 1.5 0.15 13 in·lb
2 Engine drain plug 20 2.0 14.5
3
Oil filter ( cartridge type, P/No. 16097–1070)
26 2.7 20
EO, R
3 Oil filter (cartridge type, P/No. 16097–0002) 31 3.2 23 EO, R
4 Oil cooler 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 pr
essure 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
10 Water pump cover bolts 11 1.1 95 in·lb
11 Water pump impeller bolt 10 1.0 87 in·lb
12 Coolant drain plug (water pump) 11 1.1 95 in·lb
13 Water hose clamp screws 2.0 0.2 17 in·lb
14
Oil passge plugs
20 2.0 14.5 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 Parts
SS: Apply silicone sealant (Kawasaki Bond: 56019–120).
W: Apply water.
7-4 ENGINE LUBRICATION SYSTEM
Engine Oil Flow Chart
ENGINE LUBR ICATION S YSTEM 7-5
Engine Oil Flow Chart
1. Cam shaft Oil Passage
2. Oil Passage Hole in Alternator Rotor Bolt
3. Starter Clutch O il Passage Hole
4. Main Oil Passage
5. Crankshaft Oil Passage
6. Oil Filter
7. Oil Cooler
8. Oil Pressure Switch
9. Oil Pipe
10. Oil Pump
11. To Drive Shaft
12. Oil Pipe
13. To Output Shaft
14. Drive Shaft Oil Passage Hole
15. Output Shaft Oil Passage Hole
16. Inlet Camshaft
17. Exhaust Camshaft
18. To Air Cleaner
19. Drive Shaft
20. Relief Valve
21. Oil Screen
22. Oil Drain Plug
23. Output Shaft
7-6 ENGINE LUBRICATION SYSTEM
Specif ications
Item Standard
Engine Oil:
Type API SE, SF or SG
API SH or SJ wi th JAS O 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
Kawasaki Bond (Silicone Sealant):
56019–120
Oil Filter Wrench:
57001–1249
7-8 ENGINE LUBRICATION SYSTEM
Engine Oil and Oil Filter
WARNING
Motorcycle operation with insufficient, deteri-
orated, or contaminated engine oil will cause
accelerated wear and m ay 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.
NOTE
Situate the motorcycle so that it is perpendicular to the
ground.
If the motorcycle has just been used, wait several m in-
utes for all the oil to drain down.
If the oil has just been changed, start the engine and
run it for several minutes at idle speed. This fills the oil
filter with oil. Stop the engine, then wait several minutes
until the oil settles.
CA
UTION
Racing the engine before the oil reaches every part
can cause engine seizure.
If the engine oil gets extremely low or if the oil pump
or oil passages clog up or otherwise do not function
properly, the oil pressure warning light w ill light. If
this light stays on when the engine is running above
idle speed, stop the engine immediately and find the
cause.
If the oil level is too high, remove the excess oil, using a
syring or some other suitable device.
If the oil level is too low, add the correct amount of oil
through the oil filter opening. Use the same type and
make of oil that is already in the engine.
NOTE
If the engine oil type and make are unknown, use any
b
rand of the specified oil to top off the level in preference
to running the engine with the oil level low. Then at your
earliest convenience, change the oil completely.
Engine Oil Change
Refer to the Periodic Maintenance chapter.
Oil Filter Replacement
Refer to the Periodic Maintenance chapter.
ENGINE LUBR ICATION S YSTEM 7-9
Oil Pan
Oil Pan Removal
Remove:
Engine Oil (drain, see Periodic M aintenance chapter)
Muffler (see Engine Top End chapter)
Oil Pan Bolts [A]
Oil Pan [B]
Remove the oil pipe [A], oil pressure relief valve [ B] and
oil screen [C] as necessary.
Oil Pan Installation
Clean the oil screen [A].
Install t he oil screen so that the crankcase rib [B] fits the
slot [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 of
the oil pressure relief valve, and tighten it.
CAUTION
Do not apply too much non-permanent locking
agent to the threads. This may block the oil pas-
sage.
Torque - Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11
ft·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.
Oi
l 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 comes
b
ack to its seat by spring [B] pressure.
NOTE
Inspect the valve in its assembled state. Disassembly
and 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 and
blow out any foreign particles that may be in the valve with
compressed air.
WARNING
Clean the oil pressure relief valve in a well
-ventilated area, and take care that there is no
spark 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 oil
pressure relief valve as an assembly. The oil pressure
relief valve is precision made with no allowance for re-
placement of individual parts.
ENGINE L UBRICATION SYSTEM 7-11
Oil Pump
Oil Pump Removal
Drain:
Coolant (see Periodic Maintenance chapter)
Engine O il (see Periodic Maintenance chapter)
Remove:
Water Hose [A]
Water Pipe Fitting Bolts [B]
Water Pipes [C]
Remove:
Water Pump Cover Bolts [A]
Clamp [B]
Water Pump Cover [C]
Remove:
Water Pump Impeller Bolt [A]
Water Pump Impeller [B]
Remove:
Water Pump Body
Oil Pump Cover
Oil (Water) Pump Shaft
Outer Rotor and Inner Rotor
NOTE
The oil (water) pump assembly [A] can easily be re-
moved by installing water pump cover bolt [B] into the
oil (water) pump shaft and pulling them.
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 s o that the slot [E] in its shaft fits onto
the projection [F] of the pump drive gear shaft.
7-12 ENGINE LUBRICATION SYSTEM
Oil Pump
Fit the pin [A] of the oil pump cover [B] into the hole [C] in
the crankcase.
Install:
Pins [A]
Water Pump Body [B]
Install:
Impeller [A] and Bolt [B]
Tighten:
Torque - Water Pump Impeller Bolt: 10 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, 95
in·lb)
Install:
Water Pipes [A]
Tighten:
Torque - Water Pipe Fi tting Bolts [B]: 11 N·m (1.1 kgf·m, 95
in·lb)
Install the water hose [C] so that the white mark faces
outward.
Tighten:
Torque - Water Hose Clamp Screws [ D]: 2.0 N·m (0.2 kgf·m,
17 in·lb)
ENGINE LUB RICAT ION SYSTEM 7-13
Oil Pump
Oil Pump Dri ve Gear Removal
Remove:
Clutch (see Clutch chapter)
Oil Pan (see Oil Pan Removal)
Circlip [A] and Washer [B]
Oil Pump Drive Gear [C]
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 circlip new [D] into the groove of t he oil pump
drive gear shaft.
7-14 ENGINE LUBRICATION SYSTEM
Oil Cooler
Oil Cooler Removal
Drain:
Coolan
t (see Periodic Maintenance chapter)
Engine Oil (see Periodic Maintenance chapter)
Remove:
Oil Fil
ter (see Periodic Maintenance chapter)
Water Hose [A]
Oil Cooler Mounting Bolt [B] and Washer
Oil Coo
ler [C] and Water Hose
Oil Cooler Installation
Install:
Water Hose [A]
Tighten:
Torque - Water Hose Clamp Screws: 2.0 N·m (0.2 kgf·m, 17
in·lb)
Ap
ply grease to the O-ring [B] before installation.
Install the oil cooler so that the crankcase rib [A] fits the
slot [B] of the cooler.
Apply engine oil to t he oil cooler mounting bolt [A] before
installation.
Install:
Washer [B]
Tighten:
Torque - Oil Cooler Mounting Bolt: 78.5 m (8.0 kgf·m, 58
ft·lb)
Install:
Oil Filter (see Periodic Maintenance chapter)
Pour:
Coolant (see Periodic Maintenance chapter)
Engine Oil (see Periodic Maintenance chapter)
ENGINE LUB RICAT ION SYSTEM 7-15
Oil Pressure Measurement
Oil Pressure Measurement
Remove the oil passage plug, and attach the adapter [A]
and gauge [B] to the plug hole.
Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001–164
Oil Pressure Gauge Adapter, PT 3/8:
57001
–1233
Start the engine and warm up the engine.
Run the engine at the specified s peed, and read the oil
pressure gauge.
If the oil pressure is much lower than the standard, check
the oil pump, relief valve, and/or crankshaft bearing insert
wear immediately.
If the r eading is much higher than the standard, check the
oil passages for clogging.
Oil Pressure
Standard: 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.
WARNING
Take care against burns form hot engine oil that
will drain through the oil passage when the gauge
adapter is removed.
Apply a non-permanent locking agent to the oil passage
plug, and install it.
Torque - Oil Passage Plug (Right): 20 N·m (2.0 kgf·m, 14.5
ft·lb)
7-16 ENGINE LUBRICATION SYSTEM
Oil Pressure Switch
Oil Pressure Switch Removal
Remove:
Engine
Oil (drain, see Periodic Maintenance chapter)
Switch Cover [A]
Switch Terminal [B]
Oil Pre
ssure Switch [C]
Oil Pressure Switch Installation
Apply silicone sealant to the threads of the oil pressure
switch and tighten it.
Sealant - Kawasaki Bond (Silicone Sealant): 56019–120
To
rque -
Oi
l Pressure Switch: 15 N·m (1.5 k gf·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/INSTALLATI O N 8-1
8
Engine Removal/Installation
Table of C ontents
Exploded View........................................................................................................................ 8-2
Special Tools .......................................................................................................................... 8-4
Engine Removal/Installation ................................................................................................... 8-5
Engine Removal................................................................................................................ 8-5
Engine Installation............................................................................................................. 8-9
8-2 ENGINE REMO VAL /INSTALLATION
Exploded View
ENGINE REMOVAL/INSTALLATION 8-3
Exploded View
Torque
No. Fastener
N·m kgf·m ft·lb
Remarks
1 Adjusting collar locknut 49 5.0 36 S
2 Upper engine m ounting bolts 44 4.5 32 S
3 Rear engine bracket bolts 25 2.5 18
S
4 Front engine bracket bolts 44 4.5 32 S
5 Middle engine mounting nut 44 4.5 32 S
6 Lower engine mounting nut 44 4.5 32 S
7. Adjusting Collar
8. Middle Engine Mounting Bolt
9. Lower Engine Mounting Bolt
S: Follow the specific tightening sequence.
8-4 ENGINE REMO VAL /INSTALLATION
Special Tools
Carburetor Drain Plug Wrench, Hex3:
57001–1269
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 [A].
Squeeze the brake lever slowly and hold it with a band
[A].
WARNING
Be sure to hold the front brake when removing the
engine, or the motorcycle may fall over. It could
cause an accident and injury.
CAUTION
Be sure to hold the front brake when removing the
engine, or the motorcycle may fall over. The engine
or the motorcycle could be damaged.
Drain:
Engine O il (see Periodic Maintenance chapter)
Coolant (see Periodic Maintenance chapter)
Remove:
Seats (see Frame chapter)
Fuel Tank (see Fuel System chapter)
Side Covers (see Frame chapter)
Right Frame Cover [A] (see Frame chapter)
Right Radiator Cover [B] (see Cooling System chapter)
Clutch Cable Lower End [C] (see Clutch chapter)
8-6 ENGINE REMO VAL /INSTALLATION
Engine Removal/Installation
Remove:
Radiator Hose Clamp [A] (Loosen)
Radiat
or Hose [B]
Oil Cooler Water Hose Clamp [C] (Loosen)
Oil Cooler Water Hose [D]
Radiato
r Bolt [E] (Loosen)
Radiator Bracket Bolt [F]
Disconnect
Crankshaft Sensor Lead C onnector (see Electrical Sys-
tem chapter)
Stick Coil Harness Connector [A]
Remove:
Air Cleaner Housing Bolt [A]
Loosen:
Throttle Body Assy Clamps Bolts #3, 4 [B] (see Fuel Sys-
tem (DFI) chapter)
Special Tool - Ca rburetor Drain Plug Wrench, Hex3:
57001–1269
Remove:
Left Radiator Cover [A] (see Cooling System chapter)
Left Frame Cover [ B] (see Frame chapter)
Shift Lever [C] (see Crankshaft/Transmission chapter)
Engine Sprocket Cover [D] (see Final Drive chapter)
Radiator Hose Clamp [E] (Loosen)
Radiator Hose [F]
Pull off the connectors from the engine and free the wiring
from the clamps.
For California M odel, remove the separate.
Starter Motor Lead [A] (see Electrical System chapter)
Alternator Lead Connector [B]
Neutral Switch Lead Connector [C]
Side Stand Switch Lead C onnector [D]
Remove:
Engine Sprocket (see Final Drive chapter) [E]
ENGINE REMOVAL/INSTALLATION 8-7
Engine Removal/Installation
Remove:
Camshaft Position Sensor Connector [A]
Injector Harness Connector [B]
Coolant Reserve Tank [A] ( see Cooling System chapter)
Air Cleaner Housing Bolt [B]
Vacuum Switch Valve Hose [C]
Remove:
Vacuum Switch Valve Tube [A]
Inlet Air Pressure Sensor Tube [B]
Throttle Body Assy [C]
Loosen the #1,2 body assy clamps [D] and pull the throttle
body out of the holders, and then remove it to the left side.
Special Tool - Carburetor Drain Plug Wrench, Hex3:
57001–1269
Remove:
Breather Hose End [A]
Remove:
Nuts [A]
Clamp Bolts [B]
Exhaust Pipe Assy [C]
8-8 ENGINE REMO VAL /INSTALLATION
Engine Removal/Installation
Support the engine with a suitable stand [A].
Put a plank [B] onto the suitable stand for engine balance.
Remove:
Right and Left Engine Upper Mounting Bolts [A]
Front Engine Bracket Bolts [B]
Front Engine Bracket [C]
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
ENGINE REMOVAL/INSTALLATION 8-9
Engine Removal/Installation
Using the Hexagon Wrench, turn the adjusting collar [A]
counter clockwise t o mark the gap between the engine
and flame adjusting collar.
Remove the drive chain [ A] from the output shaft [B].
Down the rear portion of the engine a little and remove
the engine ground [A].
Unscrew the ground bolt [B].
Using the stand, take out the engine.
Clear the camshaft position s ensor from the frame.
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 [A] 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)
8-10 ENGINE REMOVAL/INSTAL LATION
Engine Removal/Installation
Install the engine mounting bolts and nuts, following the
specified installing sequence.
First,
hang the drive chain over the output shaft just before
moving the engine into its final position in the frame.
Second, insert the lower engine mounting bolt [A].
Third
, install the rear engine bracket [B] temporarily.
Fourth, insert the middle engine mounting bolts [C].
Fifth, install the left upper engine mounting bolt [A] and
tighten it.
Torque - Left Upper Engine Mounting Bolt : 44 N·m (4.5
kgf·m, 32 ft·lb)
Sixth, tighten the adjusting collar [A] until the clearance
between the crankcase [B] and frame bracket [C] come
to zero 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, fit the projections [A] of the baffle plate [B] in the
holes [C] of the frame and front bracket [D].
ENGINE REMOVAL/INSTALLATION 8-11
Engine Removal/Installation
Ninth, temporarily install:
Front Engine Bracket [A]
Front Right Engine Mounting Bolt [B]
Tenth, tighten the rear bracket bolts.
Torque - Rear Engine Bracket Bolts: 25 m (2.5 kgf·m, 18
ft·lb)
Eleventh, tighten securely:
Middle Engine Mounting Nut
Lower Engine Mounting Nut
To
rque -
En
gine Mounting Nut: 44 N·m (4.5 kgf·m, 32 ft·lb)
Twelfth, tighten the right upper engine mounting bolt.
Lastly, tighten the front bracket bolts.
Torque - Right Upper Engine Mounting Bolt : 44 N·m (4 .5
kgf·m, 32 ft·lb)
Front Bracket Bolts: 44 N·m (4.5 kgf·m, 32 ft·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 Periodic Maintenance chapter)
Choke Cable (see Fuel System (DFI) chapter)
Clutch Cable (see Periodic Maintenance chapter)
Drive Chain (see Periodic Maintenance c hapter)
Fill the engine with engine oil (see Periodic M aintenance
chapter).
Fill the engine with coolant and bleed the air from the
cooling system (see Periodic Maintenance chapter).
CRANKSHAFT/TR ANSMISSION 9-1
9
Crankshaft/Transmission
Table of C ontents
Exploded View................................... 9-2
Specifications .................................... 9-6
Special Tools and Sealant ................. 9-8
Crankcase S plitting............................ 9-9
Crankcase Splitting ...................... 9-9
Crankcase Assembly ................... 9-9
Crankshaft and Connecting Rods...... 9-12
Crankshaft Removal .................... 9-12
Crankshaft Installation ................. 9-12
Connecting Rod Removal............ 9-12
Connecting Rod Installation......... 9-12
Crankshaft/Connecting Rod
Cleaning.................................... 9-15
Connecting Rod Bend.................. 9-16
Connecting Rod Twist .................. 9-16
Connecting Rod Big End Side
Clearance.................................. 9-16
Connecting Rod Big End Bearing
Insert/Crankpin Wear ................ 9-17
Crankshaft Side Clearance .......... 9-18
Crankshaft Runout....................... 9-18
Crankshaft Main Bearing
Insert/Journal Wear................... 9-19
Starter Motor Clutch .......................... 9-21
Starter Motor Clutch
Removal/Installation.................. 9-21
Starter M otor Clutch Assembly .... 9-21
Starter Motor Clutch Inspection ... 9-21
Transmission ..................................... 9-22
Shift Pedal Removal .................... 9-22
Shift Pedal Installation ................. 9-22
External Shift Mechanism
Removal .................................... 9-23
External Shift Mechanism
Installation ................................. 9-24
External Shift Mechanism
Inspection.................................. 9-24
Transmission Shaft R emoval ....... 9-25
Transmission Shaft Installation .... 9-25
Transmission Shaft Disassembly . 9-25
Transmission Shaft A ssembly...... 9-26
Shift Drum and Fork Removal...... 9-28
Shift Drum and Fork Installation... 9-29
Shift Drum Disassembly............... 9-29
Shift Drum Assembly ................... 9-29
Shift Fork B ending ....................... 9-29
Shift Fork/Gear Groove Wear ...... 9-30
Shift Fork Guide Pin/Drum
Groove Wear............................. 9-30
Gear Dog and Gear Dog Hole
Damage..................................... 9-30
9-2 CRANKSHAFT/TRANSMISSION
Exploded View
CRANKSHAFT/TR ANSMISSION 9-3
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Breather plate bolts 10 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) 49 5.0 36 MO,S
4 Crankcase bolts (M8) 27 2.8 20 S
5
Crank
case bolts (M7)
20 2.0 14.5
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 4.0 29
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 14.5 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: 92104–1063).
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 Parts
S: Tightening the fasteners following the specified sequence.
SS: Apply silicone sealant (Kawasaki Bond: 56019–120).
9-4 CRANKSHAFT/TRANSMISSION
Exploded View
CRANKSHAFT/TR ANSMISSION 9-5
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Shift pedal mounting bolt 34 3.5 25 L
2 Gear positioning lever bolt 12 1.2 104 in·lb
3 Shift shaft return spring pin 29 3.0 22 L
4 Shift drum cam holder bolt 12 1.2 104 in·lb L
5 Footpeg bracket bolts 34 3.5 25 L
6 Shift lever bolt 6.9 0.7 61 in·lb
7 Tie-rod locknuts 6.9 0.7 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
Specif ications
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 0.0
41 0.071 mm
0.1
1mm
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.)
M
arking
N
one
3
4.984 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 side clearance 0.05 0.20 mm 0.40 mm
(0.0020 0.0079 in.) (0.0157 in.)
CRANKSHAFT/TRANSMISSION 9-7
Specifications
Item Standard Service Limit
Cranks
haft runout
TIR 0.0
2 mm (0.0008 in.) or
less
TIR 0.05 mm
(0.0020 in.)
Crank
shaft main bearing insert/journal clearance
0.020 0.044 mm 0.07 mm
(0.0008 0.0017 in.) (0.0028 in.)
Cran
kshaft 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.)
C
rankcase 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 D iameter
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 m m 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.)
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.)
9-8 CRANKSHAFT/TRANSMISSION
Special Tools and Sealant
Bearing Puller:
57001–135
Bearing Puller Adapter:
57001–317
Kawasaki Bond (Silic one Sealant):
56019–120
Kawasaki Bond (Silic one Sealant):
92104–1063
CRANKSHAFT/TRANSMISSION 9-9
Crankcase Splitting
Crankcase Splitting
Remove the engine (see Engine Removal/Installation
chapter).
Set the engine on a clean surface and hold the engine
steady while parts are being removed.
Remove:
Crankshaft Sensor (see Electrical System chapter)
Clutch (see 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 Periodic Maintenance chapter)
Oil Cooler (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, oil pressure relief valve, oil screen
and oil pipes (see Engine Lubrication System chapter).
Remove the lower crankcase bolts and clamp.
First loosen the M7 bolts.
M7 Bolts [A]
M9 Bolts [B]
Tap l ightly around the crankcase mating surface with a
plastic mallet, and split the crankcase. Take care not to
damage the crankcase.
Crankcase Assembly
CAUTION
The upper and lower crankcase halves are ma-
chined at the f actory in the assembled state, so the
crankcase 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 the
crankcase halves.
9-10 CRANKSHAFT/T RANSMISSION
Crankcase Splitting
Apply liquid gasket to the breather plate mating surface
[A] 1 to 1.5 mm (0.04 to 0.06 in.) thick, and then install
the bre
ather plate.
Sealant - Three Bond: 1207B
Apply a non-permanent locking agent to the t hreads and
tighten the bolts [A].
Torque - Breather Plate Bolts: 10 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 on
the pipe.
Install the clamp [B] so that its head faces to right side.
[C] Breather Plate
Install:
Crankshaft and Connecting Rods
Camshaft Chain [A]
Transmission Shafts and Gears
Dowel Pins [B]
Shift Drum
Shift Forks and Shift Rods
Before fitting the lower case on the upper case, check t he
following.
Be sure to hang the camshaft chain on the crankshaft.
Check to see that the shift drum and transmission gears
are in the neutral position.
CRANKSHAFT/T RANSMISSION 9-11
Crankcase Splitting
Apply liquid gasket [A] to the mating surface of the lower
crankcase half.
Sealan
t-
Kawasa
ki Bond (Silicone Sealant): 92104–1063
CAUTION
Do not apply l iquid gasket around the crankshaft
main bearing inserts, and oil passage holes.
Fit the lower crankcase to the upper crankcase.
Apply molybdenum disulfide grease to the seating surface
[A] on the lower crankcase for the M9 bolts [B].
[C] Washer
Tighten the lower crankcase bolts using the following
steps.
Following the sequence numbers on the lower crankcase
half, tighten the M9 bolts [1 6] L= 81 mm (3.19 in.).
Torque - Crankcase Bolts (M9): 42 N·m (4.3 kgf·m, 30 ft·lb)
Tighten the M9 bolts [7 10] L= 95 mm (3.74 in.) with
washers.
Torque - Crankcase Bolts (M9): 49 N·m (5.0 kgf·m, 36 ft·lb)
Tighten the M7 bolts [A].
Torque - Crankcase Bolts (M6): 20 N·m (2.0 kgf·m, 14.5
ft·lb)
[B] Clamp
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, 14.5
ft·lb)
[B] L= 85 mm (3.35 in.)
[C] L= 50 mm (1.97 in.)
Crankcase Bolts (M6): 12 m (1.2 kgf·m, 104 in·lb)
[D] L= 60 mm (2.36 in.)
[E] L= 40 mm (1.57 in.)
[F] L= 90 mm (3.54 in.)
[G] Clamp
After tightening all crankcase bolts, c heck the following
items.
Crankshaft and transmission shafts turn freely.
While spinning the output shaft, gears shift smoothly from
the 1st to 6th gear, and 6th to 1st.
When the output shaft stays still, the gear can not be
shifted to 2nd gear or other higher gear positions.
9-12 CRANKSHAFT/T RANSMISSION
Crankshaft and Connecting Rods
Crankshaft Removal
Split the crankcase (see Crankcase Splitting).
Remove
the crankshaft [A].
Crankshaft Installation
CAUTION
If the crankshaft, bearing inserts, or crankcase
halves are replaced with new ones, select the bear-
ing inserts and check clearance with a plastigage
(press gauge) before assembling engine to be sure
the correct bearing inserts are installed.
Apply molybdenum disulfide oil solution to the crankshaft
main bearing inserts.
Install the crankshaft with the camshaft chain [A] hanging
on it.
Connecting Rod Removal
Split the crankcase (see Crankcase Splitting).
Remove the connecting rod nuts [A].
Remove the crankshaft.
NOTE
Mark and record the locations of the connecting rods
and their big end caps so that they can be reassembled
in 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 should
have the same weight mark.
BigEndCap[A]
Connecting Rod [B]
Weight Mark, Alphabet [C]
Diameter Mark [D]:
”ornomark
CAUTION
If the connecting rods, big end bearing inserts, or
crankshaft are replaced with new ones, select the
bearing insert and check clearance with a plasti-
gage (press gauge) before assembling engine to be
sure the correct bearing inserts are installed.
CRANKSHAFT/TR ANSMISSION 9-13
Crankshaft and Connecting Rods
Apply molybdenum disulfide grease [A] to the outer sur-
face of the upper insert and the inner surface of the con-
necting rod big end.
Apply molybdenum disulfide oil [B] to the inner surfaces
of upper and lower bearing inserts.
The molybdenum disulfide oil is a mixture of engine oil
and molybdenum disulfide grease with a weight ratio
(10:1).
Do not apply any grease or oil [C] to the cap inside and
cap insert outside.
Install the inserts so t hat their nails [D] are on the same
side and fit them into the recess of the connecting rod and
cap.
CAUTION
Wrong application of oil and grease could cause
bearing damage.
When installing the inserts [A], be careful not to damage
th
e 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 Cap
In
stallation [E] to Connecting Rod
Push [F]
Spare Dowel Pin [G]
Co
nnecting Rod Bolts [H]
Install t he cap on the connecting rod, aligning the mass
and diameter marks.
Re
move debris and clean the surface of inserts.
Apply molybdenum disulfide oil [MO] to the t hreads and
seating 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 “plastic
region fastening method”.
This method precisely achieves the needed clamping
force without exceeding it unnecessarily, allowing the
use of thinner, lighter bolts further decreasing connecting
rod m ass.
There are two types of the plastic region fastening. One is
a bolt length measurement method and other is a rotation
angle method. Observe one of the following two, but the
bolt length measurement method is preferable because
this is a more reliable w ay to tighten the big end nuts.
CAUTION
The connecting rod bolts are designed to stretch
when tightened. Never reuse the connecting rod
bolts. See the table below for correct bolt and nut
usage.
CAUTION
Be careful not to overtighten the nuts.
The bolts must be positioned on the seating surface
correctly to prevent the bolt heads from hitting the
crankcase.
9-14 CRANKSHAFT/T RANSMISSION
Crankshaft and Connecting Rods
(1) Bolt Length Measurement Method
Be sure to clean the bolts, nuts, and connecting rods
thorou
ghly with a high-flash point solvent, because the
new connecting rods, bolts, and nuts are treated with an
anti-rust solution.
WARNING
Clean the bolts, nuts, and connecting rods in a well
-ventilated area, and take care that there is no spark
or flame anywhere near the working area. This i n-
cludes any appliance with a pilot light. Because of
the danger of highly flammable liquids, do not use
gasoline 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 measure
the 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 the
following:
Threads of Nuts and Bolts
Seating Surfaces of Nuts and Con-rods
Tighten the big end nuts until the bolt elongation reaches
the 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 has
stretched too much. An overelongated bolt may break in
use.
Bolt Length Bolt Length
after tightening
before tightening
=
Bolt Stretch
Usable Range of
Bolt Nut
C
onnecting Rod
Connect-
ing
Rod Assy
Bolt Stretch
U
se the bolts
A
ttached to
0
.24 0.36 mm
New attached to new con-rod
(0.0094
new con-rod. New
0.0142 in.)
Used 0.20 0.32 mm
(0.0079Used
Replace the
bolts with
new ones.
New
0.0126 in.)
CRANKSHAFT/TR ANSMISSION 9-15
Crankshaft and Connecting Rods
(2) Rotation Angle Method
If you don’t have a point micrometer, you may tighten the
nuts using the “Rotation Angle Method”.
Be sure to clean the bolts and nuts thoroughly with a high
-flash point solvent, because the new bolts and nuts are
treated with an anti-rust solution.
