BRUTE FORCE 750 4×4i KVF750 4×4 All Terrain Vehicle Service Manual
Quick Reference Guide This quick reference guide will assist you in locating a desired topic or procedure. •Bend the pages back to match the black tab of the desired chapter number 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 specific topic required.
BRUTE FORCE 750 4×4i KVF750 4×4 All Terrain Vehicle 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 Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
LIST OF ABBREVIATIONS A ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft g h L ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celcius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) hour(s) liter(s) lb m min N Pa PS psi r rpm TDC TIR V W Ω pounds(s) meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) per minute top dead center total indicator
EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the United States Environmental Protection Agency. 1.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.
PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (US MODEL only) TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED: Federal regulations and California State law prohibit 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 purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in us
Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.
GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ..................................................................................................................... Model Identification................................................................................................................. General Specifications............................................................................................................ Unit Conversion Table ...........................
1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a vehicle, read the precautions given below. To facilitate actual operations, notes, illustrations, 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.
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.
1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them.
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 contact 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.
1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side).
GENERAL INFORMATION 1-7 Model Identification KVF750D8F Left Side View KVF750D8F Right Side View The KVF750E is a camouflage-surface-treated model and identical to the KVF750D, the base model, in every other aspect: controls, features, and specifications. The KVF750F is identical to the KVF750D in every other aspect, that is, controls, features, and specifications.
1-8 GENERAL INFORMATION Model Identification Frame Number Engine Number [A] Frame Number [B] Left Front Axle [A] Engine Number [B] Torque Converter Cover
GENERAL INFORMATION 1-9 General Specifications Items Dimensions Overall Length Overall Width Overall Height Wheelbase Ground Clearance: Seat Height Dry Mass Curb Mass: Front Rear Fuel Tank Capacity Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower KVF750D8F, E8F, F8F 2 195 mm (86.42 in.) 1 166 mm (45.90 in.) 1 233 mm (48.54 in.) 1 284 mm (50.55 in.) 247 mm (9.72 in.) 903 mm (35.6 in.) 274.5 kg (605.
1-10 GENERAL INFORMATION General Specifications Items Engine oil: Type Viscosity Capacity Drive Train Primary Reduction System: Type Reduction Ratio Transmission: Type Gear Ratios: Forward: High Low Reverse Final Drive System: Type Reduction Ratio Overall Drive Ratio: Forward: High Low Reverse Front Final Gear Case Oil: Type Viscosity Capacity Rear Final Gear Case Oil: Type Capacity Frame Type Caster (Rake Angle) Camber King Pin Angle Trail Tread: Front Rear KVF750D8F, E8F, F8F API SF or SG API SH, SJ or S
GENERAL INFORMATION 1-11 General Specifications Items Rim Size: Front Rear Front tire: Type Size Rear tire: Type Size Suspension: Front: Type Wheel Travel Rear: Type Wheel Travel Brake: Front Rear Parking Brake Electrical Equipment Battery Headlight: Type Bulb Tail/brake Light: Bulb Reverse Light: Bulb Alternator: Type Rated Output KVF750D8F, E8F, F8F 12 × 6.0 12 × 7.5 Tubeless AT25 × 8-12 Tubeless AT25 × 10-2 Double Wishbone 171 mm (6.73 in.) Double Wishbone 200 mm (7.87 in.
1-12 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Prefix mega kilo centi milli micro Symbol M k c m µ Units of Length: × × × × × Power 1 000 000 1 000 0.01 0.001 0.000001 Units of Mass: kg g × × 2.205 0.03527 = = lb oz km m mm × × × 0.6214 3.281 0.03937 = = = mile ft in = = = = = = kgf·m ft·lb in·lb N·m ft·lb in·lb = = = = = = kgf/cm² psi cmHg kPa psi kPa = mph = = = = PS HP kW HP Units of Torque: N·m N·m N·m kgf·m kgf·m kgf·m × × × × × × 0.1020 0.7376 8.851 9.
PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ................................................................................................... Torque and Locking Agent...................................................................................................... Specifications ......................................................................................................................... Special Tools ..........................................
2-2 PERIODIC MAINTENANCE Rear Brake Lever and Pedal Free Play Adjustment ......................................................... Steering ............................................................................................................................... Steering Inspection ........................................................................................................... Electrical System ..................................................................................................
PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition. The initial maintenance is vitally important and must not be neglected. FREQUENCY First Service Regular Service After 10 hrs. or 100 km (60 mi.) of use Every 90 days, 1 700 km (1 Every Every 100 mi.) 10 30 of use or days or days or Every when belt See 200 km 600 km year of indicator page (120 (360 use light turns mi.) of mi.
2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY First Service Regular Service After 10 hrs. or 100 km (60 mi.) of use Every 90 days, 1 700 km (1 Every Every 100 mi.) 10 30 of use or days or days or Every See when belt 200 km 600 km year of indicator page (120 (360 use light turns mi.) of mi.
PERIODIC MAINTENANCE 2-5 Torque and Locking Agent The following tables list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: L: Apply a non-permanent locking agent. LB: Apply a non-permanent locking agent (Three Bond TB2471, Blue). Lh: Left-hand Threads MO: Apply molybdenum disulfide oil (mixture of the engine oil and molybdenum disulfide grease in a weight ratio: 10 : 1).
2-6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Rocker Shaft Bolts Valve Adjusting Screw Locknuts Camshaft Chain Tensioner Mounting Bolts Camshaft Chain Tensioner Cap Bolts Position Plate Bolts Intermediate Shaft Chain Guide Bolts Intermediate Shaft Chain Tensioner Bolts Camshaft Sprocket Bolts Cylinder Bolts 40 mm (1.6 in.) Cylinder Bolts 30 mm (1.2 in.
PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Crankcase Bolts (M8) 75 mm (2.95 in.) Crankcase Bolts (M8) 110 mm (4.33 in.) Crankcase Bolt (M8) 110 mm (4.33 in.) Crankcase Bolts (M6) 40 mm (1.57 in.) Crankcase Bolts (M6) 65 mm (2.56 in.
2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Front Final Gear Case Center Cover Bolts (M6) Front Final Gear Case Center Cover Bolts (M8) Front Final Gear Case Oil Filler Cap Pinion Gear Bearing Holder Nut Pinion Gear Bearing Holder Front Final Gear Case Coupling Nut Front Final Gear Case Oil Drain Bolt 2WD/4WD Actuator Mounting Bolts Variable Differential Control Cable Locknut Variable Differential Control Lever Bolt Front Final Gear Case Nuts (Rear Final Gear Case) Rear Final Gear Case Front
PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Fastener Steering Knuckle Joint Nuts Rear Shock Absorber Mounting Nuts Stabilizer Holder Bolts Stabilizer Joint Nuts Rear Suspension Arm Pivot Nuts Rear Knuckle Mounting Nuts Steering Handlebar Holder Bolts Steering Stem Clamp Bolts Tie-rod End Nuts Tie-rod Locknuts Steering Stem Bearing Joint Bolts Steering Stem Bottom End Nut Steering Knuckle Joint Nuts Front Brake Master Cylinder Clamp Bolts Left Handlebar Switch Housing Screws Frame Front Guard Bolts Fro
2-10 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Forward/Reverse Detecting Sensor Mounting Bolt Speed Sensor Mounting Bolt Neutral Position Switch Reverse Position Switch Ignition Coil Mounting Bolts Ignition Coil Bracket Mounting Bolts Oil Pressure Switch Oil Pressure Switch Terminal Bolt Regulator/Rectifier Mounting Bolts Tail/Brake Light Lens Screws Torque kgf·m 1.5 0.90 1.5 1.5 0.60 0.60 1.5 0.15 0.90 0.10 N·m 15 8.8 15 15 5.9 5.9 15 1.5 8.8 1.
PERIODIC MAINTENANCE 2-11 Specifications Item Fuel System Throttle Lever Free Play Idle Speed Air Cleaner Element Oil Cooling System Coolant: Type (Recommended) Color Mixed Ratio Freezing Point Total Amount Engine Top End Valve Clearance: Exhaust Inlet Converter System Belt Width Belt Deflection Actuator Lever Guide Shoe Wear Engine Lubrication System Engine Oil: Type Viscosity Capacity Wheels/Tires Tire Tread Depth: Front Rear Standard tire: Front Rear Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.
2-12 PERIODIC MAINTENANCE Specifications Item Final Drive Front Final Gear Case: Gear Case Oil: Type Viscosity Oil Level Capacity Rear Final Gear Case: Gear Case Oil: Type Oil Level Capacity Brakes Front Brake Fluid: Type Front Disc Brake: Pad Lining Thickness Rear Brake Lever, Pedal and Cables: Rear Brake Lever Free Play Brake Pedal Free Play Electrical System Spark Plug Gap Rear Brake Light Switch Timing Standard API SF or SG API SH, SJ or SL with JASO MA SAE 10W-40 Filler opening bottom 0.40 L (0.
PERIODIC MAINTENANCE 2-13 Special Tools Oil Filter Wrench: 57001-1249 Flywheel & Pulley Holder: 57001-1605 Filler Cap Driver: 57001-1454 Belt Measuring Gauge: 57001-1646 Pulley Holder Attachment: 57001-1472
2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Throttle Lever Free Play Inspection that the throttle lever [A] moves smoothly from full • Check open to close, and the throttle closes quickly and com- • • pletely in all steering positions by the return spring. If the throttle lever does not return properly, check the throttle cable routing, lever free play, and cable damage. Then lubricate the throttle cable.
PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Idle Speed Inspection the engine and warm it up thoroughly. • Start With the idling, turn the handlebar to both sides to • check forengine any changes in the idle speed. If handlebar movement changes the idle speed, the throttle cable may be improperly adjusted, incorrectly routed, or damaged. Be sure to correct any of these conditions before riding.
2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Cleaner Element Cleaning and Inspection NOTE ○In dusty areas, the element should be cleaned more frequently than the recommended interval. ○After riding through rain or muddy terrains, the element should be cleaned immediately. ○Also, if there is a break in the element material or any other damage to the element, replace the element with a new one.
PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Fuel Hose Inspection (fuel leak, damage, installation condition) ○The fuel hose is designed to be used throughout the vehi- cle’s life without any maintenance. However, if the vehicle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) and check the fuel hose.
2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures the screwdriver to disconnect the joint lock [A]. • Twist Pull the fuel hose joint [B] out of the delivery pipe. • 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. Cover the hose connection with a clean shop towel to prevent fuel spillage. the new fuel hose.
PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Remove: Front Guard Cover (see Front Guard Removal in the • Frame chapter) Front Fender (see Front Fender Removal in the Frame chapter) Headlight Cover (see Headlight Cover Removal in the Frame chapter) Radiator Screen Mounting Screws [A] Radiator Screen [B] Clean the radiator screen in a bath of tap water, and then dry it with compressed air or by shaking it. • Clean the radiator.
2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove: Reserve Tank Screws [A] • Reserve Tank [B] with Hose Remove the reserve tank cap [C], and pour the coolant into a container. a container under the drain bolt [A] at the bottom of • Place the water pump cover [B], then remove the drain plug. the radiator cap [A] in two steps. First turn the • Remove cap counterclockwise to the first step. Then push and turn • it further in the same direction and remove the cap.
PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • Tighten: Torque - Coolant Drain Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb) the vehicle on a stand or the jack so that the front • Support wheels are off the ground. This makes air bleeding easier. the radiator up to the radiator filler neck [A] with • Fill coolant. NOTE ○Pour in the coolant slowly so that the air in the engine and radiator can escape. CAUTION Soft or distilled water must be used with the antifreeze in the cooling system.
2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE ○Check the valve clearance only when the engine is cold (at room temperature). • Remove: Front Fender (see Front Fender Removal in the Frame chapter) Battery Case Valve Adjusting Cap Bolts [A] Valve Adjusting Caps [B] • Remove the right water pipe bolt [A], if necessary. • Remove: Bolts [A] • Alternator Outer Cover [B] Remove the timing inspection plug [C].
PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures the clearance for all four valves, one at a time • Measure between the end of the valve stem and the adjusting screw [A] with the thickness gauge [B]. Valve Clearance (when cold) Exhaust 0.20 ∼ 0.25 mm (0.0079 ∼ 0.0098 in.) Inlet 0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.) If the valve clearance is not correct, adjust it (see Valve Clearance Adjustment).
2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures the drain plug [A] on the muffler. • Remove In an open area away from combustible materials, start • the engine with the transmission in neutral. Raise and lower speed while tapping on the muf• fler with a rubberengine mallet until carbon particles are purged from the muffler. WARNING Do not run the engine in a closed area. Exhaust gases contain carbon monoxide; a colorless, odorless, poisonous gas.
PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures the belt [A] for abnormal wear [B]. •○Check Measure the width [C] of the belt at abnormal wear point. If any measurements exceed 0.5 mm (0.02 in.), replace the belt. ○When using the belt of large abnormal wear, the drive belt failure detection switch could be activated. the belt for cracks, breaks, or peeling. • Check If necessary, replace the belt with a new one.
2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Converter Drive Belt Deflection Adjustment the driven pulley (see Driven Pulley Disas• Disassemble sembly in the Converter System chapter). If the belt deflection is more than 27 mm (1.06 in.), remove the spacers to decrease it. ○The rule-of-thumb is: 0.1 mm (0.004 in.) change in spacer thickness equals about 1.3 mm (0.051 in.) change in belt deflection.
PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Actuator Lever (Engine Brake Control Lever) Assembly Inspection the width [A] of the plastic guide shoe [B] of the • Measure actuator lever assembly. If the guide contact area width is greater than the service limit, replace the actuator lever assembly. Actuator Lever Guide Shoe Service Limit: 6 mm (0.24 in.
2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures the filter with a new one. • Replace When installing the oil filter, be careful of the following. •○Apply oil to the gasket [A] before installation. ○Tighten the filter with the oil filter wrench. Special Tool - Oil Filter Wrench: 57001-1249 Torque - Oil Filter: 17.5 N·m (1.8 kgf·m, 13 ft·lb) ○Pour in the specified type and amount of oil. Wheels/Tires Tire Inspection the tire for damage and wear.
PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Variable Differential Control Lever Play Adjustment • Remove: Handlebar Cover Screws [A] • Remove: Handlebar Cover Screws [A] Handlebar Cover Front [B] the locknut [A] of the differential control cable. • Loosen Turn the • play. adjuster [B] until the cable has proper amount of • Tighten the locknut securely. Front Final Gear Case Oil Change up the oil by running the vehicle so that the oil will • Warm pick up any sediment and drain easily.
2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures the gear case up to the bottom of filler opening with • Fill the oil specified below. Front Final Gear Case Oil Type: API SF or SG API SH, SJ or SL with JASO MA Viscosity: SAE 10W-40 Capacity: 0.40 L (0.42 US qt) NOTE ○Depending on the atmospheric temperature of your riding area, the engine oil viscosity should be changed according to the chart. sure the O-ring [A] is in place, and tighten the filler cap • Be [B]. ○Apply grease to the O-ring.
PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures sure the O-ring [A] is in place, and tighten the filler cap • Be [B]. ○Apply grease to the O-ring. Torque - Rear Final Gear Case Oil Filler Cap: 29 N·m (3.0 kgf·m, 22 ft·lb) Universal Joint Lubrication • Remove: Rear Propeller Shaft (see Rear Propeller Shaft Removal • in the Final Drive chapter) Force grease into the grease nipples [A] until the grease comes out from the nipple, and wipe off any excess grease.
2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Front Brake Hose Replacement the brake fluid out of the line as explained in the • Pump Brake Fluid Change. the banjo bolts at both ends of the brake hose, • Remove and pull the hose off the vehicle. • Immediately wipe up any brake fluid that spills. CAUTION Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately. a new flat washer for each side of the hose fittings.
PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Front Brake Fluid Change the reservoir cap and the rubber cap on the bleed • Remove valve. a clear plastic hose to the bleed valve on the • Attach caliper, and run the other end of the hose into a container. Fill the reservoir with new brake fluid. Change the brake fluid as follows: ○Open the bleed valve [A]. ○Apply the brake lever and hold it [B]. ○Close the bleed valve [C]. ○Release the brake lever [D].
2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Front Brake Caliper Fluid Seal Replacement 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.
PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Rear Brake Lever and Pedal Free Play Adjustment NOTE ○Since the rear brake lever and pedal free play adjustments affect each other, make them at the same time. Rear Brake Lever Loosen the knurled locknut [A] and turn the adjuster [B] at the rear brake lever in as far as it will go. Tighten the locknut. • • the brake lever adjuster [A] at the rear end of the • Turn brake cable until the rear brake lever has the correct amount of play.
2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures the steering action again. • Check If steering stem bearing lubrication does not remedy the • problem, inspect the steering stem for straightness, steering stem clamps, and tie-rod bearings. If you feel looseness, or if the steering rattles as it turns, check the tightness of the steering bolts and nuts. Tighten loose bolts and nuts to the specified torque (see Steering chapter), and check the steering action again.
PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Converter Drive Belt Failure Detection System Inspection • Remove: Seat (see Seat Removal in the Frame chapter) Check drive belt failure detection system according to • followingthechart in the next page.
2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures
PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Joint Boots Inspection Front Axle/Steering Knuckle Joint Boots Inspection inspect the front axle joint boots [A]. • Visually If the joint boot is torn, worn, deteriorated, or leaks grease, • replace the joint boot or front axle assembly (see Front Axle Joint Boot Replacement in the Final Drive chapter). Visually inspect the knuckle joint boots [B].
2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures General Lubrication Lubrication lubricating each part, clean off any rusty spots with • Before rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. ○Whenever NOTE the vehicle has been operated under wet or rainy conditions, or especially after using a high-pressure spray water, perform the general lubrication.
PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Slide Points: Lubricate with Grease. Brake Lever Brake Pedal Pivot Shaft Throttle Lever Shaft Bolts and Nuts Tightening Tightness Inspection the tightness of the bolts and nuts listed here in • Check accordance with the Periodic Maintenance Chart. Also, check to see that each cotter pin is in place and in good condition. If there are loose fasteners, retorque them to the specified torque following the specified tightening sequence.
FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................................................................................................................ DFI System............................................................................................................................. DFI Parts Location.................................................................................................................. Specifications ...................................
3-2 FUEL SYSTEM (DFI) Fuel Pump Relay Removal ............................................................................................... Fuel Pump Relay Inspection ............................................................................................. Ignition Coils (#1, #2: Service Code 51, 52)........................................................................... Ignition Coil Removal/Installation......................................................................................
FUEL SYSTEM (DFI) 3-3 Fuel Tank ................................................................................................................................ Fuel Tank Removal ........................................................................................................... Fuel Tank Installation ........................................................................................................ Fuel Tank Cleaning ..............................................................................
3-4 FUEL SYSTEM (DFI) Exploded View
FUEL SYSTEM (DFI) 3-5 Exploded View No. 1 2 3 4 5 6 7 Fastener Air Cleaner Housing Bolts ISC Valve Mounting Bolts Water Temperature Sensor Air Cleaner Element Holder Screw Air Cleaner Element Holder Tapping Screw Inlet Air Pressure Sensor Mounting Screw Delivery Pipe Mounting Screws 8. ISC Valve 9. Fuel Injectors 10. Inlet Air Pressure Sensor 11. Inlet Air Temperature Sensor G: Apply grease. O: Apply high-quality foam air filter oil. N·m 8.8 8.8 12 3.5 1.5 5.0 5.0 Torque kgf·m 0.90 0.90 1.2 0.36 0.15 0.
3-6 FUEL SYSTEM (DFI) Exploded View
FUEL SYSTEM (DFI) 3-7 Exploded View No. 1 2 3 4 5 Fastener Fuel Pump Bolts Fuel Tank Mounting Bolts Throttle Lever Limiter Screw Throttle Lever Limiter Nut Throttle Case Assembly Screws 6. ECU (Electronic Control Unit) 7. Fuel Pump Relay 8. Radiator Fan Relay 9. Vehicle-down Sensor 10. Fuel Pump 11. Ignition Coils 12. Speed Sensor 13. CrankShaft Sensor G: Apply grease. CL: Apply cable lubricant. N·m 4.0 9.8 3.6 3.6 3.6 Torque kgf·m 0.41 1.0 0.37 0.37 0.
3-8 FUEL SYSTEM (DFI) DFI System DFI System
FUEL SYSTEM (DFI) 3-9 DFI System 1. Battery 12 V 12 Ah 2. ECU (Electronic Control Unit) 3. Inlet Air Pressure Sensor 4. Throttle Sensor 5. Injectors 6. Crankshaft Sensor 7. ISC Valve 8. Fuel Pump 9. Speed Sensor 10. Water Temperature Sensor 11. Vehicle-down Sensor 12. Inlet Air Temperature Sensor 13. Multifunction Meter 14. Delivery Pipe 15. Air Cleaner Housing 16. Air Cleaner Element 17. Air Flow 18.
3-10 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram
FUEL SYSTEM (DFI) 3-11 DFI System Part Name 1. Throttle Sensor 2. Fuel Injector #1 3. Fuel Injector #2 4. Ignition Switch 5. Speed Sensor 6. Fuse Box 7. Fuel Pump Fuse 10 A 8. Main Fuse 30 A 9. Fuel Pump 10. ECU (Electronic Control Unit) 11. Vehicle-down Sensor 12. Fuel Pump Relay 13. Kawasaki Diagnostic System Connector 14. ISC Valve 15. Battery 12 V 12 Ah 16. Spark Plugs 17. Ignition Coils 18. Water Temperature Sensor 19. Crankshaft Sensor 20. Starter Button 21. Engine Stop Switch 22.
3-12 FUEL SYSTEM (DFI) DFI System Terminal Names 1. Inlet Air Pressure Sensor Signal 2. Inlet Air Temperature Sensor Signal 3. Power Supply to Sensors 4. Reverse Switch Signal 5. Reverse Power Assist Switch Signal 6. Crankshaft Sensor (–) Signal 7. Battery Monitor 8. Power Supply to ECU (from Battery) 9. External Communication Line (KDS) 10. Ground for Sensors 11. Ground for Control System 12. Unused 13. Ignition Switch Signal 14. Water Temperature Sensor Signal 15. Throttle Sensor Signal 16. Unused 17.
FUEL SYSTEM (DFI) 3-13 DFI Parts Location FI Indicator Light (LCD) [A] Water Temperature Sensor [A] Spark Plug (Front) [B] Ignition Coil (Front) [C] Crankshaft Sensor [A] ISC Valve [A] Spark Plug (Rear) [B] Ignition Coil (Rear) [C] Throttle Sensor [A] Inlet Air Pressure Sensor [B] Fuel Injectors [C]
3-14 FUEL SYSTEM (DFI) DFI Parts Location Inlet Air Temperature Sensor [A] Speed Sensor [A] ECU (Electronic Control Unit) [A] Battery 12V 12Ah [B] Fuel Pump [C] Vehicle-down Sensor [A] Fuel Pump Relay [B] Kawasaki Diagnostic System Connector [C]
FUEL SYSTEM (DFI) 3-15 Specifications Item Digital Fuel Injection System Idle Speed Throttle Body Assy: Type Bore ECU (Electronic Control Unit): Make Type Usable Engine Speed Fuel Pressure (High Pressure Line): With Engine Idling Fuel Pump: Type Discharge Fuel Injectors: Type Nozzle Type Resistance Throttle Sensor: Input Voltage Output Voltage at Idle Throttle Opening Output Voltage at Full Throttle Opening Resistance Inlet Air Pressure Sensor: Input Voltage Output Voltage Inlet Air Temperature Sensor: Resi
3-16 FUEL SYSTEM (DFI) Specifications Item Speed Sensor: Input Voltage Output Voltage Throttle Lever and Cable Throttle Lever Free Play Air Cleaner Air Cleaner Element Oil Standard Battery Voltage at ignition Switch ON less than CD 0.8 Vor over than DC 4.8 V at ignition Switch ON and 0 km/h 2 ∼ 3 mm (0.08 ∼ 0.12 in.
FUEL SYSTEM (DFI) 3-17 Special Tools and Sealant Vacuum Gauge Adapter: 57001-401 Hand Tester: 57001-1394 Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Needle Adapter Set: 57001-1457 Pilot Screw Adjuster, A: 57001-1239 Throttle Sensor Setting Adapter: 57001-1521 Fork Oil Level Gauge: 57001-1290 Throttle Sensor Setting Adapter: 57001-1538 Vacuum Gauge: 57001-1369 Sensor Harness Adapter: 57001-1561
3-18 FUEL SYSTEM (DFI) Special Tools and Sealant Fuel Pressure Gauge Adapter: 57001-1593 Fuel Hose L = 550: 57001-1707 Fuel Hose: 57001-1607 Kawasaki Bond (Silicone Sealant): 56019-120 Speed Sensor Measuring Adapter: 57001-1667
FUEL SYSTEM (DFI) 3-19 DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source. ○Do not reverse the battery cable connections. This will damage the ECU.
3-20 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.
FUEL SYSTEM (DFI) 3-21 Troubleshooting the DFI System Outline When an abnormality in the DFI system occurs, the FI indicator light (LCD) goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit). With the engine stopped and turned in the self-diagnosis mode, the service code [A] is indicated by the number of times the FI indicator light (LCD) blinks.
3-22 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○The DFI part connectors [A] have seals [B], including the • ECU. Join the connector and insert the needle adapters [C] inside the seals [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.
FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System each connector [A] apart and inspect it for corrosion, • Pull 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 Ω range, and read the tester.
3-24 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.
FUEL SYSTEM (DFI) 3-25 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.
3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Year of initial registration: Engine No.: Date problem occurred: Weather Temperature Problem frequency Road Altitude FI indicator light (LCD) Starting difficulty Engine stops Poor running at low speed Registration No. (license plate No.): Model: Frame No.: Mileage: Environment when problem occurred.
FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System Poor running or no power at high speed □other □spark plug loose (tighten it) □spark plug dirty, broken, or gap maladjusted (remedy it) □spark plug incorrect (replace it) □knocking (fuel poor quality or incorrect) □brake dragging □clutch slipping □engine overheating □engine oil level too high □engine oil viscosity too high □other
3-28 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 are 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.
FUEL SYSTEM (DFI) 3-29 DFI System Troubleshooting Guide Symptoms or possible Causes Brake lever or pedal not pulled in and gear not in neutral Vehicle-down sensor coming off Vehicle-down sensor trouble ECU ground or power supply trouble Battery voltage low Spark plug dirty, broken or gap maladjusted Ignition coil trouble Ignition coil shorted or not in good contact Spark plug incorrect IC igniter in ECU trouble Crankshaft sensor trouble Ignition coil trouble Ignition switch shorted Engine stop switch shorte
3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or possible Causes Valve spring broken or weak Valve not seating properly (valve bent, worn or carbon accumulating on seating surface) Actions (chapter) Inspect and replace (see chapter 5). Inspect and repair or replace (see chapter 5).
FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or Possible Causes Fuel injector trouble Throttle sensor trouble Fuel pressure too low or too high Inlet air pressure sensor trouble Water temperature sensor trouble Inlet air temperature sensor trouble Fuel line clogged Fuel pressure too low or too high Fuel pressure regulator trouble Crankshaft sensor trouble Ignition coil trouble Compression Low: Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder, pis
3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Too low fuel pressure Water or foreign matter in fuel Clogged fuel filter or pump screen Fuel pump trouble Fuel injector trouble Inlet air temperature sensor trouble Water temperature sensor trouble Ignition coil trouble Engine oil level to high Spark plug dirty, broken or gap maladjusted Stumble: Too low fuel pressure Fuel injector trouble Throttle sensor malfunction Water temperature sensor trouble Inlet air pressure senso
FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Engine overheating Other: Engine oil viscosity too high Brake dragging Engine overheating Intermittent any DFI fault and its recovery Actions (chapter) (see Overheating of Troubleshooting Guide, see chapter 17) Change (see chapter 2). Inspect caliper fluid seal damage or clogging of master cylinder relief and supply ports (see chapter 12).
3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Piston ring bad (worn, weak, broken or sticking) Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly (valve bent , worn or carbon accumulating on the seating surface) Knocking: Carbon built up in combustion chamber Fuel poor quality or incorrect (Use the gasoline recommended in the Owner’s Manual) Spark plug incorrect Ignition coil tr
FUEL SYSTEM (DFI) 3-35 Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has two modes and can be switched to another mode by grounding the self-diagnosis terminal. User Mode The ECU notifies the rider of troubles in DFI system and ignition system by flashing 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.
3-36 FUEL SYSTEM (DFI) Self-Diagnosis the hand tester [A] as shown. • Connect Set the tester to 5 mA range. • Special Tool - Hand Tester: 57001-1394 Connections: Adapter Hand Tester Meter Side ← Red → (+) Main Harness Side ← Black → (–) the self-diagnosis terminal to the battery (–) ter• Ground minal or battery (–) lead connector, using a wire. on the ignition switch. • Turn Connect • grounding.
FUEL SYSTEM (DFI) 3-37 Self-Diagnosis
3-38 FUEL SYSTEM (DFI) Self-Diagnosis How to Read Service Codes ○Service codes are shown by a series of long and short flicks of the tester as shown below. ○Read 10th digit and unit digit as the tester flicks. ○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 is repeated until the self-diagnosis indicator terminal is open.
FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Service Code Table Service Code Flicks of Tester Problems 11 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 short 21 Crankshaft sensor malfunction, wiring open or short 24 Speed sensor malfunction, wiring open or short 31 Vehicle-down sensor, malfunction, wiring open or
3-40 FUEL SYSTEM (DFI) Self-Diagnosis Backups ○The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles.
FUEL SYSTEM (DFI) 3-41 Self-Diagnosis 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).
3-42 FUEL SYSTEM (DFI) Throttle Sensor (Service Code 11) Throttle Sensor Removal/Adjustment CAUTION Do not remove or adjust the throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface. Such a shock to the sensor can damage it. Throttle Sensor Input Voltage Inspection NOTE ○Be sure the battery is fully charged. the ignition switch OFF.
FUEL SYSTEM (DFI) 3-43 Throttle Sensor (Service Code 11) 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 Connection ECU Connector [A] ←→ Throttle Sensor Connector [B] BR/W lead (ECU terminal 3) BR/BK lead (ECU terminal 10) If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).
3-44 FUEL SYSTEM (DFI) Throttle Sensor (Service Code 11) If the output voltage is normal, check the wiring for continuity. ○Disconnect the ECU and sensor connectors. Wiring Connection ECU Connector [A] ←→ Throttle Sensor Connector [B] Y/W lead (ECU terminal 15) BR/BK lead (ECU terminal 10) If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-45 Throttle Sensor (Service Code 11) Throttle Sensor Circuit 1. ECU (Electronic Control Unit) 2.
3-46 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Inlet Air Pressure Sensor Removal • Remove: Air Cleaner (see Air Cleaner Housing Removal) • • Screw [A] Disconnect the inlet air pressure sensor connector [B] and the vacuum hose [C]. Remove the inlet air pressure sensor [D]. Inlet Air Pressure Sensor Installation • Installation is the reverse of removal.
FUEL SYSTEM (DFI) 3-47 Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Output Voltage Inspection NOTE ○The output voltage changes according to the local atmospheric pressure. the output voltage at the ECU in the same way • Measure as input voltage inspection. Note the following. Special Tool - Needle Adapter Set: 57001-1457 Inlet Air Pressure Sensor Output Voltage Connections to ECU Connector Meter (+) → G/Y lead (terminal 1) Meter (–) → BR/BK lead (terminal 10) Usable Range: DC 3.
3-48 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Suppose: Pg: Vacuum Pressure (gauge) to Sensor Pl: Local Atmospheric Pressure (absolute) measured by a barometer Pv: Vacuum Pressure (absolute) to Sensor Vv: Sensor Output Voltage (V) then Pv = Pl – Pg For example, suppose the following data is obtained: Pg = 8 cmHg (Vacuum gauge reading) Pl = 70 cmHg (Varometer reading) Vv = 3.2 V (Digital meter reading) then Pv = 70 – 8 = 62 cmHg (Abs.
FUEL SYSTEM (DFI) 3-49 Inlet Air Pressure Sensor (Service Code 12) ID: Idling Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle Vacuum Pressure (Absolute) ST: Standard of Sensor Output Voltage (V) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (V) Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)
3-50 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Circuit 1. ECU (Electronic Control Unit) 2.
FUEL SYSTEM (DFI) 3-51 Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. the air cleaner (see Air Cleaner Housing Re• Remove moval). the screw [A]. • Remove Pull out the air temperature sensor [B]. • Put the inletinlet air temperature sensor into the air cleaner • housing. • Tighten the screw securely.
3-52 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Resistance Inspection the inlet air temperature sensor (see Inlet Air • Remove Temperature Sensor Removal/Installation). the sensor [A] in a container of machine oil so • Suspend that the heat-sensitive portion is submerged. a thermometer [B] with the heat-sensitive por• Suspend tions [C] located in almost the same depth with the sensor.
FUEL SYSTEM (DFI) 3-53 Water Temperature Sensor (Service Code 14) Water Temperature Sensor Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. the coolant (see Coolant Change in the Periodic • Drain Maintenance chapter). • Remove: Bolts [A] Disconnect the water pipe [B] from the thermostat housing • [C]. • Disconnect the sensor connector [A]. • Remove the water temperature sensor [A].
3-54 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Water Temperature Sensor Output Voltage Inspection NOTE ○Be sure the battery is fully charged. ○The output voltage changes according to the coolant temperature in the engine. the ECU (see ECU Removal). •○Remove Do not disconnect the connectors. a digital meter [A] to the ECU connector [B] with • Connect the needle adapter set.
FUEL SYSTEM (DFI) 3-55 Water Temperature Sensor (Service Code 14) Water Temperature Sensor Circuit 1. ECU (Electronic Control Unit) 2.
3-56 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condition of the crankshaft sensor. In this case, turn off the ignition switch and turn it on again to enter the Dealer 2 mode.
FUEL SYSTEM (DFI) 3-57 Speed Sensor (Service Code 24) Speed Sensor Removal to the Speed Sensor Removal in the Electrical Sys• Refer tem chapter. Speed Sensor Installation to the Speed Sensor Installation in the Electrical • Refer System chapter. Speed Sensor Inspection to the Speed Sensor Inspection in the Electrical • Refer System chapter. Input Voltage Inspection • Remove: Right Footboard (see Right Footboard Removal in the Flame chapter) NOTE ○Be sure the battery is fully charged.
3-58 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) Output Voltage Inspection this inspection, inspect the input voltage (see Input • Before Voltage Inspection in the Speed Sensor section). NOTE ○Be sure the battery is fully charged. the ignition switch OFF. • Turn • Using the jack, raise the rear wheel off the ground. Special Tool - Jack: 57001-1238 the speed sensor (see Speed Sensor Removal • Remove in the Electrical System chapter).
FUEL SYSTEM (DFI) 3-59 Speed Sensor (Service Code 24) Speed Sensor Circuit 1. ECU (Electronic Control Unit) 2. Speed Sensor 3. Engine Ground 4.
3-60 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Removal CAUTION Never drop the vehicle-down sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Seat (see Seat Removal in the Frame chapter) Screws [A] Vehicle-down Sensor [B] Connector [C] Vehicle-down Sensor Installation • The UPPER mark [A] of the sensor should face upward. WARNING Incorrect installation of the vehicle-down sensor could cause sudden loss of engine power.
FUEL SYSTEM (DFI) 3-61 Vehicle-down Sensor (Service Code 31) the vehicle-down • Remove Sensor Removal). sensor (see Vehicle-down ○Do not disconnect the sensor connector. a digital meter [A] to the connector [B] with nee• Connect dle adapter set [C]. Special Tool - Needle Adapter Set: 57001-1457 Vehicle-down Sensor Output Voltage Connections to Sensor Connector Meter (+) → Y/G lead [D] Meter (–) → BR/BK lead [E] the sensor vertically.
3-62 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Circuit 1. ECU (Electronic Control Unit) 2.
FUEL SYSTEM (DFI) 3-63 Fuel Pump Relay (Service Code 46) Fuel Pump Relay Removal • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Pump Relay [A] Fuel Pump Relay Inspection to the Relay Inspection in the Electrical System • Refer chapter.
3-64 FUEL SYSTEM (DFI) Fuel Pump Relay (Service Code 46) Fuel Pump Relay Circuit 1. ECU (Electronic Control Unit) 2. Fuel Pump Relay 3. Engine Ground Terminal 4. Battery 12 V 12 Ah 5. Engine Stop Switch 6. Ignition Switch 7. Fuel Box 8. Fuel Pump Fuse 10 A 9. Main Fuse 30 A 10.
FUEL SYSTEM (DFI) 3-65 Ignition Coils (#1, #2: Service Code 51, 52) Ignition Coil #1: Ignition Coil for Front Cylinder (Service Code 51) Ignition Coil #2: Ignition Coil for Rear Cylinder (Service Code 52) Ignition Coil Removal/Installation CAUTION Never drop the ignition coils, especially on a hard surface. Such a shock to the ignition coil can damage it. to the Ignition Coil Removal and Installation in the • Refer Electrical System chapter.
3-66 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Removal • Remove: Air cleaner (see Air cleaner Housing Removal) Screw [A] Fuel Hose (from the Delivery Pipe) Delivery Pipe [B] • Remove: Fuel Injectors [A] Connectors [B] Fuel Injector Installation the O-rings [A] and seals [B] with a new one. •○Replace Before installation, blow away dirt or dust from the deliv- • ery pipe by applying compressed air. Apply grease to the O-ring of the injectors.
FUEL SYSTEM (DFI) 3-67 Fuel Injectors the delivery pipe [A] on the throttle body assy. • Install Tighten: • Torque - Delivery Pipe Mounting Screws [B]: 5.0 N·m (0.51 kgf·m, 44 in·lb) Audible Inspection the engine. • Start the tip of a screwdriver [A] to the injector [B]. Put • Apply the grip end onto your ear, and listen whether the injector is clicking or not. ○A sound scope [C] can also be used. Do the same for the other injectors.
3-68 FUEL SYSTEM (DFI) Fuel Injectors If the meter doesn’t read as specified, check the following. Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Fuel Pump Relay (see Relay Circuit Inspection in the Electrical System chapter) Power Source Wiring (see wiring diagram below) If the power source voltage is normal, check the output voltage of the injectors.
FUEL SYSTEM (DFI) 3-69 Fuel Injectors Injector Signal Test two test light sets with terminals as shown. • Prepare 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 harness connector, leading to harness repair or replacement. Be sure to connect bulbs in series.
3-70 FUEL SYSTEM (DFI) Fuel Injectors Injector Unit Test two leads [A] and the same test light set [B] as in • Use “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. the test light set to the injector [E] as shown. • Connect Open and [F] the end of the lead to the battery • (–) terminalconnect repeatedly. The injector should click.
FUEL SYSTEM (DFI) 3-71 Fuel Injectors Fuel Injector Circuit 1. Fuel Injector #1 2. Fuel Injector #2 3. Ignition Switch 4. Fuse Box 5. Fuel Pump Fuse 10 A 6. Main Fuse 30 A 7. ECU (Electronic Control Unit) 8. Fuel Pump Relay 9. Engine Ground Terminal 10. Battery 12 V 12 Ah 11.
3-72 FUEL SYSTEM (DFI) FI Indicator Light (LCD) Inspection Flow Chart
FUEL SYSTEM (DFI) 3-73 FI Indicator Light (LCD) Light Inspection ○The FI indicator light (LCD) [A] goes ON when the ignition • switch is turned ON and the FI indicator light (LCD) goes OFF when the engine oil pressure is high enough (the engine is running). This is to ensure that the FI indicator light (LCD) has not burned out and the DFI system and the ignition system function properly.
3-74 FUEL SYSTEM (DFI) ECU CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Removal • Remove: Seat (see Seat Removal in the Frame chapter) • ECU [A] Disconnect the ECU connectors [B]. ECU Installation the ECU connectors [A] to the ECU [B]. • Connect Install the ECU to the electrical parts case. • ECU Power Supply Inspection inspect the terminals [A] of the ECU connectors.
FUEL SYSTEM (DFI) 3-75 ECU the ECU power source voltage with a digital meter • Check [A]. ○Position the terminal in accordance with terminal numbers of ECU connector [B] in this chapter figure.
3-76 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○This inspection can determine which trouble the DFI system has, mechanical or electrical trouble. ○It is preferable to measure the fuel pressure while running the vehicle just when trouble occurred in order to know symptom well. ○Be sure the battery is fully charged. the fuel hose (see Fuel Hose Replacement in the • Remove Periodic Maintenance chapter).
FUEL SYSTEM (DFI) 3-77 Fuel Line NOTE ○The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. • • If the fuel pressure is much lower than specified, the fuel pressure regulator in the fuel pump have been clogged or stuck. Replace the fuel pump (see Fuel Pump section). If the fuel pressure is much lower than specified, check the following.
3-78 FUEL SYSTEM (DFI) Fuel Line the fuel tank cap [A] to lower the pressure in the • Open tank. install the ECU [A] and actuator controller • Temporarily, [B]. the prepared fuel hose [A] to the fuel pump outlet • Connect pipe. the fuel hose with a clamp. • Secure Run the other side of the fuel hose into the measuring • cylinder [B]. WARNING Wipe off spilled out fuel immediately. Be sure to hold the measuring cylinder vertical. the fuel tank cap. • Close With the stopped, turn the ignition switch ON.
FUEL SYSTEM (DFI) 3-79 Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard surface. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explosive 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.
3-80 FUEL SYSTEM (DFI) Fuel Pump • Remove: Fuel Pump Bolts [A] Plate [B] Fuel Pump [C] O-ring Fuel Pump Installation dirt or dust from the fuel pump [A] by lightly ap• Remove plying compressed air. • Install: Fuel Pump [A] • • O-ring Install the plate [B] so that fit the projections [C] and hellows [D] of the fuel pump and plate. Tighten the fuel pump bolts to a snug fit, tighten them alternating diagonally. Torque - Fuel Pump Bolts: 4.0 N·m (0.
FUEL SYSTEM (DFI) 3-81 Fuel Pump Fuel Pump Operation Inspection NOTE ○Be sure the battery is fully charged. ○Just listen to the pump sound in the fuel tank to confirm pump operation. the ignition switch ON and make sure that the fuel • Turn 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. Fuel Pump Operating Voltage Inspection NOTE ○Be sure the battery is fully charged.
3-82 FUEL SYSTEM (DFI) Fuel Pump Pressure Regulator Removal ○The pressure regulator [A] is 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 fuel filter is suspected of clogging or being damaged, replace it with the fuel pump.
FUEL SYSTEM (DFI) 3-83 Fuel Pump Fuel Pump Circuit 1. ECU (Electronic Control Unit) 2. Fuel Pump Relay 3. Engine Ground Terminal 4. Battery 12 V 12 Ah 5. Engine Stop Switch 6. Ignition Switch 7. Fuse Box 8. Fuel Pump Fuse 10 A 9. Main Fuse 30 A 10.
3-84 FUEL SYSTEM (DFI) Throttle Lever and Cable Throttle Lever Free Play Inspection to the Throttle Lever Free Play Inspection in the • Refer Periodic Maintenance chapter. Throttle Lever Free Play Adjustment to the Throttle Lever Free Play Adjustment in the • Refer Periodic Maintenance chapter. Throttle Case Removal/Disassembly the throttle case screws [A] and pull the case • Remove open. • Slide the cable adjuster dust cover out of place. • Remove the rubber cover [A].
FUEL SYSTEM (DFI) 3-85 Throttle Lever and Cable the throttle case so that the projection [A] fit to the • Install hole [B] of the handlebar. the throttle control lever so that the carburetor throt• Swing tle valve is fully open. Turn the throttle limiter screw [A] until it is spaced about 1 mm (0.04 in.) [B] away from the throttle lever stop [C]. Tighten the locknut [D]. NOTE ○Refer to the Owner’s Manual for the function of the throttle limiter and adjustment procedure of it.
3-86 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection to the Idle Speed Inspection in the Periodic Main• Refer tenance chapter. Throttle Body Assy Removal WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Disconnect the battery (–) cable terminal. 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.
FUEL SYSTEM (DFI) 3-87 Throttle Body Assy the throttle pully [A] clockwise to remove the throttle • Turn cable tip [B]. the locknut [C] and adjusting nut [D] fully to re• Loosen move the throttle cable from the throttle body assy. the clamp screws [A] fully. • Loosen Remove the throttle body assembly [B]. • After removing the throttle body assy, stuff pieces of lint • -free, clean cloths into the throttle body assy holders.
3-88 FUEL SYSTEM (DFI) Throttle Body Assy a thin coating of grease to the throttle cable lower • Apply end. the throttle cable lower end [A] into the throttle pulley • Fit [B]. • Tighten the adjusting nut [C] and locknut [D]. sure to install the seal [A] on the throttle link case • Be cover. the removed parts. • Install Check the throttle lever free play (see Throttle Lever Free • Play Inspection in the Periodic Maintenance chapter).
FUEL SYSTEM (DFI) 3-89 Throttle Body Assy Throttle Body Assy Assembly the drain tube [A], if removed • Install the inlet air pressure sensor [B] • Install Tighten: • Torque - Inlet Air Pressure Sensor Mounting Screw [C]: 5.0 N·m (0.51 kgf·m, 44 in·lb) • Connect the vacuum hose [D]. Engine Vacuum Synchronization Inspection • Remove: Side Covers (see Left and Right Side Cover Removal in • • the Frame chapter) Throttle Link Case Cover Check idle speed.
3-90 FUEL SYSTEM (DFI) Throttle Body Assy the bypass screw [A], spring [B], washer [C] and • Remove 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 the bypass screw for wear or damage. If the bypass screw is worn or damaged, replace it.
FUEL SYSTEM (DFI) 3-91 ISC Valve ISC Valve Removal • Remove: Front Fender (see Front Fender Removal in the Frame chapter) ISC Valve Tube (Front) [A] ISC Valve Tube (Rear) [B] ISC Valve Tube (Primary) [C] Connector [D] Bolts [E] ISC Valve [F] ISC Valve Installation the ISC valve. • Install • Tighten: Torque - ISC Valve Mounting Bolts: 8.8 N·m (0.
3-92 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Element Removal • Remove: Seat (see Seat Removal in the Frame chapter) Clips [A] Air Cleaner Housing Cap [B] • Remove: Element Holder Screws [A] • Element Holder [B] Element [C] After removing the element, stuff pieces of lint-free, clean cloth into the air cleaner ducts to keep dirt out of the throttle body assy and engine. WARNING If dirt or dust is allowed to pass through into the carburetors, the throttle may become stuck, possibly causing an accident.
FUEL SYSTEM (DFI) 3-93 Air Cleaner • Remove: Screw [A] Air Intake Duct [B] Tube [C] ISC Valve Inlet Tube [D] • Remove: Tube [A] Air Cleaner Housing Bolts [B] (both side) • Loosen the clamp screw [A]. • Loosen the clamp screw [A]. pulling up the air cleaner housing, remove the • While breathe hose [A] and inlet air temperature sensor con- • nector [B]. Remove the air cleaner housing.
3-94 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Housing Installation • Install: Dust Seal [A] Air Cleaner Housing Cover [B] [C] Inside • Be sure to the inlet air temperature sensor [A] is installed. • Install: Clamp [A] and Breather Hose • • • • • Inlet Air Temperature Sensor Connector [B] Install the air cleaner housing and joint duct on the throttle body assy. Fit the joint duct on the fitting of the throttle body assy securely and tighten the clamp screws. Tighten the air cleaner housing bolts.
FUEL SYSTEM (DFI) 3-95 Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explosive 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. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. the ignition switch and engine stop switch OFF. • Turn Wait until cools down.
3-96 FUEL SYSTEM (DFI) Fuel Tank the quick rivets [A] to speparate the fuel tank [B] • Remove and tank case [C]. Fuel Tank Installation the above WARNING (see Fuel Tank Removal) • Note the insulators [A] on the tank case. • Check If the insulators are damaged or deteriorated, replace them. the rubber dampers [A] on the frame as shown. • Check If the dampers are damaged or deteriorated, replace them. the fuel tank with case, and tighten the bolts. • Install the damper [A] on the damper bracket [B].
FUEL SYSTEM (DFI) 3-97 Fuel Tank • Install: Hose [A] Clamps [B] the fuel hose joint [A] straight onto the delivery pipe • Insert until the hose joint clicks. • Push [B] the joint lock [C] . and pull [A] the hose joint [B] back and forth more • Push than two times and make sure it is locked and doesn’t come off. WARNING Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint, or the fuel could leak. • If it comes off, reinstall the hose joint.
COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................................................................................................................ Coolant Flow Chart................................................................................................................. Specifications ......................................................................................................................... Special Tools ..........................................
4-2 COOLING SYSTEM Exploded View
COOLING SYSTEM 4-3 Exploded View No. 1 2 3 4 5 6 7 8 9 Fastener Radiator Mounting Bolts Radiator Screen Mounting Bolts Radiator Fan Assembly Bolts Thermostat Housing Cover Bolts Water Pump Cover Bolts Coolant Drain Bolt Water Pump Impeller Water Pipe Joint Bolt Reserve Tank Mounting Screws G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts N·m 8.8 4.0 4.9 8.8 8.8 8.8 7.8 8.8 4.0 Torque kgf·m 0.90 0.40 0.50 0.90 0.90 0.90 0.80 0.90 0.
4-4 COOLING SYSTEM Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump (coupled with the oil pump) turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
COOLING SYSTEM 4-5 Coolant Flow Chart 1. Radiator 2. Radiator Cap 3. Radiator Fan 4. Water Temperature Switch 5. Thermostat 6. Cylinder 7. Cylinder Head 8. Water Pump 9.
4-6 COOLING SYSTEM Specifications Item Standard Service Limit Coolant Provided when Shipping Type 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 2.2 L (2.3 US qt) (reserve tank full level – – – including radiator and engine) Radiator Cap Relief Pressure 93 ∼123 kPa (0.95 ∼ 1.
COOLING SYSTEM 4-7 Special Tools Bearing Driver Set: 57001-1129 Bearing Remover Shaft, 57001-1265 Bearing Remover Head, 57001-1266 9: 10 × 12:
4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove: Left Footboard (see Left Footboard Removal in the • Frame chapter) Visually inspect the coolant in the reserve tank [A]. 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 the cooling system. If the coolant gives off an abnormal smell, check for cooling system leak.
COOLING SYSTEM 4-9 Coolant Pressure Testing • Remove: Front Fender (see Front Fender Removal in the Frame • chapter) Remove the radiator cap, and install a cooling system pressure tester [A] on the radiator filler neck. NOTE ○Wet the cap sealing surfaces with water or coolant to prevent pressure leakage. up pressure in the system carefully until the pres• Build sure reaches 123 kPa (1.25 kgf/cm², 18 psi). CAUTION During pressure testing, do not exceed the pressure for which the system is designed.
4-10 COOLING SYSTEM Water Pump Water Pump Cover Removal the coolant (see Coolant Change in the Periodic • Drain Maintenance chapter). • Remove: Radiator Hose [A] Water Pump Cover Bolts [B] Water Pump Cover [C] Water Pump Cover Installation • Install: Knock Pins [A] • New Gasket [B] Tighten: Torque - Water Pump Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) Water Pump Impeller Removal the coolant (see Coolant Change in the Periodic • Drain Maintenance chpater).
COOLING SYSTEM 4-11 Water Pump Water Pump Impeller Inspection inspect the impeller [A]. • Visually If the surface is corroded or the blades are damaged, replace the impeller. Water Pump Leakage Inspection the drainage catch tank [A] at the bottom of the • Check water pump body for coolant leakage. If there is a coolant leak, the mechanical seal in the pump could be damaged. Replace the mechanical seal with a new one (see Mechanical Seal Replacement).
4-12 COOLING SYSTEM Water Pump heat-resistance grease on the oil seal lip. • Apply From outside cover, press and insert the oil • seal [A] so thattheitsalternator surface is flush with the step portion of the cover as shown [B]. Special Tool - Bearing Driver Set: 57001-1129 inside the alternator cover, press and insert the ball • From bearing [A] until it is bottomed.
COOLING SYSTEM 4-13 Radiator Radiator Removal WARNING The radiator fan is connected directly to the battery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DISCONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES. the coolant (see Coolant Change in the Periodic • Drain Maintenance chapter).
4-14 COOLING SYSTEM Radiator the projections [A] out of from the dampers [B], and • Pull remove the radiator [C]. CAUTION Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling efficiency. Radiator Installation the projections of the radiator in the dampers. • Insert • Install: Dampers [A] • Collars [B] Tighten: Torque - Radiator Mounting Bolts [C]: 8.8 N·m (0.
COOLING SYSTEM 4-15 Radiator • Remove: Radiator Fan Mounting Nut [A] Radiator Fan [B] Radiator Fan Installation • Install: Radiator Fan • • Radiator Fan Mounting Nut Install: Radiator Fan Assembly Tighten: Torque - Radiator Fan Assembly Bolts: 4.9 N·m (0.50 kgf·m, 43 in·lb) Radiator Inspection the radiator core. • Check If there are obstructions to air flow, remove the radiator and remove obstructions. If the corrugated fins [A] are deformed, carefully straighten them.
4-16 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 leakage. the pressure gauge, slowly pump the pressure • Watching tester to build up the pressure. The relief valve opens, indicated by the gauge hand flicks downward. ○The relief valve must open within the relief pressure range in the table below and the gauge hand must remain within the specified range at least 6 second.
