Z1000 Motorcycle 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.
Z1000 Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products and Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
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) Celsius 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 pound(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 r
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 California Air Resources Board on vehicles sold in California only. 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.
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.
NOTE ○This note symbol indicates points of particular interest for more efficient and convenient operation. a procedural step or work to be • Indicates done. ○Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.
GENERAL INFORMATION 1-1 General Information 1 Table of Contents Before Servicing ..................................................................................................................... Model Identification................................................................................................................. General Specifications............................................................................................................ Technical Information – Air Inlet System ....
1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, 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 Bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally. Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench.
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 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). Electrical Wires A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.
GENERAL INFORMATION 1-7 Model Identification ZR1000–A1 Left Side View: ZR1000–A1 Right Side View:
1-8 GENERAL INFORMATION General Specifications ZR1000–A1 ∼ Items Dimensions: Overall length 2 080 mm (81.9 in.) Overall width 770 mm (30.3 in.) Overall height 1 055 mm (41.5 in.) Wheelbase 1 420 mm (55.9 in.) Road clearance 145 mm (5.7 in.) Seat height 820 mm (32.3 in.) Dry mass 198 kg (410.1 lb) Curb mass: Front 110 kg (242.6 lb) Rear 111 kg (244.8 lb) Fuel tank capacity 18 L (5.0 US gal.) Performance: Minimum turning radius 2.8 m (9.
GENERAL INFORMATION 1-9 General Specifications ZR1000–A1 ∼ Items Lubrication system Engine oil: Type Viscosity Capacity Drive Train: Primary reduction system: Type Reduction ratio Clutch type Transmission: Type Gear ratios: 1st 2nd 3rd 4th 5th 6th Final drive system: Type Reduction ratio Overall drive ratio Frame: Type Caster (rake angle) Trail Front tire: Type Size Rear tire: Type Size Front suspension: Type Wheel travel Rear suspension: Type Wheel travel Brake Type: Forced lubrication (wet sump with coo
1-10 GENERAL INFORMATION General Specifications ZR1000–A1 ∼ Items Tail/brake light 12 V 0.5/3.8 W (LED) (US, CA, Cal) 12 V 0.5/5W (LED) Alternator: Type Three-phase AC Rated output 24 A/ 14 V @5 000 r/min (rpm) Specifications are subject to change without notice, and may not apply to every country. (AU): Australia Model (US): U.S.A.
GENERAL INFORMATION 1-11 Technical Information – Air Inlet System Subthrottle Control System The ZR1000–A1 ∼ employs large bore throttle bodies to increase power output. However, sudden changes in throttle opening can cause hesitation and jerky throttle response with a single butterfly valve in a large bore. Therefore two throttle valves are placed in each inlet tract, the main throttle valve located closest to the cylinder and a subthrottle valve placed further up the inlet tract.
1-12 GENERAL INFORMATION Technical Information – Air Inlet System Operation The subthrottle control system consists of the subthrottle valve, subthrottle valve actuator with a stepping motor built in it, ECU, and subthrottle sensor. The subthrottle valve is built in the each throttle body. The subthrottle control system operates on the signal supplied from the ECU.
GENERAL INFORMATION 1-13 Technical Information – New Ignition Interlock Sidestand Outline The New Ignition Interlock Sidestand System applied to ZR1000–A1 models that cannot function if gears are engaged and/or the sidestand is not lifted upward even though clutch lever pulled in, which differs from the traditional one. Refer to the tables below as to the engine starts and/or the driving at each condition.
1-14 GENERAL INFORMATION Technical Information – Tail/Brake Lights Employing LED Outline This model employs a tail/brake light containing 21 Light Emitting Diodes (LED). The LED emits luminous beams over a longer life span than those emitted from a traditional electric heated bulb (more than 5 times longer), uses lower voltage, expends lower wattage (approx.1/5), and is quicker responsing.
GENERAL INFORMATION 1-15 Technical Information – Tail/Brake Lights Employing LED The emitting color differs according to the materials of semi-conductors.
1-16 GENERAL INFORMATION Technical Information - KLEEN (KAWASAKI LOW EXHAUST EMISSION SYSTEM) Since the emission regulations become more severe, Kawasaki has adopted a type of simplified KLEEN, which have no catalyst protection system, according to each regulation of different countries. The muffler with built-in catalyst has the same durability as the conventional muffller, however, do not use leaded gasoline and do not coast with the ignition system OFF.
GENERAL INFORMATION 1-17 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 = = = = = = = = = gal (US) gal (imp) qt (US) qt (imp) pint (US) pint (imp) oz (US) oz (imp) cu in Units of Volume: L L L L L L mL mL mL × × × × × × × × × 0.2642 0.2200 1.057 0.8799 2.113 1.816 0.03381 0.02816 0.06102 km m mm × × × 0.6214 3.281 0.
PERIODIC MAINTENANCE 2-1 Periodic Maintenance 2 Table of Contents Periodic Maintenance Chart .............. Torque and Locking Agent................. Specifications .................................... Special Tools ..................................... Periodic Maintenance Procedures..... Fuel System (DFI)........................... Fuel Hose and Connection Inspection.................................. Throttle Control System Inspection.................................. Idle Speed Inspection .............
2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected.
PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever comes first → ↓ OPERATION Clutch-adjust † Every Radiator hoses, connections - inspect † Brake fluid - change Brake master cylinder cup and dust seal - replace 2 years Coolant - change 2 years Caliper piston seal and dust seal replace 4 years Steering stem bearing - lubricate 2 years 1 000 km * ODOMETER READING (600 mile) 6 000 km (4 000 mile) 12 000 km ( 7 500 mile) 18 000 km (12 000 mile) 24 000 km (15 000 mile) 30 000 km (2
2-4 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non -permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: L: Apply a non-permanent locking agent to the threads. G: Apply grease to the threads. MO: Apply molybdenum disulfide grease oil solution. EO: Apply oil to the threads and seating surface. S: Tighten the fasteners following the specified sequence. SS: Apply silicone sealant.
PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Fastener Water pump drain bolt Water pipe bolts Thermostat housing ground bolt Thermostat bracket bolt Radiator upper bolts Radiator lower bolts Radiator screen bolt Coolant reserve tank screws Radiator fan switch Water temperature sensor Engine Top End: Air suction valve cover bolts Cylinder head cover bolts Camshaft cap bolts (L=45 mm) Camshaft cap bolts (L=40 mm) Cylinder head bolts (M10 new bolts) Cylinder head bolts (M10 used bolts) Cylinder head bolts
2-6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Engine Lubrication: Oil filler plug Engine drain plug Oil filter (cartridge type, P/No.16097–1070) Oil filter (cartridge type, P/No.
PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Wheels/Tires: Front axle clamp bolt Front axle Rear axle nut Final Drive: Engine sprocket nut Engine sprocket cover bolts Engine sprocket cover damper bolt Rear sprocket nuts Speed sensor bolt Brakes: Bleed valves Front brake hose joint bracket bolts Brake hose banjo bolts Brake lever pivot bolt Brake lever pivot bolt locknut Front brake reservoir cap screws Front brake light switch screws Front master cylinder clamp bolts Pad pin bolts (Front calip
2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Handlebar lower clamp nuts Handlebar switch housing screws Frame: Footpeg holder bolts Muffler mounting bolts Side stand bolt Side stand switch bolt Windshield screws Front fender bolts Electrical System: Spark plugs Alternator rotor bolt Stator coil bolts Alternator lead holding plate bolt Engine ground cable terminal bolt Alternator cover bolts Crankshaft sensor cover bolts Crankshaft sensor bolts Camshaft position sensor bolt Timing rotor bolt St
PERIODIC MAINTENANCE 2-9 Specifications Item Fuel System: Throttle grip free play Idle speed Bypass screws (turn out) Engine vacuum Air cleaner element Cooling System: Coolant: Type (recommended) Color Mixed ratio Freezing point Total amount Engine Top End: Valve clearance Inlet Exhaust Clutch: Clutch lever free play Engine Lubrication System: Engine Oil: Type Viscosity Capacity Level Standard 2 ∼ 3 mm (0.08 ∼ 0.12 in.) 1 100 ± 50 r/min (rpm) 2 ± 1/4 (for reference) 32.7 ± 1.
2-10 PERIODIC MAINTENANCE Specifications Item Air pressure: (when cold) Front Rear Final Drive: Drive chain slack Drive chain (20-link length) Brakes: Brake fluid: Grade Brake pad lining thickness: Front Rear Brake light timing: Front Rear Electrical System: Spark plug gap AT: Republic of Austria CH: Swiss Confederation DE: Federal Republic of Germany Standard Up to 180 kg (396 lb) load: 250 kPa (2.5 kgf/cm², 36 psi) Up to 180 kg (396 lb) load: 290 kPa (2.9 kgf/cm², 41 psi) 20 ∼ 30 mm (0.8 ∼ 1.2 in.) 317.
PERIODIC MAINTENANCE 2-11 Special Tools Steering Stem Nut Wrench: 57001–1100 Pilot Screw Adjuster, C: 57001–1292 Jack: 57001–1238 Hand Tester: 57001–1394 Oil Filter Wrench: 57001–1249 Spark Plug Wrench (Owner’s Tool): 92110–1132
2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Fuel Hose and Connection Inspection ○The fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel System (DFI) chapter) and check the fuel hoses. Replace the hose if any fraying, cracks [B] or bulges [C] are noticed.
PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Throttle Control System Inspection Throttle Grip Play Inspection Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cable (see below). • Throttle Grip Free Play Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) that the throttle grip moves smoothly from close to • Check full open, and the throttle closes quickly and completely • • • • in all steering positions by the return spring.
2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Throttle Bore Cleaning Check the throttle bore for cleanliness as follows: ○Remove the throttle body assy (see Fuel System (DFI) chapter). ○Check the main throttle valves and throttle bores [A] for carbon deposits by opening the main valves. If any carbon accumulates, wipe the carbon off the throttle bores and throttle valves, using a cotton pad [B] penetrated with a high-flash point solvent.
PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Engine Vacuum Synchronization Inspection NOTE ○These procedures are explained on the assumption that the inlet and exhaust systems of the engine are in good condition. the motorcycle so that it is vertical. • Situate Remove fuel tank (see Fuel System (DFI) chapter). • Pull off thethevacuum hoses and the rubber cap (s) from the • right fitting of each throttle body.
2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures the fuel tank (see Fuel System (DFI) chapter). • Install Start the and warm it up thoroughly. • Check theengine idle speed. • Tachometer [A] If the idle speed is out of the specified range, adjust it. CAUTION Do not measure the idle speed by the tachometer of the meter unit. While idling the engine, inspect the engine vacuum, using the vacuum gauge [B]. Front [C] Engine Vacuum Standard: 32.7 ± 1.
PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures If any one vacuum measurement is out of the standard measurement after synchronization, adjust the bypass screws [A]. Front [B] Special Tool - Pilot Screw Adjuster, C: 57001-1292 the lowest vacuum between #1 and #2 to the high• Adjust est of #1 and #2. the lowest vacuum between #3 and #4 to the high• Adjust est of #3 and #4. and close the throttle after each measurement and • Open adjust the idle speed as necessary. the vacuums as before.
2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures out the same number of turns counted when first • Back turned in. This is to set the screw to its original position. NOTE ○A throttle body has different “turns out” of the bypass screw for each individual unit. When setting the bypass screw, use the “turns out” determined during disassembly. Use the specifications in this manual only if the original number is unknown. the same procedure for other bypass screws. • Repeat Repeat the synchronization.
PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Air Cleaner Element Cleaning NOTE ○In dusty areas, the element should be cleaned more frequently than the recommended interval. ○After riding through rain or on muddily roads, the element should be cleaned immediately. WARNING If dirt or dust is allowed to pass through into the throttle assy, the throttle may become stuck, possibly causing accident.
2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures the element by tapping it lightly to loosen dust. • Clean Blow away the remaining dust by applying compressed • air [A] from the outside to the inside (from the clean side • to the dirty side). Visually inspect the element for no tears or no breaks and inspect the sponge gaskets [B] also. If the element or gasket has any tears or breaks, replace the element. the element [A] with the flat side [B], facing for• Install wards.
PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures ○Disconnect the hoses from the separator, and remove the separator [A] from the motorcycle left side. Front [B] ○Visually inspect the separator for cracks and other damage. If the separator has any cracks or damage, replace it with a new one. ○To prevent the gasoline from flowing into or out of the canister, hold the separator perpendicular to the ground.
2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures the fuel tank (see Fuel System (DFI) chapter). • Remove Remove the radiator cap [A] in two steps. First turn the • cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap. ○The coolant will drain from the radiator and engine.
PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures the air bleeder bolt [A] on the thermostat housing. • Loosen Front [B] the coolant into the radiator until the coolant • Replenish begins to flow out the air bleeder bolt hole (that is, all the • remaining air is forced out). Tap the radiator hoses to force any air bubbles caught inside. the radiator up to the filler neck [A] with coolant. • Fill Tighten the air bleeder bolt [B]. • Torque - Thermostat Air Bleeder Bolt: 7.8 N·m (0.