WARNING
Clean 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 danger
or highly flammable liquids, do not use gasoline 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.
Apply a small amount of molybdenum disulfide oil to the
following:
Threads [A] of Nuts and Bolts
Seating S urfaces [B] of Nuts and Con-rods
First, tighten the nuts to the specified torque. See the
table below.
Next, tighten the nuts 120° ± .
Mark [A] the connecting rod big end caps and nuts so that
nuts can be turned 120° [B] properly.
Tighten the hexagon nut by 2 corners.
Connecting
Torque + Angle
Rod Assy Bolt Nut
N·m (kgf·m, ft·lb)
Attached to
18 (1.8, 13.0)
new con-rod
+ 120°
20 (2.0, 14.5)
New
Use the bolts
attached to
new con-rod.
New
+ 120°
24 (2.4, 17.4)
Used
+ 120°
25 (2.6, 18.8)
Used
Replace the
bolts with
new ones
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 to
remove any foreign particles or residue that may have
accumulated in the passages.
9-16 CRANKSHAFT/T RANSMISSION
Crankshaft and Connecting Rods
Connecting Rod Bend
Remove the connecting rod big end bearing inserts, and
reinst
all 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 ro
d big end.
Select an arbor of the same diameter as the piston pin and
more than 105 m m (4.13 in.) long, and insert the arbor [B]
thro
ugh the c onnecting rod small end.
On a surface plate, set the big-end arbor on V blocks [C].
With the connecting rod held vertically, use a height
gaug
e to measure the difference in the height of the
arbor above the surface plate over a 100 mm (3.94 in.)
length to determine the amount of connecting rod bend.
If c
onnecting rod bend exceeds the service limit, the con-
necting rod must be replaced.
Connecting Rod Bend
Service 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 the con-
necting rod horizontally and measure the amount that the
arbor [B] varies from being parallel with the surface plate
over a 100 mm (3.94 in.) length of the arbor to determine
the amount of connecting rod twist.
If connecting rod twist exceeds the service limit, the con-
necting rod must be replaced.
Connecting Rod Twist
Service 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 Clearance
Standard: 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.
CRANKSHAFT/TR ANSMISSION 9-17
Crankshaft and Connecting Rods
Connecting Rod Big End Bearing Insert/Crankpin
Wear
Measure the bearing insert/crankpin [B] clearance with
plastigage [A].
Tighten the big end nuts to the specified torque (see C on-
necting Rod Installation).
NOTE
Do not move the connecting rod and crankshaft during
clearance measurement.
CAUTION
After measurement, replace the connecting rod
bolts.
Connecting Rod Big End Bearing Insert/Crankpin Clearance
Standard: 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-
me
nt is required.
If the clearance is between 0.072 mm (0.00284 in.) and
the service limit (0.11 mm, 0.0043 in.), replace the bear-
in
g inserts [A] with inserts painted blue [B]. Check i n-
sert/crankpin clearance with the plastigage. The clear-
ance may exceed the standard slightly, but it must not be
l
ess than the minimum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure the
diameter of the crankpins.
Crankpin Diameter
Standard: 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 the
crankshaft with a new one.
If the measured crankpin diameters are not less than the
service limit, but do not coincide with the original diameter
markings on the crankshaft, make new marks on it.
Crankpin Diameter Marks
None
34.984 34.992 mm (1.3773 1.3776 in.)
34.993 35.000 mm (1.3777 1.3780 in.)
: Crankpin Diameter Marks, " "ornomark.
Measure the connecting rod big end inside diameter, and
mark each connecting rod big end in accordance with the
inside diameter.
Tighten the connecting r od big end nuts to the specified
torque (see Connecting Rod Installation).
NOTE
The mark already on the big end should almost coincide
with the measurement.
9-18 CRANKSHAFT/T RANSMISSION
Crankshaft and Connecting Rods
Connecting Rod Big End I nside Diameter Marks
None
38.000mm 38.008mm (1.4961 1.4964 in.)
38.009 38.016 mm (1.4964 1.4967 in.)
BigEndCap[A]
Connecting Rod [B]
Weight Mark, Alphabet [C]
Diameter Mark (Around Weight Mark) [D]:
”orno
mark
Select the proper bearing insert [A] in accordance with the
combination of the connecting rod and crankshaft coding.
Size Color [B]
Co
n-rod Big End
Cr
ankpin
Bearing Insert
Inside Diameter Diameter
Marking Marking
S
ize Color
Part Number
None Brown 92139–1110
None None
Black 92139–1109
None Blue 92139–1108
Install the new inserts in the connecting rod and check
insert/crankpin clearance with the plastigage.
Crankshaft Side Clearance
Insert a thickness gauge [A] between the crankcase main
bearing and the crank web at the No. 2 journal [B] to
determine clearance.
If the clearance exceeds the service limit, replace t he
crankcase halves as a set.
NOTE
The upper and lower crankcase halves are machined
at the factory in the assembled state, so the crankcase
halves must be replaced as a set.
Crankshaft Side Clearance
Standard: 0.05 0.20 mm (0.0020 0.0079 in.)
Service Limit: 0.40 mm (0.0157 in.)
Crankshaft Runout
Measure the crankshaft r unout.
If the measurement exceeds the service limit, replace the
crankshaft.
Crankshaft Runout
Standard: TIR 0.02 mm (0.0008 in.) or less
Service Limit: TIR 0.05 mm (0.0020 in.)
CRANKSHAFT/TR ANSMISSION 9-19
Crankshaft and Connecting Rods
Crankshaft Main Bearing Insert/Journal Wear
Using a plastigage (press gauge) [A], measure the bear-
ing insert/journal [B] clearance.
NOTE
Tighten the crankcase bolts to the specified torque (see
Crankcase Assembly).
Do not
turn the crankshaft during clearance measure-
ment.
Journal clearance less than 0.025 mm (0.00098 in.) can
not be
measured by plastigage, however, using genuine
parts m aintains the minimum standard clearance.
Crankshaft Main Bearing Insert/Journal Clearance
Standard: 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 the
service limit 0.07 mm, (0.0028 in.), replace the bearing in-
serts [A] with inserts painted blue [B]. Check insert/journal
clearance with the plastigage. The clearance may exceed
the 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 the
diameter of the crankshaft main journal.
Crankshaft Main Journal Diameter
Standard: 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 the
crankshaft with a new one.
If the measured journal diameters are not less than the
service limit, but do not coincide with the original diameter
markings on the crankshaft, make new marks on it.
Crankshaft Main Journal Diameter Marks
None
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 no
mark.
9-20 CRANKSHAFT/T RANSMISSION
Crankshaft and Connecting Rods
Measure the main bearing inside diameter, and mark t he
upper crankcase half in accordance with the inside diam-
eter.
Crankcase Main Bearing Inside Diameter Marks : "
"
or no mark.
Tight
en the crankcase bolts to the specified torque (see
Crankcase Assembly).
NOTE
The mark already on the upper crankcase half should
almost coincide with the measurement.
Crankcase Main Bearing Inside Diameter Marks
36.000 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 the
combination of the crankcase and crankshaft coding.
Size Color [B]
Crankcase Main Crankshaft Main Bearing Insert*
Bearing Inside Journal Diameter
Diameter Marking Mark ing 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.
Install the new inserts in the crankcase halves and check
insert/journal clearance with the plastigage.
CRANKSHAFT/TR ANSMISSION 9-21
Starter Motor Clutch
Starter Motor Clutch Removal/Installation
Refer to the Alternator Rotor Removal and Installation in
the Electrical S ystem chapter.
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 of
the starter motor clutch bolts, and tighten them.
Torque - Starter Motor Clutch Bolts: 12 N·m (1.2 kgf·m, 104
in·lb)
Starter Motor Clutch Inspection
Remove:
Alternator Cover ( see Electrical System chapter)
Starter Idle G ear
Turn the starter motor clutch gear [A] by hand. The starter
motor clutch gear should turn clockwise [B] freely, but
should not turn counterclockwise [C].
If the clutch does not operate as it should or if it makes
noise, go to the next step.
Remove and disassemble the starter motor clutch, and
visually inspect the clutch parts.
If there is any worn or damaged part, replace it.
NOTE
Examine the starter motor clutch gear as well. Replace
it if it is worn or damaged.
9-22 CRANKSHAFT/T RANSMISSION
Transmission
Shift Pedal Removal
Mark [A] the position of the shift lever [B] on the shift shaft
so that
it can be installed later in the same position.
Remove:
Shift Lever Bolt [C]
Shift L
ever
Remove:
Footpeg Bracket Bolts [A]
Muffler Mounting Bolt [B]
Footpeg Bracket [C]
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 that
the oil seal surfaces are flush with the housing end [C] as
shown.
Apply grease to the sliding surfaces [A] on the footpeg
holder [B].
Apply a non-permanent locking agent to the shift pedal
mounting bolt [C].
Tighten:
Torque - Shift Pedal Mounting Bolt: 34 N·m (3.5 kgf·m, 25
ft·lb)
[D] Footpeg Bracket
[E] S hift Pedal
[F] Oil Seals
CRANKSHAFT/TR ANSMISSION 9-23
Transmission
Install the footpeg bracket [A].
Apply a non-permanent locking agent to the footpeg
bracket bolts [B].
Tighten:
Torque - Footpeg bracket Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)
Muffl
er Mounting Bolt and Nut [C]: 29 N·m (3.0
kgf·m, 22 ft·lb)
Install the shift lever [A], aligning the mark (previously
marked).
TIghten:
Torque - Shift Lever Bolt: 6.9 N·m (0.7 kgf·m, 61 in·lb)
Install the shift pedal [B] as shown.
[C] Right Angle (90°)
To adjust the pedal position, loosen the front locknut [D]
(left-hand threads) and rear locknut [E] and then turn the
tie-rod [F].
Tighten:
Torque - Tie-rod Locknuts: 6.9 N·m (0.7 kgf·m, 61 in·lb)
External Shift M echanism 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 P ipe [C] and O-ring
Remove the shift shaft assembly [A] while pulling the shift
mechanism arm [B] to the direction of the arrow.
9-24 CRANKSHAFT/T RANSMISSION
Transmission
Remove:
Gear Positioning Lever Bolt [A]
Gear Po
sitioning 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 t he O-ring on the oil pipe ends.
Ap
ply a non-permanent locking agent to the oil pipe holder
bolts and tighten them.
Torque - Oil Pipe Holder Bolts: 1 3 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 s hift m echanism 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 locking
agent 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 for
breaks or distortion.
If the lever or spring are damaged in any way, replace
them.
Visually inspect the shift drum cam [C].
If they are badly worn or i f they show any damage, replace
it.
CRANKSHAFT/TR ANSMISSION 9-25
Transmission
Transmission Shaft Removal
Split the crankcase (see Crankcase Splitting).
Remove the drive shaft [A] and output shaft [B].
Transmission Shaft Installation
Check to see that the set pins [A] and set rings [B] are in
place.
Install the drive shaft and output shaft into the upper
crankcase half.
Apply engine oil to the sliding surfaces of the gears and
bearings.
The bearing set pins and rings must match properly with
the holes or grooves in the bearing outer races. When
they are properly matched, there is 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 surface
of the oil seal is flush with the counterbore bottom surface
[C] of the crankcase.
Transmission Shaft Disassembly
Remove the transmission shafts (see Transmission Shaft
Removal).
Remove the circlips, disassemble the transmission
shafts.
The 5th gear [A] on the output shaft has three steel balls
assembled i nto i t for the positive neutral finder mecha-
nism.
Remove the 5th gear as follows.
Set the output shaft in a vertical position holding the 3rd
gear [B].
Spin the 5th gear quickly [C] and pull it off upward.
9-26 CRANKSHAFT/T RANSMISSION
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 sliding surfaces on t he transmis-
sion shafts, gears and bushings.
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 aligned
withasplinegroove[C].
The drive shaft gears can be recognized by size: the gear
with the smallest diameter is 1st gear, and the largest one
is 6th gear. B e sure that all parts are put back in the cor-
rect sequence and all circlips and washers are properly in
place (see Transmission Assembly illustration).
Install the 3rd/4th gear onto the drive shaft with their oil
holes aligned.
Install the 6th gear bushing onto the drive shaft with their
oil holes aligned.
The output shaft gears can be recognized by size: the
gear with the largest diameter is 1st gear, and the sm allest
one is 6th gear. Be sure that all parts are put back in the
correct sequence and all circlips and washers are prop-
erly in place (see Transmission Assembly illustration).
Install the 5th and 6th gears onto the output shaft with
their oil holes aligned.
Install the 3rd/4th gear bushings onto the output shaft with
their oil holes aligned.
CRANKSHAFT/TR ANSMISSION 9-27
Transmission
NOTE
When the toothed washers [28] [29] are assembled onto
the output shaft, note the following.
When the tangs [A] of the toothed washer [29] shall be
assembled, they should be installed into the notch [B]
of the toothed washer [28].
Fit the steel balls into the 5th gear holes in the output
shaft, aligning three oil holes [D] (see S ection BB in the
output shaft illustration).
5th Gear [A]
Output Shaft [B]
Steel Balls [C]
CAUTION
Do not apply grease to the balls to hold them in
place. This will cause the positive neutral finder
mechanism to malfunction.
After assembling the 5th gear with steel balls in place on
the output shaft, check the ball-locking effect that the 5th
gear doesn’t come out of the output shaft when moving it
up and down by hand.
Check that each gear spins or slides freely on the trans-
mission shafts without binding after assembly.
9-28 CRANKSHAFT/T RANSMISSION
Transmission
1. 1st Gear
2. 2nd Gear
3. 3rd Gear
4. 4th Gear
5. 5th Gear
6. 6th (Top) Gear
7. Toothed Washer,
31
mm (1.22 in.)
8. T hrust Washer,
30 mm
(1.18 in.)
9. Circlip
10. C irclip
11. B ushing
12. B ushing
13. N eedle Bearing
14. N eedle Bearing
15. B earing Outer Race
16. Steel Ball
17. N ut
18. B ushing
19. B ushing
20. C irclip
21. B all Bearing
22. C ollar
23. Washer
24. Toothed Washer
25. O il Seal
26. Thrust Washer,
31 mm
(1.22 in.)
27. Thrust Washer,
33 mm
(1.30 in.)
28. Toothed Washer
29. Toothed Washer
30. Toothed Washer,
35
mm (1.38 in.)
Shift Drum and Fork Removal
Remove:
Lower Crankcase Half (see Crankcase Splitting)
Transmission Shafts
External Shift M echanism (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].
CRANKSHAFT/TR ANSMISSION 9-29
Transmission
Shift Drum and Fork Installation
Install the shift rods [A], noting the groove position. The
rods are identical.
Position the one with shortest ears [B] on the drive shaft
and place the pin in the center groove in the shift drum
[C].
The t wo forks [D] on the output shaft are identical.
Install the forks as shown.
Apply a non-permanent locking agent to the threads of
the shift drum bearing holder bolt and screw, and tighten
them.
Torq
ue -
Shif
t Drum Bearing Ho lder Bolt: 13 N·m (1.3 kgf·m,
113 in·lb)
Shift Drum Bearing Holder Screw: 5.4 N·m (0.55
kgf·
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 shift
drum cam holder bolt.
[A] Shift Drum Cam Holder Bolt
[B] Dowel Pin
Shift Drum Assembly
Be sure to install the dowel pin.
Apply a non-permanent locking agent to the threads of
the s hift drum cam holder bolt, and tighten it.
Torque - Shift Drum Cam Holder Bolt: 12 N·m (1.2 kgf·m,
104 in·lb)
Shift Fork Bending
Visually inspect the shift forks, and replace any fork that is
bent. A bent fork could cause difficulty in shifting, or allow
the transmission to jump out of gear when under power.
90° [A]
9-30 CRANKSHAFT/T RANSMISSION
Transmission
Shift Fork/Gear Groove Wear
Measure the thickness of the shift fork ears [A], and mea-
sure th
e width [B] of the gear grooves.
If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
Shift Fork Ear Thickness
Standard: 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 l imit, the gear
must be replaced.
Gear Groove Width
Standard: 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 t he diameter of each shift fork guide pin [A], and
measure the width [B] of each shift drum groove.
If the guide pin on any shift fork is l ess than the service
limit, the fork must be replaced.
Shift Fork Guide Pin Diameter
Standard: 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, the
drum must be replaced.
Shift Drum Groove Width
Standard: 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 w ith excessively
worn dogs or dog holes.
WHEELS/TIRES 10-1
10
Wheels/Tires
Table of C ontents
Exploded View........................................................................................................................ 10-2
Specifications ......................................................................................................................... 10-4
Special Tools .......................................................................................................................... 10-5
Wheels (Rims) ........................................................................................................................ 10-6
Front Wheel Removal ....................................................................................................... 10-6
Front Wheel Installation .................................................................................................... 10-6
Rear W heel Removal........................................................................................................ 10-7
Rear Wheel Installation..................................................................................................... 10-8
Wheel Inspection .............................................................................................................. 10-9
Axle Inspection.................................................................................................................. 10-10
Balance Inspection............................................................................................................ 10-10
Balance Adjustment .......................................................................................................... 10-10
Balance Weight Removal.................................................................................................. 10-10
Balance Weight Installation............................................................................................... 10-11
Tires........................................................................................................................................ 10-13
Air Pressure Inspection/Adjustment.................................................................................. 10-13
Tire Inspection .................................................................................................................. 10-13
Tire Removal..................................................................................................................... 10-13
Tire Installation.................................................................................................................. 10-13
Tire Repair ........................................................................................................................ 10-15
Hub Bearing............................................................................................................................ 10-16
Hub Bearing Removal....................................................................................................... 10-16
Hub Bearing Installation.................................................................................................... 10-16
Hub Bearing Inspection..................................................................................................... 10-16
10-2 WHEELS/TIRES
Exploded View
WHEELS/TIRES 10-3
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Front axle clamp bolt 20 2.0 15
2 Front axle 127 13 94
3 Rear axle nut 127 13 94
G: Apply grease.
R: Replacement Parts
WL: Apply soap and water solution or rubber lubricant.
10-4 WHEELS/TIRES
Specif ications
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/100 mm (3.94
in.)
TIR 0.05 mm (0.0020 in.) or less TIR 0.2 mm
(0.008 in.)
Wheel balance 10 g (0.35 US oz) or less ---
Balance weights 10 g (0.35 US oz), 20 g (0.71 US oz), 30 g (1.06
US oz)
---
Tires: Front 250 kPa ---
Air pressure: (2.5 kgf/cm², 36 psi)
(when cold) Rear
Up to 180 kg (396 lb) load:
290 kPa ---
(2.9 kgf/cm², 41 psi)
Tread depth: Front B RIDG ESTONE 3.4 mm 1mm
(0.13 in.) (0.04 in.)
1.6 mm
(0.06 in.)
(DE, AT, CH)
Rear BRIDGESTONE 5.8 m
m
Up to 130 km/h
(0.23 in.) (80 mph): 2 mm
(0.08 in.)
Ove
r 130 km/h
(80 mph) : 3 mm
(0.12 in.)
Standard tires: Make, Type Size
Front BRIDGESTONE, BATTLAX BT-019F RADIAL 120/70 ZR17
M/C (58 W)
Rear BRIDGESTONE, BATTLAX BT-012R RADIAL J 190/50 ZR17
M/C (73 W)
WARNING
Use the same manufacturer’s tires on both front and rear wheels.
AT: R epublic of Austria
CH: S wiss Confederation
DE: Federal Republic of Germany
WHEELS/TIRES 10-5
Special Tools
Bearing Driver Set:
57001–1129
Jack:
57001–1238
Bearing Remover Head, 25 × 28:
57001–1346
Bearing Remover Shaft, 13:
57001–1377
10-6 WHEELS/TIRES
Wheels (Rims)
Front Wheel Removal
Remove:
Brake C
aliper Mounting Bolts [A]
Loosen:
Right Side Axle Clamp Bolt [A]
Axle [B]
Raise the front wheel off the ground.
Special Tool - Jack: 57001–1238
Pull out the axle to the right and drop the front wheel out
of the forks.
CAUTION
Do not lay the wheel down on one of the discs. This
can dam age or warp the disc. Place blocks un-
der the wheel so that the disc does not touch the
ground.
Front Wheel Installation
NOTE
The direction of the wheel rotation [A] is shown by an
arrow [B] on the wheel spoke.
Check the wheel rotation mark on the front wheel and
install it.
Fit t he collars [A] on the both sides of the hub.
WHEELS/TIRES 10-7
Wheels (Rims)
Tighten the axle.
Torque - Front Axle: 127 N·m (13 kgf·m, 94 ft·lb)
Before tightening the clamp bolt on the right front fork leg,
pump t he front fork up and down 4 or 5 times to allow the
right front fork leg to seat on the front axle.
NOTE
Put a block in front of the front wheel to stop moving.
Tighten the axle clamp bolt [A] on the right fork leg first.
Torque - Front Axle Clamp Bolt: 20 N·m (2.0 kgf·m, 15 ft·lb)
Check the clearance [B] between the right fork leg [D] and
collar [C] with the thickness gauge.
Standard: 2.0 mm (0.0787 in.)
Usable range: 1.1 2.9 mm (0.043 0.114 in.)
If the clearance is out of this range, remove the front wheel
again and check the axle, wheel hub and other related
parts for damage.
Tighten the axle clamp bolt on the left fork leg.
Torque - Front Axle Clamp Bolt: 20 N·m (2.0 kgf·m, 15 ft·lb)
Install the front brake calipers (see Brakes chapter).
Check the front brake effectiveness (see Brakes chapter).
WARNING
Do not attempt to drive the motorcycle until a full
brake lever is obtained by pumping the brake lever
until the pads are against the disc. The brake will
not function on the first application of the lever if
this is not done.
Rear Wheel Removal
Using the stand [A], raise the rear wheel off the ground.
Remove:
Cotter Pin [A]
Axle N ut [B]
Axle [C]
10-8 WHEELS/TIRES
Wheels (Rims)
Remove:
Caliper Mounting Bolts [A]
Calipe
r[B]
Remove the drive chain [A] from the rear sprocket toward
the left.
Move the rear wheel back and remove the wheel from the
rear caliper.
Remove the rear wheel.
CAUTION
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.
Rear Wheel Installation
Engage the drive chain w ith the rear sprocket.
Install the caliper bracket [A] onto the swingarm stop [B].
Insert the axle from the right side of the wheel, and tighten
the axle nut.
Torque - Rear Axle Nut: 127 N·m (13 kgf·m, 94 ft·lb)
Insert a new cotter pin [A].
NOTE
When inserting the cotter pin, if the s lots in the nut do
not align w ith the cotter pin hole in the axle, tighten the
nut clockwise [B] up to next alignment.
It should be within 30 degree.
Loosen once and tighten again when the slot goes past
the nearest hole.
WHEELS/TIRES 10-9
Wheels (Rims)
Bend the cotter pin [A] over the nut [B].
WARNING
If the rear axle nut is not securely tightened or the
cotter pin is not installed, an unsafe riding condi-
tion may result.
Adjust the drive chain slack after installation (see Final
Drive chapter).
Check the rear brake effectiveness.
WARNING
Do not attempt to drive the motorcycle until a full
brake pedal is obtained by pumping the brake pedal
un
til the pads are against the disc. The brake will
not function on the first application of the pedal if
this 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, or
warp.
If there i s any damage to the wheel, replace the wheel.
Remove the wheel, and support it without the tire by the
axle.
Measure the rim runout, radial [A] and axial [B], with a dial
gauge.
If rim runout exceeds the service limit, check the hub bear-
ings.
If the problem is not due to the bearings, replace the
wheel.
Rim Runout
Service Limit:
Axial
TIR 0.5 mm (0.020 in.)
Radial
TIR 0.8 mm (0.031 in.)
WARNING
Never attempt to repair a damaged wheel. If there
is any damage besides wheel bearings, the wheel
must be replaced to insure safe operational condi-
tion.
10-10 WHEELS/TIRES
Wheels (Rims)
Axle Inspection
Visually inspect the front and rear axle for damages.
If the a
xle is damaged or bent, replace it.
Place the axle in V blocks that are 100 mm (3.94 in.) [A]
apart, and set a dial gauge [B] on the axle at a point
halfw
ay between the blocks. Turn [C] the axle to mea-
sure the runout. The difference between the highest and
lowest dial readings is the amount of runout.
If ax
le 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 top
when the wheel stops.
Repeat this procedure several times. If the wheel stops
of its own accord in various positions, it is well balanced.
If the wheel always stops in one position, adjust the wheel
balance.
Balance Adjustme nt
If the wheel always stops in one position, provisionally
attach a balance weight [A] on the rim at the m arking using
adhesive tape.
Rotate the wheel 1/4 t urn [B], and see whether or not the
wheel stops in this position. If it does, the correct balance
weight is being used.
If the wheel rotates and the weight goes up, replace the
weight with the next heavier size. If the w heel rotates and
the weight goes down, replace the weight with the next
lighter size. Repeat these steps until the wheel remains
at rest after being rotated 1/4 turn.
Rotate the wheel another 1/4 turn and then another 1/4
turn to see i f the wheel is correctly balanced.
Repeat the entire procedure as many times as necessary
to achieve correct wheel balance.
Permanently install the balance weight.
Balance Weight Remov al
(a) When the tire is not on the rim.
Push [A] the blade portion toward the outside with a regu-
lar tip screw-driver, and slip the weight off the rim flange.
Discard the used balance weight.
WHEELS/TIRES 10-11
Wheels (Rims)
(b)Whenthetireisontherim.
Pry [A] the balance weight off the rim flange using a reg-
ular tip screwdriver as shown in the figure.
Insert a tip of the screwdriver between the tire bead [B]
and weight blade [C] until the end of the tip reaches the
end of the weight blade.
Push the driver grip toward the tire so that the balance
weight slips off the rim flange.
Discard the used balance weight.
Balance Weight Installation
Check if the weight portion has any play on the blade and
clip.
If it does, discard it.
WARNING
If the balance weight has any play on the rim, t he
blade and/or clip of the weight have been stretched.
Replace the l oose balance weight.
Do not reuse used balance weight.
Unbalanced wheels can create an unsafe riding
condition.
Lubricate the balance weight blade, tire bead, and rim
flange with a soap and water solution or rubber lubricant.
This helps the balance weight slip onto the rim flange.
CAUTION
Never lubricate with engine oil or petroleum distil-
lates because they will deteriorate the tire.
10-12 WHEELS/TIRES
Wheels (Rims)
When required total weight exceeds 20 g (0.71 US oz), in-
stall balance weight at both sides of rim flange as shown.
Weight Selection: g (US oz)
Required
Total Weight:
g(USoz)
OneSide[A] Other Side [B]
20 (0.71) 10 (0.35) 10 (0.35)
30 (1.06) 20 (0.71) 10 (0.35)
40 (1.41) 20 (0.71) 20 (0.71)
50 (1.76) 30 (1.06) 20 (0.71)
60 (2.12) 30 (1.06) 30 (1.06)
20 + 20
70 (2.
47)
(0.71 + 0.71)
30 (1.
06)
20 + 20 20 + 20
80 (2.82)
(0.71 + 0.71) (0.71 + 0.71)
20 + 30 20 + 20
90 (3.17)
(0.71 + 1.06) (0.71 + 0.71)
Balance Weight
Part Number
Weight (grams)
41075–1014 10
41075–1015 20
41075–1016 30
NOTE
Balance weights are available from Kawasaki dealers
in 10, 20, and 30 grams (0.35, 0.71, and 1.06 US oz).
An imbalance of less than 10 grams (0.35 US oz) will
not usually affect running stability.
Do not use four or more balance weight (more than 90
gram, 3.17 US oz). If the w heel requires an excess bal-
ance weight, disassemble the wheel to find the cause.
Install the balance weight on the rim.
Slip the weight on the rim flange by pushing or lightly ham-
mering the weight in the direction shown in the figure.
Push or Hammer [A]
Rim Flange [B]
Tire Bead [C]
Blade [D]
Check that the blade [A] and weight [B] seat fully on the
rim flange [C], and that the clip [D] is hooked over the rim
ridge [E] and reaches rim flat portion.