COOLING SYSTEM 4-17 Thermostat Thermostat Removal the coolant (see Coolant Change in the Periodic • Drain Maintenance chapter). • Remove: Front Fender (see Front Fender Removal in the Frame chapter) Water Temperature Sensor Connector [A] • Remove: Water Pipe Bolt [A] • Remove: Thermostat Housing Cover Bolts [A] Thermostat Housing Cover [B] Thermostat Thermostat Installation • Install: Thermostat [A] Be sure to install the O-rings [B] on the housing cover and • water pipe.
4-18 COOLING SYSTEM Thermostat Thermostat Inspection the thermostat, and inspect the thermostat valve • Remove [A] at room temperature. If the valve is open, replace the valve with a new one. check valve opening temperature, suspend the ther• To mostat [A] and an accurate thermometer [B] in a container of water with the heat-sensitive portions [C] in almost the same depth. NOTE ○The thermostat must be completely submerged and the thermostat and thermometer must not touch the container sides or bottom.
COOLING SYSTEM 4-19 Water Temperature Sensor Water Temperature Sensor Removal/Installation CAUTION The water temperature sensor should never be allowed to fall on a hard surface. Such a shock to water temperature sensor can damage it. to the Water Temperature Sensor Removal/Instal• Refer lation in the Fuel System (DFI) chapter. Water Temperature Sensor Inspection to the Water Temperature Sensor Inspection in the • Refer Electrical System chapter.
ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View................................... Specifications .................................... Special Tools and Sealant ................. Camshaft Chain Tensioner ................ Camshaft Chain Tensioner Removal .................................... Camshaft Chain Tensioner Installation ................................. Rocker Case...................................... Rocker Case Removal ................. Rocker Case Installation ..............
5-2 ENGINE TOP END Exploded View
ENGINE TOP END 5-3 Exploded View No. 1 2 3 4 5 5 6 7 8 9 Fastener Rocker Case Bolts 55 mm (2.2 in.) Rocker Case Bolts 130 mm (5.1 in.) Rocker Case Bolts 30 mm (1.2 in.) Rocker Case Bolts 25 mm (1.0 in.) Cylinder Head Bolts (M10), First Torque Cylinder Head Bolts (M10), Final Torque Cylinder Head Bolts (M6) Valve Adjusting Cap Bolts Rocker Shaft Bolts Valve Adjusting Screw Locknuts N·m 8.8 9.8 9.8 9.8 25 49 9.8 8.8 22 12 Torque kgf·m 0.90 1.0 1.0 1.0 2.5 5.0 1.0 0.90 2.2 1.
5-4 ENGINE TOP END Exploded View
ENGINE TOP END 5-5 Exploded View No. 1 2 3 4 5 6 7 8 9 10 Fastener Camshaft Chain Tensioner Mounting Bolts Camshaft Chain Tensioner Cap Bolts Position Plate Bolts Intermediate Shaft Chain Guide Bolts Intermediate Shaft Chain Tensioner Bolts Camshaft Sprocket Bolts Cylinder Bolts 40 mm (1.6 in.) Cylinder Bolts 30 mm (1.2 in.) Front Cylinder Camshaft Chain Guide Bolt Rear Cylinder Camshaft Chain Guide Bolt EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent.
5-6 ENGINE TOP END Exploded View
ENGINE TOP END 5-7 Exploded View No. 1 2 3 4 5 6 Fastener Exhaust Pipe Cover Bolts Muffler Clamp Bolt Muffler Cover Bolts Muffler Mounting Nuts Muffler Mounting Locknuts Exhaust Pipe Holder Nuts R: Replacement Parts N·m 8.8 8.8 8.8 19.6 31.4 17 Torque kgf·m 0.90 0.90 0.90 2.0 3.2 1.
5-8 ENGINE TOP END Specifications Item Rocker Case Rocker Arm Inside Diameter Rocker Shaft Diameter Camshafts Cam Height: Exhaust Inlet Camshaft Bearing Clearance: 18 22 Camshaft Journal Diameter: 18 22 Camshaft Bearing Inside Diameter: 18 22 Camshaft runout KACR (Kawasaki Automatic Compression Release): KACR Operating Engine Speed Cylinder Head Cylinder Compression (Usable Range) Electric Starter Cylinder head warp Valve Valve Clearance: Exhaust Inlet Valve Head Thickness: Exhaust Inlet Valve Stem Bend Val
ENGINE TOP END 5-9 Specifications Item Valve/Valve Guide Clearance (Wobble Method): Exhaust Inlet Valve Seat Cutting Angle Valve Seating Surface: Outside Diameter: Exhaust Inlet Width: Exhaust Inlet Valve Spring Free Length: Exhaust Inlet Cylinder, Piston Cylinder Inside Diameter Piston Diameter Piston/Cylinder Clearance Piston Ring/Groove Clearance: Top Second Piston Ring Groove Width: Top Second Piston Ring Thickness: Top Second Piston Ring End Gap: Top Second Oil Standard 0.09 ∼ 0.17 mm (0.0035 ∼ 0.
5-10 ENGINE TOP END Special Tools and Sealant Outside Circlip Pliers: 57001-144 Valve Seat Cutter, 32° 57001-1119 28: Compression Gauge, 20 kgf/cm²: 57001-221 Valve Seat Cutter, 60° 57001-1123 30: Valve Spring Compressor Assembly: 57001-241 Valve Seat Cutter Holder Bar: 57001-1128 Piston Pin Puller Assembly: 57001-910 Valve Seat Cutter, 45° 57001-1187 30: Valve Seat Cutter, 45° 57001-1114 Valve Seat Cutter, 32° 57001-1199 33: 27.
ENGINE TOP END 5-11 Special Tools and Sealant Valve Spring Compressor Adapter, 57001-1202 Valve Guide Arbor, 57001-1203 Valve Guide Reamer, 57001-1204 5: 22: Piston Pin Puller Adapter, 57001-1211 14: Compression Gauge Adapter, M10 × 1.
5-12 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type cam chain tensioner. The push rod does not return to its original position once it moves out to take up cam chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only partway. Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain.
ENGINE TOP END 5-13 Camshaft Chain Tensioner Camshaft Chain Tensioner Installation the stopper [A] to release the ratchet and push the • Push push rod [B] into the tensioner body. • Tighten: Torque - Camshaft Chain Tensioner Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Install: Pin [A] and Spring [B] • Washer [C] and Chain Tensioner Cap Bolt [D] Tighten: Torque - Camshaft Chain Tensioner Cap Bolt: 22 N·m (2.
5-14 ENGINE TOP END Rocker Case Rocker Case Removal Front Rocker Case Remove: Front Fender (see Front Fender Removal in the Frame chapter) Alternator Outer Cover Bolts [A] Alternator Outer Cover [B] Timing Inspection Plug [C] • Special Tool - Filler Cap Driver: 57001-1454 • Remove: Valve Adjusting Caps a wrench on the alternator bolt, turn the crankshaft • Using counterclockwise until “T-F” mark [A] is aligned with the notch [B] in the inspection window, and the cam lobes are pointing away from the rock
ENGINE TOP END 5-15 Rocker Case • Insert a suitable bar [A] under the front of the engine. [A] the front of the engine to remove the bolt [B] of the • Lift front right side on the rocker case. the rocker case to clear of the dowel pins in the cylin• Lift der head and slide the rocker case out of the frame.
5-16 ENGINE TOP END Rocker Case silicone sealant to the outer surface of the cap [A] • Apply and the cylinder head upper surface [B] as shown. Sealant - Kawasaki Bond (Liquid Gasket - Gray): 92104 -1063 the rocker case bolts following the tightening se• Tighten quence shown. Torque - Rocker Case Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) [1, 2, 3, 4] L = 55 mm (2.2 in.) with washers Rocker Case Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) [5, 6] L = 130 mm (5.1 in.) [A] L = 30 mm (1.2 in.) [B] L = 25 mm (1.0 in.
ENGINE TOP END 5-17 Rocker Case a M8 bolt [A], remove the rocker shaft [B]. • Using Remove: • Rocker Arm [C] Washers [D] ○Mark and record the rocker arm location so it can be installed in the original position. ○The rocker arms come off with the rocker shafts. Rocker Arm Installation engine oil: • Apply Rocker Shafts [A] • • • Hole in Rocker Arms [B] Replace the copper washers [C] with new ones.
5-18 ENGINE TOP END Rocker Case Rocker Shaft Diameter Measurement the diameter [A] of the rocker shaft where the • Measure rocker arm pivots on it with a micrometer. If the rocker shaft diameter is smaller than the service limit, replace it. Also check the rocker arm inside diameter (see Rocker Arm Inspection). Rocker Shaft Diameter Standard: 11.983 ∼ 11.994 mm (0.4718 ∼ 0.4722 in.) Service Limit: 11.96 mm (0.471 in.
ENGINE TOP END 5-19 Camshaft Camshaft Removal • Remove: Camshaft Chain Tensioners (see Camshaft Chain Ten• sioner Removal) Rocker Cases (see Rocker Case Removal) Camshafts [A] Support the chain using a suitable tool. Camshaft Installation a wrench on the alternator bolt, turn the crankshaft • Using clockwise until “T-R” mark [A] is aligned with the notch [B] in the inspection window. rear camshaft [A] has a groove [B]. • The First, • install the rear camshaft.
5-20 ENGINE TOP END Camshaft the arrow [A] of the front camshaft sprocket upward • Face (right side view). the front camshaft chain with the front camshaft • Engage sprocket. the marks [B] on the weights with the front cylinder • Align head upper surface. • Install: Rocker Cases (see Rocker Case Installation) • Camshaft Chain Tensioners (see Camshaft Chain Tensioner Installation) Check the valve clearance (see Valve Clearance Inspection).
ENGINE TOP END 5-21 Camshaft Camshaft Bearing Wear Inspection ○The • • journal wear is measured using plastigage (press gauge), which is inserted into the clearance to be measured. The plastigage indicates the clearance by the amount it is compressed and widened when the parts are assembled. Cut strips of plastigage to journal width.
5-22 ENGINE TOP END Camshaft KACR Inspection The Kawasaki Automatic Compression Release (KACR) momentarily opens the exhaust valves on the compression stroke at very low speeds. This allows some of the compression pressure to escape, making it easy to turn over the engine during starting. Due to the simplicity of the mechanism, no periodic maintenance is needed.
ENGINE TOP END 5-23 Camshaft • Remove: Circlips [A] Weights [B] Spring [C] NOTE ○Do not remove the shaft [A] and pin [B]. ○If the parts are removed, they cannot be reinstalled. KACR Installation • Install: Weights Circlips Spring [A] ○Hook the spring from the outside with the open side of the hook inwards. Install: KACR Unit Hook the arms [B] on the pins. Apply a non-permanent locking agent to the camshaft sprocket bolts [C] and tighten them. • • • Torque - Camshaft Sprocket Bolts: 12 N·m (1.
5-24 ENGINE TOP END Camshaft (right side view): • Remove Torque Converter Cover (see Torque Converter Cover • Removal in the Converter System chapter) Using a M6 bolt [A], pull out the cover [B].
ENGINE TOP END 5-25 Camshaft Front Camshaft Chain Install the circlip [A]. • Special Tool - Outside Circlip Pliers: 57001-144 the crankshaft clockwise 270°. • Rotate the key grooves [B] on the crankshaft with the em• Align bossed line [C] on the crankcase. the intermediate shaft [A] to the left side of the en• Move gine. the front camshaft chain [B] with the sprocket on • Engage the intermediate shaft. (left side view): • Install Position Plate [A] • Tighten: Torque - Position Plate Bolts [B]: 8.
5-26 ENGINE TOP END Camshaft the intermediate shaft chain tensioner [A] as fol• Install lows: the stopper [B] and push the push rod [C] into • Release the tensioner body. • Insert a wire [D] into the rod hole to hold the rod in place. • Install: Intermediate Shaft Chain Tensioner [A] Tighten: • Torque - Intermediate Shaft Chain Tensioner Bolts [B]: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Remove the wire [C] to free the push rod.
ENGINE TOP END 5-27 Camshaft • Install: Rocker Cases (see Rocker Case Installation) • Camshaft Chain Tensioners (see Camshaft Chain Tensioner Installation) Check the valve clearances (see Valve Clearance Inspection). Camshaft Chain Guide Wear Inspection inspect the rubber on the guides. • Visually If the rubber is damaged, cut, or is missing pieces, replace the guide.
5-28 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○Use the battery which is fully charged. up the engine thoroughly, and stop the engine. • Warm Remove spark plug (see Spark Plug Removal in the • Electricalthe System chapter). the compression gauge [A] and adapter [B] firmly • Attach into the spark plug hole. Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221 Compression Gauge Adapter, M10 × 1.
ENGINE TOP END 5-29 Cylinder Head Cylinder Head Removal the coolant (see Coolant Change in the Periodic • Drain Maintenance chapter).
5-30 ENGINE TOP END Cylinder Head molybdenum disulfide oil to the threads and seating • Apply surface of the cylinder head bolts and both sides of the • washers. Tighten the cylinder head bolts [A] following the tightening sequence as shown. First Torque - Cylinder Head Bolts (M10): kgf·m, 18 ft·lb) 25 N·m (2.5 Final Torque - Cylinder Head Bolts (M10): kgf·m, 36 ft·lb) 49 N·m (5.0 • Tighten the cylinder head bolts (M6) [B]. Torque - Cylinder Head Bolts (M6): 9.8 N·m (1.
ENGINE TOP END 5-31 Valves Valve Clearance Inspection to the Valve Clearance Inspection in the Periodic • Refer Maintenance chapter. Valve Clearance Adjustment to the Valve Clearance Adjustment in the Periodic • Refer Maintenance chapter. Valve Removal the cylinder head (see Cylinder Head Removal). •○Remove Mark and record the valve location so it can be installed • in the original position. Using the valve spring compressor assembly, remove the valve.
5-32 ENGINE TOP END Valves Valve Guide Installation oil the valve guide outer surface. • Lightly the valve guide arbor [A], drive the valve guide [B] • Using until its flange touches the cylinder head. Special Tool - Valve Guide Arbor, 5: 57001-1203 the valve guide with the valve guide reamer [A] , it • Ream may be necessary to ream the guide even if the old guide is reused.
ENGINE TOP END 5-33 Valves Valve Seat Inspection the valve (see Valve Removal). • Remove the valve seating surface [A] between the valve [B] • Check and valve seat [C]. ○Coat the valve seat with machinist’s dye. ○Push the valve into the guide. ○Rotate the valve against the seat with a lapping tool. ○Pull the valve out, and check the seating pattern on the • valve head. It must be the correct width and even all the way around. Measure the outside diameter [D] of the seating pattern on the valve seat.
5-34 ENGINE TOP END Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve seat 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 diamond 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.
ENGINE TOP END 5-35 Valves Widened 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] the outside diameter of the seating surface with • Measure vernier calipers. If the outside diameter of the seating surface is too small, repeat the 45° grind [A] until the diameter is within the specified range. Original Seating Surface [B] NOTE ○Remove all pittings of flaws from 45° ground surface.
5-36 ENGINE TOP END Valves If the seat width is too wide, make the 60° [A] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. Grind the seat at a 60° angle until the seat width is within the specified range. ○To make the 60° 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 measurement step above.
ENGINE TOP END 5-37 Valves
5-38 ENGINE TOP END Cylinder and Piston Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Oil Pipe [A] Chain Guide [B] Cylinder Bolts [C] Cylinder [D] Cylinder Base Gasket Piston Removal the cylinder block (see Cylinder Removal). • Remove a piece of clean cloth under the piston and remove • Place the piston pin snap rings [A] from the outside of each piston. CAUTION Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall.
ENGINE TOP END 5-39 Cylinder and Piston NOTE ○The oil ring rails have no “top” or “bottom”. the oil ring expander [A] in the bottom piston ring • Install groove so the ends [B] butt together. the oil ring steel rails, one above the expander and • Install 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. not mix up the top ring and second ring.
5-40 ENGINE TOP END Cylinder and Piston • Install: Cylinder [A] • Tighten: Torque - Cylinder Bolts [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install: Chain Guide [C] Apply • pipe. oil to the O-ring on the oil pipe [D], and insert the Cylinder Wear Inspection there is a difference in cylinder wear in different di• Since rections, take a side-to-side and a front-to-back measurement at each of the three locations (total of six measurements) shown in the figure.
ENGINE TOP END 5-41 Cylinder and Piston Piston Ring, Piston Ring Groove Wear Inspection for uneven groove wear by inspecting the ring seat• Check ing. • The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. With the piston rings in their grooves, make several measurements with a thickness gauge [A] to determine piston ring/groove clearance. Piston Ring/Groove Clearance Standard: Top 0.04 ∼ 0.08 mm (0.0016 ∼ 0.0032 in.) Second 0.03 ∼ 0.
5-42 ENGINE TOP END Cylinder and Piston Piston Ring End Gap Inspection the piston ring [A] inside the cylinder, using the pis• Place 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: Top 0.20 ∼ 0.30 mm (0.0079 ∼ 0.0118 in.) Second 0.30 ∼ 0.45 mm (0.0118 ∼ 0.0177 in.) Oil 0.20 ∼ 0.70 mm (0.0079 ∼ 0.0276 in.) Service Limit: Top 0.
ENGINE TOP END 5-43 Exhaust System This vehicle is equipped with a spark arrester approved for off-road use by the United States Forest Service. It must be properly maintained to ensure its efficiency. In accordance with the Periodic Maintenance Chart, clean the spark arrester. Spark Arrester Cleaning to the Spark Arrester Cleaning in the Periodic Main• Refer tenance chapter.
5-44 ENGINE TOP END Exhaust System • Remove: Front Exhaust Pipe Nuts [A] the front exhaust pipe rear end [A] under the fuel • Move tank. the front exhaust pipe front end [A] as shown. • Move Turn the front exhaust pipe front end to install the front • exhaust pipe.
ENGINE TOP END 5-45 Exhaust System cover [A], rear and middle exhaust pipe cov• Ifersthe[B]muffler [C] are removed, tighten them. Torque - Muffler Cover Bolts [D]: 8.8 N·m (0.90 kgf·m, 78 in·lb) Rear Exhaust Pipe Cover Bolts [E]: 8.8 N·m (0.90 kgf·m, 78 in·lb) Middle Exhaust Pipe Cover Bolts [F]: 8.8 N·m (0.90 kgf·m, 78 in·lb) the exhaust pipe gaskets [G] and clamp gasket • Replace [H] with new ones. (But do not tighten the following nuts and bolts.
CONVERTER SYSTEM 6-1 Converter System Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools .......................................................................................................................... Torque Converter Cover ........................
6-2 CONVERTER SYSTEM Exploded View
CONVERTER SYSTEM 6-3 Exploded View No. 1 2 3 4 5 Fastener Drive Pulley Bolt Driven Pulley Nut Drive Pulley Cover Bolts Ramp Weight Nuts Spider N·m 93 93 13 6.9 275 Torque kgf·m 9.5 9.5 1.3 0.70 28 ft·lb 68 68 115 in·lb 61 in·lb 203 Remarks R, Lh Lh G: Apply grease. Lh: Left-hand Threads R: Replacement Parts WR: Apply grease (WR500-No.2 KYODO YUSHI, POWER LITE WR #2 KYODO YUSHI, or SERAN -HV TOTAL FINA).
6-4 CONVERTER SYSTEM Exploded View
CONVERTER SYSTEM 6-5 Exploded View No. 1 2 Fastener Torque Converter Cover Bolts Engine Brake Actuator Mounting Bolts G: Apply grease. M: Apply molybdenum disulfide grease. R: Replacement Part S: Follow the specific tightening sequence. N·m 8.8 8.8 Torque kgf·m 0.90 0.
6-6 CONVERTER SYSTEM Specifications Item Torque Converter Actuator Lever Guide Shoe Drive Belt Belt Width Belt Deflection Drive Pulley Shoe Side Clearance Cover Bushing Inside Diameter Sheave Bushing Inside Diameter Spring Free Length Driven Pulley Sheave Bushing Inside Diameter Spring Free Length Standard ––– 29.7 ∼ 30.3 mm (1.17 ∼ 1.19 in.) 22 ∼ 27 mm (0.87 ∼ 1.06 in.) Service Limit 6 mm (0.24 in.) 28.0 mm (1.10 in.) – – – Up to 0.20 mm (0.008 in.) (in the text) – – – 27.985 ∼ 28.085 mm (1.1018 ∼ 1.
CONVERTER SYSTEM 6-7 Special Tools Outside Circlip Pliers: 57001-144 Drive Pulley Wrench: 57001-1474 Drive & Driven Pulley Holder: 57001-1412 Spring Holder Set: 57001-1483 Drive Pulley Puller Bolt: 57001-1429 Drive Pulley Measurement Tool: 57001-1498 Pulley Holder Attachment: 57001-1472 Actuator Lever Measurement Tool: 57001-1499 Drive & Driven Pulley Holder: 57001-1473 Drive Pulley Holder: 57001-1520
6-8 CONVERTER SYSTEM Special Tools Flywheel & Pulley Holder: 57001-1605
CONVERTER SYSTEM 6-9 Torque Converter Cover WARNING Excessive imbalance or operating rpm could cause torque converter pulley failure resulting in severe injury or death. The pulleys of the belt drive torque converter are precision balanced components designed to operate within certain rpm limits. Disassembly/assembly and servicing procedures of the pulley assemblies must be followed closely. Modifications to the engine or pulleys that increase rpm may cause failure.
6-10 CONVERTER SYSTEM Torque Converter Cover Torque Converter Cover Installation the actuator lever assembly installation length (see • Check Torque Converter Cover Assembly). the trim seal into the converter cover. •○Fit Set the trim seal juncture in the area [A] when insert the trim seal in the cover. [B] 10 mm (0.39 in.) • Check: Drive Belt Failure Detection Switch (see Switch Inspec• tion section in Electric System chapter) Set [A] the switch lever [B] to the ON mark side [C].
CONVERTER SYSTEM 6-11 Torque Converter Cover Actuator Lever (Engine Brake Control Lever) Assembly Inspection to the Actuator Lever (Engine Brake Control Lever) • Refer Assembly Inspection in the Periodic Maintenance chapter. Torque Converter Cover Assembly • Install: New Circlip Spring Actuator Lever Assembly Engine Brake Actuator (see Engine Brake Actuator Installation in the Electrical System chapter) Torque - Engine Brake Actuator Mounting Bolts: 8.8 N·m (0.
6-12 CONVERTER SYSTEM Torque Converter Cover Actuator Lever Assemblies Part Number Paint Color [A] Length [B] 13236-0046 Yellow 0.4 ±0.1 mm (0.016 ±0.004 in.) 13236-0048 None 1.0 ±0.1 mm (0.039 ±0.004 in.) 13236-0047 Green 1.6 ±0.1 mm (0.063 ±0.004 in.
CONVERTER SYSTEM 6-13 Drive Belt Drive Belt Removal • Remove the drive pulley (see Drive Pulley Removal). NOTE ○Before removing, observe the direction the belt’s printed information [A] (such as manufacturer’s name) is facing so that it may be reinstalled on the pulleys to rotate in the same direction as originally installed. • Lift the drive belt [B] off the driven pulley [C].
6-14 CONVERTER SYSTEM Drive Pulley Drive Pulley Removal • Remove: Torque Converter Cover (see Torque Converter Cover • Removal) Right Footboard (see Right Footboard Removal in the Frame chapter) Remove the three cover bolts [A] and install the drive pulley holder [B]. Special Tool - Drive Pulley Holder: 57001-1520 • Tighten the three cover bolts: Torque - Drive Pulley Cover Bolts: 13 N·m (1.
CONVERTER SYSTEM 6-15 Drive Pulley the pulley onto the pulley holder. • Set Remove: • Drive Pulley Cover Bolts [A] Drive Pulley Cover [B] • Remove: Spring [A] Spacer the drive pulley wrench [A] on the spider [B] and • Put tighten the bolt [C]. Special Tool - Drive Pulley Wrench: 57001-1474 the wrench clockwise and remove the spider with the • Turn movable sheave. ○The NOTE spider has left-hand threads. clockwise for loosening.
6-16 CONVERTER SYSTEM Drive Pulley Drive Pulley Inspection If the sheave surfaces [A] appear damaged, replace the sheaves. If the cover bushing is damaged or worn, replace the drive pulley cover. Cover Bushing Inside Diameter [A] Standard: 27.985 ∼ 28.085 mm (1.1018 ∼ 1.1057 in.) Service Limit: 28.12 mm (1.107 in.) If the sheave bushing is damaged or worn, replace it. Sheave Bushing Inside Diameter [A] Standard: 37.985 ∼ 38.085 mm (1.4955 ∼ 1.4994 in.) Service Limit: 38.12 mm (1.501 in.
CONVERTER SYSTEM 6-17 Drive Pulley If the rollers [A] are damaged or worn, replace the spider [B]. If the washers [C] are damaged or worn, replace the spider. If the spring is worn or damaged, replace the spring. Spring Free Length [A] Standard: 59.5 mm (2.34 in.) Spider Shoe Side Clearance Inspection/Adjustment • Remove: Drive Pulley (see Drive Pulley Removal) Drive Pulley Cover and Spring (see Drive Pulley Disassembly) Temporarily install the following parts on the movable sheave.
6-18 CONVERTER SYSTEM Drive Pulley the movable sheave counterclockwise. • Turn Measure the resulting clearance [A] between the shoe [B] • and the post [C] on the movable sheave at two positions as shown. [D] Arrow Mark Shoe Side Clearance Standard: up to 0.20 mm (0.008 in.), and there must be kept a clearance which the movable sheave [E] moves smoothly until it touches the fixed sheave [F] with its own weight. If the clearance is not the specified range, adjust it using the following shoes.
CONVERTER SYSTEM 6-19 Drive Pulley the fixed sheave [A] with the drive pulley holder [B] • Hold in a vise. Special Tool - Drive & Driven Pulley Holder: 57001-1473 the threads of the fixed sheave and spider. • Clean Install: • Movable Sheave Spider [A] and Shoes [B] ○Align the arrow [C] on the spider with the arrow [D] on the movable sheave. ○Insert the shoes so that the rubber side (black, small diameter) faces inward. the drive pulley wrench [A] on the spider [B] and • Put tighten the bolt [C].
6-20 CONVERTER SYSTEM Drive Pulley the drive pulley, stepped waster and two washers • Install on the drive pulley bolt as shown. Crankcase Side [A] Stepped Washer [B] Two Washers [C] Bolt Head Side [D] the three cover bolts [A] and install the drive pul• Remove ley holder [B]. Special Tool - Drive Pulley Holder: 57001-1620 • Tighten: Torque - Drive Pulley Cover Bolts: 13 N·m (1.3 kgf·m, 115 in·lb) Drive Pulley Bolt [C] (new, left-hand threads): 93 N·m (9.