2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Valve Clearance Inspection NOTE ○Valve clearance must be checked and adjusted when the engine is cold (at room temperature). • Remove: Lower Fairings (see Frame chapter) Pickup Coil Cover Cylinder Head Cover (see Cylinder Head Cover Removal) the crankshaft at 1,4 piston TDC. • Position TDC Mark [A] for #1, 4 Pistons Timing Mark [B] a thickness gauge [A], measure the valve clearance • Using between the cam and the valve lifter.
PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Valve Clearance Adjustment change the valve clearance, remove the camshaft • To chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. NOTE ○Mark and record the valve lifter and shim locations so they can be reinstalled in their original positions. ○If there is no clearance, select a shim which is several sizes smaller and then measure the clearance.
2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE 1. 2. 3. 4. Measure the clearance (when engine is cold). Check present shim size. Match clearance in vertical column with present shim size in horizontal column. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm Measured clearance is 0.45 mm Replace 2.95 mm shim with 3.20 mm shim. 5.
PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. 2. 3. 4. Measure the clearance (when engine is cold). Check present shim size. Match clearance in vertical column with present shim size in horizontal column. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm. Measured clearance is 0.47 mm. Replace 2.95 mm shim with 3.15 mm shim. 5.
2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Clutch Adjust Inspection the clutch lever just enough to take up the free play • Pull [A]. the gap between the lever and the lever holder. • Measure If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully. In either case, adjust it. Clutch Lever Free Play Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.
PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Engine Lubrication System Engine Oil Change the motorcycle so that it is vertical after warming • Situate up the engine. the engine drain plug [A] to drain the oil. •○Remove The oil in the oil filter can be drained by removing the filter • (see Oil Filter Change). Replace the drain plug gasket [B] with a new one if it is damaged. Tighten the drain plug. Torque - Engine Drain Plug: 20 N·m (2.0 kgf·m, 14.
2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheels/Tires Tire Inspection As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that 90 % of all tire failures occur during the last 10 % of tread life (90 % worn). So it is false economy and unsafe to use the tires until they are bald. Remove any imbedded stones or other foreign particles from the tread. Visually inspect the tire for cracks and cuts, replacing the tire in case of damage.
PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Air Pressure Inspection/Adjustment the air valve cap. • Remove the tire air pressure with an air pressure gauge • Measure [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours). Adjust the tire air pressure according to the specifications if necessary. Air Pressure (when cold) Front Rear Up to 180 kg (396 lb) 250 kPa (2.5 kgf/cm², 36 psi) 290 kPa (2.
2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures both chain adjuster locknuts securely. • Tighten Tighten the axle nut. • Torque - Rear Axle Nut: 127 N·m (13 kgf·m, 94 ft·lb) the wheel, measure the chain slack again at the tight• Turn est position, and readjust if necessary. • Insert a new cotter pin [A]. NOTE ○When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment.
PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures the rear wheel to inspect the drive chain for dam• Rotate aged rollers, and loose pins and links. • • If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry. Stretch the chain taut by hanging a 98 N (10 kg, 20 lb) weight [A] on the chain. Measure the length of 20 links [B] on the straight part [C] of the chain from the pin center of the 1st pin to the pin center of the 21st pin.
2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures oil to the sides of the rollers so that oil will penetrate • Apply to the rollers and bushings. Apply the oil to the O-rings so • that the O-rings will be coated with oil. Wipe off any excess oil. Oil Applied Areas [A] O-ring [B] Brakes Brake Pad Wear Inspection the lining thickness [A] of the pads in each caliper. • Check If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set.
PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures • If it does not, adjust and inspect the brake light switch. While holding the switch body, turn the adjusting nut [A] to adjust the switch. CAUTION To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. the right side cover (see Frame chapter). • Remove Disconnect connector [A].
2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Inspection (Visual Inspection) the front and rear master cylinders. • Disassemble there are no scratches, rust or pitting on the that • Check inner wall [A] of each master cylinder and on the outside • of each piston [B]. If a master cylinder or piston shows any damage, replace them. Inspect the primary cup [C] and secondary cup [D].
PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Level Inspection that the brake fluid level in the front brake reservoir • Check [A] is above the lower level line [B]. NOTE ○Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C] in the reservoir. that the brake fluid level in the rear brake reservoir • Check [A] is above the lower level line [B].
2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures the brake fluid reservoir. • Level Remove reservoir cap and diaphragm. • Remove the the • caliper. rubber cap from the bleed valve [A] on the a clear plastic hose [B] to the bleed valve, and run • Attach the other end of the hose into a container. • Fill the reservoir with fresh specified brake fluid. the brake fluid: •○Change Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. 1.
PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air enters the brake lines, brake lever or pedal movement will be partially used in compressing the air. This will make the lever or pedal feel spongy, and there will be a loss in braking power.
2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures the brake line and the caliper: •○Bleed Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A]. 2. Quickly open and close [B] the bleed valve while holding the brake applied. 3. Release the brake [C]. NOTE ○The fluid level must be checked often during the bleed- ing operation and replenished with fresh brake fluid as necessary.
PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures 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.
2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Suspension Front Fork Oil Leak Check inspect the front forks [A] for oil leakage, scoring • Visually or scratches on the outer surface of the inner tubes. Replace or repair any defective parts, if necessary. Rear Shock Absorber Oil Leak Check inspect the shock absorbers [A] for oil leakage. • Visually If the oil leakage is found on it, replace the shock absorber with a new one.
PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Steering Steering Inspection • Lift the front wheel off the ground using the jack. Special Tool - Jack: 57001–1238 the front wheel pointing straight ahead, alternately • With tap each end of the handlebar. The front wheel should • swing fully left and right from the force of gravity until the fork hits the stop. If the wheel binds or catches before the stop, the steering is too tight. Feel for steering looseness by pushing and pulling the forks.
2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Adjust the steering. Special Tool - Steering Stem Nut Wrench: 57001–1100 [B] If the steering is too tight, loosen the stem nut [A] a fraction of a turn. If the steering is too loose, tighten the stem nut a fraction of a turn. NOTE ○Turn the stem nut 1/8 turn at time maximum. the claw washer [A] so that its bent side [B] faces • Install upward, and engage the bent claws with the grooves of • • stem locknut [C].
PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures the thermostat bracket bolt [A]. •○Unscrew If removing the spark plug #2 or #3. • Disconnect: Stick Coil Connectors [A] Pull the stick coil #1 [B]. • Takeout out the camshaft position sensor connector [C] from • the bracket. • Pull out the stick coil #2 [D]. CAUTION Do not pry the connector part of the coil while removing the coil. the stick coil subharness connector [A] from the • Remove bracket.
2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures the spark plug, preferably in a sandblasting device, • Clean and then clean off any abrasive particles. The plug may • also be cleaned using a high-flash point solvent and a wire brush or other tool. If the spark plug center electrode [A] and/or side electrode [B] are corroded or damaged, or if the insulator [C] is cracked, replace the plug. Use the standard spark plug or its equivalent. Measure the gaps [D] with a wire-type thickness gauge.
PERIODIC MAINTENANCE 2-47 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 water spray, perform the general lubrication.
2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Nut, Bolt, and Fastener Tightness Tightness Inspection the tightness of the bolts and nuts listed here. Also, • Check check to see that each cotter pin is in place and in good condition. NOTE ○For the engine fasteners, check the tightness of them when the engine is cold (at room temperature). If there are loose fasteners, retighten them to the specified torque, following the specified tightening sequence.
FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View................................... DFI Parts Location............................. DFI Wiring Diagram ........................... Specifications .................................... Special Tools ..................................... DFI Servicing Precautions ................. Troubleshooting the DFI System ....... Outline ............................................ Inquiries to Rider.............................
3-2 FUEL SYSTEM (DFI) ECU Installation ........................... ECU Power Supply Inspection..... DFI Power Source ............................. ECU Fuse Removal ..................... ECU Fuse Installation .................. ECU Fuse Inspection ................... ECU Main Relay Removal ........... ECU Main Relay Inspection ......... Fuel Line............................................ Fuel Pressure Inspection ............. Fuel Flow Rate Inspection ........... Fuel Pump .................................
FUEL SYSTEM (DFI) 3-3 Exploded View Clifornia Evaporative Emission Control System 1. Canister 2. Separator 3. Right fitting of throttle body #2 4. Right fitting of throttle body #3 5. Canister purge hose (green) 6. Fuel return hose (left, red) 7. Fuel tank breather hose (right, blue) 8. Separator breather hose (blue) 9.
3-4 FUEL SYSTEM (DFI) Exploded View
FUEL SYSTEM (DFI) 3-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Throttle cable plate bolt 6 0.6 52 in·lb 2 Throttle body cover bolts 7 0.7 61 in·lb 3 Throttle assy holder clamp bolts 2 0.2 17 in·lb 4 Choke link holder screws 2.1 0.21 18 in·lb 5 Delivery pipe screws 3.4 0.35 30 in·lb 6 Bypass screws 0.2 0.02 1.7 in·lb 7 Fuel pump bolts 9.8 1.0 87 in·lb 8 Fuel level sensor bolts 6.9 0.7 62 in·lb 9. FI indicator LED light 10. Meter unit 11.
3-6 FUEL SYSTEM (DFI) Exploded View
FUEL SYSTEM (DFI) 3-7 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Inlet air pressure sensor bolt 12 1.2 104 in·lb 2 Water temperature sensor 25 2.5 18 3 Vehicle downsensor bolts 2 0.2 17 in·lb 4 Camshaft position sensor bolt 12 1.2 104 in·lb 5 Camshaft position sensor rotor bolt 12 1.2 104 in·lb 6 Air cleaner duct holder screws 3.8 0.39 34 in·lb 7 Air cleaner housing mounting bolts 9.8 1.0 87 in·lb 8 Air cleaner duct clamp bolts 2 0.
3-8 FUEL SYSTEM (DFI) DFI Parts Location DFI: DFI Parts (this chapter) F: Front 1. Water temperature Sensor (DFI) 2. Inlet Air Pressure Sensor (DFI) 3. Injectors (DFI) 4. Fuel Pump (DFI) 5. Inlet Air Temperature Sensor (DFI) 6. Sealed Battery 7. Junction Box 8. 9. 10. 11. 12. 13. 14. 15. ECU Fuse 15A ECU (DFI) Stick Coils Throttle Body Assy Self-diagnosis Terminal Neutral Switch Vehicle Down Sensor (DFI) Atmospheric Pressure Sensor (DFI) 16. Delivery Pipe 17. ECU Main Relay 18. Fuel Pump Relay (DFI) 19.
FUEL SYSTEM (DFI) 3-9 DFI Parts Location [1], [2], [10], [13], [22] and [24] are not included.
3-10 FUEL SYSTEM (DFI) DFI Wiring Diagram
FUEL SYSTEM (DFI) 3-11 DFI Wiring Diagram Terminal Names 1. Power Supply to Sensors (inlet air pressure, atmospheric pressure, and throttle sensors) from ECU. 2. Main Throttle Sensor Signal 3. Subthrottle Sensor Signal for ECU 4. Atmospheric Pressure Sensor Signal 5. Water Temperature Sensor Signal (+) 6.7.8.– 9. Camshaft Position Sensor Signal (+) 10. – 11. Crankshaft Sensor Signal (+) 12. – 13. Power Supply to ECU, Injectors, and Fuel Pump 14.
3-12 FUEL SYSTEM (DFI) Specifications Item Digital Fuel Injection System Idle Speed Throttle Assy: Type Bore ECU (Electronic Control Unit): Make Type Usable engine speed Fuel Pressure (high pressure line): Right after Ignition switch ON After 3 sec from Ignition switch ON With engine idling Fuel Pump: Type Discharge Fuel Injectors: Type Nozzle type Resistance Main Throttle Sensor: Input voltage Output voltage at idle throttle opening Output voltage at full throttle opening Resistance Inlet Air Pressure Sens
FUEL SYSTEM (DFI) 3-13 Specifications Item Detection time Output voltage Subthrottle Sensor: Input Voltage Output voltage at idle throttle opening Output voltage at full throttle opening Resistance Subthrottle Valve Actuator: Resistance Input voltage Throttle Grip and Cables Throttle grip free play Choke Cable Choke cable free play Standard Within 0.5 ∼ 1.0 sec. with the sensor tilted 60 ∼ 70° or more: 3.7 ∼ 4.4 V with sensor arrow mark pointed up: 0.4 ∼ 1.4 V Non-adjustable and non-removal 4.75 ∼ 5.
3-14 FUEL SYSTEM (DFI) Special Tools Oil Pressure Gauge: 57001–125 Fuel Pressure Gauge Adapter: 57001–1417 Carburetor Drain Plug Wrench, Hex 3: 57001–1269 Needle Adapter Set: 57001–1457 Fork Oil Level Gauge: 57001–1290 Throttle Sensor Setting Adapter: 57001–1538 Hand Tester: 57001–1394 Sensor Harness Adapter: 57001–1561 Throttle Sensor Setting Adapter: 57001–1400 Kawasaki Bond (Silicone Sealant): 56019–120
FUEL SYSTEM (DFI) 3-15 DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source. ○Do not reverse the battery cable connections. This will damage the ECU.
3-16 FUEL SYSTEM (DFI) DFI Servicing Precautions ○To maintain the correct fuel/air mixture (F/A), there must be no inlet air leaks in the DFI system. Be sure to install the oil filler plug [A] after filling the engine oil. Clutch Cover [B] Front [C] Torque - Oil Filler Plug: 1.5 N·m (0.