WHEELS/TIRES 10-13
Tires
Air Pressure Inspection/Adjustment
Refer to the Air Pressure Inspection/Adjustment in the P e-
riodic Maintenance chapter.
Tire Inspection
Refer to the Tire Inspection in the P eriodic M aintenance
chapter.
Tire Removal
Remove:
Wheel (see Front Wheel Removal, Rear Wheel R e-
moval)
Disc (s)
Valve Core (let out the air)
To maintain wheel balance, m ark the valve stem position
on the tire with chalk so that the tire can be reinstalled in
the same position.
Chalk Mark or Yellow Mark [A]
Air Valve [B]
Align [C]
Lubricate the tire beads and rim flanges on both sides with
a s oap and water solution or rubber lubricant. This helps
the 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.
NOTE
The tires cannot be removed with hand tools because
they fit the rims too tightly.
Tire Installation
WARNING
Use the same manufacturers tires on both front and
rear wheels.
Inspect the rim and tire, and replace them if necessary.
Clean the sealing surfaces of the rim and tire, and smooth
the sealing surfaces of the rim with a fine emery cloth if
necessary.
Remove the air valve and discard it.
CAUTION
Replace the air valve whenever the tire is replaced.
Do not reuse the air valve.
10-14 WHEELS/TIRES
Tires
Install a new valve in the rim.
Remove the valve cap, lubricate the stem seal with a soap
and wat
er solution or rubber lubricant, and pull [B] the
valve stem [A] through the rim from the inside out until it
snaps into place.
CAUTION
Do not use engine oil or petroleum distillates to l u-
brica
te the stem because they will deteriorate the
rubber.
Apply
a soap and water solution, or rubber lubricant to the
rim flange and tire beads.
The air valve is shown in the figure.
[A] Valve Cap
[B] Valve Core
[C] Stem Seal
[D] Valve Stem
[E] Valve Seat
[F] Valve Opened
Check the tire rotation mark on the front and rear tires and
install them on the rim accordingly.
Tire Rotation M ark [A]
Rotation Direction [B]
Position the tire on the rim so that the valve [A] is at the tire
balance mark [B] (the chalk mark made during removal,
or the yellow paint mark on a new tire).
Install the tire bead on the rim using a suitable commer-
cially available tire changer.
Lubricate the tire beads and rim flanges with a soap and
water solution or rubber lubricant to help seat the tire
beads in the sealing surfaces of the rim while inflating the
tire.
Center the rim in the tire beads, and inflate the tire with
compressed air until the tire beads seat in the sealing
surfaces.
WARNING
Be sure to install the valve core whenever inflating
the tire, and do not inflate the tire to more than 400
kPa (4.0 kgf/cm², 57 psi). Overinflation can explode
the tire with possibility of injury and loss of life.
WHEELS/TIRES 10-15
Tires
Check t o see that the rim lines [A] on both sides of the tire
sidewalls are parallel w ith 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 air
leakage.
Inflate the tire slightly above standard inflation.
Use a soap and water solution or submerge the tire, and
check for bubbles that would indicate leakage.
Adjust the air pressure to the specified pressure (see Tire
Inspection).
Install the air valve cap.
Install the brake disc(s) so that the marked side faces out
(see Brakes chapter).
Adjust the wheel balance.
Tire Repair
Currently 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 from
the 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 of
permitting a thorough examination for secondary damage
not visible from external inspection of the tire. For these
reasons, Kawasaki does not recommend temporary (exter-
nal) repair. Only appropriate permanent (internal) repairs
are recommended. Repair methods may vary slightly from
make to make. Follow the repair methods indicated by the
manufacturer of the repair tools and m aterials so that safe
results can be obtained.
10-16 WHEELS/TIRES
Hub Bearing
Hub Bearing Removal
Remove the wheel, and take out the following.
Collar
s
Coupling (out of rear hub)
Grease Seals
Circli
ps
Use the bearing remover to remove the hub bearings [A].
CAUTION
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Please
blocks under the wheel so that the disc does
not touch the ground.
Special Tools - Bearing Remover Shaft, 13: 57001–1377
[B]
Bearing Remover Head,
25 × 28:
57001–1346 [C]
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
Ins
tall the bearings so that the marked side faces out.
Install the bearings by using the bearing driver set which
does 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 circlips with new ones.
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 Inspection
Since the hub bearings are made to extremely close tol-
erances, the clearance cannot normally be measured.
NOTE
Do not remove any bearings for inspection. If any bear-
ings are removed, they will need to be replaced with
new ones.
Turn each bearing in the hub back and forth [A] while
checking for plays, roughness, or binding.
If bearing play, roughness, or binding is found, replace
the 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 C ontents
Exploded View........................................................................................................................ 11-2
Specifications ......................................................................................................................... 11-4
Special Tools .......................................................................................................................... 11-5
Drive Chain............................................................................................................................. 11-6
Drive Chain Slack Inspection ............................................................................................ 11-6
Drive Chain Slack Adjustment .......................................................................................... 11-6
Wheel Alignment Inspection/Adjustment .......................................................................... 11-6
Drive Chain Wear Inspection ............................................................................................ 11-6
Drive Chain Lubrication..................................................................................................... 11-6
Drive Chain Removal ........................................................................................................ 11-6
Drive Chain Installation ..................................................................................................... 11-6
Drive Chain Replacement ................................................................................................. 11-6
Sprocket, Coupling ................................................................................................................. 11-10
Engine Sprocket Removal ................................................................................................ 11-10
Engine Sprocket Installation ............................................................................................. 11-10
Rear Sprocket Removal.................................................................................................... 11-11
Rear Sprocket Installation................................................................................................. 11-11
Coupling Bearing Removal ............................................................................................... 11-11
Coupling Bearing Installation ............................................................................................ 11-11
Coupling Installation.......................................................................................................... 11-12
Coupling Bearing Inspection............................................................................................. 11-12
Coupling Bearing Lubrication............................................................................................ 11-12
Coupling Damper Inspection............................................................................................. 11-12
Sprocket Wear Inspection................................................................................................. 11-13
Rear Sprocket W arp Inspection ........................................................................................ 11-13
11-2 FINAL DRIVE
Exploded View
FINAL DRIVE 11-3
Exploded View
Torque
No. Fastener
N·m kgf·m ft·lb
Remarks
1 Engine sprocket cover bolts 9.8 1.0 87 in·lb
2 Engine sprocket nut 127 13 94 MO
3 Rear sprocket nut 59 6.0 43
4 Engine sprocket cover damper bolts 6.9 0.7 61 in·lb L
5 Speed sensor bolt 6.9 0.7 61 in·lb L
6 Rear axle nut 127 13 94
7. Drive chain joint (ZR1000–A2 )
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
Specif ications
Item Standard S ervice Limit
Drive Chain:
Chain slack 20 30 mm (0.8 1.2 in.) ---
20-link length
317.5 318.2 mm (12.50 12.53 in.) 323 mm (12.7 in.)
Standard chain
Make ENUMA ---
Type EK525UVXL2, Endless ---
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
Driv e Chain Slack Inspection
Refer to the Drive Chain Slack Inspection in the Periodic
Mainte
nance chapter.
Driv e Chain Slack Adjustment
Refer to the Drive Chain Slack Adjustment in the Periodic
Maintenance chapter.
Wheel Alignment Inspection/Adjustment
R
efer to the Wheel Alignment Inspection/Adjustment in
the Periodic Maintenance chapter.
Drive Chain Wear Inspection
Refer to the Drive Chain Wear Inspection in the Periodic
Maintenance 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.)
Right Side Muffler Body (see Engine Top End 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
Mud Guard
Chain Cover
Right Side Muffler Body
Adjust the chain slack after installing the chain (see Slack
Adjustment).
Drive Chain Replacement
Remove:
Chain Cover (see Drive Chain Removal)
Engine Sprocket Cover (see Engine Sprocket Removal)
FINAL DRIVE 11-7
Drive Chain
EK JOINT TOOL #50
Body [A]
Handlebar [B]
Cutting and Riveting Pin [C]
For Cutting [D]
For Riveting [E]
Plate Holder (A) [F]
Plate Holder (B) [G]
Gauge [H]
Grind [A] pin head to make it flat.
Set cutting and 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 chain
pin.
Replace the link pin, link plate and grease seals.
Apply grease to t he 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 grease seal chain, be sure to set grease seals
correctly.
11-8 FINAL DRIVE
Drive Chain
Set plate holder (A) [A] and plate holder (B) [B] on the
body.
Fit plate holder (A) to link plate.
Turn pin holder by hand until plate holder (B) touches the
other link plate.
Turn pin holder by wrench clockwise until two pins of link
come into groove of plate holder (A).
Take off plate holder.
Set plate holder (B) [A] and cutting and riveting pin [B] as
shown.
Turn pin holder until riveting pin touches link pin.
FINAL DRIVE 11-9
Drive Chain
Turn wrench clockwise until tip of r iveting pin hits of link
pin.
Rivet it.
Some work for the other link pin.
After staking, check the staked area of the link pin for
cracks.
Measure the outside diameter [A] of t he link pin and link
plates outside width [B].
Link Pin Outside Diameter
Standard: 5.6 6.0 mm (0.22 0.24 in.)
Link Plates Outside Width
Standard: 19.85 20.00 mm (0.781 0.787 in.)
If the reading exceeds the specified length, cut and rejoin
the chain again.
Check:
Movement of the rollers
Adjust the drive chain slack after installing the chain (see
Drive Chain Slack A djustment in the Periodic Mainte-
nance chapter).
11-10 FINAL DRIVE
Sprocket, Coupling
Engine Sprocket Removal
Remove:
Speed S
ensor [A] Connector
Engine Sprocket Cover Bolts [B]
Engine Sprocket Cover [C] with Speed Sensor
Flatten out the bended washer [A].
Remove the engine sprocket nut [B] and washer.
NOTE
When loosening the engine sprocket nut, hold the rear
brake on.
Using the jack, raise t he rear wheel off t he ground.
Special Tool - Jack : 57001–1238
Loosen the drive chain (see Slack Adjustment).
Remove the drive chain from the rear sprocket toward t he
right.
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 t he engine sprocket [A] so that “OUTSIDE” letters
[B] face outward.
Apply molybdenum disulfide oil to the threads of the out-
put shaft and the seating surface of the engine sprocket
nut.
After torquing the engine sprocket nut, bend the one side
of the washer over the nut.
NOTE
Tighten the nut while applying the rear brake.
Tighten:
Torque - Engine Sprocket Nut : 127 N· m (13 kgf·m, 94 f t·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 disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.
Remove the 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:
Coupling
Grease Seal
Circlip [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 flush
with th
e 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.
Ball Bearing [A]
Coupling Grease Seal [B]
Coupling Internal Surface [C]
Coupling Bearing Inspection
Since the coupling bearing is made to extremely close
tolerances, t he clearance can not normally be measured.
NOTE
It is not necessary to remove the coupling bearing for
inspection. If the bearing is removed, it will need to be
replaced with a new one.
Turn the bearing in the coupling back and forth [A] while
checking for plays, roughness, or binding.
If bearing play, roughness or binding is found, replace the
bearing.
Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.
Coupling Bearing Lubrication
Pack the bearing with good quality bearing grease. Turn
the bearing around by hand a few times to make sure the
grease is distributed uniformly inside the bearing.
Coupling Damper Inspection
Remove the r ear wheel coupling, and inspect the rubber
dampers [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 for
wear and dam age.
If the teeth are w orn as illustrated, replace the sprocket,
and inspect the drive chain wear (see Drive Chain Wear
Inspection).
[A] Worn Tooth (Engine Sprocket)
[B] Worn Tooth (Rear Sprocket)
[C] Direction of Rotation
NOTE
If a sprocket requires replacement, the chain is probably
worn also.
When r
eplacing a sprocket, inspect the chain.
Rear Sprocket Warp Inspection
Raise the rear wheel off the ground (see Wheels/Tires
chapter) so that it will turn freely.
Set a dial gauge [A] against the rear sprocket [B] near the
teeth as shown, and rotate [C] the rear wheel to measure
the sprocket runout (warp). The difference between the
highest and lowest dial gauge readings is the amount of
runout (warp).
If the runout exceeds the service limit, replace the rear
sprocket.
Rear Sprocket Warp
Standard: 0.4 mm (0.016 i n.) or less
Service Limit: 0.5 mm (0.020 in.)
BRAKES 12-1
12
Brakes
Table of C ontents
Exploded View................................... 12-2
Specifications .................................... 12-6
Special Tool ....................................... 12-7
Brake Lever, Brake Pedal.................. 12-8
Brake Lever Position Adjustment. 12-8
Brake Pedal Position Inspection .. 12-8
Brake Pedal Position Adjustment. 12-8
Calipers ............................................. 12-9
Front Caliper Removal ................. 12-9
Rear Caliper Removal.................. 12-9
Caliper Installation ....................... 12-10
Front Caliper Disassembly........... 12-10
Front Caliper Assembly................ 12-11
Rear Caliper Disassembly ........... 12-12
Rear Caliper Assembly ................ 12-13
Caliper Fluid Seal Damage.......... 12-13
Caliper Dust Seal/Friction Boot
Damage..................................... 12-13
Caliper Piston and Cylinder
Damage..................................... 12-14
Caliper Holder Shaft Wear ........... 12-14
Brake Pads ........................................ 12-15
Front Brake Pad Removal............ 12-15
Front Brake P ad Installation......... 12-15
Rear Brake Pad Removal ............ 12-15
Rear Brake Pad Installation ......... 12-16
Brake Pad Wear Inspection ......... 12-16
Master Cylinder ................................. 12-17
Front Master Cylinder Removal ... 12-17
Front Master Cylinder Installation 12-17
Rear Master Cylinder Removal.... 12-18
Rear Master C y linder Installation. 12-18
Front Master Cylinder
Disassembly.............................. 12-18
Rear Master C ylinder
Disassembly.............................. 12-19
Master Cylinder Assembly ........... 12-19
Master Cylinder Inspection (Visual
Inspection)................................. 12-19
Brake Disc ......................................... 12-20
Brake Disc Removal .................... 12-20
Brake Disc Installation ................. 12-20
Brake Disc Wear .......................... 12-20
Brake Disc Warp .......................... 12-20
Brake Fluid ........................................ 12-21
Brake Fluid Level Inspection........ 12-21
Brake Fluid Change ..................... 12-21
Brake Line Bleeding..................... 12-21
Brake Hose........................................ 12-22
Brake Hose Removal/Installation. 12-22
Brake Hose Inspection................. 12-22
12-2 BR AKES
Exploded View
BRAKES 12-3
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Front caliper m ounting bolts 25 2.5 18
2 Brake hose banjo bolt 25 2.5 18
3 Bleed valve 7.8 0.80 69 in·lb
4 Front caliper assembly bolts 22 2.2 16 L
5 Front brake pad pin bolt 17 1.7 12
6 Brake lever pivot bolt 1.0 0.10 9in·lb Si
7 Brake lever pivot bolt locknut 5.9 0.60 52 in·lb
8 Brake disc mounting bolts 27 2.8 20 L
9 Front brake light switch screws 1.2 0.12 11 in·lb
10 Front reservoir cap screws 1.5 0.15 13 in·lb
11 Front master cylinder clamp bolts 8.8 0.9 78 in·lb S
B: Apply brake fluid.
L: Apply a non-permanent locking agent.
R: Replacement parts
S: Follow the specific tightening sequence.
Si: Apply silicone grease (ex. PBC grease)
12-4 BR AKES
Exploded View
BRAKES 12-5
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Rear master cylinder push lod 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 Brake disc mounting bolts 27 2.8 20 L
7. Gasket (Before Frame No. 005854)
B: Apply brake fluid.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement parts
Si: Apply silicone grease (ex. PBC grease)
12-6 BR AKES
Specif ications
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 mm ( 0.16 in.) 1 mm (0.04 in.)
Rear 5 mm (0.20 in.) 1 mm (0.04 in.)
Brake Discs:
Thickness:
Front 5.8 6.2 mm (0.23 0.24 in.) 5.5 mm (0.217 in.)
Rear 4.8 5.2 mm (0.19 0.20 in.) 4.5 mm (0.177 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 BR AKES
Brake Lever, Brake Pedal
Brake Lever Position Adjustment
The brake lever adjuster has 5 positions so that the brake
lever p
osition can be adjusted to suit the operator’s hand.
Push the lever forward and turn the adjuster [A] to align
the number with the arrow mark [B] on the lever holder.
The di
stance 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.
[B] Footpeg
Pedal Position
Standard: About 47 mm (1.85 in.) [C] below top of
footpeg
If it is incorrect, adjust the brake pedal position.
Brake Pedal Position Adjustment
NOTE
Usually it is not necessary to adjust the pedal position,
but always adjust it when the push rod locknut has been
loosened.
Unscrew the bolts [A] and remove the guard bracket [B].
Loosen the locknut [A] and turn the push rod with the hex
head [B] to achieve the correct pedal position.
If the length [C] shown is 70 ± 1 mm (2.76 ± 0.04 in.),the
pedal position will be within the standard range.
Tighten:
Torque - Rear Master Cylinder Push Rod Locknut:
18 N·m (1.8 kgf·m, 13.0 ft·lb)
Check the brake light switch operation ( see Brake Light
Timing Inspection/Adjustment in the Periodic Mainte-
nance 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 the
caliper [C] from the disc.
CAUTION
Do not loosen the caliper assembly bo lts [D]. Take
out only the caliper mounting bolts for caliper re-
moval. Loosening the caliper assembly bolts will
cause brake fluid leakage.
Unscrew the banjo bolt and remove the brake hose [E ]
from the caliper (see Brake Hose Removal/Installation).
CAUTI
ON
Immediately wash away any brake fluid that spills.
NOTE
If the
caliper is to be disassembled after removal and if
compressed air is not available, disassemble the caliper
before the brake hose is removed (see Front Caliper
Disa
ssembly).
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 the
caliper [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.
NOTE
If the caliper is to be disassembled after removal and if
compressed air is not available, disassemble the caliper
before the brake hose is removed (see Rear Caliper
Disassembly).
12-10 BRAKES
Calipers
Cali per Installation
Install the caliper and brake hose lower end.
Replac
e the washers on each side of hose fitting with new
ones.
Tighten:
Torque - Caliper Mounting Bolts (Front): 25 N·m (2.5 kgf·m,
18 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.
WARNING
Do not attempt to drive the motorcycle until a full
brake lever or pedal is obtained by pumping the
brake lever or pedal until the pads are against the
disc. The brakes will not function on the first appli-
cation of the lever or pedal if this is not done.
Fr
ont Caliper Disassembly
Loosen the front caliper assembly bolts [A ] and banjo bolt
[B] and tighten them loosely.
Re
move:
Front Caliper (see C aliper Removal) [C]
Brake Pad
Fr
ont Caliper Assembly Bolts
O-rings
Using compressed air, remove the pistons. One way to
remove the pistons is as follows.
Install a rubber gasket [A] and a wooden board [B] more
than 10 mm (0.4 in.) thick on the caliper half, and fas-
ten them together with a suitable bolt and nut as shown.
Leave one of the oil passages [C] open.
Lightly apply compressed air [D] to the oil passage until
the pistons hit the rubber gasket. Block the hose joint
opening [E] during this operation if t he caliper half has
the opening.
[F] Bolt and Nut
[G] Oil Passage sealed by Rubber Gasket
[H] Push down.
BRAKES 12-11
Calipers
WARNING
To avoid serious injury, never place your fin gers or
palm in front of the piston. If you apply compressed
air into the caliper, the piston may crush your hand
or fingers.
Pull out the pistons by hand.
Remove the dust seals [A] and fluid seals [B].
Remove the bleed valve [C] and rubber cap [D].
Repeat the previous step to remove the pistons from the
other side of the caliper body.
NOTE
If compressed air is not available, do as follows for both
calipers coincidentally, with the brake hose connected
to the caliper.
Prepare a container for brake fluid, and perform the
work above it.
Remove the spring and pads (see Front Brake Pad R e-
moval).
Pump the brake lever until the pistons come out of the
cylinders, and then disassemble the caliper.
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)
12-12 BRAKES
Calipers
Replace the fluid seals [A] with new ones.
Apply brake fluid to the fluid seals, and install them into
the cyl
inders by hand.
Replace the dust seals [B] with new ones if they are dam-
aged.
Apply
brake f luid to the dust seals, and install them into
the cylinders by hand.
Replace the O-rings [A] if they are damaged.
Apply brake fluid to the outside of the pistons, and push
them into each cylinder by hand.
Be sure to install the O-rings.
Apply a non-permanent locking agent the caliper assem-
bly bolts and torque them.
Torq ue - Front Caliper Assembly Bolts: 22 N·m (2.2 kgf·m,
16 ft·lb)
Install the pads (see Front Brake Pad Installation).
Wipe up any spilled brake fluid on the caliper with wet
cloth.
Rear Caliper Disassembly
Remove the rear caliper.
Remove the pads and anti-rattle spring (see Rear Brake
Pad Removal).
Using compressed air, remove the piston.
Cover the caliper opening with a clean, heavy cloth [B].
Remove the piston by lightly applying compressed air [A]
to where the brake line fits into the caliper.
WARNING
To avoid serious injury, never place your fingers or
palm inside the caliper opening. If you apply com-
pressed air into the caliper, the piston may crush
your hand or fingers.
Remove the dust seal and fluid seal.
Remove the bleed valve and rubber cap.
NOTE
If compressed air is not available, do as follows with the
brake hose connected to the caliper.
Prepare a container for brake fluid, and perform the
work above it.
Remove the pads and spring (see Rear Brake Pad Re-
moval).
Pump the brake pedal to remove the caliper piston.
BRAKES 12-13
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 i t i nto the
cylinder 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 the
cylinder by hand.
Apply brake fluid to the outside of the piston, and push it
into 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 to
the caliper holder shafts [C] and holder holes [D] (PBC is
a 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 wet
cloth.
Caliper Fluid Seal Damage
Refer to Caliper Fluid Seal D amage in the Periodic Main-
tenance chapter.
Caliper Dust Seal/Friction Boot Damage
Refer to Caliper Dust Seal/Friction Boot Damage in the
Periodic Maintenance chapter.
12-14 BRAKES
Calipers
Caliper Piston and Cylinder Damage
Visually inspect t he piston [A] and cylinder surfaces.
Replac
e the caliper if the cylinder and piston are badly
scores or rusty.
Front Caliper [B]
Rear Ca
liper [C]
Caliper Holder Shaft Wear
The caliper body must slide smoothly on the caliper holder
shaft [D]. If the body does not slide smoothly, one pad will
wear more than the other, pad wear will increase, and con-
stant drag on the disc will raise brake and brake f luid tem-
perature.
Check to see that the caliper holder shaft are not badly
worn or stepped, and that the rubber friction boots are
not damaged.
If the rubber friction boot is damaged, replace the rubber
friction boot. To replace the friction boot, remove the pads
and the caliper bracket.
If the caliper holder shaft is damage, replace the caliper
bracket.
BRAKES 12-15
Brake Pads
Front Brake Pad Removal
Remove:
Mounting Bolts [A]
Remove:
Pad Pin Bolt [A]
PadSpring[B]
Brake Pads [C]
Front Brake Pad Installation
Push the caliper pistons in by hand as far as they will go.
Apply silicone grease to the stopper ring [A].
Install:
Brake Pads
Pad Spring
Pad Pin Bolts
Torque - Front Brake Pad Pin Bolts: 17 N·m ( 1.7 kgf·m, 12
ft·lb)
WARNING
Do not attempt to drive the motorcycle until a full
brake lever is obtained by pumping the brake lever
until the pads are against the disc. The brake will
not function on the first application of the lever if
this is not done.
Rear Brake Pad Removal
Remove the caliper with the hose installed.
Remove:
Clip [A]
Pad Pi n [B]
Brake Pads [C]
12-16 BRAKES
Brake Pads
Rear Brake Pad Installation
Push the caliper piston in by hand as far as it will go.
Instal
l:
Brake Pads
Pad Pin
Clip
Install the caliper (see Caliper Installation).
WARNING
Do not attempt to drive the motorcycle until a full
brake pedal is obtained by pumping the brake pedal
until the pads are against the disc. The brake will
not function on the first application of the pedal if
this is not done.
Brake Pad Wear Inspection
Refer to the Brake Pad Wear Inspection in the Periodic
Maintenance chapter.
BRAKES 12-17
Master Cylinder
Front Master Cylinder Removal
Disconnect the front brake light switch connectors [A].
Remove the banjo bolt [B] to disconnect the brake hose
from the master cylinder [C] (see Brake Hose Rem oval/In-
stallation).
Remove the rear view mirror (see Steering chapter).
Unscrew the clamp bolts [A], and take off the master cylin-
der as an assembly with the reservoir, brake lever, and
brake 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] of
the 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 low er
clamp bolt [C]. There will be a gap at the lower part of the
clamp after tightening.
Torque - Front Master Cylinder Clamp Bolts: 8.8 N·m (0.9
kgf·m, 78 in·lb)
Replace the washers on each side of the hose fitting with
new 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.
Install the rear view mirror (see Steering chapter).
12-18 BRAKES
Master Cylinder
Rear Master Cylinder Removal
Unscrew the brake hose banjo bolt [A] on the master cylin-
der (se
e Brake Hose Removal/Installation).
Pull off the reservoir hose lower end [B], and drain the
brake fluid into a container.
Loose
n t he master cylinder mounting bolts [C] lightly.
Remove the cotter pin [D].
NOTE
Pull off the joint pin while pressing down the brake
pedal.
Unscrew the master cylinder mounting bolts, and remove
the 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 new
ones.
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 Brake Line Bleeding in the Pe-
riodic Maintenance chapter).
Check the brake for good braking power, no brake drag,
and no fluid leakage.
Front Master Cylinder Disassembly
Remove the front master cylinder (see Front Master Cylin-
der R emoval).
Remove the reservoir cap and diaphragm, and pour the
brake fluid into a container.
Unscrew the locknut and pivot bolt, and remove the brake
lever.
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 piston
since removal will damage it.
BRAKES 12-19
Master Cylinder
Rear Master Cylinder Disassembly
NOTE
Do not remove the push rod clevis for master cylinder
disass
embly since removal requires brake position ad-
justment.
Remove the rear m aster cylinder (see Rear Master Cylin-
der Removal).
Slide the dust cover on the push rod out of place, and
remove 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 piston
since removal will damage it.
Master Cylinder Assembly
Before assembly, clean all parts including the master
cylinder with brake fluid or alcohol.
CAUTION
Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning of the brake parts. Do not use any other
fluid 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 will
be 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 inner
wall of the cylinder.
Take care not to scratch the piston or the inner wall of the
cylinder.
Apply silicone grease (ex. PBC grease).
Brake Lever Pivot Bolt
Brake Lever Pivot Contact
Push Rod Contact
Dust 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 (0.60
kgf·m, 52 in·lb)
Mas ter Cylinder Inspection (Visual Inspection)
Refer to the Master Cylinder Inspection (Visual Inspec-
tion) in the Periodic Maintenance chapter.
12-20 BRAKES
Brake Disc
Brake Disc Removal
Remove the wheel (see Wheels/Tires chapter).
Unscre
w t he mounting bolts, and take off the disc.
Brake Disc Installation
Install the brake disc on the wheel so that the marked side
[A] faces out.
Apply a non-permanent locking agent to the threads of
the 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 where
it has worn the most.
If the disk has worn past the service limit, replace it.
[B] Measuring Area
Front Disc Thickness
Standard: 4.8 5.1 mm (0.19 0.20 in.)
Service Limit: 4.5 mm (0.1 8 in.)
Rear Disc Thickness
Standard: 4.8 5.1 mm (0.19 0.20 in.)
Service Limit: 4.5 mm (0.1 8 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 one
side.
Set up a dial gauge against the disc [A] as shown and
measure disc runout, while turning [B] the wheel by hand.
If runout exceeds the service limit, replace the disc.
Disc Runout
Standard: Not more than 0.2 mm (0.008 in.)
Service Limit: 0.3 mm (0.012 in.)
Special Tool - Jack: 57001–1238
BRAKES 12-21
Brake Fluid
Brake Fluid Level Inspection
Refer t o the Brake Fluid Level in the Periodic Maintenance
chapter.