CONVERTER SYSTEM 6-21 Drive Pulley ○Install the drive pulley measurement tool (legs [A] and plate [B]) on the crankcase [C]. Special Tool - Drive Pulley Measurement Tool: 57001-1498 ○Measure the length [D] between the plate and collar [E] with vernier calipers [F] or a depth gauge. Measurement Length [D] Standard: 14.55 ∼ 15.65 mm (0.573 ∼ 0.616 in.) If the measurement is not within the specified range, adjust it according to following table. Status Quo Measurement Length less than 14.55 mm (0.573 in.
6-22 CONVERTER SYSTEM Driven Pulley Driven Pulley Removal • Remove: Torque Converter Cover (see Torque Converter Cover • Removal) Drive Pulley (see Drive Pulley Removal) Drive Belt (see Drive Belt Removal) Using the flywheel & pulley holder [A] and attachments [B], remove the driven pulley nut [C] and washers. (Nut has R/H threads.
CONVERTER SYSTEM 6-23 Driven Pulley the paint mark “0” [A] on the movable sheave [B] • Confirm in alignment with the point [C] on the fixed sheave [D] for phase fit of the sheaves. off the molybdenum disulfide grease. • Wipe Remove • driver [B].the four pins [A] with a thin standard tip screw• Remove the movable sheave from the fixed sheave. • Remove: Spacer(s) [A] (for Drive Belt Deflection Adjustment) Driven Pulley Inspection If the sheave surfaces [A] appear damaged, replace the sheaves.
6-24 CONVERTER SYSTEM Driven Pulley If the sheave bushings [A] are damaged or worn, replace the movable sheave. Sheave Bushing Inside Diameter Standard: 40.000 ∼ 40.039 mm (1.5748 ∼ 1.5763 in.) Service Limit: 40.07 mm (1.578 in.) seals for damage. • Inspect If seals are damaged, replace the movable sheave. If the splines [A] are damaged or worn, replace the fixed sheave. If the spring is damaged or worn, replace the spring. Spring Free Length [A] Standard: 75.1 mm (2.96 in.
CONVERTER SYSTEM 6-25 Driven Pulley the paint mark “0” [A] on the movable sheave [B] • Align with the point [C] on the fixed sheave [D] for phase fit of the sheaves. ○In that case the opening [A] and hole [B] will be matched easily. grease (WR500-No.2 (KYODO YUSHI), POWER • Apply LITE WR #2 (KYODO YUSHI), or SERAN-HV (TOTAL FINA)) to the seating surface [A] of the pins, and insert them into the holes in the movable sheave. the movable sheave onto the fixed sheave, and ap• Draw ply grease of 1 g (0.
6-26 CONVERTER SYSTEM Driven Pulley • Hold the drive & driven pulley holder in a vise. Special Tool - Drive & Driven Pulley Holder: 57001-1473 • Screw the guide bar into the holder. Special Tool - Spring Holder Set: 57001-1483 the driven pulley [A] onto the guide bar. • Put Put the thrust plate [B] so that the alloy side (gray) faces • the movable sheave. Install: • Spring Seat [C]: 18.5 mm (0.728 in.) Spring [D] Spring Seat [E]: 9.3 mm (0.366 in.
CONVERTER SYSTEM 6-27 Driven Pulley two washers [A] on the shaft as shown. • Install Crankcase Side [B] Bolt Head Side [C] the flywheel & pulley holder [A] and attachments • Using [B], tighten the driven pulley nut [C]. Special Tools - Flywheel & Pulley Holder: 57001-1605 Pulley Holder Attachment: 57001-1472 Torque - Driven Pulley Nut: 93 N·m (9.
6-28 CONVERTER SYSTEM High Altitude Setting Information Specifications Altitude m (ft) 0 ∼ 2 000 (0 ∼ 6 500) Ramp Weights P/No. 39152-0019 (STD, X1) Drive Pulley Spring Spacer P/No. 92026-1603 t = 1 mm (0.04 in.) 2 000 ∼ 3 200 (6 500 ∼ 10 400) P/No. 39152-0028 (X1H) P/No. 92026-1603 t = 1 mm (0.04 in.) X1, X1H: Identification Marks qty: quantity • Refer to the Drive Pulley section for the parts replacement.
ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools & Sealant.......................................................................................................... Engine Oil Flow Chart...............
7-2 ENGINE LUBRICATION SYSTEM Exploded View
ENGINE LUBRICATION SYSTEM 7-3 Exploded View No. 1 2 3 4 5 6 7 8 9 Fastener Oil Filter Oil Pressure Switch Oil Pipe Bolts Engine Oil Drain Bolt Oil Pressure Relief Valve Oil Pump Cover Bolts Oil Pump Chain Guide Bolts Oil Pump Drive Chain Tensioner Bolt Oil Filter Mounting Bolt N·m 17.5 15 8.8 20 15 8.8 8.8 25 25 G: Apply grease. L: Apply a non-permanent locking agent. O: Apply engine oil. R: Replacement Parts SS: Apply silicone sealant (Kawasaki Bond: 56019-120). Torque kgf·m 1.8 1.5 0.90 2.0 1.5 0.
7-4 ENGINE LUBRICATION SYSTEM Specifications Item Engine Oil Type Viscosity Capacity Oil Level (after warm-up or driving) Oil Pressure Measurement Oil Pressure @4 000 r/min (rpm), Oil Temperature 120°C (248°F) Standard API SF or SG API SH, SJ or SL with JASO MA SAE 10W-40 2.1 L (2.2 US qt) (when filter is not removed) 2.2 L (2.3 US qt) (when filter is removed) 2.6 L (2.7 US qt) (when engine is completely dry) Between upper and lower level lines 430 kPa (4.4 kgf/cm², 62.
ENGINE LUBRICATION SYSTEM 7-5 Special Tools & Sealant Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT 1/8: 57001-1033 Kawasaki Bond (Silicone Sealant): 56019-120
7-6 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1. Front Camshaft 2. Oil Filter 3. Crankshaft 4. Oil Pressure Switch 5. Oil Pipes 6. Oil Pump 7. Relief Valve 8. Transmission Idle Shaft 9. Oil Screen 10. Transmission Driven Shaft 11. Rear Camshaft 12. Breather Hose 13.
ENGINE LUBRICATION SYSTEM 7-7 Engine Oil and Oil Filter WARNING Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury. Oil Level Inspection the vehicle so that it is level, both side-to-side and • Park front-to-rear. the oil has just been changed, start the engine, and run • Ifit for several minutes to fill the oil filter.
7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Oil Screen Cleaning the oil screen [A] thoroughly whenever it is removed • Clean for any reason. the oil screen with a high-flash point solvent and • Clean remove any particles stuck to it. WARNING Clean the screen 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 solvents.
ENGINE LUBRICATION SYSTEM 7-9 Oil Pressure Switch Oil Pressure Switch Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main• tenance chapter) Remove: Switch Cover [A] Switch Lead Terminal [B] Oil Pressure Switch [C] Oil Pressure Switch Installation silicone sealant to the threads of the oil pressure • Apply switch, and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb) the terminal bolt securely.
7-10 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal the crankcase (see Crankcase Disassembly in the • Split Crankshaft/Transmission chapter). • Remove the oil pressure relief valve [A]. Oil Pressure Relief Valve Installation crankcase assembly (see Crankcase Assembly in • See the Crankshaft/Transmission chapter). a non-permanent locking agent to the threads of oil • Apply pressure relief valve, and tighten it. Torque - Oil Pressure Relief Valve: 15 N·m (1.
ENGINE LUBRICATION SYSTEM 7-11 Oil Pump Oil Pump Removal • Remove: Alternator Rotor (see Alternator Rotor Removal in the Electrical System chapter) Oil Pump Drive Chain Tensioner Bolt [A] Starter Motor Clutch Gear Chain Guide Bolt [B] and Collar Chain Guide [C] • Remove: Oil Pump Bolts [A] Oil Pump Drive Chain [B] together with Oil Pump Assembly [C] • Remove: Circlip [A] Inner Rotor [B] Outer Rotor [C] Oil Pump Drive Shaft [D] Oil Pump Cover [E] Oil Pump Installation engine oil: • Apply Oil Pump Drive S
7-12 ENGINE LUBRICATION SYSTEM Oil Pump the oil pump drive chain [A] with the oil pump as• Install sembly [B]. • Tighten: Torque - Oil Pump Cover Bolts [C]: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Install: Chain Guide [A] and Collar [B] • Tighten: Torque - Oil Pump Drive Chain Guide Bolt [C]: 8.8 N·m (0.90 kgf·m, 78 in·lb) grease to the O-ring [A]. • Apply Install: • Pin [B] • Spring [C] O-ring Oil Pump Drive Chain Tensioner Bolt [D] Tighten: Torque - Oil Pump Drive Chain Tensioner Bolt: 25 N·m (2.
ENGINE LUBRICATION SYSTEM 7-13 Oil Pipe Oil Pipe Removal Engine Left Side Oil Pipe (Engine Inside) Remove: Oil Pump (see Oil Pump Removal) Oil Pipe Bolt [A] Oil Pipe [B] • Engine Left Side Oil Pipe (Engine Outside) Drain the engine oil (see Engine Oil Change in the Periodic Maintenance chapter). Remove: Output Drive Bevel Gear Cover Bolts [A] Oil Pipe Bolts [B] Remove the bevel gear cover [C] to remove the oil pipe [D].
7-14 ENGINE LUBRICATION SYSTEM Oil Pipe Oil Pipe Installation the O-ring [A] with new ones. • Replace engine oil to the O-rings before installation. • Apply Tighten: • Torque - Oil Pipe Bolts: 8.8 N·m (0.
ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................................................................................................................ Engine Removal/Installation ................................................................................................... Engine Removal................................................................................................................ Engine Installation.........................
8-2 ENGINE REMOVAL/INSTALLATION Exploded View
ENGINE REMOVAL/INSTALLATION 8-3 Exploded View No. 1 2 3 Fastener Engine Mounting Bracket Bolts Engine Mounting Bolts Engine Mounting Nut L: Apply a non-permanent locking agent. N·m 72 72 100 Torque kgf·m 7.3 7.
8-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Remove: Engine Oil (drain) (see Engine Oil Change in the Periodic Maintenance chapter) Coolant (drain) (see Coolant Change in the Periodic Maintenance chapter) Muffler and Exhaust Pipe (see Muffler and Exhaust Pipe Removal in the Engine Top End chapter) Throttle Body (see Throttle Body in the Fuel System (DFI) chapter) Speed Sensor (see Speed Sensor Removal in the Electrical System chapter) Front Propeller Shaft (see Front Propell
ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation • Remove: Ignition Coil [A] (rear) Spark Plug Cap [B] Shift Shaft Lever [C] Breather Hose [D] Engine Ground Terminal [E] • Remove: Water Pipe [A] Spark Plug Cap [B] • Remove: Coolant Reserve Tank [A] Neutral Switch Lead Connector [B] Reverse Switch Lead Connector [C] Water Hose [D] • Remove: Forward/Reverse Detecting Sensor [A] • Remove: Engine Mounting Bolts [A] Engine Mounting Bracket Bolts [B] (both side) Engine Mounting Bracket [C]
8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove the engine [A] as shown. Engine Installation a non-permanent locking agent to the engine • Apply mounting bolts and engine mounting bracket bolts. • Install: Engine • Engine Bracket and Bolts Engine Mounting Bolts (temporary) Tighten: Torque - Engine Mounting Bracket Bolts: 72 N·m (7.3 kgf·m, 53 ft·lb) Engine Mounting Bolts: 72 N·m (7.
CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools and Sealant ...................................................................................................... Crankcase ...............................
9-2 CRANKSHAFT/TRANSMISSION Exploded View
CRANKSHAFT/TRANSMISSION 9-3 Exploded View No. 1 2 3 4 5 6 7 8 9 Fastener Connecting Rod Big End Cap Nuts Engine Oil Drain Bolt Crankcase Bolts (M8) 75 mm (2.95 in.) Crankcase Bolts (M8) 110 mm (4.33 in.) Crankcase Bolt (M8) 110 mm (4.33 in.) Crankcase Bolts (M6) 40 mm (1.57 in.) Crankcase Bolts (M6) 65 mm (2.56 in.) Bearing Position Plate Screws Rear Cylinder Camshaft Chain Guide Bolt N·m 34.3 20 20 20 20 9.8 9.8 4.9 20 Torque kgf·m 3.5 2.0 2.0 2.0 2.0 1.0 1.0 0.50 2.
9-4 CRANKSHAFT/TRANSMISSION Exploded View
CRANKSHAFT/TRANSMISSION 9-5 Exploded View No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Fastener Grip Holder Nut Shift Lever Guide Mounting Bolts Tie-rod End Front Locknut Tie-rod End Rear Locknut Tie-rod End Nut Shift Lever Assembly Nut Tie-rod End Bolt Shift Shaft Positioning Bolt Shift Shaft Spring Bolt Shift Shaft Cover Bolts Tie-rod End Locknut Neutral Position Switch Reverse Position Switch Shift Lever Clamp Bolt Shift Lever Guide Mounting Nut N·m 9.8 19.6 9.8 9.8 19.6 19.6 9.8 25 25 8.8 19.6 15 15 13.
9-6 CRANKSHAFT/TRANSMISSION Specifications Item Crankshaft, Connecting Rods Connecting Rod Bend Standard Service Limit ––– Connecting Rod Twist ––– Connecting Rod Big End Side Clearance 0.16 ∼ 0.46 mm (0.0063 ∼ 0.0181 in.) 0.028 ∼ 0.052 mm (0.0011 ∼ 0.0020 in.) 39.984 ∼ 40.000 mm (1.5742 ∼ 1.5748 in.) Connecting Rod Big End Bearing Insert/Crankpin Clearance Crankpin Diameter: Marking: None ○ Connecting Rod Big End Inside Diameter: Marking: None ○ TIR 0.2/100 mm (0.008/3.94 in.) TIR 0.2/100 mm (0.
CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Transmission Shift Fork Ear Thickness Shift Groove Width Standard 5.9 ∼ 6.0 mm (0.232 ∼ 0.236 in.) 6.05 ∼ 6.15 mm (0.238 ∼ 0.242 in.) Service Limit 5.8 mm (0.23 in.) 6.25 mm (0.246 in.
9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealant Outside Circlip Pliers: 57001-144 Crankshaft Jig: 57001-1174 Bearing Driver Set: 57001-1129 Kawasaki Bond (Liquid Gasket - Gray): 92104-1063
CRANKSHAFT/TRANSMISSION 9-9 Crankcase Crankcase Disassembly • Remove: Engine (see Engine Removal in the Engine Removal/Installation chapter) Starter Motor (see Starter Motor Removal in the Electrical System chapter) Oil Filter Cylinder Blocks and Pistons (see Cylinder and Piston Removal in the Engine Top End chapter) Intermediate Shaft and Chains (see Camshaft Chain Removal in the Engine Top End chapter) Drive Pulley (see Drive Pulley Removal in the Converter system chapter) Driven Pulley (see Driven Pulle
9-10 CRANKSHAFT/TRANSMISSION Crankcase the following parts from the right crankcase half.
CRANKSHAFT/TRANSMISSION 9-11 Crankcase • Install: Rear Cylinder Camshaft Chain Guide [A] • Tighten: Torque - Rear Cylinder Camshaft Chain Guide Bolt [B]: 20 N·m (2.0 kgf·m, 15 ft·lb) and insert the new ball bearings [A] until they are • Press bottomed. Special Tool - Bearing Driver Set: 57001-1129 and insert the new needle bearings so that the • Press bearing surfaces are flush with the end of the hole. • [B] Needle Bearing [C] Needle Bearing (Insert it from outside.) Apply engine oil to the bearings.
9-12 CRANKSHAFT/TRANSMISSION Crankcase a non-permanent locking agent to the area [C] (12 • Apply mm, 0.47 in.) except for the tip [D] (2 ∼ 3 mm, 0.08 ∼ 0.12 • in.). Left Crankcase Bolt (M8) [3] Tighten the right and left crankcase bolts (M8) following the tightening sequence [1 ∼ 8]. Torque - Crankcase Bolts (M8): 20 N·m (2.0 kgf·m, 15 ft·lb) • [1, 2, 5, 6] L = 75 mm (2.95 in.) [3, 4, 7, 8] L = 110 mm (4.33 in.) Tighten: Torque - Crankcase Bolts (M6): 9.8 N·m (1.0 kgf·m, 87 in·lb) [A] L = 40 mm (1.
CRANKSHAFT/TRANSMISSION 9-13 Crankshaft/Connection Rod Crankshaft Removal the crankcase (see Crankcase Disassembly). • Split the crankshaft [A] from the crankcase using a • Remove press. Crankshaft Installation left shaft [A] of the crankshaft is longer than the right • The shaft [B]. engine oil to the both main journals. • Apply Insert crankshaft tapered end (the shorter end) • into thetherightrightcrankcase using a press and two crankshaft jigs.
9-14 CRANKSHAFT/TRANSMISSION Crankshaft/Connection Rod molybdenum disulfide oil: • Apply Threads [A] of Connecting Rod Big End Cap Bolts • Seating Surface [B] of Connecting Rod Big End Cap Nuts [C] Tighten: Torque - Connecting Rod Big End Cap Nuts: 34.3 N·m (3.5 kgf·m, 25 ft·lb) Crankshaft/Connecting Rod Cleaning removing the connecting rods from the crankshaft, • After clean them with a high flash-point solvent.
CRANKSHAFT/TRANSMISSION 9-15 Crankshaft/Connection Rod Connecting Rod Big End Side Clearance Inspection the side clearance of the connecting rod big end • Measure [A]. ○Insert a thickness gauge [B] between the big end and either crank web to determine clearance. Connecting Rod Big End Side Clearance Standard: 0.16 ∼ 0.46 mm (0.0063 ∼ 0.0181 in.) Service Limit: 0.7 mm (0.028 in.) If the clearance exceeds the service limit, replace the connecting rod with new one and then check clearance again.
9-16 CRANKSHAFT/TRANSMISSION Crankshaft/Connection Rod If the measured crankpin diameter [A] is not less than the service limit, but does not coincide with the original diameter marking on the crankshaft, make a new mark on it. Crankpin Diameter Marks None: 39.984 ∼ 39.992 mm (1.5742 ∼ 1.57448 in.) ○: 39.993 ∼ 40.000 mm (1.57452 ∼ 1.5748 in.
CRANKSHAFT/TRANSMISSION 9-17 Crankshaft/Connection Rod Crankshaft Runout Inspection the crankshaft runout. • Measure If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: TIR 0.04 mm (0.0016 in.) or less Service Limit: TIR 0.10 mm (0.0039 in.) Crankshaft Main Bearing/Journal Wear Inspection • Measure the diameter [A] of the crankshaft main journal. Crankshaft Main Journal Diameter Standard: 41.984 ∼ 42.000 mm (1.6529 ∼ 1.6535 in.) Service Limit: 41.96 mm (1.
9-18 CRANKSHAFT/TRANSMISSION Transmission Shift Lever Removal the shift lever in the neutral position. • Set • Remove: Right Side Cover (see Right Side Cover Removal in the • Frame chapter) Shift Shaft Lever Bolt [A] Remove the shift shaft lever [B] from the shift shaft.
CRANKSHAFT/TRANSMISSION 9-19 Transmission Shift Lever Installation the tie-rod end [A] and tie-rod end locknut [B] to • Twist bottom of the screw and then turn back to dimension with • 77° ±10° [C] as shown. Tighten the locknut against the tie-rod end: Torque - Tie-rod End Locknut: 19.6 N·m (2.0 kgf·m, 14 ft·lb) molybdenum disulfide grease: • Apply Outside of Tie-rod End Collar [D] Apply • Tighten:grease to the oil seals, and install them. • Torque - Tie-rod End Bolt [E]: 9.8 N·m (1.
9-20 CRANKSHAFT/TRANSMISSION Transmission • Install: Guide [A] Tighten: • Torque - Shift Lever Guide Mounting Bolts [B]: 19.6 N·m (2.0 kgf·m, 14 ft·lb) the lever assembly in the neutral position [C] while • Set turning the tie-rod [D]. NOTE ○Do not turn the shift shaft [E] when setting the lever assembly on neutral position. ○Turn the tie-rod counterclockwise until the rod [F] of the shift lever assembly contacts with the neutral position [G] of the guide [H].
CRANKSHAFT/TRANSMISSION 9-21 Transmission ○Do not lean the tie-rod rear end after tightening the front • • • • locknut. Right [L] Wrong [M] Check that the shift lever moves from right to left automatically. Install: Spring [N] Trim Seal [O] Align the mark [P] of the grip [Q] with the projection [R] on the guide. Tighten: Torque - Grip Holder Nut [S]: 9.8 N·m (1.
9-22 CRANKSHAFT/TRANSMISSION Transmission • Remove: Circlip [A] Special Tool - Outside Circlip Pliers: 57001-144 • Remove: Spacer [A] Idle Gear Assembly [B] Washers and Spacer [C] Low and High Gears [D] • Remove: Needle Bearings [A] the driven shaft [B] from the crankcase using a • Remove press. Transmission Installation the driven shaft in the crankcase until it is bottomed • Insert using a press. • Apply engine oil to the needle bearings and install them. the following parts on the low gear [A].
CRANKSHAFT/TRANSMISSION 9-23 Transmission • Install: Idle Shaft [A] with Gear Assembly [B] • • Spacer [C] Spacer [D] (P/No. 92026-1599, 48.2 × 54.3 × 1.0) Apply engine oil to the inner surface of the spacer [E]. Install the spacer [E] so that the stepped side [F] faces outward.
9-24 CRANKSHAFT/TRANSMISSION Transmission molybdenum disulfide oil to the shift shaft [A]. • Apply Install: • Shift Shaft Spring Bolt [B] • • Spring [C] Guide [D] Apply a non-permanent locking agent: Shift Shaft Spring Bolt Tighten: Torque - Shift Shaft Spring Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) an oil seal [A] is installed in the shift shaft cover [B], • When press and insert the oil seal so that its surface is flush with the end of the hole.
CRANKSHAFT/TRANSMISSION 9-25 Transmission Transmission and Shift Mechanism Inspection inspect: • Visually Gears Dogs of Gear and Shifter If they are damaged or worn excessively, replace them.
9-26 CRANKSHAFT/TRANSMISSION Transmission 1. Driven Shaft 2. Spacer (17.3 × 30 × 2.0) 3. Reverse Gear (12T) 4. Spacer (21.2 × 29 × 1.6) 5. Shifter 6. Circlip 7. Toothed Washer (t = 1.5) 8. Spacer (28.2 × 34.5 × 1.6) 9. Spacer (Hi and Low) 10. Spacer (48.2 × 54.3 × 1.0) 11. Drive Hi Gear (26T) 12. Drive Low Gear (20T) 13. Reverse Idle Shaft 14. Reverse Driven Gear (16T) 15. Reverse Driven Output Gear (16T) 16. Idle Shaft 17. Spacer (20.3 × 33 × 2.0) 18. Drive Output Gear (18T) 19. Driven Hi Gear (30T) 20.
CRANKSHAFT/TRANSMISSION 9-27 Ball Bearing, Needle Bearing, and Oil Seal Ball and Needle Bearing Replacement CAUTION Do not remove the ball or needle bearings unless it is necessary. Removal may damage them. a press or puller, remove the ball bearing and/or • Using three needle bearings. NOTE ○In the absence of the above mentioned tools, satisfac- tory results may be obtained by heating the case to approximately 93°C (200°F) max., and tapping the bearing in or out.
WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tool ............................................................................................................................ Wheel Alignment .....................................
10-2 WHEELS/TIRES Exploded View
WHEELS/TIRES 10-3 Exploded View No. 1 2 2 3 4 Fastener Tie-rod Locknuts Wheel Nuts (First Torque) Wheel Nuts (Final Torque) Front Axle Nuts Rear Axle Nuts R: Replacement Parts S: Follow the specific tightening sequence. W: Apply water or soap and water solution. N·m 37 15 76 197 265 Torque kgf·m 3.8 1.5 7.
10-4 WHEELS/TIRES Specifications Item Wheel Alignment Toe-in of front wheels: Wheels (Rims) Rim Size: Front Rear Tires Standard tire: Front Rear Tire air pressure (when cold): Front Rear Maximum tire air pressure (to seat beads, when cold) Tire tread depth: Front Rear Standard Service Limit –10 ∼ 10 mm (–0.39 ∼ 0.39 in.) at 1G – – – 12 × 6.0 12 × 7.5 – – – – – – AT 25 × 8-12 DUNLOP, KT191, Tubeless AT 25 × 10-12 DUNLOP, KT195, Tubeless – – – 35 kPa (0.35 kgf/cm², 5.0 psi) 35 kPa (0.35 kgf/cm², 5.
WHEELS/TIRES 10-5 Special Tool Jack: 57001-1238
10-6 WHEELS/TIRES Wheel Alignment Toe-in is the difference between the distance of front and the one of rear at the axle height position in the front wheels. When there is toe-in, the distance A (Rear) is the greater than B (Front) as shown. The purpose of toe-in is to prevent the front wheels from getting out of parallel at any time, and to prevent any slipping or scuffing action between the tires and the ground.
WHEELS/TIRES 10-7 Wheel Alignment the straightedge procedure on the other side of • Repeat the vehicle. Now the front wheels are parallel to each • other and to the center line of the vehicle. Front Wheel [A] Vehicle Center Line [B] Parallel each other [C] Straightedges [D] Rear Wheels [E] Go on to the Toe-in Inspection procedure. Toe-in Inspection a heavy coat of chalk or a paint line near the center • Apply of the front tires.
10-8 WHEELS/TIRES Wheel Alignment NOTE ○The toe-in will be near the specified value, if the tie-rod length [A] is 388.5 mm (15.30 in.) on each tie-rod. CAUTION Adjust the tie-rod length so that the visible thread length [B] is even on both ends of the tie-rod. Uneven thread length could cause tie-rod damage. the toe-in. • Check Tighten: • Torque - Tie-rod Locknuts: 37 N·m (3.8 kgf·m, 27 ft·lb) • Test ride the vehicle.
WHEELS/TIRES 10-9 Wheels (Rims) Wheel Removal the brake lever slowly and hold it with a band • Squeeze [A]. the wheel nuts [A]. • Loosen Support vehicle on a stand or a jack so that the wheels • are off thetheground. Special Tool - Jack: 57001-1238 • Remove: Wheel Nuts Washers (Front Wheel) Plate [B] (Rear Wheel) Wheel Wheel Installation the tire rotation mark [A] on the tire, and install the • Check wheel accordingly.