FUEL SYSTEM (DFI) 3-17 Troubleshooting the DFI System Outline When an abnormality in the system occurs, the FI indicator LED (Light Emitting Diode) light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the 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 LED light blinks.
3-18 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 (special tool) [C] inside the seal [B] from behind the connector until the adapter reaches the terminal. Special Tool - Needle Adapter Set: 57001–1457 CAUTION Insert the needle adapter straight along the terminal in the connector to prevent short-circuit between terminals.
FUEL SYSTEM (DFI) 3-19 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.
3-20 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○There are two ways to inspect the DFI system. One is voltage Check Method and the other is Resistance Check Method. (Voltage Check Method) ○This method is conducted by measuring the input voltage [B] to a sensor [A] first, and then the output voltage [C] from the sensor. ○Sometimes this method can detect a fault of the ECU. Refer to each sensor inspection section for detail in this chapter.
FUEL SYSTEM (DFI) 3-21 Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.
3-22 FUEL SYSTEM (DFI) Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Model: Registration No. (license plate No.): Year of initial registration: Engine No.: Date problem occurred: Frame No.: Mileage: Environment when problem occurred.
FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System Poor running at low speed □ choke lever pulled out fully (push it in fully) □ very low choke speed (adjust choke cable) □ very low idle speed, □ very high idle speed, □ rough idle speed □ battery voltage is low (charge the battery) □ spark plug loose (tighten it) □ spark plug dirty, broken, or gap maladjusted (remedy it) □ backfiring □ afterfiring □ hesitation when acceleration □ engine oil viscosity too high □ brake dragging □ engine overheating □ clut
3-24 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide NOTE ○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant as a rough guide to assist the troubleshooting for some of the more common difficulties. simply ○The ECU may be involved in the DFI electrical and ignition system troubles. If these parts and circuits checked out good, be sure to check the ECU for ground and power supply. If the ground and power supply are checked good, replace the ECU.
FUEL SYSTEM (DFI) 3-25 DFI System Troubleshooting Guide Symptoms or possible Causes Ignition and engine stop switches not ON Clutch lever not pulled in and gear not in neutral whether sidestand up or not Though clutch lever pulled in, sidestand up 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 Spark plug cap trouble Spark plug cap shorted or not in good contact Spark plug in
3-26 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or possible Causes Piston ring /groove clearance excessive Cylinder head gasket damaged Cylinder head warped No valve clearance Valve guide worn 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). Replace (see chapter 5). Inspect and replace (see chapter 5). Adjust (see chapter 2). Inspect and replace (see chapter 5).
FUEL SYSTEM (DFI) 3-27 DFI System Troubleshooting Guide Symptoms or Possible Causes Atmospheric pressure sensor trouble Fuel pressure too low or too high Battery voltage low Incorrect idle speed : Water temperature sensor trouble Main throttle sensor trouble Engine stalls easily : Fuel pump trouble Fuel injector trouble Main throttle sensor trouble Camshaft position sensor trouble Fuel pressure too low or too high Inlet air pressure sensor trouble Water temperature sensor trouble Inlet air temperature senso
3-28 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Subthrottle sensor trouble Subthrottle valve actuator trouble Water temperature sensor trouble Atmospheric pressure sensor trouble Inlet air pressure sensor trouble Loose injector connectors Crankshaft sensor trouble Stick coil trouble Loose terminal of battery (–) lead or engine ground lead Delay of ignition timing Poor acceleration : Choke lever pulled Too low fuel pressure Water or foreign matter in fuel Clogged fuel filt
FUEL SYSTEM (DFI) 3-29 DFI System Troubleshooting Guide Symptoms or Possible Causes Spark plug dirty, broken or gap maladjusted Too low fuel pressure Fuel pump trouble Main throttle sensor trouble Inlet air temperature sensor trouble Water temperature sensor trouble Atmospheric pressure sensor trouble Inlet air pressure sensor trouble Vacuum switch valve broken Air suction valve trouble After fire : Crankshaft sensor trouble Spark plug burned or gap maladjusted Inlet air temperature sensor trouble Water tem
3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Poor Running or No Power at High Speed: Symptoms or Possible Causes Firing incorrect : Spark plug dirty, broken or maladjusted Spark plug cap trouble Spark plug cap shorted or not in good contact Spark plug incorrect IC igniter in ECU trouble Crankshaft sensor trouble Stick coil trouble Fuel/air mixture incorrect : Choke lever pulled Air cleaner clogged, poorly sealed or missing Air cleaner duct loose Air cleaner O-ring damaged Water or foreign matter
FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel poor quality or incorrect (Use the gasoline Change fuel (see chapter 3). recommended in the Owner’s Manual) Spark plug incorrect Replace it with the correct plug (see chapter 16). Stick coil trouble Inspect (see chapter 16). IC igniter in ECU trouble Inspect (see chapter 16). Inlet air temperature sensor trouble Inspect (see chapter 3). Atmospheric pressure sensor trouble Inspect (see chapter 3).
3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Too low fuel pressure Water temperature sensor trouble Inlet air temperature sensor trouble Actions (chapter) Inspect fuel line and fuel pump (see chapter 3). Inspect and replace (see chapter 3). Inspect and replace (see chapter 3).
FUEL SYSTEM (DFI) 3-33 Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has three modes and can be 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 lighting the FI indicator when DFI system and ignition system parts are faulty, and initiates fail-safe function. In case of serious troubles, the ECU stops the injection/ignition/starter motor operation.
3-34 FUEL SYSTEM (DFI) Self-Diagnosis enter the self-diagnosis dealer mode 2, open [B] and • To ground [A] the lead more than five times [F] within 2 seconds [C] after the lead is first grounded, and then keep it grounded continuously [D] for more than 2 seconds. ○Count the blinks of the LED light to read the service code. Keep the auxiliary lead ground until you finish reading the service code. NOTE ○To enter the dealer mode 2 from the dealer mode 1, turn off the ignition switch once.
FUEL SYSTEM (DFI) 3-35 Self-Diagnosis
3-36 FUEL SYSTEM (DFI) Self-Diagnosis How to Read Service Codes ○Service codes are shown by a series of long and short blinks of the FI indicator LED light as shown below. ○Read 10th digit and unit digit as the FI indicator LED light blinks. ○When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order.
FUEL SYSTEM (DFI) 3-37 Self-Diagnosis Service Code Table Service Code FI Indicator LED Light 11 Problems Main throttle sensor malfunction, wiring open or short Inlet air pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Atmospheric pressure sensor malfunction, wiring open or short 12 13 14 15 21 Crankshaft sensor malfunction, wiring open or short 23 Camshaft position sensor malfun
3-38 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. Service Codes Parts 11 Main Throttle Sensor 12 Inlet Air Pressure Sensor 13 14 15 21 23 24 and 25 31 32 Inlet Air Temperature Sensor Water Temperature Sensor Atmospheric Pressure Sensor Output Signal Usable Range or Criteria Main Throttle Sensor Output Voltage 0.2 ∼ 4.
FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Service Codes 51 52 53 54 62 Output Signal Usable Range or Criteria The stick coil primary Stick Coil winding must send #1 (Ignition signals (output voltage) Coil)* continuously to the ECU. The stick coil primary Stick Coil winding must send #2 (Ignition signals (output voltage) Coil)* continuously to the ECU. The stick coil primary Stick Coil winding must send #3 (Ignition signals (output voltage) Coil)* continuously to the ECU.
3-40 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Removal/Adjustment CAUTION Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Main Throttle Sensor Connector (gray) [B] Input Voltage Inspection NOTE ○Be sure the battery is fully charged. the ignition switch OFF.
FUEL SYSTEM (DFI) 3-41 Main Throttle Sensor (Service Code 11) Output Voltage Inspection the output voltage at the main throttle sensor • Measure in the same way as input voltage inspection, Note the • following. Disconnect the main throttle sensor (gray) [A] and connect the harness adapter [B] between these connectors. Special Tool - Throttle Sensor 57001–1538 Harness Adapter : the engine and warm it up thoroughly. • Start • Check idle speed to ensure the throttle opening is correct.
3-42 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Resistance Inspection the ignition switch OFF. • Turn the main throttle sensor connector. • Disconnect a digital meter [A] to the main throttle sensor • Connect connector [B]. • Measure the main throttle sensor resistance. Main Throttle Sensor Resistance Connections: BL lead [C] ←→ BR/BK lead [D] Standard: 4 ∼ 6 kΩ If the reading is out of the range, replace the throttle body assy.
FUEL SYSTEM (DFI) 3-43 Inlet Air Pressure Sensor (Service Code 12) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Removal • Remove: Fuel Tank (see Fuel System chapter) • Water Temperature Sensor Connector [A] Inlet Air Pressure Sensor Bolt [B] Raise the inlet air pressure sensor [C] and disconnect the inlet air pressure sensor connector and the vacuum hose [D].
3-44 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) 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. Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter (+) → Y/BL lead (terminal 17) Meter (–) → BR/BK lead (terminal 14) Usable Range: 3.74 ∼ 4.26 V DC at the standard atmospheric pressure (101.32 kPa, 76 cmHg abs.
FUEL SYSTEM (DFI) 3-45 Inlet Air Pressure Sensor (Service Code 12) ○Turn the ignition switch ON. ○Measure the inlet air pressure sensor output voltage from various vacuum readings, while pulling the handle of the fork oil level gauge. ○Check the inlet air pressure sensor output voltage, using the following formula and chart.
3-46 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Pv = 24 ∼ 55 cmHg
FUEL SYSTEM (DFI) 3-47 Inlet Air Pressure Sensor (Service Code 12) Pv = 55 ∼ 86 cmHg Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading) Pv: Throttle Vacuum Pressure (absolute) Ps: Standard Atmospheric Pressure (absolute) A. ECU C.
3-48 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. the fuel tank (see Fuel Tank Removal). • Remove the connector [A] from the inlet air tempera• Disconnect ture sensor. out [B] the inlet air temperature sensor. • Pull inlet air temperature sensor into the grommet. Put the • Front [C] Output Voltage Inspection NOTE ○Be sure the battery is fully charged.
FUEL SYSTEM (DFI) 3-49 Inlet Air Temperature Sensor (Service Code 13) Sensor Resistance Inspection the inlet air temperature sensor (see this sec• Remove tion). 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 tion [C] located in almost the same depth with the sensor. NOTE ○The sensor and thermometer must not touch the container side or bottom.
3-50 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. the fuel tank (see Fuel Tank Removal). • Remove the coolant about 200 mL (6.76 US oz). • Drain the sensor connector, and unscrew the water • Disconnect temperature sensor [A]. Front [B] Torque - Water Temperature Sensor: 25 N·m (2.
FUEL SYSTEM (DFI) 3-51 Water Temperature Sensor (Service Code 14) A. ECU D. Water Temperature Sensor V. Coolant Temperature Gauge in Tachometer Sensor Resistance Inspection the water temperature sensor (see this section). • Remove Refer to the System chapter for water temper• ature sensorElectrical inspection.
3-52 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. NOTE ○The atmospheric pressure sensor is the same part as the inlet air pressure sensor except that the inlet air pressure sensor has the vacuum hose and different wiring. Removal the ignition switch off. • Turn Remove seat cover (see Frame chapter).
FUEL SYSTEM (DFI) 3-53 Atmospheric Pressure Sensor (Service Code 15) Output Voltage Inspection the output voltage at the ECU in the same way • Measure as input voltage inspection. Note the following. Digital Meter [A] ECU Connector [B] Atmospheric Pressure Sensor Output Voltage Connections to ECU Meter (+) → G/W lead (terminal 4) Meter (–) → BR/BK lead (terminal 14) Usable Range: 3.74 ∼ 4.26 V DC at the standard atmospheric pressure (101.32 kPa, 76 cmHg abs.
3-54 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) Va: Atmospheric Pressure Sensor Output Voltage (v) H: Altitude (m or feet) A. ECU E.
FUEL SYSTEM (DFI) 3-55 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.
3-56 FUEL SYSTEM (DFI) Camshaft Position Sensor (Service Code 23) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condition of the camshaft position 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, 25) Speed Sensor Removal/Installation the Switches and Sensors section in the Electrical • See System chapter. Speed Sensor Inspection the Switches and Sensors section in the Electrical • See System chapter. Input Voltage Inspection NOTE ○Be sure the battery is fully charged. the ignition switch OFF.
3-58 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) the speed sensor connector [A] and connect • Disconnect the harness adapter [B] between the harness connector • and speed sensor connector. Engine Sprocket Cover [C] Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor 57001–1400 Setting the sensor output voltage with • Measure stopped, and with the connector joined. • Turn the ignition switch ON.
FUEL SYSTEM (DFI) 3-59 Vehicle-down Sensor (Service Code 31) Removal CAUTION Never drop the down-sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Connection and Vehicle-down Sensor [A] Bolts and Washers [B] Front [C] Installation • The UP mark [A] of the sensor should face upward. Torque - Vehicle-down Sensor Bolts: 2 N·m (0.2 kgf·m, 17 in·lb) WARNING Incorrect installation of the vehicle-down sensor could cause sudden loss of engine power.