Brake Fluid Change
Refer to the Brake Fluid Change in the Periodic M ainte-
nance chapter.
Brake Line Bleeding
Refer to the Brake Line Bleeding in the P eriodic Mainte-
nance chapter.
12-22 BRAKES
Brake Hose
Brake Hose Removal/Installation
CAUTION
Brake fluid quickly ruins painted or plastic sur-
faces; any spilled fluid should be completely wiped
up imme
diately with wet cloth.
When re
moving the brake hose, take care not to spill the
brake fluid on the painted or plastic parts.
When removing the brake hose, temporarily secure the
end of
the brake hose to some high place to keep fluid
loss to a minimum.
There are w ashers on each side of the brake hose fitting.
Repla
ce them with new ones when installing.
When installing the hoses, avoid sharp bending, kinking,
flattening or twisting, and route the hoses according to
Cabl
e, 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 (see
Brake Line Bleeding in the Periodic Maintenance chap-
ter).
Brake Hose Inspection
Refer to the Brake Hoses and Connection Inspection in
t
he Periodic Maintenance chapter.
SUSPENSION 13-1
13
Suspension
Table of C ontents
Exploded View........................................................................................................................ 13-2
Specifications ......................................................................................................................... 13-6
Special Tools .......................................................................................................................... 13-7
Front Fork............................................................................................................................... 13-8
Rebound Damping Force Adjustment (Only Right Fork Leg) ........................................... 13-8
Spring Preload Adjustment ............................................................................................... 13-8
Front Fork Removal (each fork leg) .................................................................................. 13-9
Front Fork Installation ....................................................................................................... 13-9
Fork Oil Change................................................................................................................ 13-10
Front Fork Disassembly .................................................................................................... 13-13
Front Fork Assembly......................................................................................................... 13-14
Inner Tube, Outer Tube Inspection ................................................................................... 13-15
Dust Seal Inspection ......................................................................................................... 13-15
Spring Tension .................................................................................................................. 13-16
Rear Shock Absorber ............................................................................................................. 13-17
Rebound Damping Force Adjustment............................................................................... 13-17
Spring Preload Adjustment ............................................................................................... 13-17
Rear Shock Absorber Removal ........................................................................................ 13-18
Rear Shock Absorber Installation ..................................................................................... 13-19
Rear Shock Absorber Inspection ...................................................................................... 13-19
Rear Shock Absorber Scrapping ...................................................................................... 13-19
Swingarm................................................................................................................................ 13-20
Swingarm Removal........................................................................................................... 13-20
Swingarm Installation........................................................................................................ 13-21
Swingarm Bearing Removal ............................................................................................. 13-21
Swingarm Bearing Installation .......................................................................................... 13-22
Swingarm Bearing, Sleeve Inspection .............................................................................. 13-22
Swingarm Pivot Lubrication .............................................................................................. 13-22
Chain Slider Inspection ..................................................................................................... 13-22
Tie-Rod, Rocker Arm.............................................................................................................. 13-23
Tie-Rod Removal .............................................................................................................. 13-23
Tie-Rod Installation . .......................................................................................................... 13-23
Rocker Arm Removal........................................................................................................ 13-23
Rocker Arm Installation..................................................................................................... 13-24
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection ............................................................. 13-24
Unit-track Linkage Lubrication .......................................................................................... 13-24
13-2 SUSPENSION
Exploded View
SUSPENSION 13-3
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Front fork clamp bolts (Upper) 8.8 0.90 78 in·lb AL
Front fork clamp bolts (Upper): ZR1000–A2 13 1.3 113 in·lb
2 Front fork clamp bolts (Lower) 20 2.0 15 AL
Front fork clamp bolts (Lower): ZR1000–A2 30 3.1 22
3
Front
fork top plugs
35 3.6 26
4 Piston rod nuts 20 2.0 15
5 Front fork bottom Allen bolts 20 2.0 15
6 Front axle clamp bolt 20 2.0 15
7. Right fork leg
8. Left fork leg
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
R: Replacement parts
13-4 SUSPENSION
Exploded View
SUSPENSION 13-5
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Rear shock absorber nuts (upper and lower) 34 3.5 25
2 Swingarm pivot shaft nut 127 13 94
3 Swingarm pivot shaft locknut 98 10 72
4 Rocker arm nut 34 3.5 25
5 Tie-rod nuts 59 6.0 43
G: Apply or add grease.
13-6 SUSPENSION
Specif ications
Item Standard
Front Fork (per one unit):
Fork inner tube outside diameter 41 mm (1.61 in.)
Air Pressure
Atmospheric pressure (Non-adjustable)
Rebound damper setting 1 turns out from the fully clockwise position
(only right fork leg) (Usable Range: 0 ←→ 14/5 2 2/5 turns out)
Fork spring preload setting Adjuster protrusion is 19 mm (0.75 in.)
(Usable Range: 10 25 mm (0.39 0.98 in.))
Fork oil viscosity SHOWA SS-8 (SAE 10W-20)
Fork oil capacity:
Right fork leg 450 ± 2.5 mL (15.21 ± 0.085 US oz) (completely dry)
approx. 385 mL (13.01 US oz) (when changing oil)
Left fork leg 468 ± 2.5 mL (15.82 ± 0.085 US oz) (completely dry)
approx. 400 mL (13.52 US oz) (when changing oil)
Fork oil level:
Fully compressed, without fork spring, below from inner
tube top
Right fork leg 62 ± 2 mm (2.44 ± 0.08 in.)
Left fork leg 47 ± 2 mm (1.85 ± 0.08 in.)
Fork spring free length 282.7 mm (11.13 in.) (Service limit 277 m m (10.91 in.))
Rear Shock Absorber:
Rebound damper set 1 turns out from the fully clockwise position
(Usable Range: 0 ←→ 3 4 turns out)
Spring setting position
Standard Spring length 188.4 mm (7.42 in.)
Usable range Spring length 193.4 183.4 mm (7.61 7.22 in.)
(weaker to stronger)
Gas pressure 980 kPa (10 kgf/cm², 142 psi, Non-adjustable)
SUSPENSION 13-7
Special Tools
Oil Seal and Bearing Remover:
57001–1058
Bearing Driver Set:
57001–1129
Jack:
57001–1238
Front Fork Oil Seal Driver:
57001–1288
Fork Oil Level Gauge:
57
001–1290
Fork Piston Rod Puller, M10 × 1.0:
57001–1298
Front Fork Spring Compressor:
57001–1338
Socket Wr ench:
57001–1370
Hook Wrench:
57001–1539
13-8 SUSPENSION
Front Fork
Rebound Damping Force Adjustment (Only Right Fork
Leg)
To adju
st the rebound damping force, turn the r ebound
damping adjuster [A] on top of the right front fork leg to
the desired position.
The st
andard adjuster setting for the average-build rider
of 68 kg (150 lb) w ith no passenger and no accessories
is 1 turns out of the fully clockwise position.
The damping force can be left soft for average riding. But
it should be adjusted harder for high speed riding or riding
with a passenger. If the damping feels too soft or too stiff,
adjust it in accordance with the following table.
Rebound Damping Force Adjustme nt
Ad
juster
Da
mping
Position Force
Setting
Load Road
Speed
14/5 22/5
Weak
Soft
Light
Good
Low
1
0
Strong
Hard Heavy Bad High
Spring Preload Adjustment
Turn the spring preload adjuster [A] to change spring
preload setting.
The standard adjuster setting for the average-build rider
of 68 kg (150 lb) w ith no passenger and no accessories
is the 19 mm [B] from top as shown.
Adjuster Protrusion (from top)
Standard: 19 mm (0.75 in.)
Usable Range: 10 25 mm (0.39 0.98 in.)
WARNING
If both adjusters are not adjusted equally, handling
may be impaired and a hazardous condition may
result.
The spring preload can be left soft f or average riding. But
it should be adjusted harder for high speed riding or riding
with a passenger. If the spring action feels too soft or too
stiff, adjust it in accordance with the following table.
Spring Action
Adjuster Damping
Position Force
Setting Load Road Speed
25 mm Weak
Soft
Light
Good
Low
(0.98 i n.)
STD 19 mm
(0.75 i n.)
10 mm
Strong
Hard Heavy Bad High
(0.39 i n.)
SUSPENSION 13-9
Front Fork
Front Fork Removal (each fork leg)
Remove:
Front Wheel (see Wheels/Tires chapter.)
Front Fender (see Frame chapter.)
Windshield and Bracket (see Frame chapter.)
Inner Cover (see Frame chapter.)
Fairing and Bracket (see Frame chapter.)
Loosen the upper fork clamp bolts [A] and fork top plug
[B] before-hand if the fork leg is to be disassembled.
NOTE
Loosen the top plug after loosening the upper fork
clamp bolts.
Loosen the upper fork clamp bolts [A] and lower fork
clamp bolts [B].
With a twisting motion, work the fork l eg down and out.
Front Fork Installation
Install the fork so that the top end [A] of the outer tube is
flush with the upper surface [B] of the steering stem head
bracket.
Tighten:
Torque - Front Fork Clamp Bolts (Lower):
20 N·m (2.0 kgf·m, 15 ft·lb)
30 N·m (3.1 kgf·m, 22 ft·lb): ZR1000–A2
Front Fork Top Plug: 35 N·m (3.6 kgf·m, 26 ft·lb)
NOTE
Tighten the two clamp bolts alternately two times to en-
sure even tightening torque.
Tighten the top plug before tightening the upper fork
clamp bolts.
Tighten:
Torque - Front Fork Clamp Bolt (Upper):
8.8 m (0.90 kgf·m, 78 in·lb)
13 N·m (1.3 kgf·m, 113 in·lb): ZR1000–A2
NOTE
Tighten the two clamp bolts alternately two times to en-
sure even tightening torque.
Adjust the spring preload and the dam ping force (right fork
leg only).
13-10 SUSPENSION
Front Fork
Fork Oil Change
Remove the front fork (see Front Fork Removal).
Turn th
e spring preload adjuster [A] counterclockwise until
the fully position.
Unscrew the top plug [B] out of the inner tube.
Avoiding the pins [A], set the front fork spring compressor
set [B] on the washer [C].
Special Tool - Front Fork S pring Compressor:
57001–1338
Compress the fork spring.
Holding the piston rod nut [A] with a wrench [B], remove
the fork top plug from the piston rod.
For the right fork leg, remove the fork top plug with the
rebound damping adjuster rod [A].
Remove:
Washer [A]
Slider [B]
Spacer [C]
SUSPENSION 13-11
Front Fork
Drain the fork oil into a suitable container.
Remove the fork spring [A].
Pump the piston rod [B] up and down at least t en times to
expel the oil from the fork.
Hold the fork tube upright, press the inner tube and the
piston rod all the way down.
Pour in the type and amount of fork oil specified.
Fork Oil
Viscosity:
SHOWA SS-8
Amount (Right fork leg)
When changing oil:
a
pprox. 385 mL (13.01 US
o
z)
After disassembly and
c
ompletely dry:
450 ± 2.5 mL (15.21 ± 0.085
US oz)
Amount (Left fork leg)
When changing oil:
approx. 400 mL (13.52 US oz)
After disassembly and
completely dry:
468 ± 2.5 mL (15.82 ± 0.085
US oz)
If necessary, measure the oil level as follows.
Hold the inner tube vertically in a vise.
Pump the inner tube several times to expel air bubbles.
Using the piston rod puller [A], move the piston rod [B] up
and down more than ten times in order to expel all the air
from the fork oil.
Special Tool - Fork Piston Rod Puller, M10 ×1.0:
57001–1298
Wait until the oil level settles.
With the fork fully compressed and the piston rod [B] fully
pushed in, insert a tape measure or rod into the inner
tube, and measure t he distance from the top of the inner
tube to the oil.
13-12 SUSPENSION
Front Fork
Oil Le vel (fully compressed, without spring)
Standard:
Rightforkleg 62±2mm(2.40.08in.)
Left fork leg 47 ± 2 mm (1.85 ± 0.08 in. )
(from the top of the outer tube)
NOTE
Fork oil level may also be measured using the fork oil
level gauge.
Special Tool - Fork Oil Level Gauge: 57001–1290 [A]
With the fork fully compressed and without fork spring,
insert the gauge tube into the inner tube [B] and position
the stopper across the top end [F] of the outer tube [C].
Set the gauge stopper [D] so that its lower side shows the
oil level distance specified [E].
Pull the handle slowly to pump out the excess oil until the
oil no longer comes out.
If no oil is pum ped out, there is insufficient oil in the inner
tube. Pour in enough oil, then pump out the excess oil as
shown above.
Pull the piston rod [A] up above the inner tube top.
Screw the rod nut [B] on to the piston rod with the cham-
fered side down.
Check that the visible thread length is 12.5 mm (0.492 in.)
[C].
Install the fork spring [A] with the smaller end [B] facing
upward.
Install the spacer.
The right fork leg spacer [A] is shorter than the left fork
leg spacer [B].
Install t he slider [C] and washer.
Screw the fork piston rod puller onto the end of the rod.
Special Tool - Fork Piston Rod Puller, M10 × 1.0:
57001–1298
SUSPENSION 13-13
Front Fork
Check the O-ring on the top plug and replace it with a new
one if damaged.
For the right fork leg, check the distance [C] between the
bottom end [A] of the top plug and rebound damping ad-
juster [B] with a pair of vernier caliper.
[C] 2 0 mm (0.79 in.)
Holding the top plug [A] with a wrench [B], tighten the
piston rod nut [C] against the top plug.
Torque - Piston Rod Nut: 20 N·m (2.0 kgf·m, 15 ft·lb)
For the right fork leg, the top plug has the rebound dam p-
ing adjuster rod.
Raise the outer tube and screw the top plug into it.
Install the front fork (see Front Fork Installation).
Front Fork Disassembly
Remove the front fork (see Front Fork Removal).
Hold the fork leg with a vise [A].
Loosen the Allen bolt [B] and tighten it loosely.
Drain the fork oil (see Fork Oil Change).
Unscrew the Allen bolt, then take the bolt and gasket out
of the bottom of the inner tube.
Take the cylinder unit and centring plate out of the inner
tube.
Do not disassemble the cylinder unit.
Cylinder Unit [A] and Center Ring Plate [C] for Right Fork
Leg
Cylinder Unit [B] and Center Ring Plate [C] for Left Fork
Leg
Separate the inner tube from the outer tube as follows.
Slide up the dust seal [A].
Remove the retaining ring [B] from the outer tube.
13-14 SUSPENSION
Front Fork
Holding the inner tube [A] by hand, pull the outer tube [B]
several times to pull out the outer tube.
Remove the inner tube guide bushing [A], outer tube
guide bushing [B], washer [C], oil seal [D] from the inner
tube.
Front Fork Assembly
Replace the following parts with new one.
Oil Seal
Guide Bushings
Bottom Allen Bolt Gasket
Install the following parts onto the inner tube.
Dust Seal
Retaining Ring
Oil Seal
Washer
Outer Tube Guide Bushing
Inner Tube Guide Bushing
Insert the inner tube to the outer tube.
Fit the new outer guide bush [A] into the outer tube.
NOTE
When assembling t he new outer tube guide bushing [A],
hold the washer against t he new one and tap the washer
with the fork oil seal driver [B] until it stops.
Special Tool - Front Fork Oil Seal Driver: 57001–1288
After installing the washer, install the oil seal by using the
fork oil seal driver.
Install the retaining ring and dust seal by hand.
SUSPENSION 13-15
Front Fork
Install the cente ring plate on the c ylinder unit.
Insert the cente r ing plate and cylinder unit as a set into
the inner tube.
Cylinder Unit [A] and Center Ring Plate [C] for Right Fork
Leg
Cylinder Unit [B] and Center Ring Plate [C] for Left Fork
Leg
Hold the front fork in a vise.
Torque the Allen bolt.
Torque - Front Fork Bottom Allen Bolt: 20 N·m (2.0 kgf·m,
15 ft·lb)
Pour in the specified type of oil (see Fork Oil Change.)
Inner Tube, O uter Tube Inspection
Visually inspect the inner tube [A], and repair any dam-
age.
Nick or rust damage can sometimes be repaired by using
a wet-stone to remove sharp edges or raised areas which
cause seal damage.
If the dam age is not repairable, replace the inner tube.
Since damage to the inner tube damages the oil seal,
replace the oil seal whenever the inner tube is repaired
or replaced.
C
AUTION
If the inner tube is badly bent or creased, replace
it. Excessive bending, followed by subsequent
straightening, can weaken the inner tube.
Temporarily assemble the inner tube [A] and outer tube
[B], and pump [C] them back and forth manually to check
for smooth operation.
If you feel binding or catching, the inner and outer tubes
must be replaced.
WARNING
A straightened inner or outer fork tube may fall in
use, possibly causing an accident. Replace a badly
bent or damaged inner or outer tube and inspect the
other tube carefully before reusing it.
Dust Seal Inspection
Inspect the dust seals [A] for any signs of deterioration or
damage.
Replace it if necessary.
13-16 SUSPENSION
Front Fork
Spring Tension
Since a spring becomes shorter as it weakens, check its
free le
ngth [A] to determine its condition.
If the spring of either fork leg is shorter than the service
limit, it must be replaced. If the length of a replacement
sprin
g and that of the remaining spring vary greatly, the
remaining spring should also be replaced in order to keep
the fork l egs balanced for motorcycle stability.
Spring Free Length
Standard: 282.7 mm (11.13 in.)
Service Limit: 277 mm (10.91 in.)
SUSPENSION 13-17
Rear Shock Absorber
Rebound Damping Force Adjustment
To adjust the rebound damping force, turn the rebound
damping adjuster [A] to the desired position.
The standard adjuster setting for an average-build rider
of 68 kg (150 lb) with no passenger and no accessories
3/4 turns out of the fully clockwise position.
Rebou
nd Damping Force Adjustment
Adjuster Damping
Position Force
Setti
ng
Load Road
Speed
3 4 Weak
Soft
Light
Good
Low
STD 1
0
Strong
Hard Heavy Bad High
Spring Preload Adjustment
Remove the rear shock absorber from the frame (see
Rear Shock Absorber Removal).
Loosen the locknut and turn out the adjusting nut to free
the spring.
Special Tools - Hook Wrenches: 57001–1539
Measure the spring free length.
Spring Free Length
Standard: 198.2 mm (7.80 in.)
To adjust the spring preload, turn in the adjusting nut [A]
to the desired position and tighten the locknut [B].
[C] Spring Length
Spring Preload S etting
Standard: Spring l ength 188.4 mm (7.42 i n.)
Usable Range:
Spring length 193.4 183.4 mm
(7.61 7.22 in.) (weaker to stronger)
The s tandard adjusting nut setting for an average-build
rider of 68 kg (150 lb) with no passenger and no acces-
sories is 188.4 mm (7.42 in.) spring length.
If the spring action feels too soft or too stiff, adjust it.
Remove:
Right Side Muffler Body (see Engine Top End chapter.)
Chain Cover (see Drive Chain Removal in the Final Drive
chapter.)
Mud Guard (see Frame chapter.)
13-18 SUSPENSION
Rear Shock Absorber
Special Tools - Hook Wrench: 57001–1539 [A]
Spring Adjustment
Adjuster Damping
Positi
on
Force
Setting Load Road Speed
193.4 mm Weak
Soft
Light
Good
Low
(7.61 in.)
183.4 mm Strong Hard Heavy Bad High
(7.22 in.)
Rear Shock Absorber Removal
Using the jack, raise t he rear wheel off t he ground.
Special Tool - Jack: 57001–1238
Squeeze the brake lever slowly and hold it with a band
[A].
WARNING
Be sure to hold the front brake when removing the
shock absorber, or the motorcycle may tall over. It
could cause an accident and injury.
Remove:
Lower Shock Absorber Nut [A]
Lower Shock Absorber Bolt [B]
Remove:
Upper Shock Absorber Nut [A]
Upper Shock Absorber Bolt [B]
SUSPENSION 13-19
Rear Shock Absorber
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 Stroke
Oil Leakage
Crack or Dent
If there is any damage to the rear shock absorber, replace
it.
Visually inspect the rubber bushing.
If it show any signs of damage, replace it.
Rear Shock Absorber Scrapping
WARNING
Since the reservoir tank of the rear shock absorber
contains nitrogen gas, do not incinerate the reser-
voir tank without first releasing the gas or it may
explode.
Remove the valve cap [A] and release t he nitrogen gas
completely from the gas reservoir.
Remove the valve.
WARNING
Since the high pressure gas is dangerous, do not
point the valve toward your face or body.
13-20 SUSPENSION
Swingarm
Swingarm Removal
Remove the m uffler bodies (see Engine Top End chapter.)
Raise t
he rear wheel off the ground with jack.
Special Tool - Jack: 57001–1238
Remove:
Rear Wheel (see Wheels/Tires chapter.)
Chain Cover (see Final Drive chapter.)
Mud Guard (see Frame chapter.)
Brake Hose Clamp [A]
Lower Shock Absorber Nut and Bolt [A]
Upper Tie-Rod Nut and Bolt [B]
Remove the right frame cover (see Frame chapter).
Loosen the upper shock absorber nut.
Unscrew the swingarm pivot locknut [A], using the socket
wrench [B].
Special Tool - Socket Wrench: 57001–1370
Unscrew the swingarm pivot nut [A] and loosen the
swingarm pivot shaft [B].
Pull off the pivot shaft and remove the swingarm.
SUSPENSION 13-21
Swingarm
Swingarm Installation
Apply plenty of grease to the ball bearing, needle bearings
and grease seals, and add plenty of grease to the grease
nipple.
Install the collars [A].
Place the right 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 t hat the clearance [D] between
the collar [A] and the frame [C] com e to zero mm.
Tighten:
Torque - Swingarm Pivot Shaft Nut: 127 N·m (13 kgf·m, 94
ft·lb)
Tighten the pivot locknut, using the socket wrench.
S
pecial Tool -
S
ocket Wrench: 57001–1370
Torque - Swingarm Pivot Shaft Locknut: 98 N·m (10.0
kgf·m, 72 ft·lb)
Swingarm Bearing Removal
Remove:
Swingarm
Collars [A]
Grease Seals [B]
Sleeve [C]
Circlip (right side) [D]
13-22 SUSPENSION
Swingarm
Remove the ball bearing and needle bearings.
Special Tool - Oil Seal and Bearing Remover: 57001–1058
[A]
Swingarm Bearing Installation
Apply plenty of grease to the ball bearing and needle
bearings.
Install the needle bearings so that the manufacturer’s
marks face in.
Install the ball bearing so that the manufacturer’s marks
faces out.
Special Tool - Bearing Driver Set: 57001–1129 [A]
Swingarm Bearing, Sleeve Inspection
CAUTION
Do not remove the bearings for inspection. Remove
may d amage 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, or
other damage.
If the needle bearing, ball bearing, and sleeve show any
sings of abnormal wear, discoloration, or damage. re-
place them as a set.
Swingarm Pivot Lubrication
Refer to Swingarm Pivot Lubrication in the Periodic Main-
tenance chapter.
Chain S lider Inspection
Visually inspect the chain slider [A].
Replace the chain slider if it shows any signs of abnormal
wear or damage.
SUSPENSION 13-23
Tie-Rod, Rocker Arm
Tie-Rod Removal
Remove the muffler bodies (see Engine Top End chapter.)
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 N ut [A]
Upper and Lower Tie-Rod Bolts and Nuts [B]
Tie-Rods [C]
Tie-Rod Installation
Apply grease to the inside of the needle bearings and
grease seals.
Install the tie-rods so that the marked side faces the bolts
and 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, 25
ft·lb)
Rocker Arm Removal
Remove the right side muffler body (see Engine Top End
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.
Remove:
Lower Rear Shock Absorber Bolt and N ut [A]
Lower Tie-Rod Bolt and Nut [B]
Rocker Arm Bolt and Nut [C]
Rocker Arm [D]
13-24 SUSPENSION
Tie-Rod, Rocker Arm
Rocker Arm Installation
Apply grease to t he inside of the needle bearings and oil
seal li
ps, and add grease to the grease nipple.
Tighten:
Torque - Rocker Arm Bolt: 34 N·m ( 3.5 kgf·m, 25 ft·lb)
Tie-Rod Nut: 59 m (6.0 kgf·m, 43 ft·lb)
Rear Shock Absorber Nut: 34 N·m (3.5 kgf·m, 25
ft·lb)
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection
Visually inspect the rocker arm/tie-rod sleeves and needle
bearings.
The rollers in a needle bearing normally wear very little,
and wear is difficult to measure. Instead of measuring,
inspect the bearing for abrasion, color change, or other
damage.
If there is any doubt as to the condition of any of the nee-
dle bearings or sleeve, replace the sleeve, and needle
bearings as a set.
Unit-track Linkage Lubrication
Refer to Unit-track Linkage Lubrication in the P eriodic
Maintenance chapter.
STEERING 14-1
14
Steering
Table of C ontents
Exploded View........................................................................................................................ 14-2
Special Tools .......................................................................................................................... 14-4
Steering .................................................................................................................................. 14-5
Steering Inspection ........................................................................................................... 14-5
Steering Adjustment.......................................................................................................... 14-5
Steering Stem......................................................................................................................... 14-6
Stem, Stem Bearing Removal........................................................................................... 14-6
Stem, Stem Bearing Installation........................................................................................ 14-7
Stem Bearing Lubrication.................................................................................................. 14-9
Steering Stem W arp.......................................................................................................... 14-9
Handlebar............................................................................................................................... 14-10
Handlebar Removal .......................................................................................................... 14-10
Handlebar Installation ....................................................................................................... 14-10
Rear View Mirrors Removal .............................................................................................. 14-11
Rear View Mirrors Installation ........................................................................................... 14-11
14-2 S TEERING
Exploded View
STEERING 14-3
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Steering stem nut 27 2.75 20
2 Steering stem head bolt 108 11 80
3 Front fork clamp bolts (Upper) 8.8 0.90 78 in·lb AL
Front fork clamp bolts (Upper): ZR1000–A2 13 1.3 113 in·lb
4
Front
fork clamp bolts (Lower)
20 2.0 15 AL
Front fork clamp bolts (Lower): ZR1000–A2 30 3.1 22
5 Handlebar clamp bolts 25 2.5 18 S
6 Handlebar lower clamp nuts 34 3.5 25
7 Handlebar housing switch screws 3.4 0.35 30 in·lb
8. Steering stem head bolt plug
9. Plug (ZR1000–A2 )
AD: Apply adhesive.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement part
AL: Tighten the two clamp bolts alternately t wo times to ensure even tighten torque.
S: Follow the specific tightening sequence.
14-4 S TEERING
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 Inspection in the Periodic Mainte-
nance chapter.
Steering Adjustment
Refer to the Steering Adjustment in the Periodic Mainte-
nance chapter.
14-6 S TEERING
Steerin g Stem
Stem, Stem Bearing Removal
Remove:
Windsh
ield and Bracket (see Frame chapter.)
Inner Cover (see Frame chapter.)
Fairing and Bracket (see Frame chapter.)
Front W
heel (see Wheels/Ti res chapter.)
Handlebar (see Handlebar Removal.)
Steering Stem Head Bolt Plug
Steerin
g Stem Head Bolt [A] and Washer
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 stem
locknut [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.
STEERING 14-7
Steering Stem
To remove the bearing outer races [C] pressed into the
head pipe [B], insert a bar [A] into the recesses [D] of head
pipe, and applying it to both recess alternately hamm er it
to drive the race out.
NOTE
If either steering stem bearing is damaged, it is recom-
mende
d that both the upper and lower bearings (includ-
ing outer races) should be replaced with new ones.
Remove the lower bearing inner race [A] which is pressed
onto the steering stem with a suitable commercially avail-
able chisel [B].
Stem, Stem Bearing Installation
Replace the bearing outer races with new ones.
Apply grease to the outer races, and drive them into the
head pipe at the same time.
Special Tools - Bearing Driver Set: 57001–1129 [A]
Replace the bearing inner races with new ones.
Drive the lower ball bearing inner race applied the grease
onto the stem.
Special Tools - Steering Stem Bearing Driver: 57001–1344
[A]
Steering Stem Bearing Driver Adapter:
57001–1345 [B]
14-8 S TEERING
Steerin g Stem
Apply grease the lower ball bearing [A] and install it onto
the stem.