10-10 WHEELS/TIRES Wheels (Rims) Wheel (Rim) Inspection both sides of the rim for dents [A]. If the rim is • Examine dented, replace it. If the tire is removed, inspect the air sealing surfaces [A] of the rim for scratches or nicks. Smooth the sealing surfaces with fine emery cloth if necessary. Wheel (Rim) Replacement the wheel (see Wheel Removal). • Remove the tire from the rim (see Tire Removal). •○Disassemble Remove the air valve and discard it.
WHEELS/TIRES 10-11 Tires Tire Removal the wheel. • Remove the valve core to deflate the tire. •○Unscrew Use a proper valve core tool [A]. the tire beads and rim flanges on both sides of • Lubricate the wheel with a soap and water solution, or water [A]. This helps the tire beads slip off the rim flanges. CAUTION Do not lubricate the tire beads and rim flanges with engine oil or petroleum distillates because they will deteriorate the tire.
10-12 WHEELS/TIRES Tires the wheel rim [A] on a suitable stand [B] to pre• Support vent the tire from slipping off. • Inflate the tire until the tire beads seat on the rim. Maximum Tire Air Pressure (to seat beads when cold) Front and Rear 250 kPa (2.5 kgf/cm², 36 psi) WARNING Do not inflate the tire to more than the maximum tire air pressure. Overinflation can explode the tire with possibility of injury and loss of life.
WHEELS/TIRES 10-13 Front Hub Front Hub Removal • Remove: Cap [A] • Cotter Pin [B] (cut) Loosen the axle nut [C]. the front wheel (see Wheel Removal). • Remove Remove caliper by taking off the mounting bolts [A], • and let thethecaliper [B] hang free. the axle nut [A], and pull off the front hub [B] • Remove together with the brake disc. the brake disc from the front hub (see Front • Separate Brake Disc Removal in the Brakes chapter).
10-14 WHEELS/TIRES Front Hub • Bend the cotter pin [A] over the nut. Front Hub Disassembly/Assembly • • If any hub bolt [A] is damaged, replace the hub [B] and bolts as a unit. Remove the hub bolt from the hub using a press. Press the hub bolt using a press.
WHEELS/TIRES 10-15 Rear Hub Rear Hub Removal • Remove: Cap [A] • Cotter Pin [B] Loosen the axle nut [C]. • Remove: Wheel (see Wheel Removal) Axle Nut [A] Rear Hub [B] Rear Hub Installation dry the spline portion of the hub. • Wipe Wipe dry • Tighten: the threads and seating surface of the nuts. • Torque - Rear Axle Nuts: 265 N·m (27 kgf·m, 195 ft·lb) • Insert a new cotter pin [A].
10-16 WHEELS/TIRES Rear Hub Rear Hub Disassembly/Assembly • • If any hub bolt [A] is damaged, replace the hub [B] and bolts as a unit. Remove the hub bolt from the hub using a press. Press the hub bolt using a press.
FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools .......................................................................................................................... Output Bevel Gears .....................................
11-2 FINAL DRIVE Rear Propeller Shaft Inspection ........................................................................................ Rear Axle................................................................................................................................ Rear Axle Removal ........................................................................................................... Rear Axle Installation .......................................................................................
FINAL DRIVE 11-3 Exploded View Dummy Page
11-4 FINAL DRIVE Exploded View
FINAL DRIVE 11-5 Exploded View No. 1 2 3 4 5 6 7 8 9 Fastener Output Driven Bevel Gear Housing Bolts Output Drive Bevel Gear Housing Bolts Bearing Holder Bevel Gear Holder Nut Bearing Holder Output Shaft Holder Nut Rotor Mounting Bolts Output Drive Bevel Gear Cover Bolts Forward/Reverse Detecting Sensor Mounting Bolt N·m 26 26 137 157 120 157 12 8.8 15 Torque Remarks kgf·m ft·lb 2.6 20 2.6 20 14 101 L 16 116 L 12 88 L 16 116 L 1.2 106 in·lb 0.90 78 in·lb 1.5 11 G: Apply grease.
11-6 FINAL DRIVE Exploded View
FINAL DRIVE 11-7 Exploded View No.
11-8 FINAL DRIVE Exploded View
FINAL DRIVE 11-9 Exploded View No. 1 2 3 4 5 6 7 8 9 10 11 Fastener Rear Final Gear Case Front Cover Bolts Rear Final Gear Case Gasket Screws Pinion Gear Bearing Holder Nut Pinion Gear Bearing Holder Rear Final Gear Case Right Cover Bolts (M12) Rear Final Gear Case Right Cover Bolts (M10) Rear Final Gear Case Right Cover Bolts (M8) Rear Final Gear Case Oil Filler Cap Rear Final Gear Case Oil Drain Bolt Rear Final Gear Case Bracket Bolts Rear Final Gear Case Nuts G: Apply grease.
11-10 FINAL DRIVE Specifications Item Output Bevel Gear Case Output Bevel Gear Backlash Front Final Gear Case Gear Case Oil (same engine oil): Type Viscosity Oil Level Capacity Coupling Bushing Inside Diameter LSD Clutch Torque: (when variable differential control lever is released.) (when variable differential control lever is pulled in.) Bevel Gear Backlash Rear Final Gear Case Gear Case Oil: Type Oil Level Capacity Rear Final Bevel Gear Backlash Standard 0.05 ∼ 0.11 mm (0.0020 ∼ 0.0043 in.
FINAL DRIVE 11-11 Special Tools Bearing Puller: 57001-135 Bearing Driver Set: 57001-1129 Steering Stem Bearing Driver: 57001-137 Rotor Puller, M16/M18/M20/M22 × 1.5: 57001-1216 Inside Circlip Pliers: 57001-143 Pinion Gear Holder, m1.
11-12 FINAL DRIVE Special Tools Socket Wrench, Hex 50: 57001-1478 Pinion Gear Holder, m1.0: 57001-1485 Output Shaft Holder & Spacer, m1.25: 57001-1479 Bearing Driver, 57001-1488 Nut Holding Bolts: 57001-1481 Gear Holder & Socket Wrench, Hex 24: 57001-1489 Socket Wench: 57001-1482 Hexagon Wench, Hex 41: 57001-1491 Socket Wrench, Hex 41: 57001-1484 Oil Seal Driver, 57001-1505 54.3: 18.
FINAL DRIVE 11-13 Special Tools Oil Seal Driver, 57001-1506 70: Output Shaft Holder: 57001-1570
11-14 FINAL DRIVE Output Bevel Gears Output Drive Bevel Gear Removal • Remove: Oil Pipe [A] (Engine Left and Outside, see Oil Pipe Removal in the Engine Lubrication System chapter) Output Drive Bevel Gear Cover Bolts [B] Output Drive Bevel Gear Cover [C] Forward/Reverse Detecting Sensor Mounting Bolt [D] • Remove: Circlip [A] Special Tool - Outside Circlip Pliers: 57001-144 • Remove: Output Drive Idle Gear [B] • Remove: Output Drive Bevel Gear Housing Bolts [A] Output Drive Bevel Gear Housing [B] Outpu
FINAL DRIVE 11-15 Output Bevel Gears grease: • Apply O-rings [A] • Install: Output Drive Bevel Gear Cover [B] • Oil Pipe (see Oil Pipe Installation in the Engine Luburication chapter) Tighten: Torque - Output Drive Bevel Gear Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Install: Forward/Reverse Detecting Sensor [A] • Tighten: Torque - Forward/Reverse Detecting Sensor Mounting Bolt [B]: 15 N·m (1.
11-16 FINAL DRIVE Output Bevel Gears the output drive bevel gear housing [A] in a vise. • Hold Loosen the bevel gear [B] using an Allen wrench about • four rotations. one nut holding bolt, and look at through the • Remove hole. If the groove of the bevel gear holder nut is not seen, loosen the other three bolts. the gear shaft end using a copper mallet until the • Drive grooves of the bearing holder nut can be seen again.
FINAL DRIVE 11-17 Output Bevel Gears Output Drive Bevel Gear Assembly • Press the new inner ball bearing until it is bottomed. Special Tool - Bearing Driver Set [A]: 57001-1129 a non-permanent locking agent to the threads of • Apply the bearing holder [A] and tighten it so that the deep side [B] faces outward. Torque - Bearing Holder: 120 N·m (12 kgf·m, 88 ft·lb) • Press the output drive bevel gear until it is bottomed.
11-18 FINAL DRIVE Output Bevel Gears lightly the front end [A] of the output driven bevel gear • Tap shaft using a plastic mallet. ○The output driven bevel gear shaft assembly comes off with the housing. Output Driven Bevel Gear Installation grease: • Apply O-ring [A] Install • Tighten:the output driven bevel gear shaft assembly. • Torque - Output Driven Bevel Gear Housing Bolts: 26 N·m (2.
FINAL DRIVE 11-19 Output Bevel Gears the housing assembly [A] with the holder [B] in a • Hold vise. Special Tool - Holder & Guide Arbor: 57001-1476 • Remove: Bearing Holder [C] Special Tool - Socket Wrench, Hex 50 [D]: 57001-1478 ○If the holder seems too difficult to break free, apply heat • to softer the locking agent.
11-20 FINAL DRIVE Output Bevel Gears a non-permanent locking agent to the threads of • Apply the bearing holder [A] and tighten it. Special Tool - Socket Wrench, Hex 50 [B]: 57001-1478 Torque - Bearing Holder: 137 N·m (14 kgf·m, 101 ft·lb) the output shaft holder [A] in a vise, and set the • Hold output shaft [B] on the holder. Special Tool - Output Shaft Holder: 57001-1570 the output driven bevel gear [C] using the steering • Press stem bearing driver [D] until it is bottomed.
FINAL DRIVE 11-21 Output Bevel Gears Output Bevel Gear (Backlash-related Parts) 1. Ball Bearings 2. Drive Bevel Gear Shims 3. Output Drive Bevel Gear 4. Bearing Housings 5. Output Driven Bevel Gear Drive Bevel Gear Shims for Tooth Contact Adjustment Thickness Part Number 0.15 mm (0.006 in.) 92180-1311 0.2 mm (0.008 in.) 92180-1312 0.5 mm (0.020 in.) 92180-1313 0.8 mm (0.031 in.) 92180-1314 1.0 mm (0.039 in.) 92180-1351 1.2 mm (0.047 in.
11-22 FINAL DRIVE Output Bevel Gears Bevel Gear Backlash Adjustment ○The amount of backlash is influenced by driven bevel gear position more than by drive bevel gear position. Remove the output drive idle gear (see Output Drive Bevel Gear Removal). • up a dial gauge [A] against the output drive shaft • Set spline groove to check gear backlash. ○To measure the backlash, turn the shaft clockwise and • counterclockwise slightly so as not to move the mate gear.
FINAL DRIVE 11-23 Output Bevel Gears Example 1: Decrease the thickness of the drive bevel gear shim(s) by 0.1 mm (0.004 in.), and/or increase the thickness of the driven bevel gear shim(s) by 0.1 mm (0.004 in.) to correct the pattern shown below. Repeat in 0.1 mm (0.004 in.) steps if necessary. Example 2: Increase the thickness of the drive bevel gear shim(s) by 0.1 mm (0.004 in.), and/or decrease the thickness of the driven bevel gear shim(s) by 0.1 mm (0.004 in.) to correct the pattern shown below.
11-24 FINAL DRIVE Output Bevel Gears Bevel Gears Inspection check the bevel gears [A] for scoring, chipping, • Visually or other damage. Replace the bevel gears as a set if either gear is damaged.
FINAL DRIVE 11-25 Front Propeller Shaft Front Propeller Shaft Removal the O-ring clamps [A] off the grooves on the small • Slip rubber boots [B], and then pull the boot. the front propeller shaft [A] rearward, and remove • Push the front end [B] from the front final gear case. the coupling [C] forward, and remove the rear end • Push from the front final gear case. Front Propeller Shaft Installation off any old grease on the splines of the propeller • Wipe shaft [A] and the coupling [B].
11-26 FINAL DRIVE Front Axle Front Axle Removal the front final gear case oil (see Front Final Gear • Drain Case Oil Change in the Periodic Maintenance chapter). • Remove: Front Wheel (see Wheel Removal in the Wheels/Tires • chapter) Steering Knuckle (see Steering Knuckle Removal in the Steering chapter) Pull the front axle [A] in a straight line out of the front final gear case. Front Axle Installation the old grease off the splines of the axle and the • Wipe gear case oil seal.
FINAL DRIVE 11-27 Front Axle the bearing housing [A] straight [B] with a plastic ham• Tap mer to separate it from the shaft. CAUTION Do not tap on the cage. Be careful not get hurt when the housing comes out. If the splined portion of shaft cracked or damaged during disassembling of outboard joint, do not reuse the shaft. • Remove: Circlip [A] Boot [B] Small Band [C] Outboard Joint Boot Installation Clean the axle shaft by wiping off the used grease on it.
11-28 FINAL DRIVE Front Axle ○Tighten the boot band [A] and bend the tangs [B] securely to hold down the end of the band. the special grease tube nozzle in the bore of the • Place housing and squeeze the tube [A] until the grease comes out from the joint bearing. the shaft end [A] straight with a plastic hammer until • Tap it is locked by the circlip. all of the special grease [A] into the new boot • Squeeze [B], and slide the boot onto the outboard joint [C].
FINAL DRIVE 11-29 Front Axle Left Front Axle: 108.7 mm (4.28 in.) [A] the edge [A] of the boot in order to equalize the air • Open pressures. the large band [A] and bend the tangs securely to • Tighten hold down the end of the band. Maximum Outside Diameter of Band: 80 mm (3.15 in.) (After tightening the outside diameter) Inboard Joint Boot Removal Remove: Front Axle (see Front Axle Removal) Boot Bands [A] Scrap the removed boot bands. Slide the joint boot toward the outboard joint [B].
11-30 FINAL DRIVE Front Axle the steel balls [A]. • Remove Slide the cage [B] toward the center of the axle. • the inner race [A] straight with a plastic hammer until • Tap it is locked by the circlip. • Remove the inboard joint boot. Inboard Joint Boot Installation Wind the tape on the splines of the axle shaft in order to protect the joint boot.
FINAL DRIVE 11-31 Front Axle the cage [A] on the inner race and install the steel • Slide balls [B]. • Apply the special grease [A] to the steel balls and cage. about half a tube (30 grams) of the special • Squeeze grease [A] into the bearing cup [B]. the balls and cage assembly [A] in the bearing cup • Insert [B] strongly. the new retaining ring [A] so that the opening [B] is • Install aligned with one of the projections [C].
11-32 FINAL DRIVE Front Axle the small band. • Tighten Squeeze remaining special grease [A] into the inboard • joint bootthe [B]. the axle assembly to the specified length while • Compress relieving the air pressure inside the inboard boot. • Hold the axle at this setting. Standard Length of Assembling Right Front Axle: 127 mm (5.00 in.) [A] Left Front Axle: 127 mm (5.00 in.) [A] the edge of the boot in order to eqalize the air pres• Open sures.
FINAL DRIVE 11-33 Front Final Gear Case Front Final Gear Case Oil Level Inspection the vehicle so that it is level, both side-to-side and • Park front-to-rear. • Remove the filler cap. CAUTION Be careful not to allow any dirt or foreign materials to enter the gear case. the oil level. The oil level should come to the bot• Check tom of the filler opening [A]. If it is insufficient, first check the front final gear case for oil leakage, remedy it if necessary, and add oil through the filler opening.
11-34 FINAL DRIVE Front Final Gear Case Variable Differential Control Lever Installation • Install: Variable Differential Control Cable Upper End • Variable Differential Control Lever [A] Apply a non-permanent locking agent to the variable differential control lever bolt [B] and tighten it. Torque - Variable Differential Control Lever Bolt: 3.4 N·m (0.
FINAL DRIVE 11-35 Front Final Gear Case Variable Differential Control Cable Inspection the variable differential control cable disconnected at • With both ends, the cable should move freely within the cable housing. If the cable does not move freely [A] after lubricating, if the cable is frayed [B], or if the housing is kinked [C], replace the cable. Front Final Gear Case Removal the gear case oil (see Front Final Gear Case Oil • Drain Change in the Periodic Maintenance chapter).
11-36 FINAL DRIVE Front Final Gear Case the variable differential control cable locknut [A] • Loosen and adjusting nut [B], and clear the cable lower end from the variable differential control lever. • Remove: Front Final Gear Case Lower Bolts and Nuts [A] the front final gear case upper nut [B]. • Remove Lift up the portion of the front final gear case, and • remove therear upper bolt. • Remove the rear final gear case [A] as shown.
FINAL DRIVE 11-37 Front Final Gear Case the lower front final gear case bolts. • Insert Tighten: • Torque - Front Final Gear Case Nuts [A]: 59 N·m (6.0 kgf·m, 44 ft·lb) • Install the removed parts. Torque - Front Final Gear Case Oil Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb) the front final gear case with the specified oil (see • Fill Front Final Gear Case Oil Change in the Periodic Maintenance chapter).
11-38 FINAL DRIVE Front Final Gear Case • Remove: Outer Disc [A] Needle Bearing • Remove: Housing [A] and Differential Disc Assembly [B] Inner Disc Needle Bearing • Remove: Cam Plate [A] • Remove: Steel Balls [A] Gasket [B] Dowel Pins [C] Front Final Gear Case Center Cover Bolts (M6) [D] Front Final Gear Case Center Cover Bolts (M8) [E] Front Final Gear Case Center Cover [F] • Remove: Ring Gear Assembly [A] Shim(s) [B]
FINAL DRIVE 11-39 Front Final Gear Case the front final gear case right cover [A] in a vise, and • Hold remove the bearing holder using the socket wrench [B]. Special Tool - Socket Wrench, Hex 41: 57001-1484 ○If the holder seems too difficult to break free, apply heat • to softer the locking agent. Remove: Pinion Gear Bearing Holder • Remove: Pinion Gear Unit [A] Shim(s) Front Final Gear Case Coupling Inspection If the coupling bushing [A] is damaged or worn, replace the front final gear case coupling.
11-40 FINAL DRIVE Front Final Gear Case • Install: Ring Gear Assembly grease to the O-ring [A] on the front final gear case • Apply center cover. • Install: Front Final Gear Case Center Cover [A] the cover bolts following the tightening sequence • Tighten as shown. Torque - Front Final Gear Case Center Cover Bolts (M8) [1, 3]: 24 N·m (2.4 kgf·m, 17 ft·lb) Front Final Gear Case Center Cover Bolts (M6) [2, 4]: 9.8 N·m (1.
FINAL DRIVE 11-41 Front Final Gear Case • Install: Cam Lever [A] • Needle Bearing [B] Apply engine oil to the needle bearing. the wear of the disc assembly as follows. •○Check Measure the thickness of the inner disc [A]. the width [A] of the disc assembly [B] in accordance • Select with the thickness of the inner disc, refer to the below table. Thickness of Inner Disc Assembly Width [A] of Disc Assembly 2.4 mm (0.0945 in.) 16.7 ∼ 17.3 mm (0.6675 ∼ 0.6811 in.) 1.8 mm (0.0709 in.) 17.31 ∼ 17.9 mm (0.
11-42 FINAL DRIVE Front Final Gear Case engine oil to the needle bearing [A]. • Apply Install: • Needle Bearing Outer Disc [B] engine oil to the variable front differential control • Apply shift shaft [A]. the shaft and spring [B] in the front final gear case • Install left cover [C] as shown. the shaft counterclockwise and insert the tab [A] of • Turn the shift shaft into the groove [B] of the cam plate.
FINAL DRIVE 11-43 Front Final Gear Case molybdenum disulfide grease to the spline [A] of • Apply the shifter [B] and inner surface [C] of the coupling. the shifter and coupling on the pinion gear shaft [D]. • Install Apply grease to the oil seal lip [E]. • Press the oil seal in the front final gear case so that • the oil seal surface[F]is flush [G] with the case end. Special Tool - Oil Seal Driver, 70: 57001-1506 the front final gear case with the gear holder & socket • Hold wrench [A] in a vise.
11-44 FINAL DRIVE Front Final Gear Case Ring Gear Disassembly • Remove: Ring Gear Assembly (see Front Final Gear Case Disassembly) Ring Gear Bolts [A] Ring Gear [B] • Remove: Differential Gear Case Cover [A] Right Side Gear (16T) [B] Pins [C] Spider Gear Shaft [D] Spider Gears (10T) [E] Left Side Gear (16T) [F] Left Differential Gear Case [G] Ring Gear Assembly the bearing [A] on the left differential gear case [B] • Press until it is bottomed.
FINAL DRIVE 11-45 Front Final Gear Case LSD Clutch Torque Inspection • • • If the vehicle has the following symptoms, check the LSD (Limited Slip Differential) clutch torque. -The handlebar is hard to turn. -The front final gear case overheats. -Abnormal noises come from the front final gear case when rounding a curve. Ensure 2WD mode. Support the vehicle so that the front wheels are off the ground.
11-46 FINAL DRIVE Front Final Gear Case Pinion Gear Unit Assembly ○The pinion gear and ring gear are lapped as a set in the • • factory to get the best tooth contact. They must be replaced as a set. Visually inspect the bearing for abrasion, color change, or other damage. If there is any doubt as to the condition of a bearing, replace the bearing.
FINAL DRIVE 11-47 Front Final Gear Case Front Final Gear Case (Backlash-related Parts) 1. Pinion Gear Shim(s) 2. Ring Gear Right Shim(s) 3. Ring Gear Left Shim(s) 4. Front Final Gear Case Center Cover 5. Front Final Gear Case Right Cover 6. Ball Bearings 7. Ring Gear 8. Ring Gear Assembly 9.
11-48 FINAL DRIVE Front Final Gear Case 1. Pinion Gear Shims for Backlash Adjustment Thickness Part Number 0.15 mm (0.006 in.) 92180-1408 0.2 mm (0.008 in.) 92180-1409 0.5 mm (0.020 in.) 92180-1410 0.7 mm (0.028 in.) 92180-1411 0.8 mm (0.031 in.) 92180-1412 0.9 mm (0.035 in.) 92180-1413 1.0 mm (0.039 in.) 92180-1414 1.1 mm (0.043 in.) 92180-1415 1.2 mm (0.047 in.) 92180-1416 2. Ring Gear Right Shims for Tooth Contact Adjustment Thickness Parts Number 0.15 mm (0.006 in.) 92180-1399 0.
FINAL DRIVE 11-49 Front Final Gear Case a dial gauge [A] so that the tip of the gauge is • Mount against the splined portion [B] of the pinion gear shaft. measure the backlash, move the pinion gear shaft • To back and forth [C] while holding the front axle steady. The difference between the highest and the lowest gauge reading is the amount of backlash. ○Measure backlash at three locations equally spaced on the splines. Front Final Bevel Gear Backlash Standard: 0.10 ∼ 0.20 mm (0.004 ∼ 0.008 in.
11-50 FINAL DRIVE Front Final Gear Case ○The tooth contact patterns of both (drive and coast) sides • should be centrally located between the top and bottom of the tooth. The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe. If the tooth contact pattern is incorrect, replace the ring gear shim(s), following the examples shown. Then erase the tooth contact patterns and check them again.
FINAL DRIVE 11-51 Front Final Gear Case Correct Tooth Contact Pattern: No adjustment is required. A. Ring Gear B. Pinion Gear C. Heel D. Bottom E. Top F. Toe Incorrect Tooth Contact Patterns (Example 1) ○Decrease the thickness of the pinion gear shim(s) by 0.1 mm (0.004 in.) shown above. Repeat in 0.1 mm (0.004 in.) steps if necessary. A. Ring Gear C. Heel B. Pinion Gear D. Bottom to correct the pattern E. Top F.
11-52 FINAL DRIVE Rear Propeller Shaft Rear Propeller Shaft Removal • Remove: Footboard (see Left and Right Footboard Removal in the • • • Frame chapter) Slip the O-ring clamps [A] off the grooves on the rubber boots [B]. Slide the rubber boot. Push the front universal joint [C] rearward, and remove the front end [D] from the engine. • Remove the rear propeller shaft [A] from the vehicle.
FINAL DRIVE 11-53 Rear Propeller Shaft molybdenum disulfide grease: • Apply Spline [A] on Output Shaft of Engine • • • • • Spline [B] on Pinion Gear of Rear Final Gear Case Install: O-rings [C] Spring [D] Rear Universal Joint [E] Align the front universal joint yoke [F] with the rear universal joint yoke [G] as shown. Install the front end [H] of the propeller shaft.
11-54 FINAL DRIVE Rear Axle Rear Axle Removal the rear final gear case oil (see Rear Final Gear • Drain Case Oil Change in the Periodic Maintenance chapter). • Remove: Rear Wheels (see Wheel Removal in the Wheels/Tires chapter) Rear Knuckle (see Rear Suspension Arm Removal in the Suspension chapter) Upper Suspension Arm (see Rear Suspension Arm Removal in the Suspension chapter) the rear axle [A] in a straight line out of the rear final • Pull gear case.
FINAL DRIVE 11-55 Rear Axle Rear Axle Joint Boot Replacement Outboard Joint Boot Removal Remove: Rear Axle (see Rear Axle Removal) Tap the joint portion of the bands [A] with a suitable tool. Scrap the removed boot bands. Slide the joint boot [B] toward the inboard joint. • • • • the bearing housing [A] straight [B] with a plastic ham• Tap mer to separate it from the shaft. CAUTION Do not tap on the cage. Be careful not get hurt when the housing comes out.
11-56 FINAL DRIVE Rear Axle the special grease tube nozzle in the bore of the • Place housing and squeeze the tube [A] until the grease comes out from the joint bearing. the shaft end [A] straight with a plastic hammer until • Tap it is locked by the circlip. all of the special grease [A] into the new boot • Squeeze [B]. the axle assembly to the specified length while • Compress relieving the air pressure inside the inboard boot. • Hold the axle at this setting.
FINAL DRIVE 11-57 Rear Axle sure outside diameter of the band [A] is less than the • Be maximum diameter. Maximum Outside Diameter of Band: 82.9 mm (3.26 in.) Inboard Joint Boot Removal Remove: Rear Axle (see Rear Axle Removal) Tap the joint portion of the bands [A] with a suitable tool. Scrap the removed boot bands. Slide the joint boot [B] toward the outboard joint. • • • • the retaining ring [A]. • Remove Separate the bearing cup from the axle shaft. • the steel balls [A].
11-58 FINAL DRIVE Rear Axle • Remove: Inner Race [A] Cage [B] Inboard Joint Boot [C] Inboard Joint Boot Installation Install: New Small Band [A] New Inboard Joint Boot [B] Cage [C] • the inner race [A] so that the tapered side [B] faces • Install outboard joint. • Install: Circlip [A] Special Tool - Outside Circlip Pliers: 57001-144 the cage [B] on the inner race and install the steel • Slide balls [C]. • Apply the special grease [A] to the steel balls and cage.