3-60 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) the ignition switch OFF. • Turn Remove sensor. • Connect athedigital • dle adapter set [B].volt meter [A] to the connector with neeSpecial Tool - Needle Adapter Set: 57001–1457 Vehicle-down Sensor Output Voltage Connections to Sensor Meter (+) → Y/G lead [D] Meter (–) → BK/Y lead [E] the sensor vertically. • Hold the ignition switch ON, and measure the output volt• Turn age with the connector joined.
FUEL SYSTEM (DFI) 3-61 Vehicle-down Sensor (Service Code 31) A. ECU S. ECU Main Relay T. Ignition Switch a. ECU Fuse 15A b. Vehicle-down Sensor d. Starter Relay f. Sealed Battery j. Joint Connector B k.
3-62 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Subthrottle Sensor Removal/Adjustment CAUTION Do not remove or adjust the subthrottle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Subthrottle Sensor Connector (black) [B] Input Voltage Inspection NOTE ○Be sure the battery is fully charged. the ignition switch OFF.
FUEL SYSTEM (DFI) 3-63 Subthrottle Sensor (Service Code 32) Output Voltage Inspection the throttle body assy (see Throttle Body Assy • Remove Removal). the output voltage at the subthrottle sensor in • Measure the same way as input voltage inspection. Note the fol- • lowing. Disconnect the subthrottle sensor (black) [A] and (black) connect the harness adapter [B] between these connectors.
3-64 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Resistance Inspection the ignition switch OFF. • Turn the subthrottle sensor connector. • Disconnect a digital meter [A] to the subthrottle sensor con• Connect nector [B]. • Measure the subthrottle sensor resistance. Throttle Sensor Resistance Connections: BL lead [C] ←→ BR/BK lead [D] Standard: 4 ∼ 6 kΩ If the reading is out of the range, replace the throttle body assy.
FUEL SYSTEM (DFI) 3-65 Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) Stick Stick Stick Stick Coil Coil Coil Coil #1: #2: #3: #4: Ignition Ignition Ignition Ignition Coil (Service Coil (Service Coil (Service Coil (Service Code Code Code Code 51) 52) 53) 54) Removal/Installation CAUTION Never drop the stick coils, especially on a hard surface. Such a shock to the stick coil can damage it. Ignition System section in the Electrical System • See chapter.
3-66 FUEL SYSTEM (DFI) Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) A. ECU M. Stick Coils N. Engine Stop Switch T. Ignition Switch X. Ignition Fuse 10 A Y. Junction Box d. Starter Relay e. Joint Connector D f. Sealed Battery k.
FUEL SYSTEM (DFI) 3-67 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the actuator , especially on a hard surface. Such a shock to the actuator can damage it. Audible Inspection NOTE ○Be sure the battery is fully charged.
3-68 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Input Voltage Inspection NOTE ○Be sure the battery is fully charged. the ignition switch OFF. • Turn Remove • Removal).the throttle body assy (see Throttle Body Assy the peak voltage adapter [A] and a digital meter • Connect [B] to the connector [C], using the needle adapter set [D].
FUEL SYSTEM (DFI) 3-69 FI Indicator LED Light Inspection Flow Chart
3-70 FUEL SYSTEM (DFI) FI Indicator LED Light LED Light Inspection the meter unit (see Electrical System chapter). • Remove two auxiliary leads, supply battery power to the FI • Using indicator LED light [A]. 12 V Battery [B] FI Indicator LED Light Check Connector: Meter Connector [C] (disconnected) Connection: BR/W Lead Terminal [1] of the Meter → Battery (+) Terminal BR/R Lead Terminal [6] of the Meter → Battery (–) Terminal Criterion: The LED light should light.
FUEL SYSTEM (DFI) 3-71 ECU CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Identification ○Most countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU’s with each other and use only the ECU’s for your country. Otherwise, the motorcycle could not clear the regulation. ECU Identification Models CA and US EUR AU and MY Type [A] TBCF25 TBCF19 TBCF27 Part No.
3-72 FUEL SYSTEM (DFI) ECU If the rubber protector [A] is removed, install it. ECU [B] ECU Power Supply Inspection inspect the terminals [A] of the ECU connectors. • Visually If the connector is clogged with mud or dust, blow it off with compressed air. Replace the main harness if the terminals of the main harness connectors are cracked, bent, or otherwise damaged. Replace the ECU if the terminals of the ECU connectors are cracked, bent, or otherwise damaged.
FUEL SYSTEM (DFI) 3-73 ECU the ECU power source voltage with a digital meter • Check [A]. ○Position the terminal in accordance with terminal numbers of ECU connectors [B] in this chapter figure. Battery [C] ECU Power Source Inspection Meter between Terminal 13 (W/Y) and Connections: Battery (–) Terminal between Terminal 43 (W/BK) and Battery (–) Terminal Ignition switch OFF: Terminal 13 (W/Y) : 0 V, Ignition switch ON: Both: Battery Voltage (12.6 V or more) Terminal 43 (W/BK) : 12.
3-74 FUEL SYSTEM (DFI) DFI Power Source ECU Fuse Removal to the Electrical System chapter for the ECU fuse • Refer removal. ECU Fuse Installation • If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage. Refer to the Electrical System chapter for the ECU fuse installation. ECU Fuse Inspection to the Electrical System chapter for the ECU Fuse • Refer Inspection.
FUEL SYSTEM (DFI) 3-75 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 motorcycle just when trouble occurred in order to know symptom well. ○Be sure the battery is fully charged. the fuel tank (see Fuel Tank Removal). • Remove Be sure to a piece of cloth around the pump outlet • pipe and theplace delivery pipe. the fuel pump outlet hose [A].
3-76 FUEL SYSTEM (DFI) Fuel Line the engine, and let it idle. • Start Measure the fuel pressure with the engine idling. • Fuel Pressure (idling) Standard: 310 kPa (3.2 kgf/cm², 46 psi) NOTE ○The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. • • If the fuel pressure is normal, the fuel circulation system (fuel pump, pressure regulator, and oil passage) is no faults.
FUEL SYSTEM (DFI) 3-77 Fuel Line the fuel tank cap [A] to lower the pressure in the • Open tank. Front [B] sure to place a piece of cloth around the fuel pump • Be outlet hose. the fuel pump outlet hose [A] from the fuel pump • Remove [B] and the delivery pipe [C] (see Fuel Pump Removal). Front [D] WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure.
3-78 FUEL SYSTEM (DFI) 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.
FUEL SYSTEM (DFI) 3-79 Fuel Pump • Replace the fuel pump gasket [A] with a new one. that the fuel pump (–) terminal [A] and band [B] are • Check in place. • • • Front [C] Apply a non-permanent locking agent to the threads of the fuel pump bolts. Tighten the fuel pump bolts to a snug fit, following the tightening sequence shown. Following the tightening sequence, tighten the fuel pump bolts to the specified torque. Torque - Fuel Pump Bolts: 9.8 N·m (1.
3-80 FUEL SYSTEM (DFI) Fuel Pump the hand tester (25 V DC) to the fuel pump con• Connect nector [A] with needle adapter set. Front [B] Special Tools - Hand Tester: 57001–1394 Needle Adapter Set: 57001–1457 ○Measure the operating voltage with the engine stopped, and with the connector joined. Turn the ignition switch ON. ○The tester needle should indicate battery voltage for 3 seconds, and then 0 V.
FUEL SYSTEM (DFI) 3-81 Fuel Pump Fuel Pump Relay Removal CAUTION Never drop the relay, especially on a hard surface. Such a shock to the relay can damage it. the seat cover (see Frame chapter). • Remove the fuel pump relay [A] from the tongue of the • Remove storage compartment. the connector. • Disconnect Front [B] Fuel Pump Relay Inspection the fuel pump relay (see above). • Remove Connect hand tester [A] and one 12 V battery [B] to • the relay the connector [C] as shown.
3-82 FUEL SYSTEM (DFI) Fuel Injectors Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Audible Inspection the engine. • Start Apply of a screwdriver [A] to the injector [C]. Put • the griptheendtiponto your ear, and listen whether the injector is clicking or not. ○A sound scope [B] can also be used. the same for the other injectors. • Do If all the injectors click at a regular intervals, the injectors are good.
FUEL SYSTEM (DFI) 3-83 Fuel Injectors Output Voltage Inspection the ignition switch OFF. • Turn the ECU (see ECU section). • Remove Connect a digital voltmeter [A] to the ECU connector [B] • with the needle adapter set [C].
3-84 FUEL SYSTEM (DFI) Fuel Injectors Injector Signal Test two test light sets with male terminals as shown. • Prepare of Rating 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 (female), leading to harness repair or replacement. Be sure to connect bulbs in series.
FUEL SYSTEM (DFI) 3-85 Fuel Injectors Injector Resistance Inspection the fuel tank (see Fuel Tank Removal). • Remove the connector from the injector [A] (see Throt• Disconnect tle Body Assy Disassembly/Assembly). the injector resistance with the hand tester [B]. • Measure Front [C] Special Tool - Hand Tester: 57001–1394 Injector Resistance Connections to Injector Meter (+) Meter (–) #1: W/R ←→ BL/R Terminal #2: W/R ←→ BL/G Terminal #3: W/R ←→ BL/BK Terminal #4: W/R ←→ BL/Y Terminal Standard: about 11.
3-86 FUEL SYSTEM (DFI) Fuel Injectors the injector fuel line for leakage as follows: •○Check Connect a commercially available vacuum/pressure pump [A] to the nipple of the delivery pipe [B] with a high-pressure fuel hose [C] (both ends connected with the clamps [D]) as shown. Torque - Fuel Hose Clamp Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb) ○Apply soap and water solution to the areas [E] as shown.
FUEL SYSTEM (DFI) 3-87 Fuel Injectors A. ECU K. Fuel Injectors N. Engine Stop Switch T. Ignition Switch X. Ignition Fuse 10 A Y. Junction Box Z. Fuel Pump Relay (for fuel pump an injectors) d. Starter Relay e. Joint Connector C f. Sealed Battery j. Joint Connector B k.
3-88 FUEL SYSTEM (DFI) Throttle Grip and Cables Throttle Grip Play Inspection/Adjustment to the Throttle Control System Inspection in the Pe• Refer riodic Maintenance chapter. Choke Lever Operation ○Do not use the choke lever except when the engine has a starting difficulty like in cold weather (10 °C, 50 °F or below) or at high altitude. The DFI system has an automatic choke system, using a water temperature sensor, and an atmospheric pressure sensor, which provide startability.
FUEL SYSTEM (DFI) 3-89 Throttle Body Assy Idle Speed Inspection/Adjustment to the Idle Speed Inspection in the Periodic Main• Refer tenance chapter . Throttle Bore Cleaning to the Throttle Control System Inspection in the Pe• Refer riodic Maintenance chapter. Engine Vacuum Inspection/Adjustment Synchronization to the Engine Vacuum Synchronization Inspection • Refer in the Periodic Maintenance chapter.
3-90 FUEL SYSTEM (DFI) Throttle Body Assy • Loosen: Throttle Assy Holder Clamp Bolts [A] Air Cleaner Duct Clamp Bolts [B] Special Tool - Carburetor Drain Plug Wrench, Hex 3: 57001–1269 • Remove: Right and Left Side Covers (see Frame chapter) Coolant Reserve Tank (see Coolant Change in the Periodic Maintenance chapter) Starter Relay, Junction Box (right) Crankcase Breather Hose Right and Left Air Cleaner Housing Mounting Bolts [A] Front [B] [A] the air cleaner housing backwards.
FUEL SYSTEM (DFI) 3-91 Throttle Body Assy the bolt [A] and the throttle cable plate [B] from • Remove the throttle body front side. the throttle cable lower ends from the throttle • Remove pulley. • Remove: Choke Cable Upper End (From choke lever) • Choke Cable Lower End [A] Throttle Body #2 [B] After removing the throttle body assy, stuff pieces of lint -free, clean cloth into the throttle body holders. CAUTION If dirt gets into the engine, excessive engine wear and possible engine damage will occur.
3-92 FUEL SYSTEM (DFI) Throttle Body Assy a thin coating of grease to the throttle cable upper • Apply ends. the upper ends of the throttle cables in the grip (see • Install Throttle Body Assy Removal). the projection [A] of the right switch housing into the • Fit hole [B] of the handlebar (front view). the throttle grip and make sure that the throttle valves • Turn move smoothly and return by spring force. the throttle grip free play (see Throttle Grip Free • Check Play Inspection).
FUEL SYSTEM (DFI) 3-93 Throttle Body Assy CAUTION Never drop the injector, especially on a hard surface. Such a shock to the injector can damage it. out [A] the injectors along with the delivery pipe [B]. • Pull If necessary, remove the injectors from the delivery pipe. Replace the O-rigs of the indicators. If necessary, cut straps and take the harness off the delivery pipe. Throttle Body Assy Assembly ○Replace the O-rings [A] of injectors and the seals [B] with • • • the new ones.
3-94 FUEL SYSTEM (DFI) Air Cleaner Element Removal/Installation to the Air Cleaner Element Cleaning in the Periodic • Refer Maintenance chapter. Air Cleaner Oil Draining A drain hose is connected to the bottom of the air cleaner to drain water or oil accumulated in the cleaner part. Visually check the drain hose [A] if the water or oil accumulates. If any water or oil accumulates in the hose, remove the plug [B] from the drain hose and drain it.
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.
3-96 FUEL SYSTEM (DFI) Fuel Tank sure to place a piece of cloth [A] around the fuel hose • Be pump outlet joint [B]. pinching the hose joint locks [C] with fingers, pull • While the joint out along the delivery pipe. Front [D] WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure.