Apply g
rease to the upper ball bearing [B] and inner race
[C].
Install the stem [A] through the head pipe and install the
ball bearing [B] and inner race [C] on it.
Install t he 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, 29
ft·lb) of torque first, and loosen it a fraction of a turn until
it turns lightly. Afterward tighten it again with specified
torque using a stem nut wrench [A] in the direction shown.
Check that there is no play and the steering stem turns
smoothly without rattles. If not, the steering stem bearings
may be damaged.
Special Tool - Steering Stem Nut Wrench: 57001–1100
Torque - Steering Stem Nut: 27 N·m (2.75 kgf·m, 20 ft·lb)
Install the claw washer [A] so that its bent side [B] faces
upward, and engage the bent claws with the grooves of
stem locknut [C].
Hand tighten the stem l ocknut until it touches the claw
washer.
Tighten the stem locknut clockwise until the claws are
aligned with the grooves (ranging from 2nd to 4th) of stem
nut [D], and bend the 2 claws downward [E].
Install the stem head.
Install the washer, and tighten the stem head bolt with
specified t orque.
Install the steering stem head bolt plug.
Install the front fork (see Suspension chapter).
STEERING 14-9
Steering Stem
NOTE
Tighten the fork upper clamp bolts first, next the stem
head nut, last the fork lower clamp bolts.
Torque - Steering Stem Head Bolt : 108 N·m (11 kgf·m, 80
ft·lb)
Front Fork Clamp Bolts (Upper):
8.8 m (0.90 kgf·m, 78 in·lb)
13 N·m (1.3 kgf·m, 113 in·lb): ZR1000–A2
Front Fork Clamp Bolts (Lower):
20 N·m (2.0 kgf·m, 15 ft·lb)
30 N·m (3.1 kgf·m, 22 ft·lb): ZR1000–A2
NOTE
Tighten the two clamp bolts alternately two times to en-
sure even tightening torque.
WARNING
Do not impede the handlebar turning by routing the
cables, harnesses and hoses improperly (see Gen-
eral Information chapter).
Install the removed parts (see appropriate chapter).
Stem Bearing Lubrication
Refer to Stem Bearing Lubrication in the Periodic M ainte-
nance chapter.
Steering Stem Warp
Whenever the steering stem is removed, or if the steering
cannot be adjusted for smooth action, check the steering
stem for straightness.
If the steering stem [A] is bent, replace the steering stem.
14-10 STEERING
Handlebar
Handlebar Removal
Remove:
Clutch
Lever Assembly [A]
Left Handlebar Switch Housing [B]
Front Brake Master Cylinder [C]
Right H
andlebar Switch Housing [D]
Handlebar Holder Bolts [E]
Remove the handlebar holders [F] and then pull out the
handle
bar [G].
Remove the cotter pins [A].
Unscrew the mounting nuts [B] and remove the handlebar
lower 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 corner
edge [B] on the lower clamp.
Tighten the front clamp bolts first, and then the rear clamp
bolts. There will be a gap [A] at the rear part of the clamp
after tightening.
Torq ue - Handlebar Clamp Bolts: 25 N·m ( 2.5 kgf·m, 18
ft·lb)
STEERING 14-11
Handlebar
Rear View Mirrors Removal
Loosen the lower hexagonal area [A] for tightening to re-
move the rear view mirror from the holder.
CAUTIO
N
Do not force to tighten and/or loosen the upper
hexagonal area (Adapter) [B] with a pair of span-
ners. D isassembly of this area is Not Available.
Non-permanent locking agent [D] is already applied
to the threads of this inner area. Forcible loosen-
ing may damage the adapter and/or the turning
mechanism of the stay [C].
Rea
r View Mirrors Installation
Screw the mounting area of the right rear view mirror into
the holder all the way, and tighten the lower hexagonal
ar
ea for tightening securely.
[A] Lower Hexagonal Area for Tightening
[B] Upper Hexagonal Area (Adapter)
[C]
Rear View Mirror (Right)
FRAME 15-1
15
Frame
Table of C ontents
Exploded View........................................................................................................................ 15-2
Seats ...................................................................................................................................... 15-7
Rear Seat Removal........................................................................................................... 15-7
Rear Seat Installation........................................................................................................ 15-7
Front Seat Removal .......................................................................................................... 15-7
Front Seat Installation ....................................................................................................... 15-7
Side Covers ............................................................................................................................ 15-8
Side Cover Removal ......................................................................................................... 15-8
Side Cover Installation ...................................................................................................... 15-8
Fairings................................................................................................................................... 15-9
Windshield Removal ......................................................................................................... 15-9
Windshield Installation ...................................................................................................... 15-9
Inner Cover Removal ........................................................................................................ 15-9
Inner Cover Installation ..................................................................................................... 15-9
Fairing Removal................................................................................................................ 15-9
Fairing Installation............................................................................................................. 15-10
Faring Bracket Removal ................................................................................................... 15-10
Seat Covers............................................................................................................................ 1 5-11
Seat Cover Removal......................................................................................................... 15-11
Seat Cover Installation...................................................................................................... 15-11
Mud Guard.............................................................................................................................. 15-12
Mud Guard Removal......................................................................................................... 15-12
Mud Guard Installation...................................................................................................... 15-12
Fenders .................................................................................................................................. 15-13
Front Fender Removal...................................................................................................... 15-13
Front Fender Installation ................................................................................................... 15-13
Rear Fender Rear Rem oval.............................................................................................. 15-13
Rear Fender Rear Installation........................................................................................... 15-14
Frame Cover........................................................................................................................... 15-15
Frame Cover Removal...................................................................................................... 15-15
Battery Case........................................................................................................................... 15-16
Battery Case Removal ...................................................................................................... 15-16
Battery Case Installation . .................................................................................................. 15-16
Side Stand .............................................................................................................................. 15-17
Side Stand Removal ......................................................................................................... 15-17
Side Stand Installation ...................................................................................................... 15-17
Frame ..................................................................................................................................... 15-18
Frame Inspection .............................................................................................................. 15-18
15-2 FRAME
Exploded View
FRAME 15-3
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Footpeg holder bolts 34 3.5 25
2 Muffler mounting nuts 29 3.0 22
3 Side stand bolt 44 4.5 33
4 Side stand switch bolt 8.8 0.9 78 in·lb
G: Apply grease.
15-4 FRAME
Exploded View
FRAME 15-5
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Windshield screws 0.35 0.50 0.035 0.050 3 4in·lb
2 Front fender bolts 3.9 0.4 34.7 in·lb L
15-6 FRAME
Exploded View
FRAME 15-7
Seats
Rear Seat Removal
Insert the ignition switch key into the seat lock [A], turning
the key counterclockwise, pulling up on the rear of the
seat [B], and pulling the seat backward.
WARNING
The muffler surface is hot once the engine has been
started. When operating the seat lock be careful not
to touch the muffler or you may be burned.
NOTE
Insert the ignition key to the bottom of the seat lock, and
turn the key counterclockwise while strongly pushing
down the rear of the seat for easier removal.
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 R emoval
Remove:
Rear Seat (see Rear Seat Removal)
Mounting Bolts [A]
Seat Bracket [B]
Remove the front seat [C] by pulling it up on the rear and
to the rear.
Front Seat Installation
Slip the front seat hook [A] under the brace [B] on the fuel
tank bracket.
15-8 FRAME
Side Covers
Side Cover Removal
Remove the bolt [A].
Pull th
e 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
Windshield Removal
Remove:
Bolts [ A]
Windshield [B]
Windshield Installation
Windshield Installation is the reverse of removal.
Torque - Windshield Screw: 0.35 0.50 N·m
(0.035 0.050 kgf·m, 3 4in·lb)
Inner Cover Removal
Remove:
Inner Cover Screws [A] (both side)
Inner Cover [B]
Inner Cover Installation
Fit t he projections [A] on the inner cover [B] into the holes
[C] in the firing bracket.
Install the inner cover screws.
Fairing Removal
Remove:
Windshield
Windshield Bracket nuts [A]
15-10 FRAME
Fairings
Remove:
Fairing Mounting Bolts [A] (both side)
Headli
ght Connectors
Fairing Installation
Fairing installation is the reverse of removal.
Faring Bracket Removal
Remove:
Fairing (see Fairing Removal)
Turn Signal Lights (see Electrical System chapter)
Meter Unit [A] (see Electrical System chapter)
C
lamp [B]
Bolts [C]
Firing Bracket [D]
FRAME 15-11
Seat Covers
Seat Cover R emoval
Remove:
Seats
Screws [A]
Push the central pin, and then remove the quick rivets [A].
Pull the front portions [A] of the seat cover outside [B],
and then remove the seat cover backward.
Seat Cover Installation
Installation is reverse of removal.
Put the projections [A] into the grommets [B] on the frame.
15-12 FRAME
Mud Guard
Mud Guard Removal
Remove:
Chain C
over (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].
FRAME 15-13
Fenders
Front Fender Removal
Remove:
Brake Hose Clamps [ A]
Bolts [B] (both side)
Remove the front fender [C].
Front Fender Installation
Install the brake hose clamps to the front fender holes.
Rear Fender Rear Removal
Remove:
Seats
Seat Cover
Canister (California model only)
Diodes [A] (pull out)
Stop and Turn Signal Light Lead Connectors [B]
Seat Lock Mounting Bolts [C]
Rear Fender Assy Bolts [D]
Remove:
Screws and Washers [A]
Tail Lamp Assembly [B]
Remove:
Bolts [ A]
Storage Compartment [B]
15-14 FRAME
Fenders
Remove:
Quick Rivets [A ]
Rear Fe
nder 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.
FRAME 15-15
Frame Cover
Frame Cover Removal
Remove:
Bolts [ A]
Frame Cover [B] (both side)
15-16 FRAME
Battery Case
Battery Case Removal
Remove:
Seats
Seat Cover
Rear Fender Assy
Side Co
vers
Battery
Left Side Screw [A] (with reserver tank)
Pull ou
t the battery case [B] backward [C].
Battery Case Installation
Put the battery case attachments [A] at the projections [B]
on the frame.
FRAME 15-17
Side Stand
Side Stand Remov al
Raise the rear wheel off the ground with the stand.
Remove:
Muffler (both side)
Exhaust pipe
Side Stand Switch Bolt [A]
Side Stand Sw itch [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, 32 ft·lb)
Hook the spring
Install the side stand switch.
Apply a non-permanent locking agent to the thread of the
switch bolt.
Torque - Side Stand Switch Bolt: 8.8 N·m (0.9 kgf·m, 78
in·lb)
15-18 FRAME
Frame
Frame Inspection
Visually inspect the frame for cracks, dents, bending, or
warp.
If there is any damage to the frame, replace it.
WARNING
A repaired frame may fail in use, possibly causing
an accident. If the frame is bent, dented, cracked,
or warped, replace it.
ELECTRICAL SYSTEM 16-1
16
Electrical System
Table of C ontents
Parts Location.................................... 16-3
Exploded View................................... 16-4
Specifications .................................... 16-10
Special Tools and Sealant ................. 16-11
Wiring Diagram (U.S.A. and Canada) 16-12
Wiring Diagram (Australia) ................ 16-14
Wiring Diagram (Other than U.S.A.,
Canada, Australia, and Malaysia)... 16-16
Wiring Diagram (Malaysia) ................ 16-18
Precautions........................................ 16-20
Electrical Wiring................................. 16-22
Wiring Inspection ......................... 16-22
Battery ............................................... 16-23
Battery Removal .......................... 16-23
Battery Installation ....................... 16-23
Electrolyte Filling.......................... 1 6-23
Initial Charge................................ 1 6-25
Precautions .................................. 16-26
Interchange.................................. 16-27
Charging Condition Inspection..... 16-27
Refreshing Charge....................... 16-27
Charging System............................... 16-29
Alternator Cover Removal............ 16-29
Alternator Cover Installation......... 16-29
Stator Coil Removal ..................... 1 6-29
Stator Coil Installation .................. 16-30
Alternator Rotor Removal ............ 16-30
Alternator Rotor Installation ......... 16-30
Alternator Inspection .................... 16-32
Regulator/Rectifier Inspection...... 16-33
Charging Voltage Inspection........ 16-35
Ignition System .................................. 16-37
Crankshaft Sensor Removal ........ 16-37
Crankshaft Sensor Installation..... 16-38
Crankshaft Sensor Inspection...... 16-38
Crankshaft Sensor Peak Voltage
Inspection.................................. 1 6-39
Timing Rotor Removal ................. 16-39
Timing Rotor Installation .............. 16-39
Camshaft Position Sensor
Removal.................................... 16-40
Camshaft Position Sensor
Installation................................. 16-40
Camshaft Position Sensor
Inspection.................................. 1 6-40
Camshaft Position Sensor Peak
Voltage Inspection..................... 16-41
Stick Coil (Ignition Coil together
with Spark Plug Cap) Removal . 16-41
Stick Coil (Ignition Coil together
with S park Plug Cap)
Installation ................................. 16-42
Stick Coil (Ignition Coil together
with Spark Plug Cap) Inspection 16-43
Stick Coil Primary Peak Voltage .. 16-43
Spark Plug Removal .................... 16-44
Spark Plug Installation ................. 16-44
Spark Plug Cleaning and
Inspection.................................. 1 6-44
Spark Plug Gap Inspection .......... 16-44
Interlock Operation Inspection ..... 16-45
IC Igniter Inspection ..................... 16-46
Electric Starter System...................... 16-49
Starter M otor Rem oval................. 16-49
Starter M otor Installation.............. 16-49
Starter Motor Disassembly........... 1 6-49
Starter Motor Assembly ............... 16-50
Brush Inspection .......................... 16-51
Commutator Cleaning and
Inspection.................................. 1 6-51
Armature Inspection..................... 16-51
Brush Lead Inspection ................. 16-52
Brush Plate and Terminal Bolt
Inspection.................................. 1 6-52
Starter Relay Inspection............... 16-52
Lighting System ................................. 16-54
Headlight Beam Horizontal
Adjustment ................................ 16-54
Headlight Beam Vertical
Adjustment ................................ 16-54
Headlight Bulb Replacement ....... 16-55
Headlight R emoval/Installation .... 16-56
City Light Bulb Replacement
(European Model) ..................... 16-56
Turn Signal Light B ulb
Replacement............................. 16-59
Turn S ignal Relay Inspection ....... 16-61
Tail/Brake Light (LED) Removal... 16-61
Tail/Brake Light (LED) Installation 16-62
Radiator Fan System......................... 16-63
Fan System Circuit I nspection ..... 16-63
16-2 ELECTRICAL SYSTEM
Fan Motor Inspection ................... 16-63
Meter, Gauge, Indicator Unit.............. 16-65
Meter Unit Removal ..................... 16-65
Meter, Gauge Disassembly.......... 16-65
Electronic Combination Meter
Unit Inspection .......................... 16-66
Switches and Sensors ....................... 16-75
Brake Light Timing Inspection...... 16-75
Brake Light Timing Adjustment .... 16-75
Switch Inspection ......................... 16-75
Radiator Fan Switch I nspection ... 16-75
Water Temperature Sensor
Inspection.................................. 16-76
Speed Sensor Inspection............. 16-77
Fuel Level Sensor Inspection....... 16-79
Fuel Reserve Switch Inspection... 16-79
Diode (Rectifier) Inspection.......... 16-80
Junction Box ...................................... 16-81
Junction Box Fuse Circuit
Inspection.................................. 16-81
Starter Circuit/Headlight Relay
Inspection.................................. 16-82
Diode Circuit Inspection............... 16-83
Fuse................................................... 16-84
30A Main Fuse Removal.............. 16-84
Junction Box Fuse Removal ........ 16-84
Fuse Installation........................... 16-84
15A ECU Fuse Removal.............. 16-84
Fuse Inspection............................ 16-84
ELECTRICAL SYSTEM 16-3
Parts Location
[A] Starter Lockout Switch
[B] Camshaft Position Sensor
[C] Radiator Fan Switch
[D] Starter Motor
[E] Alternator
[F] Speed Sensor
[G] Neutral Switch
[H] Side Stand Switch
[I] Water Tem perature Sensor
[J] Battery
[K] Junction Box
[L] Front Brake Light Switch
[M] Stick Coils
[N] Crankshaft Sensor
[O] R ear Brake Light Switch
[P] Starter Relay and Main Fuse
[Q] ECU Fuse
[R] Turn Signal Relay
[S] Diode (Rectifier)
[T] ECU
(Electronic Control Unit)
[U] Oil Pressure Switch
[V] Radiator Fan
[W] Fuel Level Sensor
16-4 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-5
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Meter mounting screws 1.2 0.12 11 in·lb
2 Tail/brake light mounting screws 1.2 0.12 11 in·lb
3 License plate light mounting screws 1.2 0.12 11 in·lb
4 Front brake light switch screw 1.2 0.12 11 in·lb
5
Start
er locknut switch screws
- - - L
6 Left switch housing screws 3.4 0.35 30 in·lb
7 Right switch housing screws 3.4 0.35 30 in·lb
8 Headlight m ounting bolts 5.9 0.6 53 in·lb
9. Tail/brake lights (LED)
10. Vibration Resistance Bulb
11. Install the rear brake spring as shown.
Longer Side [A]
L: Apply a non–permanent locking agent.
EUR: European Community
AU: Australia
CA: Canada
US: U.S.A.
16-6 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-7
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Water temperature sensor 25 2.5 18 SS
2 Spark plugs 13 1.3 115 in·lb
3 Alternator lead holding plate bolts 11 1.1 95 in·lb L
4 Starter motor mounting bolts 11 1.1 95 in·lb
5
Stato
r motor coil bolts
11 1.1 95 in·lb
6 Alternator rotor bolt 110 11 80
7 Starter 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 0.6 53 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 0.4 35 in·lb L
15 Oil pressure switch terminal bolts 1.5 0.15 13 in·lb G
16 Oil pressure switch 15 1.5 11 SS
17. Radiator fan
18. Crankshaft sensor
19. Camshaft position sensor
20. Starter r elay/main fuse
21. Stick coils
22. Ignition switch
G: 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
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Regulator/rectifier bolts 6.9 0.7 62 in·lb
2 Fuel level sensor bolts 6.9 0.7 62 in·lb
3 Side stand switch bolt 8.8 0.9 78 in·lb
4 Neutral switch 15 1.5 11
5
Speed
sensor bolt
6.9 0.7 62 in·lb L
6 Speed sensor cover bolts 6.9 0.7 62 in·lb L
7 Regulator/rectifier bracket bolts 6.9 0.7 62 in·lb
8 Engine ground cable terminal bolt 9.8 1.0 87 in·lb
9. Turn signal relay
10. Junction box
11. ECU (Electrical Unit C ontrol)
12. 15 A ECU fuse
13. Fuel reserve switch
14. Diode (Rectifier)
15. Speed sensor
16. Regulator/rectifier
17. Battery 12 V 8 Ah
L: Apply a non-permanent locking agent.
16-10 ELECTRICAL SYSTEM
Specif ications
Item Standard
Battery:
Type Sealed Battery
Capacity 12 V 8 Ah
Volta
ge
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
Charging voltage 14.7 ± 0.5 V
(regulator/rectifier output voltage)
Ignition System:
Crankshaft sensor resistance 376 564
Crankshaft sensor peak voltage 1.9 V or more
Camshaft Position Sensor resistance 400 460
Camshaft Position Sensor peak voltage 0.2 V or m ore
Stick coil:
Primary winding resistance 1.04 1.56
Secondary winding resistance 10.8 16.2 k
Primary peak voltage 88 V or more
Spark plug:
Spark plug gap 0.7 0.8 mm (0.028 0.031 in.)
IC igniter inspection:
in the text
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 m m, 1.06 in.)
Switch and Sensor:
Speedometer sensor
in the text
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 temperature
Fan s tops with the temperature 3 C(38 46 °F)
lower than the operation temperature range.
ON: Less than 0.5
OFF: More than 10 M
Water temperature sensor resistance in the text
Fuel level sensor resistance:
Fuel position
4 10
Empty position 90 100
Fuel reserve switch in the text
ELECTRICAL SYSTEM 16-11
Special Tools and Sealant
Hand Tester:
57001–1394
Flywheel Puller, M 38 × 1.5:
57001–1405
Rotor Holder:
57001–1543
Lead Wire-Peak Voltage Adapter:
57001–1449
Kawasaki Bond (Silicone Sealant):
56
019–120
Rotor Puller, M16/M18/M20/M22 × 1.5:
57001–1216
Flywheel and Pulley Holder:
57001–1343
Needle Adapter:
57001–1457
Spark Plug Wrench (Owners Tool):
92110–1132
Harness Adapter:
57
001–1542
16-12 ELECTRICAL SYSTEM
Wiring Diagr am (U.S.A. and Canada)
ELECTRICAL SYSTEM 16-13
Wiring Diagram (U.S.A. and Canada)
16-14 ELECTRICAL SYSTEM
Wiring Diagram (Australia)
ELECTRICAL SYSTEM 16-15
Wiring Diagram (Australia)
16-16 ELECTRICAL SYSTEM
Wiring Diagram (Other than U.S.A., Canada, Australia, and Malaysia)
ELECTRICAL SYSTEM 16-17
Wiring Diagram (Other than U.S.A., 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 are
musts when servicing electrical systems. Learn and ob-
serve a
ll the rules below.
Do not reverse the battery lead connections. This will
burn out the diodes on the electrical parts.
Alway
s check battery condition before condemning other
parts of an electrical system. A fully charged battery is a
must for conducting accurate electrical system tests.
The e
lectrical parts should never be struck sharply, as
with a hammer, or allowed to fall on a hard surface. Such
a shock to the parts can damage them.
To p r
event damage to electrical parts, do not disconnect
the battery leads or any other electrical connections when
the ignition switch is on, or while the engine is running.
Bec
ause of the large amount of current, never keep the
starter button pushed when the starter motor will not turn
over, or the current may burn out the starter motor wind-
ing
s.
Take care not to short the leads that are directly con-
nected to the battery positive (+) terminal to the chassis
gr
ound.
Troubles m ay involve one or in some cases all items.
Never replace a defective part without determining what
CA
USED the failure. If the failure was caused by some
other item or items, they must be repaired or r eplaced, or
the new replacement will soon fail again.
M
ake sure all connectors in the circuit are clean and tight,
and exam ine wires for signs of burning, fraying, etc. Poor
wires and bad connections will affect electrical system op-
e
ration.
Measure coil and winding resistance when the part is cold
(at room temperature).
Color Codes:
BK Black
GGreen
PPink
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
YYellow
Electrical Connectors
Female 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 it
is damaged, replace it.
Chec
k the wiring for continuity.
Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
Conn
ect the hand tester between the ends of the leads.
Special Tool - Hand Tester: 57001–1394
Set the tester to the × 1 range, and read the tester.
If the tester does not read 0 , the lead is defective. Re-
place the lead or the wiring harness [B], [C], [D], [E] if
necessary.
ELECTRICAL SYSTEM 16-23
Battery
Battery Removal
CAUTION
Do not disconnect the battery cables or any other
electrical connections when the ignition switch is
ON, as this could damage the ECU (Electronic Con-
trol Unit).
Never reverse the connections of the battery, this
could damage the ECU.
Remove:
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 prevent
corrosion.
Install the positive (+) cable [A] first.
Cover the (+) terminal with the c ap [B].
Install the negative (–) cable [C].
Electrolyte Fillin g
Make sure that the model name [A] of the electrolyte con-
tainer matches the model name [B] of the battery. These
names must be the same.
Battery Model Name for ZR1000–A1 :YTX9BS
CAUTION
Be sure to use the electrolyte container with the
same model name as t he battery since the elec-
trolyte volume and specific gravity vary with t he
battery t ype. This is to prevent overfilling of the
electrolyte, 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] sealing
the filler ports [B] until just before use.
Check to see that there is no peeling, tears or holes in the
seal sheet on the top of the battery.
Place the battery on a level surface.
Remove the seal sheet.
NOTE
A battery whose sealing sheet has any peeling, tears,
holes, or from which the air–sucking sound was not
heard requires a refreshing charge (initial charge).
Take the electrolyte container out of the vinyl bag.
Detach the seal caps [A] from the container.
NOTE
Do not discard the seal caps because it is used as the
battery plugs later.
Do not peel back or pierce the seals [B] on the container.
Place the electrolyte container upside dow n aligning the
six seals with the six battery filler ports.
Push the container down strongly enough to break the
seals. Now the electrolyte should start to flow into the
battery.
NOTE
Do not tilt the container as the electrolyte flow may be
interrupted.
Make sure air bubbles [A] are coming up from all six filler
ports.
Leave the container this way for 5 minutes or longer.
NOTE
If no air bubbles are coming up from a filler port, tap
[B] the bottom of the bottle two or three times. Never
remove the container from the battery.
CAUTION
Fill the electrolyte into the battery until the con-
tainer is completely emptied.
Be certain that all the electrolyte has flowed out.
Tap the bottom the same way as above if there is any
electrolyte left in the container.
Now pull the container gently out of the battery.
Let the battery sit for 20 minutes. During this time, the
electrolyte permeates the special separators and the gas
generated by chemical reaction is released.
ELECTRICAL SYSTEM 16-25
Battery
Fit the seal caps [A] tightly into the filler ports until the seal
caps are at the sam e level as the top of the battery.
NOTE
Do not h
ammer. Press down evenly with both hands.
CAUTION
Once you installed the seal caps after filling the bat-
tery, never remove it, nor add any water or elec-
trolyte.
Initial Charge
While the sealed battery can be used after only filling with
electrolyte, the battery may not be able to sufficiently move
a starter motor to start an engine in the cases shown in the
table below, where an initial charge is required before use.
However, if a battery shows the terminal voltage of 12.6 V
or more, using a digital voltmeter, after 10 minutes of filling,
no initial charge is necessary.
NOTE
To measure battery terminal voltage, use a digital volt-
meter which can be read one decimal place voltage.
Condition requiring initial charge Charging method
At low temperatures (lower than 0°C) 0.9 A × 2 3 hours
Battery has been stored in high temperature and humidity.
Seal has been removed, or broken peeling, tear or hole.
(If you did not hear the air–sucking sound "Shoosh!" as you removed
the seal.)
Battery as old as 2 years or more after manufacture.
Battery manufacturing date is printed on battery top.
Example) 12 10 01 T1
Day Month Year Mfg. location
0.9 A × 15 20 hours
16-26 ELECTRICAL SYSTEM
Battery
Precautions
1) No need of topping–up
No topp
ing–up is necessary in this battery until it ends
its life under normal use. F
orcibly prying off th e sealing
plug to add wate r is very dangerou s. Never do that.
2) Refre
shing charge
If an engine will not start, a horn sounds weak, or
lamps are dim, it indicates the battery has been dis-
charg
ed. Give refresh charge for 5 to 10 hours with
charge current shown in the specification (see the this
chapter).
When a
fast charge is inevitably required, do it fol-
lowing precisely the maximum charge current and tim e
conditions indicated on the battery.
CAUTION
This battery is desig ned to sustain no unusual
deter
ioration if refresh–charged according to the
method specified above. H
owever, the battery’s
performance may be reduced noticeably if charged
unde
r conditions other than given above.
Never remove the sea l caps during refresh charge.
If by chance an excessive amount of gas is gener-
ated
due to overcharging, the relief valve releases
the gas to keep the battery normal.
3) When you do not use the motorcycle for months:
Give a refresh charge before you store the m otorcycle
and s
tore it with the negative cable removed. Give a
refresh charge once a month during storage.
4) Battery life:
If t
he battery will not start the engine even after sev-
eral refresh charges, t he battery has exceeded i ts use-
ful life. Replace it. (Provided, however, the vehicle’s
sta
rting system has no problem.)
WARNING
Keep the battery away from sparks and open flames
during charging, since the battery gives off an ex-
plosive gas mixture of hydrogen and oxygen. When
using a battery charger, connect the battery to the
charger before turning on the charger. This proce-
dure prevents sparks at the battery terminals which
could ignite any battery gases.
No fire should be drawn near the battery, or no ter-
minals should have the tightening loosened.
The electrolyte contains sulfuric acid. Be careful
not to have it touch your skin or eyes. If touched,
wash it off with liberal amount of water. Get medical
attention if severe.