FINAL DRIVE 11-59 Rear Axle about half a tube (30 grams) of the special • Squeeze grease [A] into the bearing cup [B]. the balls and cage assembly in the bearing cup • Insert strongly. the new retaining ring [A] so that the opening [B] is • Install aligned with one of the projections [C]. the remaining special grease [A] into the inboard • Squeeze joint boot [B]. the axle assembly to the specified length while • Compress relieving the air pressure inside the inboard boot. • Hold the axle at this setting.
11-60 FINAL DRIVE Rear Axle sure the outside diameter of the band [A] is less than • Be the maximum diameter. Maximum Outside Diameter of Band: 73.4 mm (2.89 in.) • Install the new circlip [A] to the shaft of the bearing cup.
FINAL DRIVE 11-61 Rear Final Gear Case Rear Final Gear Case Oil Level Inspection the vehicle so that it is level, both side-to-side and • Park front-to-rear. • Remove the filler cap. CAUTION Be careful not to allow any dirt or foreign materials to enter the gear case. the oil level. The oil level should come to the bot• Check tom of the filler opening [A]. • • If it is insufficient, first check the rear final gear case for oil leakage, remedy it if necessary, and add oil through the filler opening.
11-62 FINAL DRIVE Rear Final Gear Case • Remove: Bolts [A] and Nut [B] Brake Cam Lever [C] Spring [D] • Remove: Bracket Bolts [A] Collars [B] Bracket [C] Vent Hose [D] • Remove: Rear Final Gear Case Bolts and Nuts [A] • Remove the rear final gear case [A] as shown.
FINAL DRIVE 11-63 Rear Final Gear Case Rear Final Gear Case Installation • Install: Rear Final Gear Case • Bracket [A] Collars [B] Bracket Bolts [C] [D] Front [E] Hole Washers (rear side) Tighten: Torque - Rear Final Gear Case Nuts [F]: 91 N·m (9.3 kgf·m, 67 ft·lb) Rear Final Gear Case Bracket Bolts: 59 N·m (6.
11-64 FINAL DRIVE Rear Final Gear Case a press [A], sparate the ring gear [B] and coupling • Using [C].
FINAL DRIVE 11-65 Rear Final Gear Case • Remove: Steel Balls [A] • Remove: Pinion Gear Bearing Holder [A] ○Hold the rear final gear case [A] in a vise, and remove the bearing holder using the socket wrench [B]. Special Tool - Socket Wrench, Hex 50: 57001-1478 ○If it is difficult to break free the holder, apply the heat to it to softer the locking agent. • Remove: Pinion Gear Unit [A] Shim(s) [B] out the spring pin [A] with a drill bit of 3 mm (0.12 in.) • Drill diameter and remove it.
11-66 FINAL DRIVE Rear Final Gear Case Rear Final Gear Case Right Cover Assembly • [A] Rear Final Gear Case Right Cover Press: Ball Bearing (until bottomed) Special Tool - Bearing Driver, • 54.
FINAL DRIVE 11-67 Rear Final Gear Case a press [A], press the coupling [B] to the ring gear • Using [C] until it bottom out. [D] Suitable Tool check the pinion gear [A] and ring gear [B] for • Visually scoring, chipping, or other damage. • Replace the bevel gear as a set if either gear is damaged since they are lapped as a set in the factory to get the best tooth contact.
11-68 FINAL DRIVE Rear Final Gear Case • Install: Brake Cam Plate [A] ○Fit the cam plate and brake camshaft [B] as shown. • Install: Steel Plate [A] (P/No. 41080-1483, two holes) Set Pins [B] and Springs [C] (alternately): • Install Friction Plates [A] Steel Plates [B](P/No. 41080-1484, without holes) • Install: Steel Plate [A] (P/No. 41080-1483, two holes) ○Insert the pins [B] into the holes of steel plate.
FINAL DRIVE 11-69 Rear Final Gear Case • Install: Rear Final Gear Case Front Cover [A] • Tighten: Torque - Rear Final Gear Case Front Cover Bolts [B]: 24 N·m (2.4 kgf·m, 18 ft·lb) • Inspect: Ball Bearing [A] (see Bearing and Oil Seal section) • • Oil Seal [B] (see Bearing and Oil Seal section) If they are damaged, replace them. Apply grease to the oil seal lips and O-ring [C].
11-70 FINAL DRIVE Rear Final Gear Case Rear Final Gear Case (Backlash-related Parts) 1. Pinion Gear 2. Pinion Gear Bearing Holder 3. Gear Case Right Cover 4. Ball Bearings 5. Ring Gear 6. Pinion Gear Shim(s) 7. Ring Gear Shim(s) 8.
FINAL DRIVE 11-71 Rear Final Gear Case 6. Pinion Gear Shims for Backlash Adjustment Thickness Part Number 0.15 mm (0.006 in.) 92180-1423 0.2 mm (0.008 in.) 92180-1424 0.5 mm (0.020 in.) 92180-1425 0.8 mm (0.031 in.) 92180-1426 1.0 mm (0.039 in.) 92180-1427 1.2 mm (0.047 in.) 92180-1428 7. Ring Gear Shims for Tooth Contact Adjustment Thickness Part Number 0.15 mm (0.006 in.) 92180-1417 0.2 mm (0.008 in.) 92180-1418 0.5 mm (0.020 in.) 92180-1419 0.8 mm (0.031 in.) 92180-1420 1.0 mm (0.
11-72 FINAL DRIVE Rear Final Gear Case • If the backlash is not within the standard, replace the pinion gear shim(s). To increase backlash, increase the thickness of the shim(s). To decrease backlash, decrease the thickness of the shim(s). Change the thickness a little at a time. Recheck the backlash, and readjust as necessary. Tooth Contact Adjustment Clean any dirt and oil off the bevel gear teeth. Apply checking compound to 4 or 5 teeth of the pinion gear.
FINAL DRIVE 11-73 Rear Final Gear Case Pinion Gear Unit Disassembly • Remove: Pinion Gear Unit [A] (see Rear Final Gear Case Disas• sembly) Hold the pinion gear bearing holder nut [B] with the socket wrench [C] in a vise, and loosen the pinion gear shaft using the pinion gear holder [D]. Special Tools - Socket Wrench: 57001-1363 Pinion Gear Holder, m1.0: 57001-1281 • Remove the ball bearing [E] as necessary.
11-74 FINAL DRIVE Bearing and Oil Seal Ball or Needle Bearing Inspection Since the bearings are made to extremely close tolerances, the clearance cannot normally be measured. CAUTION Do not remove any bearings for inspection except the right rear axle bearing. each bearing in the case or hub back and forth [A] • Turn while checking for plays, roughness, or binding. If bearing play, roughness, or binding is found, replace the bearing. the needle bearings [A].
FINAL DRIVE 11-75 Bearing and Oil Seal Oil Seal Inspection the oil seals [A]. • Inspect Replace any if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened, or been otherwise damaged.
BRAKES 12-1 Brakes Table of Contents Exploded View................................... Specifications .................................... Special Tool ....................................... Brake Fluid ........................................ Front Brake Fluid Recommendation ...................... Front Brake Fluid Level Inspection.................................. Front Brake Fluid Change............ Front Brake Line Air Bleeding ...... Master Cylinder .................................
12-2 BRAKES Exploded View
BRAKES 12-3 Exploded View No. 1 2 3 4 5 6 7 8 9 10 11 Fastener Reservoir Cap Screws Front Brake Lever Pivot Bolt Front Brake Lever Pivot Bolt Locknut Front Brake Master Cylinder Clamp Bolts Brake Hose Banjo Bolts Front Brake Caliper Mounting Bolts Bleed Valves Front Brake Disc Mounting Bolts Front Brake Caliper Holder Shafts Front Brake Pad Mounting Bolts Front Brake Light Switch Mounting Screw B: Apply brake fluid. L: Apply a non-permanent locking agent.
12-4 BRAKES Exploded View
BRAKES 12-5 Exploded View No. 1 2 3 4 5 Fastener Rear (Parking) Brake Lever Pivot Bolt Rear (Parking) Brake Lever Pivot Nut Rear Brake Lock Lever Pivot Screw Variable Differential Control Lever Bolt Rear Final Gear Case Gasket Screws N·m 2.2 3.4 2.2 3.4 1.25 6. Bend both hooks after installing the spring. G: Apply grease. L: Apply a non-permanent locking agent. MF: Apply gear oil (MOBILE FLUID 424) or equivalent oil. O: Apply engine oil. R: Replacement Parts Torque kgf·m 0.22 0.35 0.22 0.35 0.
12-6 BRAKES Specifications Item Brake Fluid Type Front Brake Pad Lining Thickness Disc Thickness Disc Runout Rear Brake Lever, Pedal and Cables Rear Brake Pedal Position Rear Brake Lever Free Play Rear Brake Pedal Free Play Standard DOT 3 or DOT 4 4.0 mm (0.16 in.) 3.3 ∼ 3.7 mm (0.13 ∼ 0.14 in.) TIR 0.4 mm (0.016 in.) or less see text 1 ∼ 2 mm (0.04 ∼ 0.08 in.) 15 ∼ 25 mm (0.6 ∼ 1.0 in.) Service Limit – – – 1 mm (0.04 in.) 3 mm (0.12 in.) TIR 0.5 mm (0.020 in.
BRAKES 12-7 Special Tool Inside Circlip Pliers: 57001-143
12-8 BRAKES Brake Fluid WARNING When working with the disc brake, observe the precautions 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.
BRAKES 12-9 Brake Fluid Front Brake Line Air Bleeding the air whenever brake parts are replaced or re• Bleed assembled. the reservoir cap and fill the reservoir with new • Remove brake fluid. pump the brake lever several times until no air • Slowly bubbles can be seen rising up through the fluid from the hose at the bottom of the reservoir. This bleeds the air from the master cylinder and the brake line.
12-10 BRAKES Master Cylinder Front Brake Master Cylinder Removal • Remove: Brake Hose Banjo Bolt [A] Master Cylinder Clamp Bolts [B] Master Cylinder [C] CAUTION Brake fluid quickly ruins painted surface; any spilled fluid should be completely washed away immediately. Front Brake Master Cylinder Installation the punch mark [A] on the handlebar with the mating • Align surface end of the master cylinder clamp. master cylinder clamp must be installed with the “UP” • The mark [A] upwards.
BRAKES 12-11 Master Cylinder Front Brake Master Cylinder Disassembly • Remove: Front Brake Master Cylinder (see Front Brake Master Cylinder Removal) Brake Lever Pivot Bolt Locknut [A] Brake Lever Pivot Bolt [B] Brake Lever [C] Dust Cover [D] Circlip [E] Piston [F] Spring [G] Special Tool - Inside Circlip Pliers: 57001-143 CAUTION Do not remove the secondary cup [H] from the piston since removal will damage it.
12-12 BRAKES Master Cylinder Front Master Cylinder Inspection (Visual Inspection) the master cylinder (see Front Brake Master • Disassemble Cylinder Disassembly). that there are no scratches, rust or pitting on the • Check inner wall of the master cylinder [A] and on the outside of • • • • the piston [B]. If the master cylinder or piston shows any damage, replace them. Inspect the primary [C] and secondary [D] cups.
BRAKES 12-13 Calipers Front Brake Caliper Removal the front wheel (see Wheel Removal in the • Remove Wheels/Tires chapter). the banjo bolt [A] at the brake hose lower end, • Loosen and tighten it loosely. the caliper mounting bolts [B], and detach the • Unscrew caliper [C] from the disc. the banjo bolt and remove the brake hose [D] • Unscrew from the caliper. CAUTION Immediately wash away any brake fluid that spills.
12-14 BRAKES Calipers Front Brake Caliper Disassembly • Remove: Caliper (see Front Brake Caliper Removal) Pads (see Front Brake Pad Removal) Anti-rattle Spring Using compressed air, remove the piston. ○Cover the caliper opening with a clean, heavy cloth [A]. ○Remove the piston by lightly applying compressed air [B] to where the brake line fits into the caliper. • WARNING To avoid serious injury, never place your fingers or palm inside the caliper opening.
BRAKES 12-15 Calipers brake fluid to the outside of the pistons [A], and • Apply push them into the cylinder by hand. Take care that nei- • • • • ther the cylinder nor the piston skirt gets scratched. Replace the rubber boots [B] if they are damaged. Apply a thin coat of silicone grease to the caliper holder shafts [C] [D] (Silicone grease is a special high temperature, water-resistant grease). Install: Wave Washer [E] Tighten: Torque - Front Brake Caliper Holder Shaft [D]: 17 N·m (1.
12-16 BRAKES Brake Pads Front Brake Pad Removal the caliper from the disc (see Front Brake Caliper • Detach Removal). • Remove: Pad Mounting Bolts [A] • Remove: Brake Pads [A] Front Brake Pad Installation the caliper piston in by hand as far as it will go. • Push sure that the anti-rattle spring is in place. • Be Install: • Brake Pads • Pad Mounting Bolts Tighten: Torque - Front Brake Pad Mounting Bolts: 17 N·m (1.
BRAKES 12-17 Brake Discs Front Brake Disc Cleaning Poor braking can be caused by oil on a disc. Oil on a disc must be cleaned off with an oilless cleaning fluid such as trichloroethylene or acetone. WARNING These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods. Be sure to heed the fluid manufacturer’s warnings.
12-18 BRAKES Brake Hoses Front Brake Hose Inspection to the Front Brake Hose and Connections Inspec• Refer tion in the Periodic Maintenance chapter. Front Brake Hose Replacement to the Front Brake Hose Replacement in the Peri• Refer odic Maintenance chapter.
BRAKES 12-19 Rear Brake Lever, Pedal and Cables Rear Brake Pedal Position Inspection NOTE ○The position of the brake pedal has been decided by the position of the adjusting bolt [A]. that the adjusting bolt is in the correct position as • Check shown. Adjusting Bolt Position [B] Standard: 5 ∼ 6 mm (0.20 ∼ 0.24 in.) (between Frame and Adjusting Bolt Head) If it is incorrect, adjust the adjusting bolt.
12-20 BRAKES Rear Brake Lever, Pedal and Cables Rear Brake Pedal Installation grease: • Apply Brake Pedal Pivot [A] O-ring [B] • Install: Spring [A] • • • • • Brake Pedal [B] Apply grease: O-rings [C] Install: Brake Cable Joint and Pin [D] Brake Switch Spring [E] Washers [F] Replace the cotter pins [G] with new ones. Bend both side hooks [H] of switch spring [E] after installing the spring. Adjust the brake pedal position (see Rear Brake Pedal Position Adjustment).
BRAKES 12-21 Rear Brake Lever, Pedal and Cables • Remove: Circlip [A] Cotter Pin, Washer and Pin [B] Brake Pedal Cable [C] Rear Brake Cable Installation the brake cable front ends. • Grease the cotter pin with a new one. • Replace Route the brake cables according to the Cable, Wire, and • Hose Routing section in the Appendix chapter. Adjust the rear brake pedal and rear brake lever.
12-22 BRAKES Internal Wet Brake Internal Wet Brake Disassembly to Rear Final Gear Case section in the Final Drive • Refer chapter. Internal Wet Brake Assembly to Rear Final Gear Case section in the Final Drive • Refer chapter.
SUSPENSION 13-1 Suspension Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools .......................................................................................................................... Shock Absorbers ..........................................
13-2 SUSPENSION Exploded View
SUSPENSION 13-3 Exploded View No. 1 2 3 Fastener Front Shock Absorber Mounting Nuts Front Suspension Arm Pivot Nuts Steering Knuckle Joint Nuts G: Apply grease. R: Replacement Parts N·m 34 42 29 Torque kgf·m 3.5 4.3 3.
13-4 SUSPENSION Exploded View
SUSPENSION 13-5 Exploded View No. 1 2 3 4 5 Fastener Rear Shock Absorber Mounting Nuts Stabilizer Holder Bolts Stabilizer Joint Nuts Rear Suspension Arm Pivot Nuts Rear Knuckle Mounting Nuts G: Apply grease. R: Replacement Parts RL: Apply rubber lubricant. N·m 34 22 46 46 46 Torque kgf·m 3.5 2.2 4.7 4.7 4.
13-6 SUSPENSION Specifications Item Shock Absorbers Spring Preload Setting Position: Front Rear Standard 2nd Step 3rd Step Service Limit (Usable Range) 1 ∼ 5 1 ∼ 5
SUSPENSION 13-7 Special Tools Inside Circlip Pliers: 57001-143 Steering Stem Nut Wrench: 57001-1100 Outside Circlip Pliers: 57001-144 Jack: 57001-1238
13-8 SUSPENSION Shock Absorbers Front Shock Absorber Preload Adjustment The spring adjusting sleeve [A] on the front shock absorber has 5 positions so that the spring can be adjusted for different terrain and loading conditions. If the spring action feels too soft or too stiff, adjust it in accordance with the following table.
SUSPENSION 13-9 Shock Absorbers Front Shock Absorber Inspection the bushings [A] in the upper and lower pivots. • Check If bushings are worn, cracked, hardened, or otherwise damaged, replace them. Front Shock Absorber Scrapping WARNING Since the front shock absorber contains nitrogen gas, do not incinerate or disassemble the front shock absorber. Before a front shock absorber is scrapped, drill a hole at a point about 15 mm (0.59 in.
13-10 SUSPENSION Shock Absorbers Rear Shock Absorber Removal the vehicle on a stand or a jack so that the rear • Support wheels are off the ground. Special Tool - Jack: 57001-1238 holding the rear wheels, remove the lower and up• While per shock absorber mounting bolts [A] and nuts. • Remove the rear shock absorber [B]. Rear Shock Absorber Installation grease to the inside of bushing [A] and grease seal • Apply lips [B].
SUSPENSION 13-11 Suspension Arms Front Suspension Arm Removal • Remove: Wheel Hub (see Front Hub Removal in the Wheels/Tires chapter) Bolt [A] and Brake Hose Clamp [B] Front Shock Absorber Mounting Bolt and Nut [C] (lower) • Remove: Cotter Pins, Knuckle Joint Nuts [A] and Washers the knuckle joint [A] from the lower suspension • Remove arm using a suitable joint remover [B]. the brake hose [A] from the front upper suspension • Clear arm.
13-12 SUSPENSION Suspension Arms • Remove: Suspension Arm Pivot Bolts [A] and Nuts [B] Front Lower Suspension Arm [C] Front Suspension Arm Installation the taper surface [A] of the suspension arm [B] and • Clean shank of the knuckle joint.
SUSPENSION 13-13 Suspension Arms Front Lower Suspension Arm Remove: Bolts [A] Collar [B] Axle Guard [C] Collars [D] (rear side) Oil Seals [E] Circlips [F] • Special Tool - Inside Circlip Pliers: 57001-143 • Remove: Ball Joint Bearing [G] (rear side) Sleeve [H] (front side) Needle Bearing [I] (front side) Front Suspension Arm Assembly grease: • Apply Ball Joint Bearing Needle Bearing • Install the following parts as shown.
13-14 SUSPENSION Suspension Arms • Install the following parts as shown. Front Lower Suspension Arm Front Side [A]: Needle Bearing [B] 7.5 ±0.1 mm (0.295 ±0.004 in.
SUSPENSION 13-15 Suspension Arms • Remove: Screw [A] Bolts [B] Axle Guard [C] • Remove: Rear Shock Absorber Mounting Bolt [A] and Nut (lower) Suspension Arm Bolts and Nuts [B] Rear Lower Suspension Arm [C] Rear Suspension Arm Installation • Install: Rear Upper Suspension Arm • Rear Lower Suspension Arm Suspension Arm Pivot Bolts and Nut (temporary) Rear Shock Absorber Mounting Bolt (lower) Stabilizer Joint Tighten: Torque - Rear Suspension Arm Pivot Nuts: 46 N·m (4.
13-16 SUSPENSION Suspension Arms Rear Lower Suspension Arm Remove: Screw [A] Bolts [B] Collars [C] Axle Guard [D] Collars [E] (rear side) Oil Seals [F] Circlips [G] • Special Tool - Outside Circlip Pliers: 57001-144 • Remove: Ball Joint Bearing [H] (rear side) Sleeve [I] (front side) Needle Bearing [J] (front side) Rear Suspension Arm Assembly grease: • Apply Ball Joint Bearing Needle Bearing Rear Upper Suspension Arm Install the bushings [A] using a press.
SUSPENSION 13-17 Suspension Arms Rear Side [A]: Circlip [B] (front side) Ball Joint Bearing [C] Circlip [D] (rear side) Special Tool - Inside Circlip Pliers: 57001-143 grease: • Apply Oil Seal Lips • Install: Sleeve (front side) Collars (rear side) Stabilizer Removal • Remove: Rear Wheels (see Wheel Removal in the Wheels/Tires chapter) Stabilizer Joint [A] ○Hold the joint bolt with an Allen wrench [B], and remove the nut [C].
STEERING 14-1 Steering Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools .......................................................................................................................... Steering .....................................................
14-2 STEERING Exploded View
STEERING 14-3 Exploded View No. 1 2 3 4 5 6 7 8 9 Fastener Handlebar Holder Bolts Steering Stem Clamp Bolts Tie-rod End Nuts Tie-rod Locknuts Steering Stem Bearing Joint Bolts Steering Stem Bottom End Nut Steering Knuckle Joint Nuts Front Brake Master Cylinder Clamp Bolts Left Handlebar Switch Housing Screws AD: Apply adhesive agent. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specific tightening sequence. N·m 29 25 42 37 22 62 29 8.8 3.5 Torque kgf·m 3.
14-4 STEERING Specifications Item Tie-rods Tie-rod Length Standard 388.5 mm (15.30 in.
STEERING 14-5 Special Tools Inside Circlip Pliers: 57001-143 Bearing Driver Set: 57001-1129
14-6 STEERING Steering Steering Stem Removal • Remove: Handlebar (see Handlebar Removal) Cotter Pins and Tie-rod End Nuts [A] CAUTION Do not loosen the locknuts [B] at the ends of the tie-rod adjusting sleeve, or the toe-in of the front wheels will be changed. • Remove: Steering Stem Bearing Joint Bolts [A] Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) • Cut the bands [A] to remove the heat guard [B] out the bended washer [A].
STEERING 14-7 Steering Steering Stem Installation grease up the seal grooves [A] in the steering stem • Fill bearing. • Install: Collar Tighten: • Torque - Steering Stem Bottom End Nut: 62 N·m (6.3 kgf·m, 46 ft·lb) • Bend both ends of the cotter pin. a non-permanent locking agent to the steering stem • Apply bearing joint bolts [A]. • Tighten: Torque - Steering Stem Bearing Joint Bolts: 22 N·m (2.2 kgf·m, 16 ft·lb) grease to the inside of steering clamp [A].
14-8 STEERING Steering Steering Knuckle Removal • Remove: Front Hub (see Front Hub Removal in the Wheel/Tiers chapter) Cotter Pin [A] CAUTION Do not loosen the locknuts [B] at the ends of the tie-rod, or the toe-in of the front wheels will be changed. the flat surfaces [A] of the tie-rod end with a thin • Hold wrench [B], and remove the tie-rod end nut [C] and wash- • ers. Tap the tie-rod end shaft lightly and remove the tie-rod end from the knuckle.
STEERING 14-9 Steering Steering Knuckle Installation the spherical bearings in the knuckle joints [A]. • Inspect If roughness, excessive play, or seizure is found, replace the knuckle joint. the joint boot [A] is not torn, worn, deteriorated, or • Check is leaking grease. • If it is found, replace the knuckle joint. Clean the shanks [B] of the knuckle joint. the taper surface [A] in the front suspension arm • Clean [B].
14-10 STEERING Steering the bearing [A] out using a suitable bearing driver • Drive from the bearing driver set. Special Tool - Bearing Driver Set: 57001-1129 Steering Knuckle Bearing Installation marked side of the bearing faces outward. • The in the bearing until it is bottomed. • Press [A] V Block Special Tool - Bearing Driver Set [B]: 57001-1129 • Replace the circlip with a new one.
STEERING 14-11 Steering Tie-rod End Removal the tie-rod (see Tie-rod Removal). • Remove the tie-rod flattened area [A], loosen the locknut • Holding [B] and unscrew the tie-rod end [C]. NOTE ○The locknut near the L mark on the tie-rod has left-hand threads. Turn the wrench clockwise for loosening. CAUTION Do not remove the grease seal. It is packed with grease. Tie-rod End Installation • Check that the boot lip [A] is on the shank [B].
14-12 STEERING Steering Maintenance Steering Inspection to the Steering Inspection in the Periodic Mainte• Refer nance chapter. Steering Stem Straightness Inspection the steering stem (see Steering Stem Removal). • Remove the steering stem for straightness. •○Check Use a straightedge along the stem. If the steering stem is bent, replace the steering stem. Steering Bearing Sleeve Lubrication the steering stem bearings. •○Lubricate Remove the steering stem (see Steering Stem Removal).
STEERING 14-13 Steering Maintenance Steering Knuckle Bearing Inspection CAUTION Do not remove any bearings for inspection. the steering knuckle (see Steering Knuckle Re• Remove moval). [A] the bearing back and forth while checking for • Turn roughness or binding. • If 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. Tie-rod End Inspection each spherical bearing [A].
14-14 STEERING Handlebar Handlebar Removal • Remove: Multifunction Meter Unit (see Multifunction Meter Unit Removal in the Electrical System chapter) Throttle Case Front Brake Master Cylinder Left-hand Switch Housing Rear Brake Lever Assembly Handlebar Holder Bolts [A] and Bracket [B] Handlebar Holders [C] Handlebar [D] Handlebar Installation the punch mark [A] on the handlebar with the mating • Align surface end [B] of the steering stem. the bracket [A]. • Install Tighten • bolts [C].
STEERING 14-15 Handlebar • Install: Left Switch Housing [A] Rear Brake Lever Assembly [B] Punch Mark [C] [D] = 6 mm (0.24 in.) Apply a non-permanent locking agent to the thread of the ○ variable differential control lever bolt, and tighten it securely.
FRAME 15-1 Frame Table of Contents Exploded View................................... Seat ................................................... Seat Removal .............................. Seat Installation ........................... Carriers.............................................. Front Carrier Removal ................. Front Carrier Installation .............. Front Carrier Bracket Installation . Rear Carrier Removal .................. Rear Carrier Installation ...............
15-2 FRAME Exploded View
FRAME 15-3 Exploded View No. 1 2 3 4 5 6 7 Fastener Front Guard Bolts Front Carrier Bolts, L = 50 mm (2.0 in.) Front Carrier Bolts, L = 70 mm (2.8 in.) Front Carrier Bracket Bolts Rear Carrier Bolts, L = 14 mm (0.55 in.) Rear Carrier Bolts, L = 44 mm (1.7 in.) Rear Carrier Bracket Bolts 8. CA Model L: Apply a non-parmanent locking agent. N·m 46 32 32 32 54 54 46 Torque kgf·m 4.7 3.3 3.3 3.3 5.5 5.5 4.