FUEL SYSTEM (DFI) 3-97 Fuel Tank Fuel Tank Installation the above WARNING (see Fuel Tank Removal). • Note the hoses correctly (see Appendix chapter). • Route Check the rubber dampers [A] are on the frame and • the fuelthat tank. Front [B] that the dampers [A] are in place on the fuel tank • Check as well. Front [B] If the dampers are damaged or deteriorated, replace them. If the dampers are damaged or deteriorated, replace them.
3-98 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank and Cap Inspection inspect the gasket [A] on the tank cap for any • Visually damage. • Replace the gasket if it is damaged. Check to see if the water drain pipe [B] and fuel breather pipe [C] in the tank are not clogged. Check the tank cap breather also. If they are clogged, remove the tank and drain it, and then blow the breather free with compressed air. CAUTION Do not apply compressed air to the air vent holes [D] in the tank cap.
FUEL SYSTEM (DFI) 3-99 Evaporative Emission Control System Parts Removal/Installation WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. CAUTION If gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly reduced.
3-100 FUEL SYSTEM (DFI) Evaporative Emission Control System Separator Operation Test WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. the hoses to the separator, and install the sepa• Connect rator on the motorcycle.
COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................................................................................................................ Coolant Flow Chart................................................................................................................. Specifications ......................................................................................................................... Special Tool ...........................................
4-2 COOLING SYSTEM Exploded View
COOLING SYSTEM 4-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 2 0.2 17 in·lb 1 Radiator hose clamp screws 2 Thermostat air bleeder bolt 7.8 0.80 69 in·lb 3 Radiator fan bolts 8.3 0.85 74 in·lb 4 Water pump impeller bolt 9.8 1.0 87 in·lb 5 Water pump cover bolts 11 1.1 95 in·lb 6 Water pump drain bolt 11 1.1 95 in·lb 7 Water pipe bolts 11 1.1 95 in·lb 8 Thermostat housing ground bolt 7 0.7 61 in·lb 9 Thermostat bracket bolt 7 0.
4-4 COOLING SYSTEM Coolant Flow Chart
COOLING SYSTEM 4-5 Coolant Flow Chart 1. Drain Bolt 2. Water Pump 3. Cylinder Jacket 4. Cylinder Head Jacket 5. Thermostat Housing 6. Thermostat Air Bleeder Bolt 7. Radiator Cap 8. Radiator 9. Oil Filter 10. Outlet Hose 11. Inlet Hose 12. Oil Cooler 13. Reserve Tank 14. Reserve Tank Hose 15. Reserve Tank Overflow Hose 16. Radiator Fan 17. Water Temperature Sensor 18. Radiator Fan Switch 19. Hot Coolant 20. Cold Coolant 21.
4-6 COOLING SYSTEM Specifications Item Standard Coolant provided when shipping: Type (recommended) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed ratio Soft water 50%, coolant 50% Freezing point – 35°C (– 31°F) Total amount 2.9 L (3.1 US qt) (reserve tank full level, including radiator and engine) Radiator cap Relief pressure 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13.5 ∼ 17.
COOLING SYSTEM 4-7 Special Tool Bearing Driver Set: 57001–1129 Bearing Driver: 57001–382 Kawasaki Bond (Silicone Sealant): 56019–120
4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection the left side cover (see Frame chapter). • Remove inspect the coolant [A] in the reserve tank. • Visually Front [B] If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system. If the coolant gives off an abnormal smell, check for a cooling system leak. It may be caused by exhaust gas leaking into the cooling system.
COOLING SYSTEM 4-9 Coolant Pressure Testing the fuel tank (see Fuel System (DFI) chapter). • Remove the radiator cap, and install a cooling system • Remove pressure tester [A] on the filler neck [B]. NOTE ○Wet the cap sealing surfaces with water or coolant to prevent pressure leaks. up pressure in the system carefully until the pres• Build sure reaches 123 kPa (1.25 kgf/cm², 17.8 psi). CAUTION During pressure testing, do not exceed the pressure for which the system is designed.
4-10 COOLING SYSTEM Water Pump Water Pump Removal to Oil Pump Removal in the Engine Lubrication Sys• Refer tem chapter. Water Pump [A] Front [B] Water Pump Installation to Oil Pump Installation in the Engine Lubrication • Refer System chapter. Water Pump Inspection the drainage outlet passage [A] at the bottom of • Check the water pump body for coolant leaks. If the mechanical seal is damaged, the coolant leaks through the seal and drains through the passage.
COOLING SYSTEM 4-11 Water Pump sure to replace the mechanical seal, oil seal, and O • Be -ring with new ones because these parts will be damaged • • • • by removal. Apply plenty of high temperature grease to the oil seal lips. Apply oil to the outer circumference of the oil seal. Press the oil seal [A] into the water pump body [B] with the bearing driver [C] so that the spring side [D] of the seal lips is toward the inside of the water pump body. Press the oil seal until it bottoms out.
4-12 COOLING SYSTEM 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).
COOLING SYSTEM 4-13 Radiator necessary, remove: • IfRadiator Fan Mounting Bolts [A] Radiator Fan [B] Radiator Inspection the radiator core. • Check If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20 % by unremovable obstructions or irreparably deformed fins, replace the radiator with a new one.
4-14 COOLING SYSTEM Radiator • Install the cap [A] on a cooling system pressure tester [B]. NOTE ○Wet the cap sealing surfaces with water or coolant to prevent pressure leaks. the pressure gauge, pump the pressure tester • Watching to build up the pressure until the relief valve opens: the gauge needle flicks downward. Stop pumping and measure leak time at once.
COOLING SYSTEM 4-15 Thermostat Thermostat Removal • Remove: Coolant : Drain about 200 mL • Fuel Tank (see Fuel System (DFI) chapter) Thermostat Bracket Bolt [A] Water Temperature Sensor Connector [B] Three Water Hoses [C] Remove the thermostat housing [D]. Front [E] the screws [A], take off the cap [B], and take out • Remove the thermostat. Thermostat Installation the thermostat [A] in the housing so that the air • Install bleeder hole [B] is on top. a new O-ring into the housing.
4-16 COOLING SYSTEM Thermostat check valve opening temperature, suspend the ther• To mostat [A] in a container of water and raise the temperature of the water. ○The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an accurate thermometer [B] in the water so that the heat sensitive portions [C] are located in almost the same depth. It must not touch the container, either. If the measurement is out of the specified range, replace the thermostat with a new one.
COOLING SYSTEM 4-17 Hose and Pipes Hose Installation the hoses and pipes, being careful to follow bend• Install ing direction. Avoid sharp bending, kinking, flattening or twisting. Run the hoses in accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter. Wet the internal diameter of both ends of the water hose with water or coolant and install the hose onto the pipe. Install the clamp [A] as near as possible to the hose end to clear the raised rib of the fitting.
4-18 COOLING SYSTEM Radiator Fan Switch, Water Temperature Sensor CAUTION The fan switch or the water temperature sensor should never be allowed to fall on a hard surface. Such a shock to their parts can damage them. Radiator Fan Switch Removal the coolant (see Coolant Change in the Periodic • Drain Maintenance chapter). the screws [A] and take off the left radiator cover • Remove [B].
ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View................................... Specifications .................................... Special Tools and Sealant ................. Clean Air System............................... Air Suction Valve Removal........... Air Suction Valve Installation........ Air Suction Valve Inspection ........ Vacuum Switch Valve Removal ... Vacuum Switch Valve Installation Vacuum Switch Valve Test ........... Clean Air System Hose Inspection..................
5-2 ENGINE TOP END Exploded View
ENGINE TOP END 5-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Air suction valve cover bolts 10 1.0 87 in·lb 2 Cylinder head cover bolts 10 1.0 87 in·lb 3 Camshaft cap bolts (L=45 mm) 12 1.2 104 in·lb 4 Camshaft cap bolts (L=40 mm) 12 1.2 104 in·lb 5 Cylinder head bolts (M10 new bolts) 54 5.5 40 Remarks MO, S (Washer) 5 Cylinder head bolts (M10 used bolts) 49 5.0 36 MO, S (Washer) 6 Cylinder head bolts (M6) 12 1.
5-4 ENGINE TOP END Exploded View
ENGINE TOP END 5-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Coolant Drain Plug (Cylinder) 10 1.0 87 in·lb 2 Exhaust pipe manifold holder nuts 17 1.7 12 3 Muffler body clamp bolts 17 1.7 12 4 Muffler body mounting bolts and nuts 34 35 25 5 Crankshaft sensor cover bolts 11 1.1 95 in·lb Remarks 6: "R" marked side faces up. 7. "RN" marked side faces up. 8. Hollow mark faces forward. EO: Apply engine oil. R: Replacement Parts Exhaust System UK: U.K.
5-6 ENGINE TOP END Specifications Item Clean Air System: Vacuum switch valve closing pressure: Camshafts: Cam height: Exhaust Inlet Camshaft journal, camshaft cap clearance Camshaft journal diameter Camshaft bearing inside diameter Camshaft runout Cylinder Head: Cylinder compression Valve head thickness: 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.) 23.950 ∼ 23.972 mm (0.9429 ∼ 0.9438 in.) 24.000 ∼ 24.021 mm (0.9449 ∼0.9457 in.) TIR 0.02 mm (0.0008 in.) or less 0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.) 0.15 ∼ 0.
ENGINE TOP END 5-7 Specifications Item Valve/valve guide clearance (wobble method): Exhaust Inlet Valve seat cutting angle Valve seating surface: Width: Exhaust Inlet Outside diameter: Exhaust Inlet Valve spring free length: Exhaust Inlet Cylinder, Piston: Cylinder inside diameter Standard 0.09 ∼ 0.18 mm (0.0035 ∼ 0.0071 in.) 0.03 ∼ 0.12 mm (0.0012 ∼ 0.0047 in.) 45°, 32°, 60° 0.40 mm (0.016 in.) 0.33 mm (0.013 in.) - - - 0.8 ∼ 1.2 mm (0.031 ∼ 0.047 in.) 0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.) 25.2 ∼ 25.4 mm (0.
5-8 ENGINE TOP END Special Tools and Sealant Compression Gauge: 57001–221 Valve Seat Cutter, 32° 57001–1119 28: Valve Spring Compressor Assembly: 57001–241 Valve Seat Cutter, 32° 57001–1120 30: Piston Pin Puller Assembly: 57001–910 Valve Seat Cutter, 60° 57001–1123 30: Valve Seat Cutter, 45° 57001–1114 27.
ENGINE TOP END 5-9 Special Tools and Sealant Valve Spring Compressor Adapter, 57001–1202 22: Valve Seat Cutter Holder, 57001–1330 4.5: Spark Plug Wrench, Hex 16: 57001–1262 Valve Guide Reamer, 57001–1333 Fork Oil Level Gauge: 57001–1290 Valve Seat Cutter, 60° 57001–1334 Compression Gauge Adapter, M10 × 1.0: 57001–1317 Kawasaki Bond (Silicone Sealant): 56019–120 Valve Guide Arbor, 57001–1331 4.5: 4.
5-10 ENGINE TOP END Clean Air System Air Suction Valve Removal • Remove: Fuel Tank (see Fuel System (DFI) chapter) Connector [A] (from Clamp [B]) Air Suction Valve Cover Bolts [C] and Clamp Air Suction Valve Cover [D] Air Suction Valve Air Suction Valve Installation the air suction valve [A] so that its wider side [B] of • Install the reed valve case faces the front. • Tighten: Torque - Air Suction Valve Cover Bolts: 9.8 N·m (1.
ENGINE TOP END 5-11 Clean Air System Vacuum Switch Valve Test • Remove: Fuel Tank (see Fuel System (DFI) chapter) • Vacuum Switch Valve Connect a vacuum gauge [A] and syringe [B] or fork oil level gauge to the vacuum hoses as shown. Special Tool - Fork Oil Level Gauge: 57001–1290 Air Flow [C] raise the vacuum (lower the pressure) applied • Gradually to the vacuum switch valve, and check the valve operation. When the vacuum is low, the vacuum switch valve should permit air to flow.
5-12 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal • Remove: Fuel Tank (see Fuel System (DFI) chapter) Vacuum Switch Valve and Hoses Stick Coils (see Electrical System chapter) Air Suction Valve Covers [A] the cylinder head cover bolts [A] and take off the • Remove cover. Cylinder Head Cover Installation the head cover gasket with a new one if dam• Replace aged. • Apply silicone sealant [A] to the cylinder head as shown.
ENGINE TOP END 5-13 Cylinder Head Cover the washer [A] with the metal side faces upward. • Install Tighten: • Torque - Cylinder Head Cover Bolts [B]: 10 N·m (1.
5-14 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway. Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain.
ENGINE TOP END 5-15 Camshaft, Camshaft Chain Camshaft Removal • Remove: Fuel Tank (see Fuel System (DFI) chapter) Stick Coils (see Electrical System) Cylinder Head Cover (see Cylinder Head Cover Removal) Pickup Coil Cover the crankshaft at #1, 4 piston TDC.