ELECTRICAL SYSTEM 16-27
Battery
Interchange
The sealed battery can fully display its performance
only when combined with a proper vehicle electric system.
Therefore, replace the sealed battery only on a motorcycle
which was originally equipped with the sealed battery.
Be careful, if a sealed battery is installed on a motorcycle
which had an ordinary battery as original equipment, the
sealed battery’s life will be shortened.
Charging Condition Inspection
Battery charging condition can be checked by m easuring
battery terminal voltage.
Remove the seats (see Frame chapter).
Disconnect the battery (–) cables.
CAUTION
Be sure to disconnect the negative (–) cable first.
Measure the battery terminal voltage.
NOTE
Measure with a digital voltmeter [A] which can be read
to one decimal place voltage.
If the reading is below the specified, refreshing charge is
r
equired.
Battery Terminal Voltage
Standard:
12.6 V or more
Refreshing Charge
Remove the battery [A] ( see Battery Removal).
Refresh–charge by following method according to the bat-
tery terminal voltage.
WARNING
This battery is sealed type. Never remove seal cap
[B] even at charging. Never add water. Charge with
current and time as stated below.
16-28 ELECTRICAL SYSTEM
Battery
Terminal Voltage: 11.5 less than 12.6 V
Standard Charge
0.9 A × 5 10 h
Quick C harge
4.0 A ×
1.0 h
Battery Terminal Voltage (V) [A]
Charge Time (h) [B]
CAUTION
If possible, do not quick charge. If the quick charge
is done due to unavoidable circumstances, do stan-
dard charge later on.
Terminal Voltage : less than 11.5 V
Charging Method : 0.9 A × 2 0 h
NOTE
Increase the charging voltage to a maximum voltage of
25 V if the battery will not accept current initially. Charge
for no more than 5 minutes at the increased voltage then
check if the battery is drawing current. If the battery
will accept current decrease the voltage and charge by
the standard charging method described on the battery
case. If t he battery will not accept current after 5 min-
utes, replace the battery.
Battery [A]
Battery Charger [B]
Standard Value [C]
Current starts to flow [D]
Determine battery condition after refreshing charge.
Determine the condition of the battery 30 minutes after
completion of the charge by measuring the terminal volt-
age according to the table below.
Criteria
Judgement
12.6 V or higher Good
12.0 12.6 V or lower Charge insufficient Recharge.
12.0 V or lower Unserviceable Replace
ELECTRICAL SYSTEM 16-29
Charging System
Alternator Cover Removal
Remove:
Frame Cover Bolts [A]
Left Frame Cover [B]
Clamp (open) [A]
Alternator Lead Connector [B]
For California model, remove the separator.
Place a suitable container under the alternator cover [ A],
and remove the cover bolts [B].
Pull the alternator cover outside.
Alternator Cover Installation
Apply silicone sealant to the alternator lead grommet and
crankcase halves mating surface [A] on the front and rear
sides of the cover mount.
Sealant - Kawasaki Bond (Silicone Sealant): 56019– 120
Check that knock pins [B] are in place on the crankcase.
Install a new gasket and the alternator cover.
Tighten:
Torque - Alternator Cover Bolts: 11 N·m (1.1 kgf·m, 95 in·lb)
Stator Coil Removal
Remove:
Alternator Cover (see Alternator Cover Removal)
Holding Plate Bolt [A] and Plate
Alternator Lead Grommet [B]
Stator Coil Bolts [C]
Remove the stator coil [D] from the alternator cover.
16-30 ELECTRICAL SYSTEM
Chargi ng System
Stator Coil Installation
Apply a non-permanent locking agent to the stator coil
bolts a
nd tighten it.
Torque - Stator Coil Bolts: 11 N·m (1.1 k g f· m, 95 in·lb)
Secure the alternator lead with a holding plate, and
tighten the bolt.
Apply a non-permanent locking agent to the plate bolt.
Torque - Alternator Lead Holding Plate Bolt: 11 N·m (1.1
kgf·m, 95 in·lb)
Apply silicone sealant to the circumference of the alter-
nator lead grommet, and fit the grommet into the notch of
the c
over securely.
Sealant - Kawasaki Bond (Silicone Sealant): 56019–120
Install the alternator cover (see Alternator Cover Installa-
tion).
Al
ternator Rotor Removal
Remove:
Alternator Cover (see Alternator Cover Removal)
Wi
pe oil off the outer circumference of the rotor.
Hold the alternator rotor steady with the rotor holder [A],
and remove the rotor bolt [B].
Special Tool - Rotor Holder: 57001–1543
Using the flywheel puller [A] and rotor puller [B], remove
the alternator rotor from the crankshaft.
Special Tools - Flywheel Puller, M38 × 1.5: 57001–1405
Rotor Puller, M16/M18/M20/M22 × 1.5:
57001–1216
NOTE
Screw in the puller while tapping the head [C] of the
puller with a hammer.
CAUTION
Do not attempt to strike the alternator rotor itself.
Striking the rotor can cause the magnets to lose
their magnetism.
Alternator Rotor Installation
Using a cleaning fluid, clean off any oil or dirt on the fol-
lowing portions and dry them with a clean cloth.
[A] Crankshaft Tapered Portion
[B] Alternator Rotor Tapered Portion
Apply a thin coat of molybdenum disulfide grease to the
crankshaft [C] and the f ace [D] of the starter clutch gear.
ELECTRICAL SYSTEM 16-31
Charging System
Install the starter gear [A].
Again, clean the crankshaft tapered portion [B] and dry
there.
Fit the woodruff key [C] securely in the slot in the crank-
shaft before installing the alternator rotor.
Install t he alternator rotor [A] while turning [B] the starter
clutch gear [C].
Install the washer [A] so that the chamfer side [B] faces
outward.
NOTE
Confirm the alternator rotor fit or not to the crankshaft
before tightening it with specified torque.
Install the rotor and tighten it with 70 N·m (7 kgf·m, 52
ft·lb) of torque.
Remove the washer and rotor bolt.
Check the tightening torque with rotor puller.
If the rotor is not pulled out with 20 N·m (2 kgf·m, 15 ft·lb)
of drawing torque, it is installed correctly.
If the rotor is pulled out with under 20 N·m ( 2 kgf·m, 15
ft·lb) of drawing torque, clean off any oil dirt or flaw of the
crankshaft and rotor tapered portion, and dry t hem with
a clean cloth. Then, confirm that it is not pulled out with
above t orque.
Tighten the alternator rotor bolt while holding the alterna-
tor rotor steady with the rotor holder.
Special Tool - Rotor Holder: 57001–1543
Torque - Alternator Rotor B olt: 110 N ·m (11.0 kgf·m, 80 ft·lb)
16-32 ELECTRICAL SYSTEM
Chargi ng System
Apply a thin coat of molybdenum disulfide grease to the
shaft [A], and install it and starter idle gear [B].
Instal
l the alternator cover (see Alternator Cover Installa-
tion).
Alternator Inspection
There are three types of alternator failures: short, open
(wire burned out), or loss in rotor magnetism. A short or
open in one of the coil wires will result in either a low output,
or no output at all. A loss in rotor magnetism, which may be
caused by dropping or hitting the alternator, by leaving it
near an electromagnetic field, or just by aging, will result in
low output.
To check the alternator output voltage, do the following
procedures.
Turn off the ignition switch.
Remove the frame cover (see Alternator Cover Removal).
Disconnect the alternator lead connector [A].
Connect the hand tester as shown in the table 1.
Start the engine.
Run it at the rpm given in the table 1.
Note the voltage readings (total 3 measurements).
Table 1 Alternator Output Voltage
Tes t e r Connections Reading
Range
Tes t er ( +) t o Teste r ( ) t o @4,000rpm
250 V One Black Another 42 V or
AC
lead Black lead
more
If the output voltage shows the value in the table, the al-
ternator operates properly.
If the output voltage shows a much higher than the v alue
in the table, the regulator/rectifier is damaged. A much
lower reading than that given in the table indicates that
the alternator is defective.
Check the stator coil resistance as follows.
Stop the engine.
Connect the hand tester as shown in the table 2.
Note the readings (total 3 measurement).
Table 2 Stator Coil Resistance
Tes t e r
Connections
Range Tes t er ( +) t o Teste r ( ) t o
Reading
One Black
Another
×1
lead Black lead
0.3 0.4
ELECTRICAL SYSTEM 16-33
Charging System
If there is more resistance than shown in the table, or no
hand tester reading (infinity) for any two leads, the stator
has an open lead and must be replaced. Much less than
this resistance means the stator is shorted, and must be
replaced.
Using the highest resistance range of the hand tester,
measure the resistance between each of the black leads
and chassis ground.
Any hand tester reading less than infinity () indicates a
short, necessitating stator replacement.
If the stator coils have normal resistance, but the voltage
check showed the alternator to be defective; then the rotor
magnets have probably weakened, and the rotor must be
replaced.
Spe
cial Tool -
Han
d Tester: 57001–1394
Regulator/Rectifier Inspection
Remove:
Bolts [ A]
Regulator/rectifier [B]
Connector [C] (disconnect)
Rectifier Circuit Check:
Check conductivity of the following pair of terminals.
Rectifier Circuit Inspection
W-BK1, W–BK2, W–BK3
Tester connection
BK/Y-BK1, BK/Y-BK2, BK/Y-BK3
The resistance should be low in one direction and more
than ten times as much in the other direction. If any two
leads are low or high i n both directions, the rectifier is
defective and must be replaced.
NOTE
The actual meter r eading varies with the meter used
and the individual rectifier, but, generally speaking the
lower reading should be from zero to one half the scale.
Regulator Circuit Check:
To test the regulator out of circuit, use three 12 V batteries
and a test l ight (12 V 3 6 W bulb in a socket with leads).
CAUTION
The test light works as an indicator and also a cur-
rent limiter to protect the regulator/rectifier from ex-
cessive current. D o not use an ammeter instead of
a test light.
Check to be sure the rectifier circuit is normal before con-
tinuing.
16-34 ELECTRICAL SYSTEM
Chargi ng System
Do the 1st step regulator circuit test:
Connect the test light and the 12 V battery to the regula-
tor/re
ctifier as shown.
Check BK1, BK2, and BK3 terminal respectively.
If the test light turns on, the regulator/rectifier is defective.
Repla
ce it.
If the test light does not turn on, continue the test.
Do the 2nd step regulator circuit test:
Connect the test light and the 12 V battery in the sam e
manner as specified in t he "Regulator Circuit Test–1st
Step".
Apply 12 V to the voltage B R terminal.
Check BK1, BK2, and BK3 terminal respectively.
If the test light turns on, the regulator/rectifier is defective.
Replace it.
If the test light does not turn on, continue the test.
Do the 3rd step regulator circuit test:
Connect the test light and the 12 V battery in the sam e
manner as specified in t he "Regulator Circuit Test–1st
Step".
Momentarily apply 24 V to the voltage BR terminal by
adding a 12 V battery.
Check BK1, BK2, and BK3 terminals respectively.
CAUTION
Do not apply more t han 24 volts. If more than 24
volts is applied, the regulator/rectifier may be dam -
aged. Do not apply 24 V more than a few seconds.
If 24 volts is applied f or more than a few seconds,
the regulator/rectifier may be damaged.
If the test light did not light when the 24 V was applied
momentarily to the voltage monitoring terminal, the regu-
lator/rectifier is defective. Replace it.
If the regulator/rectifier passes all of the tests described,
it may still be defective. If the charging system still does
not work properly after checking all of the components
and the battery, test the regulator/rectifier by replacing it
with a known good unit.
ELECTRICAL SYSTEM 16-35
Charging System
Charging Voltage Inspection
Check the battery condition (see Battery s ection).
Warm up the engine to obtain actual alternator operating
conditions.
Remove the seats (see Frame chapter).
Check that the ignition switch is turned off, and connect
the hand tester [A] to the battery terminals [B].
Special Tool - Hand Tester: 57001–1394 [A]
Start the engine, and note t he voltage readings at various
engine speeds with the headlight turned on and then
turned off. (To turn off the headlight, disconnect the
headlight connector on the headlight unit.) The readings
should show nearly battery voltage when the engine
speed is low, and, as the engine speed rises, the read-
ings should also rise. But they must be kept under the
specified voltage.
Charging Voltage
Tes t er Connections
Range
Te s t e r (+) t o Te s t er ( ) to
Reading
25 V DC Battery (+) Battery (–) 14.2 15.2 V
Turn off the ignition switch to stop the engine, and discon-
nect the hand tester.
If the charging voltage is kept between the values given in
the table, the charging system is considered to be working
normally.
If the charging voltage is much higher than the values
specified in the table, the regulator/rectifier is defective
or the regulator/rectifier leads are loose or open.
If the charging voltage does not rise as the engine speed
increases, then the regulator/rectifier is defective or the
alternator output is insufficient for the loads. Check the
alternator and regulator/rectifier to determine w hich part
is defective.
16-36 ELECTRICAL SYSTEM
Chargi ng System
Charging System Circuit
1. Ignition Switch
2. To Starter Circuit Relay
3. A lternator
4. R egulator/Rectifier
5. Joint Connector C
6. B attery 12 V 8 Ah
7. M ain Fuse 30A
8. Load
ELECTRICAL SYSTEM 16-37
Ignition System
WARNING
The ignition system produces extremely high volt-
age. Do not touch the spark plugs or stick coils
while the engine is running, or you could receive
a severe electrical shock.
CAUTION
Do not disconnect the battery cables or any other
electrical connections when the ignition switch is
on, or while the engine is running. This is to prevent
ECU (Electrical Control Unit) damage.
Do not install the battery backwards. The negative
side is grounded. This is to prevent damage to the
diodes and ECU.
Cran
kshaft Sensor Removal
Remove:
Frame Cover (see Frame chapter)
Cran
kshaft Sensor Lead Connector [A]
Remove:
Rubber Boot (slide out) [A]
Oil Pressure Switch Lead Terminal [B]
Crankshaft Sensor Cover Bolts [C] with Clamps
Crankshaft Sensor Cover [D]
Remove the crankshaft sensor [A] by taking off the crank-
shaft sensor bolts [B].
16-38 ELECTRICAL SYSTEM
Ignition System
Crankshaft Sensor Installation
Route the crankshaft sensor lead correctly (see Cable,
Wire, a
nd Hose Routing in Appendix chapter).
Tighten:
Torque - Crankshaft Sensor Bolts: 5.9 N·m (0.6 kgf·m, 53
in·lb)
Apply silicone sealant [A] to the crankshaft sensor lead
grommet and crankcase halves mating surface on the
front and rear sides of the crankshaft sensor cover mount.
Sealant - Kawasaki Bond (Silicone Sealant): 56019–120
Install the clamps [A] direction as shown.
Tighten:
Torque - Crankshaft Sensor Cover B olts: 11 N·m (1.1 kgf·m,
95 in·lb)
Hold the sensor lead [A] with the clamp [B].
Upper Crankcase [C]
Install oil pressure switch lead terminal [A] securely.
Install the lead terminal direction upward.
Torque - Oil Pressure Switch Terminal Bolt: 1.5 N·m (0.15
kgf·m, 13 in·lb)
Install t he other removed parts.
Crankshaft Sensor Inspection
Remove:
Frame Cover (see Frame chapter)
Crankshaft Sensor Lead Connector [A]
Set the hand tester to the × 100 range and connect (+)
lead to the yellow/black lead and (–) lead to the black lead
in the connector.
Special Tool - Hand Tester: 57001– 1394
If there is more resistance than the specified value, the
coil has an open lead and must be replaced. Much less
than this resistance means the coil is shorted, and must
be replaced.
ELECTRICAL SYSTEM 16-39
Ignition System
Crankshaft Sensor Resistance: 375 565
Using the highest resistance range of the tester, measure
the resistance between the crankshaft sensor leads and
chassis ground.
Any tester reading less than infinity () indicates a short,
necessitating replacement of the crankshaft sensor as-
sembly.
Crankshaft Sensor Peak Voltage Inspection
NOTE
Be sure the battery is fully charged.
Using the peak voltage adapter is a more reliable way
to determine the condition of the crankshaft sensor than
crankshaft sensor internal resistance m easurements.
Remove:
Frame Cover (see Frame chapter)
Crankshaft Sensor Lead Connector (see Crankshaft
Sensor Removal)
Set the hand tester [B] to the × 10 V DC range, and con-
nect it a commercially available peak voltage adapter [A]
as shown in the diagram.
Connect the black lead of the adapter to black lead and
red lead to yellow lead in the crankshaft sensor connector
[C].
T urn the ignition switch and engine stop switch on.
Pushing the starter button, turn the engine 4 5sec-
onds with the transmission gear in neutral to measure the
crankshaft sensor peak voltage.
Repeat the m easurement 5 or m ore times.
Crankshaft Sensor Peak Voltage
Standard:
1.9 V or more
Special Tool - Hand Tester: 57001–1394
Recommended Tool- Peak Voltage Adapter
Type: KEK-54-9-B
Brand: KOWA SEIKI
If the tester reading is not specified one, check the crank-
shaft sensor.
Timing Rotor Removal
Remove the crankshaft sensor cover (see Crankshaft
Sensor Removal)
Remove the timing rotor [A].
Holding the timing rotor with the flywheel and pulley holder
[B] and unscrew the bolt [C].
Special Tool - Flywheel and Pulley Holder : 57001–1343
Timing Rotor Installation
Fit the rotor to the crankshaft.
Tighten the rotor bolt.
Torque - Timing Rotor Bolt : 39 N·m (4.0 kgf·m, 29 ft·lb)
Install the crankshaft sensor cover ( see Crankshaft Sen-
sor Installation).
16-40 ELECTRICAL SYSTEM
Ignition System
Camshaft Position Sensor Removal
Remove:
Fuel Ta
nk (see Fuel System (DFI) chapter)
Camshaft Position Sensor Lead Connector [A] (discon-
nect)
Push th
e tongue [B] upside and take out the connector
from the bracket.
Remove:
Camshaft Position Sensor Bolt [A]
Camshaft Position Sensor [B]
Camshaft Position Sensor Installation
Apply grease or engine oil to t he O-ring on the camshaft
position sensor.
Apply a non-parmanent locking agent to the sensor bolt.
Tighten:
Torque - Camshaft Position Sensor Bolt: 12 N·m (1.2 kgf·m,
104 in·lb)
Camshaft Position Sensor Inspection
Remove:
Fuel Tank (see Fuel System (DFI) chapter)
Camshaft Position Sensor Lead Connector [A] (discon-
nect)
Set the hand tester to the × 10 range and connect it to
the yellow and black leads in the connector.
Special Tool - Hand Tester: 57001–1394
If there is more resistance than the specified value, the
sensor coil has an open lead and must be replaced. Much
less than this resistance means the sensor coil is shorted,
and must be replaced.
Camshaft Position Sensor Resistance: 400 460
Using the highest resistance range of the tester, mea-
sure the resistance between the Camshaft Position Sen-
sor leads and chassis ground.
Any tester reading l ess than infinity ( ) indicates a short,
necessitating replacement of the Camshaft Position Sen-
sor.
ELECTRICAL SYSTEM 16-41
Ignition System
Camshaft Position Sensor Peak Voltage Inspection
Remove:
Fuel Tank (see Fuel System (DFI) chapter)
Camshaft Position Sensor Lead Connector [A] (discon-
nect)
Set the hand tester [B] to t he 10 V DC range.
Connect the peak voltage adapter [C] to the hand tester
and Camshaft Position Sensor leads in the connector.
Speci
al Tool -
Hand T
ester: 57001–1394
Recommended Tool- Peak Voltage Adapter
Type: KEK-54-9-B
Bran
d: KOWA SEIKI
Connections:
Camshaft Position
Sensor Lead
Adapter Hand Tester
Black
Red
(+)
Yellow
Black
(–)
T urn the ignition switch and engine stop switch on.
Pushing the starter button, turn the engine 4 5sec-
onds with the transmission gear in neutral to measure the
Camshaft Position Sensor peak voltage.
Repeat the m easurement 5 or m ore times.
Camshaft Position Sensor Peak Vo ltage
Standard:
0.2 V or more
If the peak voltage is lower than the standard, inspect the
Camshaft Position Sensor.
Stick Coil (Ignition Coil together with Spark Plug Cap)
Removal
Remove the fuel tank (see Fuel System (DFI) chapter).
Unscrew the thermostat bracket bolt [A].
If removing the stick coil #2 or #3.
Disconnect the stick coil connectors [A].
Pull the stick coil #1 [B] off the spark plug.
Take out the camshaft position sensor connector [ C] from
the bracket (see Camshaft Position Sensor Removal).
Pull the stick coil #2 [D] off the spark plug.
CAUTION
Do not pry the connector part of the coil while re-
moving the coil.
16-42 ELECTRICAL SYSTEM
Ignition System
Remove the stick coil harness [A] from the bracket.
Remove:
Stick C
oil Connector #4 [B] (disconnect)
Stick Coil #4 [C]
Stick Coil Connector #3 [D] (disconnect)
Disconnect:
Water Tem perature Sensor Connector [A]
Left Switch Housing Connector [B]
Pull the main harness [C] upward and remove the stick
coil #3 [D].
Stick Coil (Ignition Coil together with Spark Plug Cap)
Installation
Install the coil using the following steps.
Insert the coil as shown being careful of the coil head [A]
direction.
Be sure the stick coils are installed by pulling up [B] it
lightly.
Connect and/or install the connectors.
CAUTION
Do not tap the coil head while installing the coil.
Install t he thermostat bracket bolt.
ELECTRICAL SYSTEM 16-43
Ignition System
Stick Coil (Ignition Coil together with Spark Plug Cap)
Inspection
Remove the stick coils (see this chapter).
Measure the primary winding resistance [A] as follows.
Connect the hand tester between the coil terminals.
Set the tester to the × 1 range, and read the tester.
Measure the secondary w inding resistance [B] as follows.
Connect the tester between the plug terminal and (–) coil
terminal.
Set the tester to the × 1 k range and read the t ester.
Ignition Coil Winding Resistance
Primary Windings:
1.04 1.56
Secondary Windings: 10.8 16.2 k
If the tester does not read as specified, replace the coil.
Stick Coil Primary Peak Voltage
NOTE
Be sure the battery is fully charged.
Remove the stick coils (see this chapter), but do not re-
move the spark plugs.
Measure the primary peak voltage as follows.
Connect a commercially peak voltage adapter [B] into the
hand tester [C] which is set to the × 250 V DC range.
Connect the adapter to the lead wire-peak voltage
adapter [A] which is connected between the stick coil
connector and stick coil.
Install the new spark plug [D] into each stick coil [E], and
ground them onto the engine.
[F] ECU
[G] Battery
Recommended Tool- Peak Voltage Adapter
Type: KEK-54-9-B
Brand: KOWA SEIKI
Special Tools - Hand Tester: 57001–1394
Lead Wire-Peak Voltage Adapter:
57001–1449
Primary Lead Connection
Adapter (R, +) to lead wire-peak voltage adapter (W)
Adapter (BK, –) to lead wire-peak voltage adapter (R)
16-44 ELECTRICAL SYSTEM
Ignition System
WARNING
To avoid extremely high voltage shocks, do not
touch the spark plugs or tester connections.
Turn the ignition switch and the engine stop switch ON.
Pushing the starter button, turn the engine 4 5 seconds
with the transmission in neutral to measure the primary
peak voltage.
Repeat the measurements 5 times for one stick coil.
Stick
Coil Primary Peak Voltage
Stand
ard: 88 V or more
Repeat the test for the other stick coil.
If the reading is less than the specified value, check the
following.
Stick Coils (see Stick Coil Inspection)
Crankshaft Sensor (see Crankshaft S ensor I nspection)
If the stick coils, and crankshaft sensor are normal, check
the ECU (see Fuel System (DFI) chapter).
Spark Plug Removal
Refer to the Electrical System in the Periodic Mainte-
nance chapter.
Spark Plug Installation
Refer to the Electrical System in the Periodic Mainte-
nance chapter.
Spark Plug Cleaning and Inspection
Refer to the Electrical System in the Periodic Mainte-
nance chapter.
Spark Plug G ap Inspection
Refer to the Electrical System in the Periodic Mainte-
nance chapter.
ELECTRICAL SYSTEM 16-45
Ignition System
Interlock Operation Inspection
Remove:
Seats (see Frame chapter)
Junction Box (see this chapter)
Do not disconnect the connectors.
1st Check
Measure the terminal voltage of the G/BK lead in the junc-
tion box connector [A] in accordance w ith the following
procedure.
Insert the needle adapter [B] in the Green/Black lead ter-
minal.
Set the tester [C] to the 25 V DC range, connect it to the
needle adapter and frame ground [D].
Connection:
Tester (+) Terminal G/BK Lead Terminal
Tester (–) Terminal Frame Ground
Condition:
Transmission Gear 1st Position
Clutch Lever Release or Pulled In
Side Stand Down
Special Tool - Needle Adapter Set: 57001–1457
Turn the ignition switch on.
Read the voltage.
Interlock Operation Voltage
Standard:
4Vormore
If the voltage is lower than the standard, inspect the side
stand switch, starter lockout switch, and junction box.
And their parts are normality, replace the ECU.
If the voltage is standard, push the starter button to check
as follows.
If the starter motor does not turn, the ECU is good, and
check the starter system circuit.
If the starter motor turned, ECU is defective. Replace the
ECU.
2nd Check
Raise the rear wheel off the ground with a stand.
Inspect the engine for its secure stop after the following
operations are completed.
Run the engine to the following conditions.
Condition:
Transmission Gear 1st Position
Clutch Lever Release
Side Stand Up
Set the side stand on the ground, then the engine will
stop.
If whichever may not be stopped, inspect the starter lock-
out switch, side stand switch and junction box.
If their parts are normality, replace the ECU.
16-46 ELECTRICAL SYSTEM
Ignition System
IC Igniter Inspection
The IC Igniter is built in the ECU [A].
Refer t
o the Interlock O peration Inspection, Ignition
System Troubleshooting Chapter and Fuel System (DFI)
chapter for ECU Inspection.
ELECTRICAL SYSTEM 16-47
Ignition System
16-48 ELECTRICAL SYSTEM
Ignition System
Ignition System Circuit
1. Ignition Switch
2. E ngine Stop Switch
3. S tarter Button
4. S park Plugs
5. S tick Coils
6. S ide Stand Switch
7. C rankshaft Sensor
8. C amshaft Position Sen-
sor
9. Throttle Sensor
10. N eutral Switch
11. Junction Box
12. Ignition Fuse 10A
13. S tarter Lockout Switch
14. D iode
15. E CU Main Relay
16. E CU Fuse 15A
17. Vehicle-down Sensor
18. M ain Fuse 30A
19. Battery 12 V 8 Ah
20. ECU
(Electrical Control Unit)
21. Joint Connector A
22. Joint Connector B
23. Joint Connector C
24. Joint Connector D
ELECTRICAL SYSTEM 16-49
Electric Starter System
Starter Motor Removal
CAUTION
Do not tap the starter motor shaft or body. Tapping
the shaft or body could damage the motor.
Remove the mounting bolts [A].
Pull out the starter motor [B].
Slide back the rubber cap [A].
Remove the starter motor t erminal nut [B].
Starter Motor Installation
CAUTION
Do not tap the starter motor shaft or body. Tapping
the shaft or body could damage the motor.
When installing t he starter motor, clean the starter mo-
tor legs [A] and crankcase [B] where the starter motor is
grounded.
Replace the O-ring [A] w ith a new one.
Apply a small am ount of engine oil to the O –ring.
Tighten:
Torque - Starter Motor Mounting Bolts: 11 N·m (1.1 kgf·m,
95 in·lb)
Starter Motor Disassembly
Take off the starter motor through bolts [A] and remove
both end covers [B] and pull the armature out of the yoke
[C].
16-50 ELECTRICAL SYSTEM
Electric Starter System
The brush plate [A] and brushes come off with the
right–hand end cover [B].
Remove the terminal locknut [A] and terminal bolt [B], and
then remove the brush with the brush plate [C] from the
right–hand end cover.
Starter Motor Assembly
Install the brush plate and brushes [A], and then put the
armature [B] among the brushes.
Install t he O-rings [A] as shown.