15-4 FRAME Exploded View
FRAME 15-5 Exploded View No. 1 2 3 Fastener Footboard Bracket Bolts Trailer Hitch Bracket Bolts Rear Final Gear Case Mounting Bracket Bolts L: Apply a non-permanent locking agent. OP: Optional Parts N·m 46 82 59 Torque kgf·m 4.7 8.4 6.
15-6 FRAME Exploded View
FRAME 15-7 Exploded View OP: Optional Parts
15-8 FRAME Seat Seat Removal the seat [A] by lifting the latch lever [B] and then • Remove pulling the seat up to the rear. Seat Installation the front seat hooks [A] into the receivers [B] in the • Insert bracket. the rear seat hooks [A] into the dampers [B]. • Insert Push the • [C].
FRAME 15-9 Carriers Front Carrier Removal • Remove: Front Carrier Bolts [A] Collars Front Carrier [B] Front Carrier Installation • Install: Long Collars, L = 44.6 mm (1.8 in.) [A] • • Short Collars, L = 21.6 mm (0.9 in.) [B] Front Carrier [C] Apply a non-parmanent locking agent to the front carrier bolts. Tighten: Torque - Front Carrier Bolts [D], L = 70 mm (2.8 in.): 32 N·m (3.3 kgf·m, 24 ft·lb) Front Carrier Bolts [E], L = 50 mm (2.0 in.): 32 N·m (3.
15-10 FRAME Carriers Rear Carrier Installation • Install: Collar [A] • Rear Carrier [B] Rear Carrier Bolts, L = 44 mm (1.7 in.) [C] Rear Carrier Bolts, L = 14 mm (0.55 in.) [D] Rear Carrier Bolts, L = 25 mm (0.98 in.) [E] Apply a non-permanent locking agent on the thread of the rear carrier bolts [C], [D], and tighten them with a specified torque. Torque - Rear Carrier Bolts [C] [D]: 54 N·m (5.
FRAME 15-11 Fenders Front Fender Removal • Remove: Seat (see Seat Removal) • Front Carrier (see Front Carrier Removal) Footboard (see each Footboard Removal) Middle Cover (see Middle Cover Removal) Quick Rivets [A] (both sides) Bolts [B] and Collars Bolts [C] While pulling the front fender [D] backward, remove it.
15-12 FRAME Fenders • Remove: Screws [A] and Collars • Bolts [B] and Collars Fuel Tank Cap [C] Rear Fender [D] Install the fuel tank cap after removing the rear fender.
FRAME 15-13 Covers Middle Cover Removal • Disconnect: Power Outlet Lead Connectors [A] • Remove: Middle Cover Screws [A] and Collars • Remove: Middle Cover Screw [A] and Collar Middle Cover [B] Middle Cover Installation • Connect: Power Outlet Lead Connectors Install: • Middle Cover [A] Middle Cover Screws [B] and Collars [C] Storage Box Removal the lid. • Open Remove the screws [A].
15-14 FRAME Covers • Remove: Screws [A] • Remove: Screws [A] Storage Box [B] Storage Case Removal • Remove: Ignition Switch Nut [A] Screws [B] Storage Case [C] Storage Case Installation • Install: Storage Case • • Screws Fit projection [A] on the ignition switch into the recess in the storage case. Tighten the nut [B] securely.
FRAME 15-15 Covers • Remove: Screws [A] and Collars Left Side Cover [B] Left Side Cover Installation • Install: Left Side Cover [A] Insulator [B] Screws [C] and Collars [D] Washers [E] Storage Case Right Side Cover Removal • Remove: Seat (see Seat Removal) • Middle Cover (see Middle Cover Removal) Storage Case (see Storage Case Removal) Remove: Shift Knob [A] Screws [B] and Collars Screws [C], Washers and Nuts Screws [D] • Remove: Screws [A] and Collars Right Side Cover [B] Right Side Cover Install
15-16 FRAME Covers Electrical Parts Case Removal • Remove: Seat (see Seat Removal) Rear Fender (see Rear Fender Removal) Vehicle-down Sensor [A] (see Vehicle-down Sensor Removal in the Fuel System (DFI) chapter) Stater Control Relays [B] the following parts from the case.
FRAME 15-17 Covers • Remove: Radiator Cover Screws [A] and Collars Radiator Cover [B] Radiator Cover Installation the seal [A] so that along it to the bottom [B] and • Install corner line [C].
15-18 FRAME Guards Front Guard Removal • Remove: Front Bottom Guard (see Front Bottom Guard Removal) Bolts [A] and Collars Front Guard Cover [B] • Remove: Front Carrier Bracket Bolts [A] • Radiator Cover Screws [B] and Collars (both sides) Front Guard Bolts [C] (both sides) Remove the front guard [D] from the radiator bottom stoppers [E]. Front Guard Installation the radiator bottom stoppers in the grommet in the • Insert front guard.
FRAME 15-19 Guards Front Bottom Guard Removal • Remove: Bolts [A] and Collars • Remove: Bolts [A] and Collars Quick Rivets [B] Front Bottom Guard [C] Front Bottom Guard Installation the front bottom guard [A] between the frame and • Install engine bottom guard [B].
15-20 FRAME Guards Rear Bottom Guard Removal • Remove: Bolts (M6) [A] and Collars Bolt (M8) [B] and Collar Rear Bottom Guard [C] Rear Bottom Guard Installation • Install: Rear Bottom Guard [A] Bolt (M8) [B] and Collar Bolts (M6) [C] and Collars
FRAME 15-21 Flaps and Footboards Left Footboard Removal • Remove: Screws [A] and Collars Bolts [B] and Collars • Remove: Screws [A] and Collars Bolts [B] and Collars Left Footboard [C] Left Footboard Installation • Install: Left Footboard [A] Bolts [B] and Collars [C] Screws [D] and Collars [E] Right Footboard Removal • Remove: Screws [A] and Collars Bolt [B] and Collar • Remove: Screws [A] and Collars Bolts [B] and Collars Right Footboard [C]
15-22 FRAME Flaps and Footboards Right Footboard Installation • Install: Right Footboard [A] Bolts [B] and Collars [C] Screws [D] and Collars [E] Footboard Bracket installation • Install: Footboard Bracket [A] Tighten: • Torque - Footboard Bracket Bolts [B]: 46 N·m (4.
FRAME 15-23 Trailer Hitch Bracket Trailer Hitch Bracket Removal • Remove: Trailer Hitch Bracket Bolts [A] Trailer Hitch Bracket [B] Trailer Hitch Bracket Installation the trailer hitch bracket [A] as shown. • Install a non-parmanent locking agent to the trailer hitch • Apply bracket bolts. • Tighten: Torque - Trailer Hitch Bracket Bolts: 82 N·m (8.
ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Parts Location......................................................................................................................... Exploded View........................................................................................................................ Specifications ......................................................................................................................... Wiring Diagram...............................
16-2 ELECTRICAL SYSTEM Armature Inspection.......................................................................................................... Brush Lead Inspection ...................................................................................................... Right-hand End Cover Inspection ..................................................................................... Starter Relay Inspection................................................................................................
ELECTRICAL SYSTEM 16-3 Parts Location Light/Dimmer Switch [A] Starter Button [B] Engine Stop Switch [C] Reverse Power Assist Switch (Override) [D] Rear Brake Light Switch [E] Power Outlet Connector [F] (120 W) 2WD/4WD Shift Switch [A] Front Brake Light Switch [B] Ignition Switch [C] Radiator Fan [A] Frame Ground [B] Crankshaft Sensor [A] Alternator [B] Oil Pressure Warning Light Switch [C] Starter Motor [D] Ignition Coil (Front) [A] Spark Plug Cap (Front) [B] Spark Plug (Front) [C]
16-4 ELECTRICAL SYSTEM Parts Location Ignition Coil (Rear) [A] Engine Brake Actuator [B] Drive Belt Failure Detection Switch [C] Engine Ground [D] Spark Plug Cap (Rear) [E] Neutral Position Switch [A] Reverse Position Switch [B] Forward/Reverse Detecting Sensor [C] Rear Brake Light Switch [A] Speed Sensor [B] Battery 12 V 12 Ah [A] ECU (Electronic Control Unit) [B] Fuse Box [C] Actuator Controller [A] Reset Connectors [B] Starter Control Relay (Neutral) [C] Starter Control Relay (Brake) [D] Radiator Fan
ELECTRICAL SYSTEM 16-5 Parts Location Regulator/Rectifier [A] 2WD/4WD Actuator [A] Multifunction Meter [A] “SET/RESET” Button [B] Belt Check Indicator Light [C] Neutral Indicator Light [D] Reverse Indicator Light [E] Oil Pressure Warning Indicator Light [F] “4WD” Indicator Light [G] “2WD” Indicator Light [H] Water Temperature Warning Symbol [I] FI Indicator Light [J] Fuel Level Gauge [K] “TIME SET” Button [L] Clock [M] Speedometer [N] Trip Meter/Odometer/Hour Meter [O] “MODE” Button [P]
16-6 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 16-7 Exploded View No. 1 2 3 4 5 6 7 8 9 10 11 12 Fastener Starter Motor Mounting Bolts Starter Motor Cable Mounting Nut Starter Motor Terminal Locknut Starter Motor Through Bolts Starter Motor Clutch Bolts Alternator Stator Bolts Crankshaft Sensor Mounting Bolts Alternator Cover Plugs Alternator Rotor Bolt Alternator Cover Bolts Alternator Outer Cover Bolts Harness Clamp Bolt EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent.
16-8 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 16-9 Exploded View No. Fastener 1 2 3 4 5 6 7 8 9 Spark Plugs 2WD/4WD Actuator Mounting Bolts Engine Brake Actuator Mounting Bolts Forward/Reverse Detecting Sensor Mounting Bolt Speed Sensor Mounting Bolt Neutral Position Switch Reverse Position Switch Ignition Coil Mounting Bolts Ignition Coil Bracket Mounting Bolts N·m 13 9.8 8.8 14.9 8.8 15 15 5.9 5.9 10. Power Outlet Connector (120 W) AG: Apply grease (Amoco rykon premium grease No.2 EP Green). G: Apply grease.
16-10 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 16-11 Exploded View No. 1 2 3 4 Fastener Oil Pressure Switch Oil Pressure Switch Terminal Bolt Regulator/Rectifier Mounting Bolts Tail/Brake Light Lens Screws N·m 15 1.5 8.8 1.0 Torque kgf·m 1.5 0.15 0.90 0.10 5. Radiator Fan Breaker 6. Starter Control Relay (Brake) 7. Starter Control Relay (Neutral) 8. Other than US and CA Models AG: Apply grease (Amoco rykon premium grease No.2 EP Green). SS: Apply silicone sealant (Kawasaki Bond: 56019-120). ft·lb 11 13 in·lb 78 in·lb 8.
16-12 ELECTRICAL SYSTEM Specifications Item Battery Type Model Name Capacity Voltage Charging System Alternator Type Charging Voltage (Regulator/Rectifier Output Voltage) Alternator Output Voltage Stator Coil Resistance Ignition System Spark Plug: Spark Plug Gap Spark Plug Cap Resistance Ignition Coil: 3 Needle Arcing Distance Primary Winding Resistance Secondary Winding Resistance Primary Peak Voltage Crankshaft Sensor Resistance Crankshaft Sensor Peak Voltage Electric Starter System Starter Motor: Brush L
ELECTRICAL SYSTEM 16-13 Wiring Diagram Dummy Page
16-14 ELECTRICAL SYSTEM Wiring Diagram
ELECTRICAL SYSTEM 16-15 Wiring Diagram
16-16 ELECTRICAL SYSTEM Special Tools and Sealant Timing Light: 57001-1241 Peak Voltage Adapter: 57001-1415 Spark Plug Wrench, Hex 16: 57001-1262 Filler Cap Driver: 57001-1454 Flywheel Holder: 57001-1313 Needle Adapter Set: 57001-1457 Hand Tester: 57001-1394 Drive Pulley Holder: 57001-1520 Flywheel Puller Assembly, M38 × 1.5/M35 × 1.
ELECTRICAL SYSTEM 16-17 Precautions There are a number of important precautions that should be taken when servicing electrical systems. Learn and observe all the rules below. ○Do not reverse the battery lead connections. This will burn out the diodes in the electrical parts. ○Always check battery condition before condemning other parts of an electrical system. A fully charged battery is required for conducting accurate electrical system tests.
16-18 ELECTRICAL SYSTEM Precautions ○Electrical Connectors: Connectors [A] Connectors [B]
ELECTRICAL SYSTEM 16-19 Electrical Wiring Wiring Inspection inspect the wiring for signs of burning, fraying, • Visually etc. If any wiring is defective, replace the damaged wiring. Pull each connector [A] apart and inspect for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Check the wiring for continuity. ○Use the wiring diagram to find the ends of the lead which is suspected of being a problem.
16-20 ELECTRICAL SYSTEM Battery Battery Removal off the ignition switch. • Turn • Remove: Seat (see Seat Removal in the Frame chapter) • • Battery Holder Bolts [A] and Collars Battery Holder [B] Disconnect the battery negative (–) cable [C] first, and then the positive (+) cable [D]. Take out the battery [E]. Battery Installation off the ignition switch. • Turn • Install: Rubber Dampers [A] • • • Clamp Nut [B] Connect the positive cable first and then the negative.
ELECTRICAL SYSTEM 16-21 Battery CAUTION Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. the battery on a level surface. • Place to see that the sealing sheet has no peeling, tears, • Check or holes in it. • Remove the sealing sheet. NOTE ○The battery is vacuum sealed. If the sealing sheet has leaked air into the battery, it may require a longer initial charge.
16-22 ELECTRICAL SYSTEM Battery remove the container from the battery. • Gently Let the battery sit for 30 minutes prior to charging to allow • the electrolyte to permeate into the plates for optimum performance. ○Charging NOTE the battery immediately after filling can shorten service life. Let the battery sit for at least 30 minutes after filling. Initial Charge Place the strip [A] of caps loosely over the filler ports. Newly activated sealed batteries require an initial charge.
ELECTRICAL SYSTEM 16-23 Battery If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification (see Refreshing Charge). When a fast charge is inevitably required, do it following precisely the maximum charge current and time conditions indicated on the battery.
16-24 ELECTRICAL SYSTEM Battery If the reading is below the specified, refreshing charge is required. Battery Terminal Voltage Standard: 12.8 V or more Terminal Voltage (V) [A] Battery Charge Rate (%) [B] Good [C] Refresh charge is required [D] Refreshing Charge the battery [A] (see Battery Removal). • Remove by following method according to the bat• Refresh-charge tery terminal voltage. WARNING This battery is sealed type. Never remove seal sheet [B] even at charging. Never add water.
ELECTRICAL SYSTEM 16-25 Battery battery condition after refreshing charge. •○Determine Determine the condition of the battery 30 minutes after completion of the charge by measuring the terminal voltage according to the table below. Criteria 12.8 V or higher 12.0 ∼ 12.8 V or lower 12.
16-26 ELECTRICAL SYSTEM Charging System Alternator Cover Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte• • • nance chapter) Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter) Remove: Water Pump Impeller (see Water Pump Impeller Removal in the Cooling System chapter) Torque Converter Cover (see Torque Converter Cover Removal in the Converter System chapter) Middle Cover (see Middle Cover Removal in the Frame chapter) Remove the three bolts of the drive pulley cover
ELECTRICAL SYSTEM 16-27 Charging System • Open the clamps [A]. the drive pulley with the drive pulley holder, • Holding loosen the alternator rotor bolt [A]. • Remove: Alternator Rotor Bolt • Remove: Collar [A] ○Install the M6 bolt [B] to the collar, and pull out it.
16-28 ELECTRICAL SYSTEM Charging System • Check that the bearing [A] is in place. the grommets [A] into the notch in the cover. • Fit Grease • Tighten:the alternator cover oil seal. • Torque - Alternator Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) that the O-ring [A] in the collar [B] is in good con• Check dition. grease to the O-ring. • Apply • Install the collar on the alternator cover. • Hold the drive pulley with the drive pulley holder [A].
ELECTRICAL SYSTEM 16-29 Charging System Alternator Rotor Removal • Remove: Alternator Cover (see Alternator Cover Removal) • Screw the flywheel puller [A] onto the alternator rotor. Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: 57001-1405 the flywheel puller, turn the rotor puller bolt until • Holding the alternator rotor is forced off the end of the crankshaft. CAUTION If the rotor is difficult to remove, turn the puller while tapping the end of the puller.
16-30 ELECTRICAL SYSTEM Charging System Alternator Stator Removal • Remove: Alternator Cover (see Alternator Cover Removal) Crankshaft Sensor [A] (see Crankshaft Sensor Removal) Bolts [B] and Alternator Stator [C] Alternator Stator Installation • Tighten: Torque - Alternator Stator Bolts: 13.5 N·m (1.4 kgf·m, 119 in·lb) • Install: Crankshaft Sensor (see Crankshaft Sensor Installation) Fit the lead grommets into the notch on the alternator • cover.
ELECTRICAL SYSTEM 16-31 Charging System If the battery voltage does not increase 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 which part is defective. Alternator Inspection There are three types of alternator failures: short, open, 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.
16-32 ELECTRICAL SYSTEM Charging System the stator coil resistance as follows: •○Check Stop the engine. ○Disconnect the alternator connector. ○Connect a hand tester as shown in the table. ○Note the readings (total 3 measurement). Stator Coil Resistance Tester Range × 1 Ω • @20°C (68°F) Connections Tester (+) to Tester (–) to One black lead Another black lead Reading 0.25 ∼ 0.
ELECTRICAL SYSTEM 16-33 Charging System Regulator/Rectifier Inspection • Remove: Regulator/Rectifier (see Regulator/Rectifier Removal) the hand tester to the × 1 kΩ range and make the • Set measurements shown in the table. Special Tool - Hand Tester: 57001-1394 the hand tester to the regulator rectifier. • Connect If the tester readings are not as specified, replace the regulator/rectifier. CAUTION Use only Kawasaki Hand Tester 57001-1394 for this test.
16-34 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high voltage. Do not touch the spark plug, ignition coil, or spark plug lead 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 igniter damage. Do not install the battery backwards. The negative side is grounded.
ELECTRICAL SYSTEM 16-35 Ignition System lifting up the air duct [A], remove the spark plug cap • While [B]. • Using a spark plug wrench, remove the spark plug [A]. Special Tool - Spark Plug Wrench, Hex 16: 57001-1262 Spark Plug Installation • Tighten: Torque - Spark Plugs: 13 N·m (1.3 kgf·m, 115 in·lb) Special Tool - Spark Plug Wrench, Hex 16: 57001-1262 the spark plug caps securely. • Fit Pull up the spark pug caps lightly to make sure of the • installation of the spark plug caps.
16-36 ELECTRICAL SYSTEM Ignition System Rear Side Remove: Right Side Cover (see Right Side Cover Removal in the Frame chapter) Rubber Air Duct (see Spark Plug Removal) Spark Plug Cap [A] Cut the band [B]. • • • Remove: Primary Lead Connectors [A] Bolts [B] Ignition Coil [C] Ignition Coil Installation • Install: Ignition Coil Torque - Ignition Coil Mounting Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) the primary leads to the ignition coil terminals as • Connect shown.
ELECTRICAL SYSTEM 16-37 Ignition System Ignition Coil Inspection the ignition coil. • Remove the arcing distance with a coil tester [A] to check • Measure the condition of the ignition coil [B]. the ignition coil (with the spark plug cap left at• Connect tached at the end of the spark plug lead) to the tester in the manner prescribed by the manufacturer and measure the arcing distance. Ignition Coil Arcing Distance 7 mm (0.28 in.
16-38 ELECTRICAL SYSTEM Ignition System Ignition Coil Primary Peak Voltage Inspection NOTE ○Be sure the battery is fully charged. the spark plug cap (see Spark Plug Removal), • Remove but do not remove the spark plug. the primary peak voltage as follows. •○Measure Connect a commercially peak voltage adapter [A] to the hand tester [B] (250 V DC range).
ELECTRICAL SYSTEM 16-39 Ignition System Crankshaft Sensor Installation • Install: Stator Coil Leads [A] • Plate [B] Crankshaft Sensor [C] Tighten: Torque - Crankshaft Sensor Mounting Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) the lead grommets into the notch on the alternator • Fit cover. Grommets [A] for Alternator Leads Grommets [B] for Crankshaft Sensor Leads Crankshaft Sensor Inspection the middle cover (see Middle Cover Removal in • Remove the Frame chapter). the crankshaft sensor lead connector [A].
16-40 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak Voltage Inspection NOTE ○Be sure the battery is fully charged. the middle cover (see Middle Cover Removal in • Removal the Frame chapter). the spark plug caps, but do not remove the spark • Remove plugs. • Disconnect: Crankshaft Sensor Lead Connector [A] Set the hand tester [B] to the 10 V DC range. • Connect the peak voltage adapter [C] to the hand tester • and crankshaft sensor leads in the connector.
ELECTRICAL SYSTEM 16-41 Ignition System a timing light [A] and a tachometer in the manner • Attach prescribed by the manufacturer. Special Tool - Timing Light: 57001-1241 the engine and aim the timing light at the timing mark • Start on the alternator rotor. the engine at the speeds specified and note the align• Run ment of the timing marks. [A] F or R mark Ignition Timing Slot [B] aligned with: Advanced mark [C] on alternator rotor NOTE ○Do not mix up the timing marks with mark [A].
16-42 ELECTRICAL SYSTEM Ignition System Ignition System Troubleshooting
ELECTRICAL SYSTEM 16-43 Ignition System Ignition System Circuit 1. Throttle Sensor 2. Ignition Switch 3. Reverse Switch 4. Neutral Switch 5. Speed Sensor 6. Frame Ground Terminal 7. Fuse Box 8. Main Fuse 30 A 9. ECU (Electronic Control Unit) 10. Vehicle-down Sensor 11. Engine Ground Terminal 12. Battery 12 V 12 Ah 13. Spark Plugs 14. Ignition Coils 15. Water Temperature Sensor 16. Crankshaft Sensor 17. Reverse Power Assist Switch (Override) 18. Engine Stop Switch 19.
16-44 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal • Loosen: Clamp Bolts [A] Remove: • Air Intake Rubber Duct [B] • Remove: Bolts [A] Joint Duct [B] and Collars the rubber boots [A]. • Slide Remove: • Starter Motor Cable Mounting Nut [B] Starter Motor Cable [C] Starter Motor Mounting Bolts [D] Clamp [E] Starter Motor [F] CAUTION Do not tap the end of the starter motor shaft or the motor may be damaged.
ELECTRICAL SYSTEM 16-45 Electric Starter System • If the O-ring [A] shows wear or damage, or if it is hardened, replace it with a new one. Apply a small amount of engine oil to the O-ring. • Install: Starter Motor [A] • Clamp [B] (as shown) Tighten: Torque - Starter Motor Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) the starter motor cable [A] as shown. • Position About 20° [B] • Tighten: Torque - Starter Motor Cable Mounting Nut: 6.8 N·m (0.
16-46 ELECTRICAL SYSTEM Electric Starter System • Pull out the armature [A] out of the yoke [B]. NOTE ○Do not remove the circlip [C] from the shaft. • Remove: Starter Motor Terminal Locknut [A] Washer [B] Collar [C] out the brushes from the brush holder [A].
ELECTRICAL SYSTEM 16-47 Electric Starter System the O-ring [A] with a new one. • Replace Install the • O-ring following parts to the starter motor terminal [B]. Collar [C] Washer [D] Starter Motor Terminal Locknut [E] ○Install the collar so that stepped side faces outward. Tighten: • Torque - Starter Motor Terminal Locknut: kgf·m, 97 in·lb) 11 N·m (1.1 the brush springs [A]. • Install Insert the brushes [B] to the brush holder. • • Apply thin coat of grease to the oil seal [A].
16-48 ELECTRICAL SYSTEM Electric Starter System • Tighten: Torque - Starter Motor Through Bolts [A]: 5.0 N·m (0.51 kgf·m, 44 in·lb) Brush Inspection the length of each brush [A]. • Measure If any is worn down to the service limit, replace the brush assy. Starter Motor Brush Length Standard: 12 mm (0.47 in.) Service Limit: 6.5 mm (0.26 in.) Commutator Cleaning and Inspection the metallic debris off the between commutator • Clean segments [A]. NOTE ○Do not use emery or sand paper on the commutator.
ELECTRICAL SYSTEM 16-49 Electric Starter System Brush Lead Inspection the × 1 Ω hand tester range, measure the resis• Using tance as shown. Terminal Bolt and Positive Brushes [A] Right-hand End Cover and Negative Brushes [B] Special Tool - Hand Tester: 57001-1394 If there is not close to zero ohms, the brush lead has an open. Replace the brush plate assy. Right-hand End Cover Inspection the highest hand tester range, measure the resis• Using tance as shown.
16-50 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit 1. Ignition Switch 2. Neutral Switch 3. Rear Brake Light Switch (Lever) 4. Front Brake Light Switch 5. Rear Brake Light Switch (Pedal) 6. Fuse Box 7. Main Fuse 30 A 8. Stater Control Relay (Brake) 9. Stater Control Relay (Neutral) 10. Engine Ground Terminal 11. Battery 12 V 12 Ah 12. Starter Relay 13. Starter Motor 14. Starter Button 15.
ELECTRICAL SYSTEM 16-51 Electric Starter System Starter Motor Clutch Removal the alternator rotor (see Alternator Rotor Re• Remove moval). the rotor with the flywheel holder and take out the • Hold starter motor clutch bolts [A]. Special Tool - Flywheel Holder: 57001-1313 • Take out the one-way clutch [A]. Starter Motor Clutch Installation the one-way clutch so that the flange [A] fits on the • Install recess [B] of the race. a non-permanent locking agent to the starter motor • Apply clutch bolts.
16-52 ELECTRICAL SYSTEM Electric Starter System Torque Limiter Inspection • Remove: Alternator Rotor (see Alternator Rotor Removal) the torque limiter [A] and visually inspect it. • Remove If the limiter has wear, discoloration, or other damage, replace it as a unit.
ELECTRICAL SYSTEM 16-53 Lighting System Headlight Beam Vertical Adjustment the adjusting screw [A] on each headlight rim in or • Turn out to adjust the headlight vertically. NOTE ○On high beam, the brightest point should be slightly be- low horizontal with the vehicle on its wheels and the rider seated. Adjust both headlights to the same angle.
16-54 ELECTRICAL SYSTEM Lighting System the bulb socket [A] counterclockwise [B], and remove • Turn the bulb. ○The headlight bulb can not be removed from the socket. the mark [A] of a new bulb socket with the mark [B] • Align of the headlight body. • Turn the bulb socket clockwise until it is stopped. the bulb socket [A] counterclockwise [B], and remove • Turn it. the bulb [A] from the socket [B]. • Pull • Install the new bulb to the socket.