5-16 ENGINE TOP END Camshaft, Camshaft Chain engine oil to all cam parts and journals. • Apply If a new camshaft is to be used, apply a thin coat of molyb• denum disulfide grease to the cam surfaces. NOTE ○The exhaust camshaft has a 030 EX mark [A] and the inlet camshaft has a 030 IN mark [B]. Be careful not to mix up these shafts. the crankshaft at #1, 4 piston TDC. • Position Pull the tension side (exhaust side) [A] of the chain taut • to install the chain.
ENGINE TOP END 5-17 Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear • Remove: Camshaft Chain Guide • • • Camshaft Cap Cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position. Measure each clearance between the camshaft journal and the camshaft cap using plastigage (press gauge) [A]. Tighten: Torque - Camshaft Cap Bolts: 12 N·m (1.2 kgf·m, 104 in·lb) Camshaft Chain Guide Bolts: 12 N·m (1.
5-18 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Chain Removal the crankcase (see Crankshaft/Transmission chap• Split ter). the camshaft chain [A] from the crankshaft • Remove sprocket.
ENGINE TOP END 5-19 Cylinder Head Cylinder Compression Measurement NOTE ○Use the battery which is fully charged. up the engine thoroughly. • Warm Stop the • Remove: engine. • Seats (see Frame chapter) Fuel Tank (see Fuel System (DFI) chapter) Stick Coils Spark Plugs Owners Tool - Spark Plug Wrench, Hex 16 the compression gauge [A] and adapter [B] firmly • Attach into the spark plug hole.
5-20 ENGINE TOP END Cylinder Head Cylinder Head Removal the coolant (see Cooling System chapter).
ENGINE TOP END 5-21 Cylinder Head • Install: Front Camshaft Chain Guide [A] • O-ring [B] Collar [C] Tighten: Torque - Front Camshaft Chain Guide Bolt (Upper) [D]: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Camshaft Chain Guide Bolt (Lower) [E]: 12 N·m (1.2 kgf·m, 104 in·lb) • Install: Rear Camshaft Chain Guide [F] Tighten: • Torque - Rear Camshaft Chain Guide Bolt [G]: 25 N·m (2.5 kgf·m, 18 ft·lb) • Install the camshafts (see Camshaft Installation). Cylinder Head Warp the cylinder head.
5-22 ENGINE TOP END Valves Valve Clearance Inspection to the Engine Top End in the Periodic Maintenance • Refer chapter. Valve Clearance Adjustment to the Engine Top End in the Periodic Maintenance • Refer chapter. Valve Removal the cylinder head (see Cylinder Head Removal). • Remove Remove valve lifter and shim. •○Mark andthe record the valve lifter and shim locations so they • can be installed in their original positions. Using the valve spring compressor assembly, remove the valve.
ENGINE TOP END 5-23 Valves Valve Guide Installation oil to the valve guide outer surface before installa• Apply tion. the area around the valve guide hole to about 120 ∼ • Heat 150 °C (248 ∼ 302 °F). the valve guide in from the top of the head using the • Drive valve guide arbor. The flange stops the guide from going in too far. Special Tool - Valve Guide Arbor, 4.
5-24 ENGINE TOP END Valves Valve Seat Inspection the valve (see Valve Removal). • Remove the valve seating surface [A] between the valve [B] • Check and valve seat [C]. ○Measure the outside diameter [D] of the seating pattern on the valve seat. If the outside diameter is too large or too small, repair the seat (see Seat Repair). Valve Seating Surface Outside Diameter Standard: Inlet 29.4 ∼ 29.6 mm (1.1575 ∼ 1.1654 in.) Exhaust 25.2 ∼25.4 mm (0.992 ∼ 1.000 in.
ENGINE TOP END 5-25 Valves Seat Cutter Operation Care: 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the 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.
5-26 ENGINE TOP END Valves the outside diameter of the seating surface with • Measure a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the specified range. 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 a vernier caliper.
ENGINE TOP END 5-27 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.
5-28 ENGINE TOP END Valves
ENGINE TOP END 5-29 Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) • Water Hose [A] Remove the cylinder [B]. Cylinder Installation NOTE ○If a new cylinder is used, use new piston ring. the pins [A] and new cylinder gasket [B]. • Install • Apply engine oil to the cylinder bore. piston ring openings must be positioned as shown in • The the figure. The openings of the oil ring steel rails must be about 30 – 40° of angle from the opening of the top ring.
5-30 ENGINE TOP END Cylinder, Pistons • Remove the piston pins. Special Tool - Piston Pin Puller Assembly: 57001–910 [A] • Remove the pistons. spread the ring opening with your thumbs and • Carefully then push up on the opposite side of the ring [A] to remove • it. Remove the 3-piece oil ring with your thumbs in the same manner.
ENGINE TOP END 5-31 Cylinder, Pistons NOTE ○If a new piston is used, use new piston ring. the piston with its hollow facing forward. • Install pin snap ring into the side of the piston Fit a new • so that thepiston ring opening [A] does not coincide with the slit [B] of the piston pin hole. ○Apply molybdenum disulfide oil solution to the piston pins and piston journals. ○When installing the piston pin snap ring, compress it only enough to install it and no more.
5-32 ENGINE TOP END Cylinder, Pistons Piston Ring Groove Width the piston ring groove width. •○Measure Use a vernier caliper at several points around the piston. Piston Ring Groove Width Standard Top [A] 0.83 ∼ 0.85 mm (0.0327 ∼ 0.0335 in.) 0.82 ∼ 0.84 mm Second [B] (0.0323 ∼ 0.0331 in.) Service Limit 0.93 mm (0.037 in.) 0.92 mm (0.036 in.) If the width of any of the two grooves is wider than the service limit at any point, replace the piston. Piston Ring Thickness the piston ring thickness.
ENGINE TOP END 5-33 Throttle Body Holder Throttle Body Holder Installation sure to install the O-rings [A]. • Be the clamps [B] as shown and so that its hole fit on • Install the projection [C] of the holder. • Tighten: Torque - Throttle Body Holder Bolts [D]: 12 N·m (1.2 kgf·m, 104 in·lb) Throttle Body Holder Clamp Screws [E]: 2.0 N·m (0.
5-34 ENGINE TOP END Muffler WARNING To avoid a serious burn, do not remove the mufflers when the engine is still hot. Wait until the mufflers cool down.
ENGINE TOP END 5-35 Muffler ○Install the muffler body clamp bolts as shown. [L] Upper Side [M] Inside [N] Connection Part Detail warm up the engine, wait until the engine • Thoroughly cools down, and retighten all the bolts and nuts.
CLUTCH 6-1 Clutch Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools and Sealant ...................................................................................................... Clutch Lever and Cable ....................................................
6-2 CLUTCH Exploded View
CLUTCH 6-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Clutch lever clamp bolts 7.9 0.8 69 in·lb 2 Clutch cover bolts (L = 32 mm) 11 1.1 95 in·lb 3 Clutch cover bolts (L = 45 mm) 11 1.1 95 in·lb 4 Clutch cover bolts (L = 30 mm) 11 1.1 95 in·lb 5 Clutch cover bolts 11 1.1 95 in·lb 6 Oil filler plug 1.5 0.15 13 in·lb 7 Clutch spring bolts 8.8 0.9 78 in·lb 8 Clutch hub nut 135 14 100 CL: Apply cable lubricant. EO: Apply engine oil. G: Apply grease.
6-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) - - - Clutch plate assembly 48.4 ∼ 49.0 mm (1.91 ∼ 1.93 in.) - - - Friction plate thickness 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) 2.4 mm (0.094 in.) Friction and steel plate warp 0.2 mm (0.008 in.) or less 0.3 mm (0.012 in.) Clutch spring free length 75.42 mm (2.97 in.) 71.8 mm (2.83 in.
CLUTCH 6-5 Special Tools and Sealant Inside Circlip Pliers: 57001–143 Clutch Holder: 57001–1243 Kawasaki Bond (Silicone Sealant): 56019–120
6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection to the Clutch Adjust Inspection in the Periodic Main• Refer tenance chapter. Clutch Lever Free Play Adjustment to the Clutch Adjust Inspection in the Periodic Main• Refer tenance chapter. Cable Removal the dust cover [A] at the clutch cable lower end out • Slide of place. the nuts [B], and slide the lower end of the clutch • Loosen cable to give the cable plenty of play. in the adjuster.
CLUTCH 6-7 Clutch Cover Clutch Cover Removal • Remove: Engine Oil (drain, see Engine Oil Change section in the Periodic Maintenance chapter) Clutch Cable Lower End [A] Clutch Cover Mounting Bolts [B] Clutch Cable Bracket [C] the release lever [A] toward the rear as shown, and • Turn remove the clutch cover [B]. [C] about 90° Clutch Cover Installation silicone sealant to the area [A] where the mating • Apply surface of the crankcase touches the clutch cover gasket.
6-8 CLUTCH Clutch Cover spring [A] as shown. • Fit[B]theViewed from Rear [C] Release Shaft [D] Clutch Cover Clutch Cover Disassembly • Remove: Oil Seal [A] Needle Bearings • Remove: Circlip [A] Special Tool - Inside Circlip Pliers [B]: 57001–143 • Remove: Oil Level Gauge [C] Clutch Cover Assembly • Replace the needle bearings and oil seal with new ones. NOTE ○Install the needle bearings so that the manufacture’s mark face out. the needle bearings [A] and oil seal [B] position as • Install shown.
CLUTCH 6-9 Clutch Clutch Removal • Remove: Engine Oil (drain, see Engine Oil Change section in the Periodic Maintenance chapter) Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with thrust bearing and pusher [C]) • Remove: Friction Plates, Steel Plates Spring, Spring Seat Clutch Hub Nut [A] ○Holding the clutch hub [B], remove the nut. Special Tool - Clutch Holder [C]: 57001–1243 • Remove: Clutch Hub Spcer the two 4 mm (0.16 in.
6-10 CLUTCH Clutch ○Install the spacer [A] so that the tapered side [B] faces inward. ○Install the washer [A] so that the OUT SIDE mark faces outward. ○Replace the clutch hub nut with a new one. ○Holding the clutch hub, tighten the clutch hub nut. Special Tool - Clutch Holder: 57001–1243 Torque - Clutch Hub Nut: 135 N·m (14 kgf·m, 100 ft·lb) the spring seat [A] and spring [B] as shown.
CLUTCH 6-11 Clutch molybdenum disulfide grease to the pusher ends • Apply [A] and install the pusher [B]. engine oil to the needle bearing [C] and install it. • Apply Install the washer [D]. • the mark [A] of the clutch spring plate [B] with the • Align groove [C] of the clutch hub. the clutch spring plate and spring, and tighten the • Install clutch spring bolts. Torque - Clutch Spring Bolts: 8.8 N·m (0.9 kgf·m, 78 in·lb) • Install the clutch cover (see Clutch Cover Installation).
6-12 CLUTCH Clutch Clutch Plate Assembly Adjustment the clutch plate assembly length, and then re• Inspect place the steel plate(s) which brings the length within the • • specified range. Remove: Spring Bolts Spring Holders Springs Spring Plate Replace the following steel plate(s). Part No. 13089–1073 13089–1084 13089–1115 Thickness 2.0 mm (0.08 in.) 2.3 mm (0.09 in.) (STD) 2.6 mm (0.10 in.) NOTE ○Do not use the steel plate of 2.0 mm (0.08 in.) and 2.6 mm (0.10 in.) thickness at the same time.
ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................................................................................................................ Engine Oil Flow Chart............................................................................................................. Specifications ......................................................................................................................... Special Tools and Sealant .........
7-2 ENGINE LUBRICATION SYSTEM Exploded View
ENGINE LUBRICATION SYSTEM 7-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Oil filler plug 1.5 0.15 13 in·lb 2 Engine drain plug 20 2.0 14.5 3 Oil filter (cartridge type, P/No. 16097–1070) 26 2.7 20 EO, R 3 Oil filter (cartridge type, P/No. 16097–0002) 31 3.2 23 EO, R 4 Oil cooler mounting bolt 76 7.8 56 EO 5 Oil pan bolts 11 1.1 95 in·lb 6 Oil pipe holder bolts 13 1.3 113 in·lb L 7 Oil pressure relief valve 15 1.
7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart
ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart 1. Camshaft Oil Passage 2. Oil Passage Hole in Alternator Rotor Bolt 3. Starter Clutch Oil Passage Hole 4. Main Oil Passage 5. Crankshaft Oil Passage 6. Oil Filter 7. Oil Cooler 8. Oil Pressure Switch 9. Oil Pipe 10. Oil Pump 11. To Drive Shaft 12. Oil Pipe 13. To Output Shaft 14. Drive Shaft Oil Passage Hole 15. Output Shaft Oil Passage Hole 16. Inlet Camshaft 17. Exhaust Camshaft 18. To Air Cleaner 19. Drive Shaft 20. Relief Valve 21. Oil Screen 22.
7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil: Type API SE, SF or SG API SH or SJ with JASO MA Viscosity SAE 10W-40 Capacity: 3.1 L (3.3 US gt) (when filter is not removed) 3.3 L (3.5 US gt) (when filter is removed) 3.8 L (4.0 US gt) (when engine is completely dry) Level Between upper and lower level lines Oil Pressure Measurement: Oil pressure@4 000 r/min (rpm), oil temp. 90°C (194°F) 255 ∼ 314 kPa (2.6 ∼ 3.
ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: 57001–164 Kawasaki Bond (Silicone Sealant): 56019–120 Oil Pressure Gauge Adapter, PT3/8: 57001–1233 Oil Filter Wrench: 57001–1249
7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle 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 that the engine oil level is between the upper [A] • Check and lower [B] levels in the gauge. NOTE ○Situate the motorcycle so that it is perpendicular to the ground.
ENGINE LUBRICATION SYSTEM 7-9 Oil Pan Oil Pan Removal • Remove: Engine Oil (drain, see Periodic Maintenance chapter) Muffler (see Engine Top End chapter) Oil Pan Bolts [A] Oil Pan [B] ○Remove the oil pipe [A], oil pressure relief valve [B] and oil screen [C] as necessary. Oil Pan Installation the oil screen [A]. • Clean Install the screen so that the crankcase rib [B] fits the • slot [C] of oil the oil screen. Apply engine oil to the O-rings on the oil pipe.
7-10 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • See Oil Pan Removal. Oil Pressure Relief Valve Installation • See Oil Pan Installation. Oil Pressure Relief Valve Inspection to see if the valve [A] slides smoothly when push• Check ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure. NOTE ○Inspect the valve in its assembled state. Disassembly and assembly may change the valve performance.
ENGINE LUBRICATION SYSTEM 7-11 Oil Pump Oil Pump Removal • Drain: Coolant (see Periodic Maintenance chapter) • Engine Oil (see Periodic Maintenance chapter) Remove: Water Hose [A] Water Pipe Fitting Bolts [B] Water Pipes [C] • Remove: Water Pump Cover Bolts [A] Clamp [B] Water Pump Cover [C] • Remove: Water Pump Impeller Bolt [A] Water Pump Impeller [B] • Remove: Water Pump Body Oil Pump Cover Oil (Water) Pump Shaft Outer Rotor and Inner Rotor NOTE ○The oil (water) pump assembly [A] can easily be rem
7-12 ENGINE LUBRICATION SYSTEM Oil Pump the pin [A] of the oil pump cover [B] into the hole [C] in • Fit the crankcase. • Install: Pins [A] Water Pump Body [B] • Install: Impeller [A] and Bolt [B] • Tighten: Torque - Water Pump Impeller Bolt: 10 N·m (1.0 kgf·m, 87 in·lb) • Install: Pins [C] Water Pump Cover and Bolts Torque - Water Pump Cover Bolts: 11 N·m (1.1 kgf·m, 95 in·lb) • Install: Water Pipes [A] Tighten: • Torque - Water Pipe Fitting Bolts [B]: 11 N·m (1.
ENGINE LUBRICATION SYSTEM 7-13 Oil Pump Oil Pump Drive Gear Removal • Remove: Clutch (see Clutch chapter) Oil Pan (see Oil Pan Removal) Circlip [A] and Washer [B] Oil Pump Drive Gear [C] Oil Pump Drive Gear Installation molybdenum disulfide oil solution to the journal por• Apply tions [A] on the oil pump gear shaft [B]. • Install: Washers [C] Install the circlip new [D] into the groove of the oil pump • drive gear shaft.
7-14 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Removal • Drain: Coolant (see Periodic Maintenance chapter) • Engine Oil (see Periodic Maintenance chapter) Remove: Oil Filter (see Periodic Maintenance chapter) Water Hose [A] Oil Cooler Mounting Bolt [B] and Washer Oil Cooler [C] and Water Hose Oil Cooler Installation • Install: Water Hose [A] • Tighten: Torque - Water Hose Clamp Screws: 2.0 N·m (0.2 kgf·m, 17 in·lb) • Apply grease to the O-ring [B] before installation.
ENGINE LUBRICATION SYSTEM 7-15 Oil Pressure Measurement Oil Pressure Measurement the oil passage plug, and attach the adapter [A] • Remove and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001–164 Oil Pressure Gauge Adapter, PT 3/8: 57001–1233 the engine and warm up the engine. • Start Run the at the specified speed, and read the oil • pressureengine gauge.
7-16 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal • Remove: Engine Oil (drain, see Periodic Maintenance chapter) Switch Cover [A] Switch Terminal [B] Oil 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 switch lead direction upward. • Install Tighten the terminal bolt.
ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................................................................................................................ Special Tools .......................................................................................................................... Engine Removal/Installation ................................................................................................... Engine Removal....................
8-2 ENGINE REMOVAL/INSTALLATION Exploded View
ENGINE REMOVAL/INSTALLATION 8-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Adjusting collar locknut 49 5.0 36 S 2 Upper engine mounting bolts 44 4.5 32 S 3 Rear engine bracket bolts 25 2.5 18 S 4 Front engine bracket bolts 44 4.5 32 S 5 Middle engine mounting nut 44 4.5 32 S 6 Lower engine mounting nut 44 4.5 32 S 7. Adjusting Collar 8. Middle Engine Mounting Bolt 9. Lower Engine Mounting Bolt S: Follow the specific tightening sequence.
8-4 ENGINE REMOVAL/INSTALLATION Special Tools Carburetor Drain Plug Wrench, Hex3: 57001–1269 Engine Mount Nut Wrench: 57001–1450
ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal • Support the rear part of the swingarm with a stand [A]. the brake lever slowly and hold it with a band • Squeeze [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It could cause an accident and injury. CAUTION Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. The engine or the motorcycle could be damaged.
8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Radiator Hose Clamp [A] (Loosen) Radiator Hose [B] Oil Cooler Water Hose Clamp [C] (Loosen) Oil Cooler Water Hose [D] Radiator Bolt [E] (Loosen) Radiator Bracket Bolt [F] • Disconnect Crankshaft Sensor Lead Connector (see Electrical System chapter) Stick Coil Harness Connector [A] • Remove: Air Cleaner Housing Bolt [A] Loosen: • Throttle Body Assy Clamps Bolts #3, 4 [B] (see Fuel System (DFI) chapter) Special Tool - Carburetor Drain Pl
ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Remove: Camshaft Position Sensor Connector [A] Injector Harness Connector [B] Coolant Reserve Tank [A] (see Cooling System chapter) Air Cleaner Housing Bolt [B] Vacuum Switch Valve Hose [C] • Remove: Vacuum Switch Valve Tube [A] Inlet Air Pressure Sensor Tube [B] Throttle Body Assy [C] ○Loosen the #1,2 body assy clamps [D] and pull the throttle body out of the holders, and then remove it to the left side.
8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation the engine with a suitable stand [A]. •○Support Put a plank [B] onto the suitable stand for engine balance. • Remove: Right and Left Engine Upper Mounting Bolts [A] Front Engine Bracket Bolts [B] Front Engine Bracket [C] the middle and lower engine mounting nuts [A] • Remove and bolts. • Remove: Rear Engine Bracket Bolts [B] Rear Engine Bracket [C] • Using the nut wrench [A], loosen the locknut [B].
ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation the Hexagon Wrench, turn the adjusting collar [A] • Using counter clockwise to mark the gap between the engine and flame adjusting collar. • Remove the drive chain [A] from the output shaft [B]. the rear portion of the engine a little and remove • Down the engine ground [A]. ○Unscrew the ground bolt [B]. the stand, take out the engine. •○Using Clear the camshaft position sensor from the frame.
8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation the engine mounting bolts and nuts, following the • Install specified installing sequence. ○First, hang the drive chain over the output shaft just before moving the engine into its final position in the frame. ○Second, insert the lower engine mounting bolt [A]. ○Third, install the rear engine bracket [B] temporarily. ○Fourth, insert the middle engine mounting bolts [C]. ○Fifth, install the left upper engine mounting bolt [A] and tighten it.
ENGINE REMOVAL/INSTALLATION 8-11 Engine Removal/Installation ○Ninth, temporarily install: Front Engine Bracket [A] Front Right Engine Mounting Bolt [B] ○Tenth, tighten the rear bracket bolts. Torque - Rear Engine Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) ○Eleventh, tighten securely: Middle Engine Mounting Nut Lower Engine Mounting Nut Torque - Engine Mounting Nut: 44 N·m (4.5 kgf·m, 32 ft·lb) ○Twelfth, tighten the right upper engine mounting bolt. ○Lastly, tighten the front bracket bolts.
CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View................................... Specifications .................................... Special Tools and Sealant ................. Crankcase Splitting............................ Crankcase Splitting ...................... Crankcase Assembly ................... Crankshaft and Connecting Rods...... Crankshaft Removal .................... Crankshaft Installation ................. Connecting Rod Removal ............
9-2 CRANKSHAFT/TRANSMISSION Exploded View
CRANKSHAFT/TRANSMISSION 9-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Breather plate bolts 10 1.0 87 in·lb L 2 Crankcase bolts (M9, L=81 mm) 42 4.3 31 MO,S 3 Crankcase bolts (M9, L=95 mm) 49 5.0 36 MO,S 4 Crankcase bolts (M8) 27 2.8 20 S 5 Crankcase bolts (M7) 20 2.0 14.5 S 6 Crankcase bolts (M6) 12 1.2 104 in·lb S 7 Starter motor clutch bolts 12 1.2 104 in·lb L 8 Oil pipe holder bolts 13 1.
9-4 CRANKSHAFT/TRANSMISSION Exploded View
CRANKSHAFT/TRANSMISSION 9-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Shift pedal mounting bolt 34 3.5 25 2 Gear positioning lever bolt 12 1.2 104 in·lb 3 Shift shaft return spring pin 29 3.0 22 L 4 Shift drum cam holder bolt 12 1.2 104 in·lb L 5 Footpeg bracket bolts 34 3.5 25 L 6 Shift lever bolt 6.9 0.7 61 in·lb 7 Tie-rod locknuts 6.9 0.7 61 in·lb 8 Neutral switch 15 1.5 11 EO: Apply engine oil. G: Apply grease.
9-6 CRANKSHAFT/TRANSMISSION Specifications Item Crankshaft, Connecting Rods: Connecting rod bend Standard --- Connecting rod twist --- Connecting rod big end side clearance 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.) 0.041 ∼ 0.071 mm (0.0016 ∼ 0.0028 in.) 34.984 ∼ 35.000 mm (1.3773 ∼ 1.3780 in.) 34.984 ∼ 34.992 mm (1.3773 ∼ 1.3776 in.) 34.993 ∼ 35.000 mm (1.3777 ∼ 1.3780 in.) 38.000 ∼ 38.016 mm (1.4961 ∼ 1.4967 in.) 38.000 ∼ 38.008 mm (1.4961 ∼ 1.4964 in.) 38.009 ∼ 38.016 mm (1.4964 ∼ 1.4967 in.
CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard TIR 0.02 mm (0.0008 in.) or less Crankshaft runout Crankshaft main bearing insert/journal clearance 0.020 ∼ 0.044 mm (0.0008 ∼ 0.0017 in.) main journal diameter: 32.984 ∼ 33.000 mm Crankshaft (1.2986 ∼ 1.2992 in.) Marking None 32.984 ∼ 32.992 mm (1.2986 ∼ 1.2989 in.) 1 32.993 ∼ 33.000 mm (1.2989 ∼ 1.2992 in.) 36.000 ∼ 36.016 mm Crankcase main bearing inside diameter: (1.4173 ∼ 1.4179 in.) Marking 36.000 ∼ 36.008 mm (1.4173 ∼ 1.4176 in.) None 36.
9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealant Bearing Puller: 57001–135 Kawasaki Bond (Silicone Sealant): 56019–120 Bearing Puller Adapter: 57001–317 Kawasaki Bond (Silicone Sealant): 92104–1063
CRANKSHAFT/TRANSMISSION 9-9 Crankcase Splitting Crankcase Splitting the engine (see Engine Removal/Installation • Remove chapter). the engine on a clean surface and hold the engine • Set steady while parts are being removed.
9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting liquid gasket to the breather plate mating surface • Apply [A] 1 to 1.5 mm (0.04 to 0.06 in.) thick, and then install the breather plate. Sealant - Three Bond: 1207B a non-permanent locking agent to the threads and • Apply tighten the bolts [A]. Torque - Breather Plate Bolts: 10 N·m (1.0 kgf·m, 87 in·lb) the breather hose [A]. •○Install Align the white mark on the hose with the white mark on the pipe.
CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting liquid gasket [A] to the mating surface of the lower • Apply crankcase half. Sealant - Kawasaki Bond (Silicone Sealant): 92104–1063 CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts, and oil passage holes. • Fit the lower crankcase to the upper crankcase. molybdenum disulfide grease to the seating surface • Apply [A] on the lower crankcase for the M9 bolts [B].
9-12 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal the crankcase (see Crankcase Splitting). • Split • Remove the crankshaft [A]. Crankshaft Installation CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bearing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.
CRANKSHAFT/TRANSMISSION 9-13 Crankshaft and Connecting Rods molybdenum disulfide grease [A] to the outer sur• Apply face of the upper insert and the inner surface of the connecting rod big end. Apply molybdenum disulfide oil [B] to the inner surfaces of upper and lower bearing inserts. ○The molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease with a weight ratio (10:1). ○Do not apply any grease or oil [C] to the cap inside and cap insert outside.
9-14 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods (1) Bolt Length Measurement Method Be sure to clean the bolts, nuts, and connecting rods thoroughly with a high-flash point solvent, because the new connecting rods, bolts, and nuts are treated with an anti-rust solution. • WARNING Clean the bolts, nuts, and connecting rods in a well -ventilated area, and take care that there is no spark or flame anywhere near the working area. This includes any appliance with a pilot light.