Align the notch [A] in the brush plate with the end cover
notch [B] and the mark [C] on the yoke.
ELECTRICAL SYSTEM 16-51
Electric Starter System
Align the line [A] marked on the yoke with the through bolt
hole [B].
Brush Inspection
Measure the length [A] of each brush.
If any is worn down to t he service limit, replace the carbon
brush holder assembly [B] and the terminal bolt assembly
[C].
Starter Motor Brush Length
Standard: 12 mm (0.47 in.)
Service Limit: 8.5 mm (0.33 in.)
Commutator Cleaning and Inspection
Smooth the commutator surface [A] if necessary with fine
emery cloth [B], and clean out the grooves.
Measure t he diameter [A] of the commutator [B].
If the commutator diameter is less than the service limit,
replace the starter motor with a new one .
Commutator Diameter
Standard: 28 mm (1.10 in.)
Service Limit: 27 mm (1.06 in.)
Armature Inspection
Using the × 1 hand tester range, measure the resis-
tance between any two commutator segments [A].
Special Tool - Hand Tester: 57001–1394
If there is a high resistance or no reading () between any
two segments, a winding is open and the starter motor
must be replaced.
Using the highest hand tester range, measure the resis-
tance between the segments and the shaft [B].
If there is any reading at all, the armature has a short and
the starter m otor must be replaced.
16-52 ELECTRICAL SYSTEM
Electric Starter System
NOTE
Even if the foregoing checks show the armature t o be
good, i
t may be defective in some manner not readily
detectable with the hand tester. If all other starter motor
and starter motor circuit components check good, but
the st
arter motor still does not turn over or only turns
over weakly, replace the starter motor with a new one.
Brush Lead Inspection
Using the × 1 hand tester range, measure the resis-
tance as shown.
[A] Terminal Bolt and Positive Brush
[B] Brush Plate and Negative Brush
Special Tool - Hand Tester: 57001–1394
If there is not close to zero ohms, the brush lead has
an open. Replace the terminal bolt assembly and/or the
brush holder assembly.
Brush Plate and Terminal Bolt Inspection
Using the highest hand tester range, measure the resis-
tance as shown.
[A] Terminal Bolt and Brush Plate
[B] Terminal Bolt and Right–hand End Cover
Special Tool - Hand Tester: 57001–1394
If there is any reading, the brush holder assembly and/or
terminal bolt assembly have a short. Replace the brush
holder assembly and the t erminal bolt assembly.
Starter Relay Inspection
Remove the battery negative (–) cable from the battery
negative ( –) terminal (see Battery Rem oval).
Remove the right side cover.
Pull out the starter relay.
Disconnect the connector [A]
Disconnect the starter motor cable [B] and battery positive
(+) cable [C] from the starter relay [D].
CAUTION
The battery positive (+) cable with the rubber cap is
connected directly to the battery positive (+) termi-
nal even when the ignition switch off, so take care
not to short the removed cable to chassis ground.
ELECTRICAL SYSTEM 16-53
Electric Starter System
Connect the hand tester [A] and 12 V battery [B] to the
starter relay [C] as shown.
Specia
l Tool -
Hand Te
ster: 57001–1394
If the relay does not work as specified, the relay is defec-
tive. Replace the relay.
Testing Relay
Tester Range:
×1 range
Criteria: When battery is connected 0
When b
attery is disconnected →∞
Electric Starter Circuit
1. Ignition Switch
2. Joint Connector D
3. Engine Stop Switch
4. Starter Button
5. Junction Box
6. Starter Circuit Relay
7. Ignition Fuse 10A
8. Side Stand Switch
9. Joint Connector A
10. Starter Lockout Sw itch
11. Neutral Switch
12. Diode (Rectifier)
13. Starter Motor
14. Starter Relay
15. Main Fuse 30A
16. Battery 12 V 8 Ah
17. Joint Connector B
18. Meter Ground
19. Frame Ground
16-54 ELECTRICAL SYSTEM
Lighting System
This models adopt the daylight system and have a head-
light relay in the junction box. In these models, the head-
light d
oes not go on when the ignition switch and the engine
stop switch are first turned on. The headlight comes on after
the starter button is released and stays on until the ignition
switc
h is turned off. The headlight will go out m omentarily
whenever the starter button i s pressed and come back on
when the button is released.
Headlight Beam Horizontal Adjustment
Turn the horizontal adjuster [A] on the headlight with the
screwdriver [ B] in or out until the beam points straight
ahead.
Headlight Beam Vertical Adjustment
Turn the vertical adjusters [A] on the headlight with the
screwdriver [B] in or out to adjust t he headlight vertically.
NOTE
On high beam, the brightest points should be slightly
below horizontal with the motorcycle on its wheels and
the rider seated. Adjust the headlight(s) to the proper
angle according to local regulations.
For US model, the proper angle is 0.4 degrees below
horizontal. This is 50 mm (2 in.) drop at 7.6 m (25
ft) measured from the center of the headlights with the
motorcycle on its wheels and the rider seated.
50 mm (2 in.) [A]
Center of Brightest Spot [B]
7.6 m (25 ft) [C]
Height of Headlight Center [D]
Low Beam [E]
High Beam [F]
ELECTRICAL SYSTEM 16-55
Lighting System
Headlight Bulb Replacement
Remove:
Headlight Connector [A]
Headlight Bulb Dust Cover [B]
Remove:
Hook [A]
Headlight Bulb [B]
CAUTION
When handling t he quartz–halogen bulb, never
touch the glass portion with bare hands. Always
use a clean cloth. Oil contamination from hands or
dirty rags can reduce bulb life or cause the bulb to
explode.
NOTE
Clean off any contamination that inadvertently gets on
the bulb with alcohol or soap and water solution.
Replace the headlight bulb.
Fit the projection [A] of the bulb in the hollow [B] of the
headlight.
16-56 ELECTRICAL SYSTEM
Lighting System
Fit the dust cover [A] with the arrow mark upward onto the
bulb [B] firmly as shown.
Good [C
]
Bad [D]
Arrow Mark [E]
After i
nstallation, adjust the headlight aim (see this chap-
ter).
Headlight Removal/Installation
Remove:
Fairing (see Frame chapter)
Disconnect the headlight connectors [A].
For the european model disconnect the city light connec-
tor [B].
Remove:
Bolts [A]
Headlight Assy [B]
Headlight installation is revers of removal.
Torque - Headlight Mounting Bolts : 5.9 N·m (0.6 kgf·m, 5.3
in·lb)
City Light Bulb Replacement (European Model)
Remove the fairing (see Frame chapter).
Pull out the socket [A] together with the bulb.
ELECTRICAL SYSTEM 16-57
Lighting System
Pull the bulb [A] out of the socket [B].
CAUTION
Do not turn the bulb. Pull the bulb out to prevent
damage to the bulb. Do not use bulb rated for
greater wattage then the specified valve.
Replace the bulb with a new one.
16-58 ELECTRICAL SYSTEM
Lighting System
Headlight/Tail Light Circuit (US, CA, AS)
Headlight/Tail Light Circuit (Other than US, CA, AS)
US: United States of America
CA: Canada
AS: Australia
1. Ignition Switch
2. M eter Ground
3. A lternator
4. H eadlight Diodes
5. Taillight Fuse 10A
6. H eadlight Fuse 10A
7. Junction Box
8. H igh Beam Indicator
Light (LED)
9. Joint Connector D
10. C ity Light (European
Model)
11. H eadlight (High)
12. H eadlight (Low)
13. Joint Connector A
14. D immer Switch
15. Pussing Button
16. M ain Fuse 30A
17. Battery 12 V 8 Ah
18. Taillight (LED)
19. License Plate Light
20. Joint Connector B
21. R unning Position Light
22. Frame G round
ELECTRICAL SYSTEM 16-59
Lighting System
Turn Signal Light Circuit
US: U.S.A. model
CA: Canada model
MY: Malaysia model
1. Joint Connector D
2. Meter Unit
3. Right Turn S ignal Indicator Light (LED)
4. Left Turn Signal Indicator Light (LED)
5. Front Right Turn Signal Light
6. Front Left Turn Signal Light
7. Joint Connector A
8. Frame Ground
9. Hazard Button
10. Turn Signal Switch
11. Meter G round
12. Turn Signal Relay
13. Junction B ox
14. Turn Signal Fuse 10A
15. Ignition Sw itch
16. Rear Right Turn Signal Light
17. Rear Left Turn Signal Light
18. Joint Connector B
19. Main Fuse 30A
20. Battery 12 V 8 Ah
Turn Signal Light Bulb R eplacement
For the European, Malaysian and Australian M odels:
Unscrew the screw [A ] and remove the lens [B].
16-60 ELECTRICAL SYSTEM
Lighting System
Push and turn the bulb [A] counterclockwise and remove
it.
Insert the new bulb [A] by aligning its upper and lower pins
[B] with the upper and lower grooves [C] in the socket, and
turn the bulb clockwise.
Turn the bulb about 15° degrees.
For the U.S.A. and Canadian Models:
Unscrew the screw [A].
Unscrew the screws [A].
Push and turn the bulb [A] counter clockwise and remove
it.
ELECTRICAL SYSTEM 16-61
Lighting System
Insert the new bulb [A] by aligning its upper and lower pins
[B] with the upper and lower grooves [C] in the socket, and
turn the bulb clockwise.
CAUTIO
N
The front turn signal/running position lights use
a vibration resistant bulb. Replacement of the
front turn signal/running position bulbs with a
non-vibration resistant bulb may result in prema-
ture bulb failure.
Turn Signal Relay Inspection
Remove:
Seats (see Frame chapter)
Upper Seat C over (see Frame chapter)
Turn Signal Relay [A]
Connect one 12 V battery and turn signal lights as indi-
cated in the figure, and count how may times the lights
flash for one minute.
Turn Signal Relay [A]
Turn Signal Lights [B]
12 V Battery [C]
If the lights do not flash as specified, replace the turn sig-
nal relay.
Testing Turn Signal Relay
Load
The Number of Turn
Signal Lights
Wattage (W)
Flashing times
(c/m*)
1** 21 or 23 140 - 250
2 42 or 46 75 95
(*): Cycle(s) per minute
(**): Corrected to “one light burned out”.
Tail/Brake Light (LED) Removal
Remove:
Seats (see Frame chapter)
Upper Seat C over (see Frame chapter)
Disconnect the tail/brake light (LED) connector [A] and
rear turn signal connectors [B].
Open the clamp [C].
16-62 ELECTRICAL SYSTEM
Lighting System
Unscrew the bolts [A].
Loosen the bolts [B].
Unscrew the mounting screws [A].
Remove the tail/brake light (LED) [B].
Pull out the mount portion [C].
Ta il/Brake Light (LED) Installation
Tighten the tail/brake light mounting screws.
Torque - Tail/Brake Light Mounting Screws: 1.2 N·m (0.12
kgf·m, 11 in·lb)
ELECTRICAL SYSTEM 16-63
Radiator Fan System
Fan System Circuit Inspection
Disconnect the lead connector [A] from the radiator fan
switch.
Using an auxiliary wire [A], connect the radiator fan switch
leads.
If the fan rotates, inspect the fan switch.
If the fan does not rotate, inspect the following.
Leads and Connectors
Main Fuse and Fan Fuse
Fan Motor
Fan Motor Inspection
Remove the fuel tank (see Fuel System (DFI) chapter).
Disconnect the 2–pin connector [A] in the fan motor leads.
Pull the lead until come out the connector.
Using two auxiliary wires [A], supply battery [B] power to
the fan motor.
If the fan does not rotate, t he fan motor is defective and
must be replaced.
16-64 ELECTRICAL SYSTEM
Radiator Fan System
Radiator Fan Circuit
1. R adiator Fan
2. R adiator Fan Switch
3. Joint Connector A
4. Joint Connector D
5. M eter Ground
6. Frame G round
7. Joint Connector B
8. Junction Box
9. Fan Fuse 10A
10. M ain Fuse 30A
11. Battery 12 V 8 Ah
ELECTRICAL SYSTEM 16-65
Meter, Gauge, Indic ator Unit
Meter Unit Removal
Remove:
Wind Sealed (see Frame chapter)
Slide the dust cover [A] and remove the wiring connector
[B].
Remove the meter unit by taking off the mounting screws
[C] with the washers.
CAUTION
Place the m eter or gauge so that the face is up. If a
meter or gauge is left upside down or sideways for
any length of time, it will malfunction.
Met
er, Gauge Disassembly
Remove:
Meter Unit (see Meter Unit Removal)
Scr
ews [A]
Lower Meter Cover [B]
Separate the meter assembly [A] and upper meter cover
[B].
16-66 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
Electro nic Combination Meter Unit Inspection
Remove the meter unit [A].
[1] Ignition [10]
Battery (+)
[2]
Fuel Reserve Switch
[11]
Oil Pressure Warning
[3] Unused
Indicator Light (LED)
[4]
Fuel Level Sensor Ground (–)
[5] Neutral Indicator Light [12] Speed Sensor Supply
(LED) Ground (–)
Voltage
[6] FI Indicator Light [13]
Right Turn Signal Light
(LED) Ground (–) (LED) (+)
[7] Tachometer Pulse [14]
Left Turn Signal Indicator
[8] Water Temperature
Lig
ht (LED) (+)
Sensor
[15] High Beam Indicator Light
[9] Ground (–) (LED)
[16]
Speed Sensor Pulse
CAUTION
Do not drop the meter unit. Place the meter unit so
that it faces upward. If the m eter unit is left upside
down or sideways for a long time or dropped, it w ill
malfunction. Do not short each terminals.
Liquid Crystal Display (LCD) Segments Check:
Use t he harness adapter for meter inspection.
Special Tool - Harness Adapter : 57001–1542
Using the auxiliary wires, connect the 12 V battery to the
meter unit connector as follows.
Connect the battery positive terminal to the terminal [10].
Connect the battery negative terminal to the terminal [9].
Connect the terminal [1] to the terminal [10].
The tachometer LCD segments momentarily to it last
readings two times and segment movement is reversal.
When the terminals are connected, all the LCD segments
[A] and LED warning light [B] appear for three seconds.
If the LCD segments and LED warning light will not ap-
pear, r eplace the meter assembly.
Disconnect the terminal [1].
All the LCD segments and LED warning light disappear.
If the segments do not disappear, replace the meter as-
sembly.
ELECTRICAL SYSTEM 16-67
Meter, Gauge, Indic ator Unit
MODE AND RESET BUTTON Operation Check:
Connect the 12 V battery and terminals in the same man-
ner as specified in the "Liquid Crystal Display (LCD) Seg-
ments Check".
Check that the display change to the ODO, TRIP, and
CLOCK displays each tim e the MODE button [A] is
pressed.
If the fuel level gauge flashed, display change to ODO,
TRIP, CLOCK and FUEL.
If the display function does not work, replace the meter
assembly.
Indicate the clock mode.
Check that when the RESET button in CLOCK mode is
pushed for more t han two seconds, the meter display
turns to the clock set mode.
Both the hour and minute display start flashing.
In the HOUR/MINUTE setting mode, press the RESET
button again to effect the HOUR setting mode.
The hour display flashes on the display.
Press the MODE button to s et the hour.
16-68 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
In the HOUR setting mode, press the RESET button to
effect the MINUTE setting mode.
The min
ute display flashes on the display.
Press the MODE button to set the minute.
In the MINUTE setting mode, press the RESET button to
return to the HOUR/MINUTE setting mode.
Press the MODE button to complete the time setting
process.
The clock starts counting the seconds as soon as the
MODE button is pressed.
Indicate the ODO mode.
Check that the display [A] [B] change to the mile and °F,
Mile and °C, km and °F, km and °C display each time by
pushing the R ESET bottom while MODE bottom pushed
in.
NOTE
Mile/Km Display can alternate between English and
metric modes (mile and km) in the digital meter. Make
sure that km or mile according to local regulations is
correctly displayed before riding.
If the display function does not w ork and adjust, replace
the meter assembly.
Speedometer Check:
Connect t he 12 V battery and terminals in the same man-
ner as specified in the "Liquid Crystal Display (LCD) Seg-
ments C heck".
The speed equivalent to the input frequency is indicated in
the oscillator [A], if the square wave (illustrated as shown)
would be input into the terminal [16].
Indicates approximately 60 mph in case the input fre-
quency would be approximately 141 Hz.
Indicates approximately 60 km/h in case the input fre-
quency would be approximately 88 Hz.
ELECTRICAL SYSTEM 16-69
Meter, Gauge, Indic ator Unit
If the oscillator is not available, the speedometer can be
checked as follows.
Install the meter unit.
Raise the rear wheel off the ground, using the jack.
Turn on the ignition switch.
Rotate the rear wheel by hand.
Check that the speedometer shows the speed.
If the speedometer does not work, check the speed sen-
sor electric source voltage and speed sensor.
The electric source voltage and speed sensor are normal,
replace the meter assembly.
Speed Sensor Electric Source Check:
Connect the 12 V battery and terminals in the same man-
ner as specified in the "Liquid Crystal Display (LCD) Seg-
ments Check".
Set the hand tester to the DC25 V range and connect it to
the terminals [12] and [9].
If the voltage is less than 8 V, replace the meter assembly.
Odometer Check:
Check the odometer with the speedometer in the same
way.
If value indicated in the odometer is not added, replace
the meter assembly.
NOTE
The data is maintained even if the battery is discon-
nected.
When the figures come to 999999, they are stopped and
locked.
Trip Meter Check:
Check the trip meter with the speedometer in the same
way.
If value indicated in the trip meter is not added, replace
the meter assembly.
Check that when the RESET button is pushed for more
than tw o seconds, the figure display turns to 0.0.
If the figure display does not indicate 0.0, replace the me-
ter assembly.
16-70 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
Water Temperature Meter Check:
Connect t he 12 V battery and terminals in the same man-
ner as s
pecified in the "Liquid Crystal Display (LCD) Seg-
ments C heck".
Connect the variable rheostat [A] to the terminal [8] as
shown
.
Check that the number of segments matches the resis-
tance value of the variable rheostat.
Resistance Temperature Warning
Value ()
Meter Indicate
[A]
209.8
50°C (122°F)
[B]
69.1 80°C (176°F) [B]
21.2
120°C (248°F) [C] Flash
17 HI [D] Flash
If any display function does not work, replace the meter
unit.
ELECTRICAL SYSTEM 16-71
Meter, Gauge, Indic ator Unit
Fuel Level Gauge Inspection:
Connect the 12 V battery and terminals in the same man-
ner as specified in the “Liquid Crystal Display (LCD) Seg-
ments Check”.
Connect a variable rheostat [A] to terminal [4] and [9] as
shown.
Check that the num ber of segment [B] matches the resis-
tance value of the variable rheostat.
Resistance () Number of Segments
0 16.5 F8
11.5 28.5 7
21.5 40.5 6
31.5 52.5 5
41.5 64.5 4
51.5 76.5 3
61.5 88.5 2
71.5 above E1
If this display function does not work, replace the meter
assembly.
Connect an other variable rheostat [C] to terminal [2] and
[9].
Set the hand tester [D] to the DC 10 V range and connect
it to terminals of the variable rheostat as shown.
When the 1 segment [E] appears, adjust the variable
rheostat [C] so that the terminal voltage is less than 5.7 V.
Then the 1 and FUEL segments should flush.
If this display function does not flush, replace the meter
assembly.
Tachometer C heck:
Connect the 12 V battery and terminals in the same man-
ner as specified in the "Liquid Crystal Display (LCD) Seg-
ments Check".
The revolutions per minute (rpm) equivalent to the input
frequency is indicated in the oscillator [A] if the square
wave (illustrated as shown) would be i nput into the termi-
nal [7].
Indicates approximately 6 000 rpm in case the input fre-
quency would be approximately 200 Hz.
16-72 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
If the oscillator is not available, the tachometer can be
checked as f ollows.
Connec
t t he 12 V battery and terminals in the same man-
ner as specified in the "Liquid Crystal Display (LCD) Seg-
ments C heck".
Using
an auxiliary wire, quick open and connect the ter-
minal [1] to the terminal [7] repeatedly.
Then the tachometer segment [A] should flick [B].
If th
e segment does not flick, replace the meter assembly.
LED Lights Inspection:
Connect t he 12 V battery and terminals in the same man-
ner as specified in the “Liquid Crystal Display (LCD) Seg-
ments check.
Neutral Indicator Light (LED) [A]
FI Indicator Light (LED) [B]
Oil Pressure Warning Indicator Light (LED) [C]
Right Turn Signal Indicator Light (LED) [D]
Left Turn Signal Indicator Light (LED) [E]
High Beam Indicator Light (LED) [F]
U
sing the auxiliary leads, connect a 12 V battery to the
meter unit connector as follows.
Neutral Indicator Light (LED):
B
attery Negative (–) Terminal To Terminal [5]
FI Indicator Light (LED):
Battery Negative (–) Terminal To Terminal [6]
Oil Pressure Warning Indicator Light (LED):
Battery Negative (–) Terminal To Terminal [11]
ELECTRICAL SYSTEM 16-73
Meter, Gauge, Indic ator Unit
Right and Left Turn Signal Indicator Light (LED):
For Right Turn Signal Indicator Light (LED)
Battery Positive (+) Terminal to Terminal [13]
For Left Turn Signal Indicator Light (LED)
Battery Positive (+) Terminal to Terminal [14]
High Beam Indicator Light:
Battery Positive (+) Terminal to Terminal [15]
If each LED lights does not go on, replace the meter as-
sembly.
16-74 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
Meter Circuit
1. R ight Turn Signal Indicator Light (LED)
2. H igh Beam Indicator Light (LED)
3. N eutral Indicator Light (LED)
4. O il Pressure Warning Indicator Light (LED)
5. F I Indicator Light (LED)
6. O dometer/Trip Meter/Clock/Fuel Indicator
7. Water Temperature Gauge
8. Fuel Level G auge
9. Tachom eter
10. S peedometer
11. M eter Light (LED)
12. Left Turn Signal Indicator Light (LED)
13. M eter Unit
14. Joint Connector D
15. Frame G round
16. M eter Ground
17. Speed Sensor
18. Fuel Reserve Switch
19. Fuel Level Sensor
20. Water Temperature Sensor
21. Oil Pressure Switch
22. Neutral Switch
23. Joint Connector A
24. Ignition Switch
25. Junction Box
26. ACC Fuse 10A
27. Ignition Fuse 10A
28. M ain Fuse 30A
29. Battery 12 V 8 Ah
30. E.C.U.
31. Joint Connector B
ELECTRICAL SYSTEM 16-75
Switches and Sensors
Brake Light Timing Inspection
Refer to the Brakes in the Periodic Maintenance chapter.
Brake Light Timing Adjustment
Refer to the Brakes in the Periodic Maintenance chapter.
Switch Inspection
Using a hand tester, check to see that only the con-
nections shown in the table have continuity (about zero
ohms).
For the handlebar switches and the ignition switch, refer
to the tables in the Wiring Diagram.
If the switch has an open or short, repair it or replace it
with a new one.
Special Tool - Hand Tester: 57001–1394
Rear Brake Light Switch Connections
Side Stand Switch Connections
Neutral Switch Connections
Oil Pressure S witch Connections*
*: Engine lubrication system is in good condition
Radiator Fan Switch Inspection
Unscrew the radiator cover screws [A] and remove the left
radiator cover [B]
16-76 ELECTRICAL SYSTEM
Switches and Sensors
Disconnect the connector [A].
Remove the fan switch [B].
Suspend the switch [A] in a container of coolant so that
the t emperature–sensing projection and threaded portion
are submerged.
Suspend an accurate thermometer [B] in the coolant so
that the sensitive portions are located in almost the sam e
depth.
NOTE
The switch and thermometer must not touch the con-
tainer sides or bottom.
Place the container over a source of heat and gradu-
ally raise the temperature of the coolant while stirring the
c
oolant gently.
Using the hand tester, measure the internal resistance
of the switch across the terminals at the temperatures
shown in the table.
Special Tool - Hand Tester: 57001–1394
If the hand tester does not show the specified values, re-
place the switch.
Fan S witch Resistance
Rising temperature:
From OFF to ON a t 93 103°C (199 217°F)
Falling temperature:
Fan stops with the temperature 3 C(38 46 °F)
lower than the operation temperature range.
ON: Less than 0.5
OFF: More than 10 M
Water Temperature Sensor Inspection
Remove the fuel tank (see Fuel System (DFI) chapter).
Disconnect the water temperature sensor connector [A].
Remove the water temperature sensor [B] (see Fuel Sys-
tem (DFI) chapter).
ELECTRICAL SYSTEM 16-77
Switches and Sensors
Suspend the sensor [A] in a container of coolant so that
the temperature-sensing projection [E] and threaded por-
tion [E] are submerged.
Suspend an accurate thermometer [B] in the coolant.
NOTE
The sensor and thermometer must not touch the con-
taine
r side or bottom.
Place the container over a source of heat and gradu-
ally raise the temperature of the coolant while stirring the
coolant gently.
Using the hand tester, measure the internal resistance of
the sensor.
The s ensor sends electric signals to the E CU (Electronic
Control U nit) and coolant temperature gauge in the meter
unit.
Measure the resistance across the terminals and the body
(for the gauge) at the temperatures shown in the table.
If the hand tester does not show the specified values, re-
place the sensor.
Water Temperature Sensor
Res
istance for ECU [C]
Resistance (k)
Temperature
(T
erminal [1] - [3])
+0.155
20°C (68°F) 2.46
–0.143
80°C (176°F) 0.32 ± 0.011
110°C (230°F) 0.1426 ± 0.0041
Resistance for Water Temperature Gauge [D]
Resistance ()
Temperature
(Terminal [2] - Body)
50°C (122°F)
210 ± 40
120°C (248°F) 21.2 ± 1.5
Speed Sensor Inspection
Disconnect:
Speed Sensor Connector [A]
Remove:
Engine Sprocket Cover [B] (see Final Drive chapter)
16-78 ELECTRICAL SYSTEM
Switches and Sensors
Remove:
Bolts [A]
Speed S
ensor Cover
Remove:
Bolt [A]
Take out the speed sensor [B].
Connect the speed sensor connector [A] with the battery
[B], 10 k resistor [C] and hand tester [D] as shown.
Set the tester to the DC 25 V range.
Special Tool - Hand Tester: 57001–1394
Trace [A] each side of the speed sensor surface with the
screw driver.
Then the tester indicator should flick [B].
If the tester indicator does not flick, replace the speed
sensor.
Apply a non-permanent locking agent to the sensor bolt
and sensor cover bolts.
Torque - Speed Sensor Bolt : 6.9 N·m (0.7 kgf·m, 62 in·lb)
Speed Sensor Cover Bolts : 6.9 N·m (0.7 kgf·m, 62
in·lb)
ELECTRICAL SYSTEM 16-79
Switches and Sensors
Fuel Level Sensor Inspection
Remove:
Fuel Tank (see Fuel System (DFI) chapter)
Open the clamps [A].
Remove:
Bolts [ B]
Fuel Level Sensor [C]
Check that the float moves up and down smoothly without
binding. It should go down under its own weight.
If the float does not move smoothly, replace the sensor.
Float in Full Position [A]
Float in Empty Position [B]
Float Arm Stoppers [C]
105.2 112.2 mm (4.142 4.417 in.) from the Sensor
Base Line [D]
33.6 40.6 mm (1.32 1.60 in.) from the Sensor Base
Line [E]
Sensor Base Line [F]
Using the hand tester [A], measure the resistance across
the terminals in the fuel level sensor lead connector [B].
Black/Yellow [C]
White/Yellow [D]
Special Tool - Hand Tester: 57001-1394
If the tester readings are not as specified, or do not
change smoothly according as the float moves up and
down, replace the sensor.
Fuel Level Sensor Resistance
Standard: Full position: 4 10
Empty position [E]: 90 100
Apply a non-permanent locking agent to the threads of
the l evel sensor m ounting bolts and tighten it.
Torque - Fuel Level Sensor Bolts: 6.9 N·m (0.7 kgf·m, 61
in·lb)
Fuel Reserve Switch Inspection
Fill the fuel tank with fuel.
Close the fuel tank cap surely.
Remove:
Frame Cover (see Frame chapter)
Disconnect the fuel level sensor connector [A].