ELECTRICAL SYSTEM 16-55 Lighting System the removed parts. • Install [A] Bolt and Collar [L = 6 mm (0.24 in.)] [B] Bolt and Collar [L = 4 mm (0.16 in.)] [C] Bolt (only) Tail/Brake Light Bulb Replacement • Remove: Tail/Brake Light Lens Mounting Screws [A] Tail/Brake Light Lens [B] the bulb [A] in, turn it counterclockwise, and pull it • Push out. • Be sure the socket is clean. the new bulb by aligning the pins [A] with the • Insert grooves in the walls of the socket.
16-56 ELECTRICAL SYSTEM Lighting System • Remove: Tail/Brake Light Mounting Nuts [A] Tail/Brake Light [B] Lighting System Circuit 1. Ignition Switch 2. Reverse Switch 3. Fuse Box 4. Main Fuse 30 A 5. Reverse Light (Europe Models) 6. Tail/Brake Lights 12 V 5/21 W 7. Engine Ground Terminal 8. Battery 12 V 12 Ah 9. Light/Dimmer Switch 10. Position Light (Left) 12 V 5 W 11. Headlight (Left) 12 V 40/40 W 12. Frame Ground 13. Multifunction Meter 14. Headlight (Right) 12 V 40/40 W 15.
ELECTRICAL SYSTEM 16-57 Radiator Fan System Radiator Fan Motor Inspection the connector [A] in the fan lead. • Disconnect Using two auxiliary wires, supply battery voltage to the fan • motor. If the fan does not rotate, the fan motor is defective and must be replaced. Radiator Fan Motor Lead Connections: BL → Battery (+) BK → Battery (–) Radiator Fan Breaker Inspection • Remove: Seat (see Seat Removal in the Frame chapter) Radiator Fan Breaker [A] the breaker for operation.
16-58 ELECTRICAL SYSTEM Radiator Fan System Radiator Fan Circuit 1. Ignition Switch 2. Radiator Fan Breaker 10 A 3. Fuse Box 4. Main Fuse 30 A 5. ECU (Electronic Control Unit) 6. Radiator Fan Relay 7. Engine Ground Terminal 8. Battery 12 V 12 Ah 9. Water Temperature Sensor 10.
ELECTRICAL SYSTEM 16-59 Meter Multifunction Meter Unit Removal • Remove: Handlebar Cover Screws [A] • Remove: Handlebar Cover Screws [A] Handlebar Cover Front [B] • Remove: Meter Unit Lead Connectors [A] Handlebar Cover Screws [B] Handlebar Cover Rear [C] with Meter Unit • Remove: Bracket Mounting Screws [A] Meter and Bracket [B] Upper Damper • Remove: Multifunction Meter Mounting Nuts [A] and Washers Bracket [B] Multifunction Meter Unit [C] CAUTION Do not drop the meter unit.
16-60 ELECTRICAL SYSTEM Meter Multifunction Meter Unit Inspection • Remove: Multifunction Meter Unit (see Multifunction Meter Unit Removal) CAUTION Do not drop the meter unit.
ELECTRICAL SYSTEM 16-61 Meter the meter to TRIP A or TRIP B mode. • Cycle Check that when the SET/RESET button [A] is pushed, • the display turns to 0.0. If this display function does not indicate 0.0 [B], replace the meter unit. that when the TIME SET [A] and SET/RESET [B] • Check buttons are pushed, the time [C] will reset. If the meter function does not work, replace the meter unit. Check 3: Speedometer Check Connect the wires in the same manner as Check 1.
16-62 ELECTRICAL SYSTEM Meter Check 5: Trip Meter A/B Check Connect the wires in the same manner as Check 3. Pushing the MODE button [A], cycles the trip meter A or B [B]. Raise the input frequency of the oscillator to see the result of this inspection. If the value indicated by the trip meter A or B does not increase, replace the meter unit. • • • Check 6: Fuel Meter Check Connect the wires in the same manner as Check 1. ○The first segment (LCD) [A] should flash.
ELECTRICAL SYSTEM 16-63 Meter ○The 4WD indicator light (LCD) [A] should appear. If this display function does not work, replace the meter unit. Check 8: Water Temperature Warning Symbol Check Connect the wires in the same manner as Check 1. Connect terminal [3] to the battery (–) terminal. • • ○The water temperature warning symbol (LCD) [A] should appear. If this display function does not work, replace the meter unit.
16-64 ELECTRICAL SYSTEM Meter Check 10: Neutral Indicator Light Check Connect the wires in the same manner as Check 1. Connect terminal [8] to the battery (–) terminal. • • ○The neutral indicator light (LED) [A] should go on. If the LED light does not go on, replace the meter unit. Check 11: Reverse Indicator Light Check Connect the wires in the same manner as Check 1. Connect terminal [7] to the battery (–) terminal. • • ○The reverse indicator light (LED) [A] should go on.
ELECTRICAL SYSTEM 16-65 Meter ○The meter illumination [A] should go on. If the illumination does not go on, replace the meter unit. Check 13: Belt Check Indicator Light check Connect the wires in the same manner as Check 1. Connect terminal [2] to the battery (–) terminal. • • ○The belt check indicator light (LED) [A] should go on. It the LED does not go on, replace the meter unit. Check 14:FI Indicator Light check Connect the wires in the same manner as Check 1.
16-66 ELECTRICAL SYSTEM Meter Drive Belt Failure Mode Memory Clearing Procedure A flashing BELT check indicator LED (Light Emitting Diode) light means that the drive belt failure detection system has activated. The belt check indicator light will illuminate and stay on when activated by the 100 hour belt check system. NOTE ○Follow the instruction on page 2-25 of this Service Manual to complete the necessary inspections.
ELECTRICAL SYSTEM 16-67 Meter the mismatched 4 pin connector sets and re• Disconnect connect them normally. (Black to black, gray to gray) [A] the belt switch 2 pin connector [A]. • Connect Turn on the switch. • Confirm thatignition no belt check indicator light is flashing. • Put the connectors back and bend the clamps.
16-68 ELECTRICAL SYSTEM Meter Meter Circuit 1. Ignition Switch 2. Reverse Switch 3. Neutral Switch 4. Fuse Box 5. Main Fuse 30 A 6. Fuel Level Sensor 7. Actuator Controller 8. ECU (Electronic Control Unit) 9. Engine Ground Terminal 10. Battery 12 V 12 Ah 11. Oil Pressure Switch 12. Engine Stop Switch 13. Light/Dimmer Switch 14. Reset Connector 15. Drive Belt Failure Detecting Switch 16. Multifunction Meter 17.
ELECTRICAL SYSTEM 16-69 Actuator Control System 2WD/4WD Actuator Removal the front final gear case oil (see Front Final Gear • Drain Case Oil Change in the Periodic Maintenance chapter). • Remove: Actuator Lead Connector [A] Clamps [B] • Remove: Actuator Mounting Bolts [A] Actuator [B] 2WD/4WD Actuator Installation installing the pin [A], apply engine oil to the rod of • When the actuator and install the collar [B] on the actuator and • • • then press the pin. Apply grease to the O-ring [C].
16-70 ELECTRICAL SYSTEM Actuator Control System Engine Brake Actuator Installation grease and Install: • Apply O-ring [A] Apply molybdenum disulfide grease to the pin [B]. • • Apply grease to the trim seal [A] and install the cover [B]. the pin into the collar [A] of the engine brake lever • Insert assembly [B]. • Wipe off any protruding grease. the actuator mounting bolts following the tighten• Tighten ing sequence [1 ∼ 3]. Torque - Engine Brake Actuator Mounting Bolts: 8.8 N·m (0.
ELECTRICAL SYSTEM 16-71 Actuator Control System Actuator Control System Actuator Controller Removal • Remove: Seat (see Seat Removal in the Frame chapter) • Actuator Controller [A] Disconnect the connector [B]. Actuator Controller Installation grease (Amoco Rykon Premium grease No.2 EP • Apply Green) to the connector [A], and connect it to the actuator controller [B].
16-72 ELECTRICAL SYSTEM Actuator Control System Actuator Control System Troubleshooting When the actuator fails, the controller enters failure mode and the indicator light illuminates 2WD and 4WD alternately.
ELECTRICAL SYSTEM 16-73 Actuator Control System Failure Indication Pattern and Failure Part No. Failure Indication Pattern Failure Part 1 Selectable 2WD/4WD actuator 2 Engine brake actuator 3 Both the selectable 2WD/4WD actuator and the engine brake actuator Malfunction Mode No. Malfunction Mode 1 The 2WD/4WD actuator does not operate correctly. 2 The engine brake actuator does not operate correctly. 3 The 2WD/4WD indicator light does not switch. Check 1.
16-74 ELECTRICAL SYSTEM Actuator Control System the resistance between the following terminals • Measure in the actuator lead connector [A]. Special Tool - Hand Tester: 57001-1394 Actuator Internal Resistance 4 (Red) - 6 (Black): 3 ∼ 15 Ω 1 (Orange) - 3 (Blue): 3.5 ∼ 6.5 kΩ 2 (Yellow) - 3 (Blue): 630 ∼ 3,720 Ω If any reading is not within the specified range, replace the 2WD/4WD actuator. Check 2.
ELECTRICAL SYSTEM 16-75 Actuator Control System Check 4. Speed Sensor Inspection NOTE ○Be sure the battery is fully charged. the vehicle on a stand or a jack so that the wheels • Support are off the ground. • Remove: Seat (see Seat Removal in the Frame chapter) Connect: • Controller Connector [A] Hand Tester [B] (range: DC 25 V) Tester (+) → Connector (P) Terminal [5] Tester (–) → Connector (BK/Y) Terminal [10] ○Install the needle adapters on the tester leads.
16-76 ELECTRICAL SYSTEM Actuator Control System • Push the switch to the 2WD position. Controller Output Voltage (at 2WD/4WD Shift Switch ON, 2WD) Standard: 0 V If the reading is not standard, check the 2WD/4WD shift switch or actuator controller unit. Check 6. Controller Unit Inspection NOTE ○Be sure the battery is fully charged.
ELECTRICAL SYSTEM 16-77 Actuator Control System the 2WD/4WD shift switch lead connector. • Disconnect Connect: • Controller Connector [A] Hand Tester [B] (range: DC 10 V) Tester (+) → Connector (G) Terminal [7] Tester (–) → Connector (BK/Y) Terminal [10] ○Install the needle adapters on the tester leads. Special Tools - Hand Tester: 57001-1394 Needle Adapter Set: 57001-1457 ON the ignition switch. • Turn Measure the controller output voltage for the 2WD/4WD • shift switch.
16-78 ELECTRICAL SYSTEM Actuator Control System ON the ignition switch. • Turn Shift to position. • Measurethethe2WD output voltage for the 2WD/4WD • actuator until controller the actuator stops. Controller Output Voltage (to 2WD/4WD actuator) Standard: 5 ∼ 12 V If the reading is not standard, check the 2WD/4WD shift switch. If the 2WD/4WD shift switch is normal, replace the actuator controller unit. Check 7.
ELECTRICAL SYSTEM 16-79 Actuator Control System Actuator Control System Circuit 1. Ignition Switch 2. Speed Sensor 3. Fuse Box 4. Actuator Controller Fuse 10 A 5. Main Fuse 30 A 6. Actuator Controller 7. Engine Brake Actuator 8. 2WD/4WD Actuator 9. ECU (Electronic Control Unit) 10. Engine Ground Terminal 11. Battery 12 V 12 Ah 12. Forward/Reverse Detecting Sensor 13. Drive Belt Failure Detecting Switch 14. Multifunction Meter 15.
16-80 ELECTRICAL SYSTEM Drive Belt Failure Detection System If the drive belt failure detection system activated by abnormal belt, the drive belt failure detection switch is damaged. Make sure replace the torque converter cover (see Torque Converter Cover Removal/Installation in the Converter System chapter). Drive Belt Failure Detection System Inspection to the Drive Belt Failure Detection System Inspec• Refer tion in the Periodic Maintenance chapter. Drive Belt Failure Detection System Circuit 1.
ELECTRICAL SYSTEM 16-81 Switches and Sensor Fuel Level Sensor Inspection • Remove: Fuel Pump (see Fuel Pump Removal in the Fuel System • (DFI) chapter) 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 fuel pump assembly. a hand tester [A], measure the resistance across • Using the terminals in the fuel pump lead connector [B].
16-82 ELECTRICAL SYSTEM Switches and Sensor Fuel Level Sensor Circuit 1. Multifunction Meter 2. Ignition Switch 3. Fuse Box 4. Main Fuse 30 A 5. Fuel Level Sensor 6. Engine Ground Terminal 7. Battery 12 V 12 Ah Brake Light Switch Adjustment to the Brake Light Switch Inspection and Adjust• Refer ment in the Periodic Maintenance chapter.
ELECTRICAL SYSTEM 16-83 Switches and Sensor Water Temperature Sensor Inspection the water temperature sensor (see Water Tem• Remove perature Sensor Removal/Installation in the Fuel System • • (DFI) chapter). Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion and threaded portion are submerged. Suspend an accurate thermometer [B] with heat-sensitive portions [C] located in almost the same depth.
16-84 ELECTRICAL SYSTEM Switches and Sensor [A] each side of the speed sensor surface with the • Trace screw driver. ○Then the tester indicator should flick [B]. If the tester indicator does not flick, replace the speed sensor. Switch Inspection the hand tester, check to see that only the con• Using nections shown in the table have continuity (about zero ohms). ○For the handlebar switches, ignition switch, refer to tables in the Wiring Diagram.
ELECTRICAL SYSTEM 16-85 Switches and Sensor Drive Belt Failure Detection Switch Inspection If the drive belt failure detection system is activated by abnormal belt, the drive belt failure detection switch is damaged. Make sure to replace the torque converter cover (see Torque Converter Cover Removal/Installation in the Converter System chapter).
16-86 ELECTRICAL SYSTEM Relay Relay Inspection • Remove: Seat (see Seat Removal in the Frame chapter) Starter Control Relay (Neutral) [A] Radiator Fan Relay [B] Fuel Pump Relay [C] Starter Control Relay (Brake) [D] ○The relays are identical. the hand tester [A] and a 12 V battery [B] to the • Connect starter circuit relay [C] as shown. If the relay does not work as specified, the relay is defective. Replace the relay.
ELECTRICAL SYSTEM 16-87 Fuses Fuse Removal • Remove: Seat (see Seat Removal in the Frame chapter) Fuse Box Lid [A] the fuses [A] straight out of the fuse box with needle • Pull nose pliers. Fuse Installation • If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amperage. Install the fuses on the original position as specified on the fuse box lid [A]. Fuse Inspection the fuse element.
APPENDIX 17-1 Appendix Table of Contents Troubleshooting Guide ........................................................................................................... Cable, Wire, and Hose Routing ..............................................................................................
17-2 APPENDIX Troubleshooting Guide NOTE ○Refer to the Fuel System chapter for most of DFI trouble shooting guide. ○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties.
APPENDIX 17-3 Troubleshooting Guide Brake dragging Front or rear final gear case oil viscosity too high Poor Running or No Power at High Speed: Firing incorrect: Spark plug dirty, broken, or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good contact Spark plug incorrect Crankshaft sensor trouble Ignition coil trouble Drive belt failure detection switch activated Fuel/air mixture incorrect: Air cleaner clogged, poorly sealed, or missing Water or foreign matter in fuel
17-4 APPENDIX Troubleshooting Guide Drive pulley movable sheave doesn’t move smoothly Drive pulley spring incorrect installed (too tight) Driven pulley movable sheave doesn’t move smoothly Gear Shifting Faulty: Doesn’t go into gear: Shift arm bent or seized Gear stuck on the shaft Shift tie-rod maladjusted Shift tie-rod damaged Jumps out of gear: Shifter groove worn Gear dogs worn Shift block worn Shift arm positioning bolt spring weak or broken Shift tie-rod maladjusted Drive shaft, output shaft, and/or ge
APPENDIX 17-5 Troubleshooting Guide Handling and/or Stability Unsatisfactory Handlebar hard to turn: Tire air pressure too low Steering stem bearing damaged Steering stem bearing lubrication inadequate Steering stem bent Damaged steering knuckle joint Damage tie-rod end LSD clutch maladjusted (front final gear case) Noise when turning: Damaged side gear or pinion (front final gear case) Worn LSD clutch friction plates (Front final gear case) Handlebar shakes or excessively vibrates: Tire worn Wheel rim warp
17-6 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Band 2. Main Harness 3. Clamp 4. To Fuel Injectors and Throttle Sensor 5. Fuel Injector Throttle Sensor Subharness 6. Fuel Injector Throttle Sensor Subharness Connector (Clamp the connector to the bracket of the cylinder head.) 7. To Fuel Injector #1 8. To Fuel Injector #2 9. White Tape 10.
17-8 APPENDIX Cable, Wire, and Hose Routing 1. Front Fender Inner Cover 2. Tube (for Winch Harness) 3. Band (Pass the band through the hole of the frame bracket.) 4.
APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Engine Breather Hose 2. Clamps (Install the clamps direction as shown.) 3. Align the white paint of the breather hose with the projection of the crankcase. 4. Starter Motor 5. Run the oil pressure switch lead so that it does not touch the starter motor. 6. About 20° 7.
17-10 APPENDIX Cable, Wire, and Hose Routing 1. Starter Motor Cable 2. Engine Ground Lead (Install the lead so that the flat side of the lower terminal faces toward the engine.) 3. Install the clamp on the engine ground lead terminal. 4. Drive Belt Failure Detecting Switch Lead Connector 5. Engine Brake Actuator Lead Connector 6. Clamp 7.
APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Water Hose (Thermostat Housing ∼ Front Cylinder Head) 2. Water Hose Clamp 3. Clamps 4. White Paint of Water Hose 5. White Paint of Water Pipe 6. Radiator Hose (Radiator ∼ Water Pump) 7. Radiator Hose Clamp 8. White Paint of Radiator Hose 9. Projection of Water Pump Cover 10. Detail A 11.
17-12 APPENDIX Cable, Wire, and Hose Routing 1. Main Harness 2. Bands 3. Rear Final Gear Case Vent Hose 4. Spark Plug Lead of Rear Ignition Coil (Run the spark plug lead along the concave of the exhaust duct.) 5. Torque Converter Exhaust Duct 6. Fuel Hose 7. Clamp 8. Drain Hose 9. 2WD/4WD Actuator Connector 10. 60° 11. Install the clamp so that it do not touch the harness. Set the position of the clamp within 60°. 12. Frame Pipe 13. Outside of Vehicle 14. Starter Motor Cable 15. Engine Ground Lead 16.
APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Rear Final Gear Case Vent Hose 2. Front Final Gear Case Vent Hose 3. Vacuum Hose 4. Radiator Fan Motor Vent Hose 5. Bands 6. Main Harness 7. Outside of Vehicle 8. Radiator Fan Motor Connector 9. Band (Clamp the main harness and radiator fan motor lead.) 10. Band (Clamp the rear final gear case vent hose to the right side of the frame.) 11. About 5 mm (0.20 in.) 12. Clamps 13. Reserve Tank 14. Reserve Tank Hose 15. Radiator Hose 16. To Water Pump 17.
17-14 APPENDIX Cable, Wire, and Hose Routing 1. Do not crush the radiator fan motor vent hose to pull it. 2. Clamps 3. Clamp the reserve tank hose to the radiator cover. 4. Radiator Fan Motor Vent Hose 5. Radiator Fan Motor Connector 6. To Thermostat Housing 7. To Water Pump 8. Reserve Tank Hose 9. Reserve Tank 10. Band (Clamp the reserve tank hose and rear final gear case vent hose.
APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Water Hose (Thermostat Housing ∼ Front Cylinder Head) 2. Water Pipe (Thermostat Housing ∼ Rear Cylinder Head) 3. Water Temperature Sensor 4. Radiator Hose (Thermostat Housing ∼ Radiator) 5. Thermostat 6. Clamps 7. Reserve Tank 8. Reverse Switch Lead Connector (R/W Lead) 9. Neutral Switch Lead Connector (LG Lead) 10. Forward/Reverse Detecting Sensor Lead Connector 11. Band 12.
17-16 APPENDIX Cable, Wire, and Hose Routing 1. Clamp 2. 2WD/4WD Actuator Lead 3. Air Intake Duct 4. Band 5. Front Final Gear Case 6. Run the 2WD/4WD actuator lead so that it do not touch the front final gear case. 7. 2WD/4WD Actuator Lead Connector (Apply grease all around on the top surface of connector to be waterproof.) 8.
APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Main Harness 2. Drive Belt Failure Detecting Switch Lead 3. Engine Brake Actuator Lead 4. Starter Motor Cable 5. Clamp 6. Drive Belt Failure Detecting Switch 7. Engine Brake Actuator 8. Engine Brake Actuator Lead Connector (Apply grease all around on the top surface of connector to be waterproof.
17-18 APPENDIX Cable, Wire, and Hose Routing 1. Rear Brake Lever 2. Parking Brake Lock Lever 3. Variable Differential Control Cable 4. Cable Adjuster 5. Variable Differential Control Lever 6. Handle Holder Clamp 7. Variable Differential Operating Lever 8. Fit the dust cap. 9. 27 ∼ 35 mm (1.1 ∼ 1.4 in.
APPENDIX 17-19 Cable, Wire, and Hose Routing 1. Clamp 2. Bands 3. Radiator Fan Motor Vent Hose 4. Vacuum Hose 5. Front Final Gear Case Vent Hose 6. Fitting 7. Tube 8. Dampers 9. Bands 10. 220 mm (8.66 in.) 11. 60 mm (2.36 in.) 12. “L” Formed Side 13. Rear Final Gear Case Vent Hose 14.
17-20 APPENDIX Cable, Wire, and Hose Routing 1. Right Headlight Lead 2. Radiator Cover 3. Frame Ground Lead 4. Horn Switch Lead (Australia and Europe Models) 5. Alternator Lead 6. Rear Brake Light Switch Lead 7. 2WD/4WD Shift Switch Lead 8. Left Handlebar Switch Lead 9. Meter Unit Lead 10. Front Brake Light Switch Lead 11. Bands 12. Left Headlight Lead 13. Front Ignition Coil Primary Lead (Run the primary lead under the frame.) 14. Top View 15. Front 16. Radiator Fan Motor Lead 17. Front View 18.
APPENDIX 17-21 Cable, Wire, and Hose Routing 1. Right Handlebar Switch Lead 2. Throttle Cable 3. Meter Unit Lead 4. Variable Differential Control Cable 5. Parking Brake Cable 6. Left Handlebar Switch Lead 7. Bands 8. Front Brake Light Switch Lead 9. Brake Hose 10. Hoses 11. Cables and Brake Hose 12. Leads 13. Rear Brake Light Switch Lead 14.
17-22 APPENDIX Cable, Wire, and Hose Routing 1. Air Intake Duct 2. Bands 3. Parking Brake Cable 4. Rear Brake Cable 5. Bracket 6. Clamp 7. Rear Brake Light Switch 8. Speed Sensor Lead Connector 9. Run the lead front side of frame pipe. 10. Clamps 11. Reverse Switch Lead Connector (BK Lead) 12. Neutral Switch Lead Connector (W Lead) 13. Forward/Reverse Detecting Sensor Lead Connector 14. Apply grease (Amoco Rykon Premium Grease No.2 EP Green) 15. View A 16. View B 17.
APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Fuse Box 2. ECU 3. Main Harness (Run the main harness under the frame pipe.) 4. Clamps 5. Actuator Controller 6. Reset Connectors (Clamp the connector to the electrical parts case.) 7. Starter Control Relay (Neutral) 8. Radiator Fan Relay 9. Vehicle-down Sensor 10. Starter Control Relay (Brake) 11. Kawasaki Diagnostic System Connector (Connector of Gray) 12. Fuel Pump Relay 13. Radiator Fan Breaker 14. Starter Relay 15. Battery (+) Cable 16.
17-24 APPENDIX Cable, Wire, and Hose Routing 1. Main Harness (Run the main harness under the frame pipe.) 2. Battery (–) Cable 3. Bands 4. To Rear Brake Light Switch 5. To Fuse Box 6. To ECU 7. To Actuator Controller 8. To Starter Circuit Relay 9. To Battery (–) Cable 10. Reset Connector 11. Fuel Pump Lead Connector 12. To Radiator Fan Relay and Fuel Pump Relay 13. Kawasaki Diagnostic System Connector 14. To Starter Control Relay (Brake) 15. To Vehicle-down Sensor 16. To Starter Control Relay (Neutral) 17.
APPENDIX 17-25 Cable, Wire, and Hose Routing 1. To Left Headlight Lead 2. Clamps (Insert the clamp into the hole of the radiator cover.) 3. Clamps 4. To Power Outlet Connector 5. Front Ignition Coil 6. To ISC Valve 7. Clamps 8. Main Harness (Run the main harness under the frame pipe.) 9. Rear Ignition Coil 10. Frame Ground Terminal 11. Band 12. To Inlet Air Pressure Sensor 13. To Fuel Injector Throttle Sensor Subharness Connector 14. To Water Temperature Sensor 15. Accessory Connector 16.
17-26 APPENDIX Cable, Wire, and Hose Routing 1. Battery 2. Red Cap 3. Battery (–) Cable 4. Battery (+) Cable 5. Clamp (Insert the clamp into the hole of the frame from inside.) 6. Run the battery (+) cable under the frame. 7. ECU 8. Starter Motor Cable 9. Starter Relay 10.
APPENDIX 17-27 Cable, Wire, and Hose Routing 1. Air Intake Duct 2. Bands 3. Rear Final Gear Case Vent Hose 4.
17-28 APPENDIX Cable, Wire, and Hose Routing 1. ISC Valve Tube (Rear) 2. Tube 3. ISC Valve Tube (Primary) 4. Clamps 5. ISC Valve Tube (Front) 6. ISC Valve 7. Run the spark plug lead of the front ignition coil to the guide of the frame. 8. To Throttle Body #2 9. To Air Cleaner Housing 10. To Throttle Body #1 11.
APPENDIX 17-29 Cable, Wire, and Hose Routing 1. ISC Valve Tube (Rear) 2. ISC Valve Tube (Primary) 3. ISC Valve 4. ISC Valve Tube (Front) 5. Clamp 6. Fuel Injector/Throttle Sensor Subharness 7.
MODEL APPLICATION Year Model 2008 KVF750D8F 2008 2008 2008 KVF750E8F KVF750E8FA KVF750F8F Beginning Frame No. JKAVFDD1□8B500001 or JKAVF750DDB600001 JKAVFDE1□8B500001 JKAVFDE1□8B500001 JKAVFDF1□8B500001 □:This digit in the frame number changes from one machine to another. Part No.