16-80 ELECTRICAL SYSTEM
Switches and Sensors
Connect the test light [A] (12 V 3.4 W bulb a socket with
leads) and the 12 V battery [B] to the fuel level s ensor
connec
tor [C].
Connections:
Battery (+) 12 V 3.4 W Bulb (one side)
12 V 3.4 W Bulb (other side) Blue Lead Terminal
Battery (–) BK/Y Lead Terminal
If the test light turn on, the reverse switch is defective.
Replace the fuel level sensor.
Remove:
Fuel Level Sensor (see Fuel Level Sensor Inspection)
Connect the test light (12 V 3.4 W bulb in a socket with
leads) and the 12 V battery to the fuel pump connector as
shown.
12 V Battery [A]
Test Light [B]
Fuel Pump Connector [C]
FuelReserveSwitch[D]
If the test light doesn’t light, replace the fuel level sensor.
NOTE
It may take a long time to turn on the t est light in case
that the fuel reserve switch is inspected just after the
fuel level sensor is removed. Leave the fuel reserve
switch with leads for inspection connected for ten (10)
minute.
Diode (Rectifier) Inspection
Remove the fairing (see Frame chapter)
Cut the vinyl tape.
Disconnect the diode [A].
Set the hand tester to the × 100 range.
Special Tool - Hand Tester: 57001–1394
Check the continuity between the diode terminals in both
directions.
If there is continuity in one direction (forward direction) but
no continuity (infinity) in the reverse direction, the diode
is normal.
The diode is defective if there is continuity after changing
the direction, or it if remains with no continuity.
NOTE
The actual resistance measurement in the forward
direction varies with the tester used and the individual
diodes. Generally speaking, it is acceptable if the
tester ’s indicator swings approximately halfway.
ELECTRICAL SYSTEM 16-81
Junction Box
The junction box [A] has fuses [B], relays, and diodes.
The relays and diodes can not be removed.
Junction Box Fuse Circuit Inspection
Remove the seats (see Frame chapter).
Remove the junction box [A].
Pull off the connectors [A] from the junction box [B].
Make sure all connector terminals are clean and tight, and
none of them have been bent.
Clean the dirty terminals, and straighten slightly–bent ter-
minals.
Check conductivity of the numbered terminals with the
hand tester.
Refer to the Junction Box Internal Circuit.
If the tester does not read as specified, replace the junc-
tion box.
Special Tool - Hand Tester: 57001–1394
Fuse Circuit Inspection
Tes t er Te s t e r Tes t e r Test er
Connection Reading () Connection Reading ()
1-1A 0 1A - 8
1-2 0 2-8
3A - 4 0 3A - 8
6-5 0 6-2
6-10 0 6-3A
6-7 0 17 - 3A
6-17 0
16-82 ELECTRICAL SYSTEM
Junction Box
Starter Circuit/Headlight Relay Inspection
Remove the j unction box (see Junction Box Fuse Circuit
Inspec
tion).
Check conductivity of the following numbered terminals
by connecting the hand tester and one 12 V battery to the
junct
ion box as shown.
Refer to the Junction Box Internal Circuit.
If the tester does not read as specified, replace the junc-
tion
box.
Special Tool - Hand Tester: 57001–1394
Relay Circuit Inspection (with the battery disconnected)
Tes t er Tes t er
Connection Reading ()
7-8
7-13
(+) (–)
Headlight
Relay
13 - 9
Not *
9-11
12 -13
(+) (–)
13 - 11
(+) (–)
Starter
Circuit
Relay
12 - 11
Not *
(*): The actual reading varies with the hand tester used.
(+): Apply tester positive lead.
(–): Apply tester negative lead.
Relay Circuit Inspection (with the battery connected)
Battery Teste r Tes t e r
Connection (+) (–) Connection Reading ()
Headlight
Relay
9–13 7–8 0
Starter
Circuit
Relay
11–12
(+) (–)
13 11
Not *
(*): The actual reading varies with the hand tester used.
(+): Apply tester positive lead.
(–): Apply tester negative lead.
ELECTRICAL SYSTEM 16-83
Junction Box
Diode Circuit Inspection
Remove the junction box.
Check conductivity of the following pairs of terminals.
Diode C
ircuit Inspection
Te s t e r
Conne
ction
13–8, 13–9, 12–11, 12–14, 15–14, 16–14
The resistance should be low in one direction and more
than ten times as much in the other direction. If any diode
shows low or high in both directions, the diode is defective
and the junction box must be replaced.
NOTE
The actual meter r eading varies with the meter used
and the individual diodes, but, generally speaking, the
lower reading should be from zero to one half the scale.
Junction Box Int ernal Circuit
A. Accessory Fuse 10A
B. Fan Fuse 10A
C. Turn Signal Relay Fuse
10A
D. Horn Fuse 10A
E. Ignition Fuse 10A
F. Headlight Fuse 10A
G. Headlight Relay
H. Headlight Diodes
I. Starter Diode
J. Starter Circuit Relay
K. Interlock Diodes
L. Taillight Fuse 10A
16-84 ELECTRICAL SYSTEM
Fuse
30A Main Fuse Removal
Remove:
Right S
ide Cover (see Frame chapter)
30A Main Fuse Connector [A]
Pull out the main fuse [B] from the starter relay with needle
nose pl
iers.
Junction Box Fuse Removal
Remove the seats (see Frame chapter).
Unlock the hook to lift up the lid [A].
Pull the fuses [B] straight out of the junction box with nee-
dle nose pliers.
Fuse Installation
If a fuse fails during operation, inspect the electrical sys-
tem to determine the cause, and then replace it with a
new fuse of proper amperage.
Install the junction box fuses on the original position as
specified on the lid.
15A ECU Fuse Removal
Remove:
Seats (see Frame chapter)
Unlock the hook [A] to pull the lid [B].
Pull out the ECU Fuse from the fuse box.
Fuse Inspection
Remove the f use (see Fuse Removal).
Inspect the fuse element.
If it is blown out, replace the fuse. Before replacing a
blown fuse, always check the amperage in the affected
circuit. If the amperage is equal to or greater than the
fuse rating, check the wiring and related components for
a short circuit.
Housing [A]
Fuse Elem ent [B]
Terminals [C]
Blown Element [D]
CAUTION
When replacing a fuse, be sure the new fuse
matches the specified fuse rating for that circuit.
Installation of a fuse with a higher rating may cause
damage to wiring and com ponents.
APPENDIX 17-1
17
Appendix
Table of C ontents
Cable, Wire, and Hose Routing . ............................................................................................. 17-2
Troubleshooting Guide ........................................................................................................... 17-20
17-2 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-3
Cable, Wire, and Hose Routing
1. Fixes by the left side clamp of the tank.
2. Tank drain hose passes the side cover installation under the bracket.
3. Air cle
aner drain hose
4. Fuel tank drain hose
5. Cooling reserve tank hose
6. Fixes
by the swingarm clamp
7. Fuel level sensor
8. Fixes by the right side clamps two places of the tank.
9. The o
utside of the frame passed
10. Fuel level sensor lead
17-4 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-5
Cable, Wire, and Hose Routing
1. Clutch cable
2. Meter ground
3. Clamp (
Ignition switch connector)
4. Ignition switch connector
5. Inlet air pressure sensor
6. To ign
ition coil
7. Fan motor connector (Connect the con-
nector on the inlet air pressure sensor.)
8. Clam
p
9. To fuel pump
10. To fuel level gauge and fuel reserve
swit
ch
11. To pickup coil and oil pressure switch
12. Insert the clamp of mainharness into the
fla
me hole.
13. Mainharness
14. Starter relay
15. To r
ear brake switch
16. Connect the battery negative cable and
battery.
17
.
Ba
ttery negative cable
18. Self-diagnosis indicator terminal
19. Turn signal relay
20
.
Fu
el pump relay
21. ECU main relay
22. License light connector
2
3.
T
ail light connector
24. Rear right turn signal light connector
25. Rear left turn signal light connector
2
6.
A
tmospheric pressure sensor
27. Bracket
28. ECU fuse
29. Junction Box
30. ECU
31. Run the lead of ECU under the end sur-
face of battery case.
32. Battery Positive Cable (to starter r elay)
33. Regulator/rectifier
34. Vehicle-down sensor
35. Inlet air temperature sensor
36. Side stand switch
37. Neutral Switch
38. Speed sensor
39. Altern
ator
40. Engine harness
41. Water temperature sensor
42. Run th
e lead of ignition switch above the
hose connected with the thermostat body,
and the front of inlet air pressure sensor
as we
ll.
43. Frame ground (with thermostat)
44. To cam sensor, fan switch, horn
45. The h
arness passes on the clutch cable.
46. Battery case
47. Damper
48. Fro
nt
49. Run the brake hose between upper
bracket and clamp of bracket.
50. Run
the Throttle Cable together with the
Right Grip Switch wire through the of
Cowl Bracket clamp.
Ru
n the wire thought the center of the
frame, which has to be located nearer to
the center than the cable.
51
.
Ri
ght switch housing lead
52. Run the Clutch Cable, the Starter Cable
and the Left Grip Switch wire through the
s
pace made between the Cowl Bracket
clamp and the Upper Bracket.
Run the Main Harness under the right
s
ide of the thermostat body.
53. Left switch housing lead
54. Starter cable
5
5.
R
un the s tarter cable through under the
throttle cable.
56. Run the clutch cable between the water
hose and the mainharness.
57. Throttle cable (decelerator)
58. Throttle cable (accelerator)
59. No slip of cable
60. Band (near of the air cleaner duct holder
screw)
17-6 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-7
Cable, Wire, and Hose Routing
1. Run the main harness through lower and right side of the thermostat.
2. Frame ground (with thermostat bracket)
3. Igniti
on switch connector
4. Meter ground (with thermostat)
5. Engine harness (Connect the harness on the cross pipe.)
6. Water
temperature sensor
7. Inlet air pressure sensor
8. Clamp
9. To pi
ckup coil and oil pressure switch
10. To fuel level gauge and fuel reserve switch
11. To fuel pump
12. Brac
ket
13. Insert the fuse holder under the left side bolt that connects the battery case with tool case to
tighten temporarily.
14. Sto
rage compartment
15. Battery case
16. ECU fuse
17. Reg
ulator/rectifier
18. Run the lead through the inside of the pipe.
19. Speed sensor
20
.
Si
de stand switch
21. Neutral switch
22. To alternator
23
.
To
ignition coil
24. Horn
25. Horn lead
2
6.
C
am sensor
27. Fan switch
28. Run the harness between the engine bracket and the left side space of the baffle plate.
2
9.
S
tarter cable
17-8 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-9
Cable, Wire, and Hose Routing
1. Tail light
2. Clamp
3. Atmosp
heric pressure sensor
4. To ECU fuse
5. Junction Box
6. To sel
f-diagnosis indicator terminal
7. Pickup coil and oil pressure switch
8. Fuel pump
9. Fuel
level gauge and fuel reserve switch
10. To inlet air temperature sensor
11. Fan motor connector
12. Inle
t air pressure sensor
13. Water temperature sensor
14. Engine harness
15. Met
er ground
16. Ignition switch
17. Frame ground (with thermostat)
18. Rig
ht switch housing lead
19. Left switch housing lead
20. Running position lights
21
.
He
adlight
22. Turn signal lights
23. Fun motor
24
.
Ig
nition coil
25. Vehicle-dwon sensor
26. To rear brake switch
2
7.
S
tarter relay
28. Regulator/rectifier
29. Battery positive cable
3
0.
C
onnect the battery negative cable and battery.
31. Battery
32. ECU
33. Turn signal light relay
34. Fuel pump relay
35. ECU main relay
36. License light
37. Rear right turn signal light
38. Rear left turn signal light
39. Throttle cable (accelerator)
40. Throttle cable (decelerator)
41. Clutch cable
42. Run the clutch cable inside the chain tensioner.
43. Band (ZR1000–A2 )
17-10 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-11
Cable, Wire, and Hose Routing
1. Clamp all the wires as shown in the encircled area.
2. Meter
3. Take ou
t the lead of the meter from the right side of the tie lap to connect with the meter.
4. Clutch cable
5. Starter cable
6. To fro
nt left turn signal light (Run the harness above the bolt for fairing installation.)
7. Run the ignition switch lead front the clutch cable and starter cable.
8. To left switch housing
9. Run t
he leads for the clutch starter and the ignition switch in order from the head pipe then run
the cables with their acceleration side facing outward.
10. Headlight high and low
11. Inst
all the lead with its inner side facing inward.
12. Running position light
13. To right switch housing
14. Thr
ottle cable (Run the cable through the front of main harness.)
15. Brake hose (to caliper right side)
16. To front right turn signal light (Run the harness above the bolt for fairing installation.)
17. Sea
tlock
18. Seat lock cable
17-12 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-13
Cable, Wire, and Hose Routing
1. Clamp
2. Brake hose
3. Punch m
ark
4. Run the brake hose through the inside of the frame.
5. Tight the bolt to the specified torque with the stopper (for turning prevention) applied.
17-14 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-15
Cable, Wire, and Hose Routing
1. Cam sensor lead (Run the lead between the convex area of cap center and bolt head to secure
the coupler.)
2. Radiat
or fan switch lead (Run the lead through into the water hose.)
3. Cap
4. Catch cable (Run the cable through forward the water hose.)
5. Air su
ction valve
6. Water hose (Thermostat Radiator)
7. Water hose (Head Thermostat)
8. Inle
t air pressure sensor
9. Vacuum hose (Run the vacuum hose under the throttle cable to connect with the inlet air pres-
sure sensor.)
10. Thro
ttle cables (accelerator)
11. Throttle cables (decelerator)
12. Vacuum balance tube
13. Cho
ke Cable
14. Hose (air suction valve air cleaner)
15. Stick coil
16. Fue
l pump
17. Fuel hose
18. To inlet air pressure sensor
19
.
To
air suction valve
20. To prevent the throttle cable from unexpected coming down.
21. Cover
22
.
Th
rottle body
17-16 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-17
Cable, Wire, and Hose Routing
1. Bend the bracket as shown to secure the lead.
2. Bend the bracket.
3. Run the
lead end till it touches the boss of the crankcase.
4. Install the exterior of the lead with staking area facing downward.
17-18 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-19
Cable, Wire, and Hose Routing
1. Run the hose (cap reserve) through upside of the throttle cable.
2. Run the hose (white) through into the throttle cables.
3. Run the
throttle body harness throttle upside of the hose (white) and hose (throttle fitting).
4. Run the harness through upside of the hose.
5. Throttle cables
6. Hose (
fitting throttle body #2 right)
7. Hose (canister fitting) (green)
8. Hose (throttle body #3 right under the separator) (white)
9. Hose
(canister upside the separator) (blue)
10. Hose (tank (blue) upside the separator) (blue)
11. Hose (tank (red) side the separator) (red)
12. A top
view (separator)
13. Harness
14. Hose (cap reserve)
15. Run
the hose (red) through inside the frame.
16. Connector
17. Run the hose (white) through inside the bracket.
18. Cho
ke cable
19. Run the hose (green) through inside the rib.
20. Clamp the hose
21
.
Ru
n the hose (blue) through outside the flame.
22. Run the hose (cap reserve) through upside the cross pipe.
23. Run the hose (reserve tank drain hose) through backside the cross pipe.
24
.
Ru
n the air cleaner drain hose through backside the cross pipe.
25. Cross pipe
26. Separator
2
7.
B
and
28. Cramp
29. Vacuum hose
3
0.
C
anister
31. To separator
32. To fitting
17-20 APPENDIX
Troubleshooting Guide
NOTE
Refer to the Fuel System chapter for most
of DFI t
rouble shooting guide.
This is not an exhaustive list, giving every
possible cause for each problem listed. It
is mea
nt simply as a rough guide to assist
the troubleshooting for some of the more
common difficulties.
Engine Doesn’t Start, Starting
Difficulty:
Starter motor not rotating:
Starter lockout switch or neutral switch trou-
ble
Starter motor trouble
Battery voltage low
Starter relay not contacting or operating
Starter button not contacting
Wiring open or shorted
Ignition switch trouble
Engine stop switch trouble
Fuse blown
Starter motor rotating but engine doesn’t
turn over:
Starter clutch trouble
Vehicle-down sensor (DFI) coming off
Engine won’t turn over:
Valve seizure
Valve lifter seizure
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end seizure
Connecting rod big end seizure
Transmission gear or bearing seizure
Camshaft seizure
Starter idle gear seizure
No fuel flow:
No fuel in tank
Fuel pump trouble
Fuel tank air vent obstructed
Fuel filter clogged
Fuel line c logged
Engine flooded:
Clean spark plug and adjust plug gap
Starting technique faulty
(When flooded, do not crank the engine with
the throttle fully opened. This promotes
engine flood because more fuel is supplied
automatically by DFI.)
No spark; spark weak:
Vehicle-down sensor (DFI) coming off
Ignition switch not ON
Engine stop switch turned OFF
Clutch lever not pulled in or gear not in neu-
tral
Battery voltage low
Spark plug dirty, broken, or gap malad-
justed
Stick c
oil shorted or not in good contact
Stick coil trouble
Spark plug incorrect
IC igni
ter in ECU trouble
Camshaft position sensor trouble
Neutral, starter l ockout, or side stand switch
troubl
e
Crankshaft sensor trouble
Ignition switch or engine stop switch
shorted
Wiring shorted or open
Fuse blown
Fuel/ai
r mixture incorrect:
Bypass screw and/or idle adjusting screw
maladjusted
Air pass
age clogged
Air cleaner clogged, poorly sealed, or miss-
ing
Compres
sion Low:
Spark plug loose
Cylinder head not sufficiently tightened
down
No valve clearance
Cylinder, piston worn
Piston ri
ng bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinde
r head gasket damaged
Cylinder head warped
Valvespringbrokenorweak
Valve not
seating properly (valve bent,
worn, or carbon accumulation on the
seating surface)
Poor Running at Low Speed:
Spark weak:
Battery voltage low
Spark plug dirty, broken, or maladjusted
Stick coil wiring trouble
Stick coil not in good contact
Spark plug incorrect
IC igniter in ECU trouble
Camshaft position sensor trouble
Crankshaft sensor trouble
Stick coil trouble
Fuel/air mixture incorrect:
Bypass screw maladjusted
Air passage clogged
Air bleed pipe bleed holes clogged
Pilot passage clogged
Air cleaner clogged, poorly sealed, or miss-
ing
Fuel tank air vent obstracted
Fuel pump trouble
Throttle body assy holder loose
APPENDIX 17-21
Troubleshooting Guide
Air cleaner duct loose
Compression low:
Spark p
lug loose
Cylinder head not sufficiently tightened
down
No valv
e clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticki
ng)
Piston ring/groove clearance excessive
Cylinder head warped
Cylinde
r head gasket damaged
Valvespringbrokenorweak
Valve not seating properly (valve bent,
worn, or
carbon accumulation on the
seating surface)
Other:
IC ignit
er in ECU trouble
Throttle body assy not synchronizing
Engine oil viscosity too high
Drive tr
ain trouble
Brake dragging
Air suction valve trouble
Vacuum sw
itch valve trouble
Engine overheating
Clutch slipping
Poor Running or No Power at High
Speed:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Stick coil wiring trouble
Stick coil not in good contact
Spark plug incorrect
Camshaft postion trouble
IC igniter in ECU trouble
Crankshaft sensor trouble
Stick coil trouble
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or miss-
ing
Air cleaner O-ring damaged
Air cleaner duct loose
Water or foreign matter in fuel
Throttle body assy holder loose
Fuel to injector insufficient (DFI)
Fuel tank air vent obstructed
Fuel line clogged
Fuel pump trouble (DFI)
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened
down
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticki
ng)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylind
er head warped
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, o
r carbon accumulation on the
seating surface.)
Knocking:
Carbon b
uilt up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
IC ignit
er in ECU trouble
Camshaft position sensor trouble
Crankshaft sensor trouble
Miscell
aneous:
Throttle valve won’t fully open
Brake dragging
Clutch sl
ipping
Engine overheating
Engine oil level too high
Engine oi
l viscosity too high
Drive train trouble
Air suction valve trouble
Vacuum sw
itch valve trouble
Catalytic converter melt down due to muffler
overheating (KLEEN)
Overh eating:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug incorrect
IC igniter in ECU trouble
17-22 APPENDIX
Troubleshooting Guide
Muffler overheating:
For KLEEN, do not run the engine even if
with on
ly one cylinder misfiring or poor
running (Request the nearest service fa-
cility to correct it)
For KLE
EN, do not push-start with a dead
battery (Connect another full-charged
battery with jumper cables, and start the
engin
e using the electric starter)
For KLEEN, do not start the engine under
misfire due to spark plug fouling or poor
conne
ction of the stick coil
For KLEEN, do not coast the motorcycle
with the ignition switch off (Turn the igni-
tion s
witch O N and run the engine)
IC igniter in ECU trouble
Fuel/air mixture incorrect:
Throt
tle body assy holder loose
Air cleaner duct loose
Air cleaner poorly sealed, or missing
Air cl
eaner O-ring damaged
Air cleaner clogged
Compression high:
Carbon
built up in combustion chamber
Engine load faulty:
Clutch slipping
Engine
oil level too high
Engine oil viscosity too high
Drive train trouble
Brake d
ragging
Lubrication inadequate:
Engine oil level too low
Engine o
il poor quality or incorrect
Oil cooler incorrect:
Oil cooler clogged
Gauge in
correct:
Water temperature gauge broken
Water temperature sensor broken
Coolant i
ncorrect:
Coolant level too low
Coolant deteriorated
Wrong coo
lant mixed ratio
Cooling system component incorrect:
Radiator fin damaged
Radiator
clogged
Thermostat trouble
Radiator cap trouble
Radiator f
an switch trouble
Radiator fan relay trouble
Fan motor broken
Fan blade d
amaged
Water pump not turning
Water pum p impeller damaged
Over Cooling:
Gauge incorrect:
Water t
emperature gauge broken
Water temperature sensor broken
Cooling system component incorrect:
Radiato
r fan switch trouble
Thermostat trouble
Clutch Operation Faulty:
Clutch slipping:
Friction plate worn or warped
Steel plate worn or warped
Clutch spring broken or weak
Clutch hub or housing unevenly worn
No clutch lever play
Clutch inner cable trouble
Clutch release mechanism trouble
Clutch not disengaging properly:
Clutch plate warped or too rough
Clutch spring compression uneven
Engine oil deteriorated
Engine oil viscosity too high
Engine oil level too high
Clutch housing frozen on drive shaft
Clutch hub nut loose
Clutch hub spline damaged
Clutch friction plate installed wrong
Clutch lever play excessive
Clutch release mechanism trouble
Gear Shifting Faulty:
Doesn’t go into gear; shift pedal doesn’t
return:
Clutch not disengaging
Shift fork bent or seized
Gear stuck on the shaft
Gear positioning lever binding
Shift return spring weak or broken
Shift return spring pin loose
Shift mechanism arm spring broken
Shift mechanism arm broken
Shift pawl broken
Jumps out of gear:
Shift fork ear worn, bent
Gear groove worn
Gear dogs and/or dog holes worn
Shift drum groove worn
Gear positioning lever spring weak or bro-
ken
Shift fork guide pin worn
Drive shaft, output shaft, and/or gear
splines worn
Overshifts:
Gear positioning lever spring weak or bro-
ken
Shift mechanism arm spring broken
APPENDIX 17-23
Troubleshooting Guide
Abnormal Engine Noise:
Knocking:
IC igni
ter in ECU trouble
Carbon built up in com bustion chamber
Fuel poor quality or incorrect
Spark pl
ug incorrect
Overheating
Piston slap:
Cylinde
r/piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pi
n, piston pin hole worn
Valve noise:
Valve clearance incorrect
Valve spr
ingbrokenorweak
Camshaft bearing worn
Valve lifter worn
Other noi
se:
Connecting rod small end clearance exces-
sive
Connecti
ng rod big end clearance exces-
sive
Piston ring/groove clearance excessive
Piston ri
ng worn, broken, or stuck
Piston ring groove worn
Piston seizure, damage
Cylinder h
ead gasket leaking
Exhaust pipe leaking at cylinder head con-
nection
Crankshaf
t runout excessive
Engine mount loose
Crankshaft bearing worn
Primary ge
ar worn or chipped
Camshaft chain tensioner trouble
Camshaft chain, sprocket, guide worn
Air suctio
n valve damaged
Vacuum switch valve damaged
Alternator rotor loose
Catalytic c
onverter melt down due to muffler
overheating (KLEEN)
Abnormal Drive Train Noise:
Clutch noise:
Clutch damper weak or damaged
Clutch housing/friction plate clearance ex-
cessive
Clutch housing gear worn
Wrong installation of outside friction plate
Transmission noise:
Bearings worn
Transmission gear worn or chipped
Metal chips jammed in gear teeth
Engine oil insufficient
Drive line n oise:
Drive c
hain adjusted improperly
Drive chain worn
Rear and/or engine sprocket worn
Chain lu
brication insufficient
Rear wheel misaligned
Abnormal Frame Noise:
Front fork noise:
Oil insufficient or too thin
Spring weak or broken
Rear shock absorber noise:
Shock absorber damaged
Disc brake noise:
Pad installed incorrectly
Pad surface glazed
Disc warped
Caliper trouble
Other noise:
Bracket, nut, bolt, etc. not properly
mounted or tightened
Oil Pressure Warning Light Goes On:
Engine oil pump damaged
Engine oil screen clogged
Engine oil filter clogged
Engine oil level too low
Engine oil viscosity too low
Camshaft bearing worn
Crankshaft bearing worn
Oil pressure switch damaged
Wiring faulty
Relief valve stuck open
O-ring at the oil passage in the crankcase
damaged
Exhaust Smokes Excessively:
White smoke:
Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Engine oil level too high
Black smoke:
Air cleaner clogged
Brown smoke:
Air cleaner duct loose
Air cleaner O-ring damaged
Air cleaner poorly sealed or missing
17-24 APPENDIX
Troubleshooting Guide
Handling and/or Stability
Unsatisfactory:
Handle
bar hard to turn:
Cable routing incorrect
Hose routing incorrect
Wiring
routing incorrect
Steering stem nut too tight
Steering stem bearing damaged
Steerin
g stem bearing lubrication inade-
quate
Steering stem bent
Tire air
pressure too low
Handlebar shakes or excessively vibrates:
Tire worn
Swingar
m pivot bearing worn
Rim warped, or not balanced
Wheel bearing worn
Handleb
ar clamp bolt loose
Steering stem nut loose
Front, rear axle runout excessive
Engine mo
unting bolt loose
Handlebar pulls to one side:
Frame bent
Wheel mis
alignment
Swingarm bent or twisted
Swingarm pivot shaft runout excessive
Steering m
aladjusted
Front fork bent
Right and left front fork oil l evel uneven
Shock abso
rption unsatisfactory:
(Too hard)
Front fork oil excessive
Front fork
oil viscosity too high
Rear shock absorber adjustment too hard
Tire air pressure too high
Front fork b
ent
(Too soft)
Tire air pressure too low
Front fork o
il insufficient and/or leaking
Front fork oil viscosity too low
Rear shock adjustment too soft
Front fork,
rear shock absorber spring weak
Rear shock absorber oil l eaking
Brake Doesn’t Hold:
Air in the brake line
Pad or d
isc worn
Brake fluid leakage
Disc warped
Contami
nated pad
Brake fluid deteriorated
Primary or secondary cup damaged in master
cylinde
r
Master cylinder scratched inside
Battery Trouble:
Battery discharged:
Charge insufficient
Battery faulty (too low terminal voltage)
Battery lead making poor contact
Load excessive (e.g., bulb of excessive
wattage)
Ignition switch trouble
Alternator trouble
Wiring faulty
Regulator/rectifier trouble
Battery overcharged:
Alternator trouble
Regulator/rectifier trouble
Battery faulty
MODEL APPLICATION
Year Model Beginning Frame No.
2003 ZR1000–A1
JKAZRCA13A000001
ZRT00A–000001
JK
AZRT00AAA000001
2004 ZR1000–A2
JKAZRCA1 4A 015001
JKAZRT00AAA015001
ZRT00A–015001
:This digit in the f rame number changes from one machine to another.
Part No.99924-1310-03
Printed in Japan
514

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