CRANKSHAFT/TRANSMISSION 9-15 Crankshaft and Connecting Rods (2) Rotation Angle Method If you don’t have a point micrometer, you may tighten the nuts using the “Rotation Angle Method”. Be sure to clean the bolts and nuts thoroughly with a high -flash point solvent, because the new bolts and nuts are treated with an anti-rust solution. • WARNING Clean the bolts and nuts in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area.
9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Bend the connecting rod big end bearing inserts, and • Remove the connecting rod big end cap. reinstall an arbor [A] of the same diameter as the connect• Select ing rod big end, and insert the arbor through the connect- • • • ing rod big end. Select an arbor of the same diameter as the piston pin and more than 105 mm (4.13 in.) long, and insert the arbor [B] through the connecting rod small end.
CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert/Crankpin Wear the bearing insert/crankpin [B] clearance with • Measure plastigage [A]. ○Tighten the big end nuts to the specified torque (see Connecting Rod Installation). NOTE ○Do not move the connecting rod and crankshaft during clearance measurement. CAUTION After measurement, replace the connecting rod bolts. Connecting Rod Big End Bearing Insert/Crankpin Clearance Standard: 0.041 ∼ 0.071 mm (0.
9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Big End Inside Diameter Marks None 38.000mm ∼ 38.008mm (1.4961 ∼ 1.4964 in.) 38.009 ∼ 38.016 mm (1.4964 ∼ 1.4967 in.) Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark (Around Weight Mark) [D]: “ mark ” or no the proper bearing insert [A] in accordance with the • Select combination of the connecting rod and crankshaft coding.
CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods Crankshaft Main Bearing Insert/Journal Wear a plastigage (press gauge) [A], measure the bear• Using ing insert/journal [B] clearance. NOTE ○Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). ○Do not turn the crankshaft during clearance measurement. ○Journal clearance less than 0.025 mm (0.00098 in.) can not be measured by plastigage, however, using genuine parts maintains the minimum standard clearance.
9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods the main bearing inside diameter, and mark the • Measure upper crankcase half in accordance with the inside diam- • eter. Crankcase Main Bearing Inside Diameter Marks : " " or no mark. Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). NOTE ○The mark already on the upper crankcase half should almost coincide with the measurement. Crankcase Main Bearing Inside Diameter Marks 36.000 ∼ 36.008 mm (1.4173 ∼ 1.4176 in.
CRANKSHAFT/TRANSMISSION 9-21 Starter Motor Clutch Starter Motor Clutch Removal/Installation to the Alternator Rotor Removal and Installation in • Refer the Electrical System chapter. Starter Motor Clutch Assembly sure to install the one-way clutch [A] so that its flange • Be [B] fits in the holder recess [C]. a non-permanent locking agent to the threads of • Apply the starter motor clutch bolts, and tighten them. Torque - Starter Motor Clutch Bolts: 12 N·m (1.
9-22 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal [A] the position of the shift lever [B] on the shift shaft • Mark so that it can be installed later in the same position. • Remove: Shift Lever Bolt [C] Shift Lever • Remove: Footpeg Bracket Bolts [A] Muffler Mounting Bolt [B] Footpeg Bracket [C] • Remove the bolt [A], footpeg [B], and shift pedal [C]. Shift Pedal Installation grease to the oil seal lip.
CRANKSHAFT/TRANSMISSION 9-23 Transmission the footpeg bracket [A]. • Install Apply non-permanent locking agent • bracketabolts [B]. Tighten: • to the footpeg Torque - Footpeg bracket Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Muffler Mounting Bolt and Nut [C]: 29 N·m (3.0 kgf·m, 22 ft·lb) the shift lever [A], aligning the mark (previously • Install marked). • TIghten: Torque - Shift Lever Bolt: 6.9 N·m (0.7 kgf·m, 61 in·lb) the shift pedal [B] as shown.
9-24 CRANKSHAFT/TRANSMISSION Transmission • Remove: Gear Positioning Lever Bolt [A] Gear Positioning Lever [B], Collar and spring External Shift Mechanism Installation the gear positioning lever [A] as shown. • Install Spring [B] • Collar [C] Bolt [D] Tighten: Torque - Gear Positioning Lever Bolt: 12 N·m (1.2 kgf·m, 104 in·lb) grease to the O-ring on the oil pipe ends. • Apply a non-permanent locking agent to the oil pipe holder • Apply bolts and tighten them.
CRANKSHAFT/TRANSMISSION 9-25 Transmission Transmission Shaft Removal the crankcase (see Crankcase Splitting). • Split • Remove the drive shaft [A] and output shaft [B]. Transmission Shaft Installation to see that the set pins [A] and set rings [B] are in • Check place. the drive shaft and output shaft into the upper • Install crankcase half. engine oil to the sliding surfaces of the gears and • Apply bearings.
9-26 CRANKSHAFT/TRANSMISSION Transmission • Remove the ball bearing [A] from each shafts. Special Tools - Bearing Puller: 57001–135 [B] Bearing Puller Adapter: 57001–317 [C] • Discard the bearing. Transmission Shaft Assembly engine oil to the sliding surfaces on the transmis• Apply sion shafts, gears and bushings. the gear bushings [A] on the shaft with their holes • Install [B] aligned. any circlips removed with new ones.
CRANKSHAFT/TRANSMISSION 9-27 Transmission NOTE ○When the toothed washers [28] [29] are assembled onto the output shaft, note the following. ○When the tangs [A] of the toothed washer [29] shall be assembled, they should be installed into the notch [B] of the toothed washer [28]. ○Fit the steel balls into the 5th gear holes in the output shaft, aligning three oil holes [D] (see Section BB in the output shaft illustration).
9-28 CRANKSHAFT/TRANSMISSION Transmission 1. 1st Gear 2. 2nd Gear 3. 3rd Gear 4. 4th Gear 5. 5th Gear 6. 6th (Top) Gear 7. Toothed Washer, 31 mm (1.22 in.) 8. Thrust Washer, 30 mm (1.18 in.) 9. Circlip 10. Circlip 11. Bushing 12. Bushing 13. Needle Bearing 14. Needle Bearing 15. Bearing Outer Race 16. Steel Ball 17. Nut 18. Bushing 19. Bushing 20. Circlip 21. Ball Bearing 22.
CRANKSHAFT/TRANSMISSION 9-29 Transmission Shift Drum and Fork Installation the shift rods [A], noting the groove position. The • Install rods are identical. the one with shortest ears [B] on the drive shaft • Position and place the pin in the center groove in the shift drum [C]. ○The two forks [D] on the output shaft are identical. Install the forks as shown. Apply a non-permanent locking agent to the threads of the shift drum bearing holder bolt and screw, and tighten them.
9-30 CRANKSHAFT/TRANSMISSION Transmission Shift Fork/Gear Groove Wear the thickness of the shift fork ears [A], and mea• Measure width [B] of the gear grooves. sure the If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced. Shift Fork Ear Thickness Standard: 5.9 ∼ 6.0 mm (0.232 ∼ 0.236 in.) Service Limit: 5.8 mm (0.228 in.) If the gear groove is worn over the service limit, the gear must be replaced. Gear Groove Width Standard: 6.05 ∼ 6.15 mm (0.238 ∼ 0.
WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools .......................................................................................................................... Wheels (Rims) ........................................
10-2 WHEELS/TIRES Exploded View
WHEELS/TIRES 10-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Front axle clamp bolt 20 2.0 15 2 Front axle 127 13 94 3 Rear axle nut 127 13 94 G: Apply grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
10-4 WHEELS/TIRES Specifications Item Wheels (Rims): Rim runout: Axial Radial Standard ----- Axle runout/100 mm (3.94 TIR 0.05 mm (0.0020 in.) or less in.) Wheel balance Balance weights Tires: Air pressure: (when cold) Front Tread depth: Front Rear 10 g (0.35 US oz) or less 10 g (0.35 US oz), 20 g (0.71 US oz), 30 g (1.06 US oz) 250 kPa Up to 180 kg (396 lb) load: (2.5 kgf/cm², 36 psi) 290 kPa (2.9 kgf/cm², 41 psi) BRIDGESTONE 3.4 mm (0.13 in.
WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: 57001–1129 Bearing Remover Head, 57001–1346 25 × Jack: 57001–1238 Bearing Remover Shaft, 57001–1377 13: 28:
10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Brake Caliper Mounting Bolts [A] • Loosen: Right Side Axle Clamp Bolt [A] Axle [B] • Raise the front wheel off the ground. Special Tool - Jack: 57001–1238 out the axle to the right and drop the front wheel out • Pull of the forks. CAUTION Do not lay the wheel down on one of the discs. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.
WHEELS/TIRES 10-7 Wheels (Rims) • Tighten the axle. Torque - Front Axle: 127 N·m (13 kgf·m, 94 ft·lb) tightening the clamp bolt on the right front fork leg, • Before pump the front fork up and down 4 or 5 times to allow the right front fork leg to seat on the front axle. NOTE ○Put a block in front of the front wheel to stop moving. • Tighten the axle clamp bolt [A] on the right fork leg first. Torque - Front Axle Clamp Bolt: 20 N·m (2.
10-8 WHEELS/TIRES Wheels (Rims) • Remove: Caliper Mounting Bolts [A] Caliper [B] the drive chain [A] from the rear sprocket toward • Remove the left. the rear wheel back and remove the wheel from the • Move rear caliper. • Remove the rear wheel. CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. Rear Wheel Installation the drive chain with the rear sprocket.
WHEELS/TIRES 10-9 Wheels (Rims) • Bend the cotter pin [A] over the nut [B]. WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condition may result. the drive chain slack after installation (see Final • Adjust Drive chapter). • Check the rear brake effectiveness. WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc.
10-10 WHEELS/TIRES Wheels (Rims) Axle Inspection inspect the front and rear axle for damages. • Visually If the axle is damaged or bent, replace it. the axle in V blocks that are 100 mm (3.94 in.) [A] • Place apart, and set a dial gauge [B] on the axle at a point halfway between the blocks. Turn [C] the axle to measure the runout. The difference between the highest and lowest dial readings is the amount of runout. If axle runout exceeds the service limit, replace the axle. Axle Runout/100 mm (3.94 in.
WHEELS/TIRES 10-11 Wheels (Rims) (b) When the tire is on the rim. Pry [A] the balance weight off the rim flange using a regular tip screwdriver as shown in the figure. ○Insert a tip of the screwdriver between the tire bead [B] and weight blade [C] until the end of the tip reaches the end of the weight blade. ○Push the driver grip toward the tire so that the balance weight slips off the rim flange. Discard the used balance weight.
10-12 WHEELS/TIRES Wheels (Rims) required total weight exceeds 20 g (0.71 US oz), in• When stall balance weight at both sides of rim flange as shown. Required Total Weight: g (US oz) One Side [A] Other Side [B] 20 (0.71) 10 (0.35) 10 (0.35) 30 (1.06) 20 (0.71) 10 (0.35) 40 (1.41) 20 (0.71) 20 (0.71) 50 (1.76) 30 (1.06) 20 (0.71) 60 (2.12) 30 (1.06) 30 (1.06) 70 (2.47) 80 (2.82) 90 (3.17) Weight Selection: g (US oz) 20 + 20 (0.71 + 0.71) 30 (1.06) 20 + 20 20 + 20 (0.71 + 0.71) (0.
WHEELS/TIRES 10-13 Tires Air Pressure Inspection/Adjustment to the Air Pressure Inspection/Adjustment in the Pe• Refer riodic Maintenance chapter. Tire Inspection to the Tire Inspection in the Periodic Maintenance • Refer chapter. Tire Removal • Remove: Wheel (see Front Wheel Removal, • Rear Wheel Re- moval) Disc (s) Valve Core (let out the air) To maintain wheel balance, mark the valve stem position on the tire with chalk so that the tire can be reinstalled in the same position.
10-14 WHEELS/TIRES Tires a new valve in the rim. •○Install Remove the valve cap, lubricate the stem seal with a soap and water solution or rubber lubricant, and pull [B] the valve stem [A] through the rim from the inside out until it snaps into place. CAUTION Do not use engine oil or petroleum distillates to lubricate the stem because they will deteriorate the rubber. a soap and water solution, or rubber lubricant to the • Apply rim flange and tire beads. ○The air valve is shown in the figure.
WHEELS/TIRES 10-15 Tires to see that the rim lines [A] on both sides of the tire • Check sidewalls are parallel with the rim flanges. If the rim flanges and tire sidewall rim lines are not parallel, remove the valve core. Lubricate the rim flanges and tire beads. Install the valve core and inflate the tire again. After the tire beads seat in the rim flanges, check for air leakage. ○Inflate the tire slightly above standard inflation.
10-16 WHEELS/TIRES Hub Bearing Hub Bearing Removal the wheel, and take out the following. • Remove Collars • Coupling (out of rear hub) Grease Seals Circlips Use the bearing remover to remove the hub bearings [A]. CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Please blocks under the wheel so that the disc does not touch the ground.
FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools .......................................................................................................................... Drive Chain.............................................
11-2 FINAL DRIVE Exploded View
FINAL DRIVE 11-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Engine sprocket cover bolts 9.8 1.0 87 in·lb 2 Engine sprocket nut 127 13 94 3 Rear sprocket nut 59 6.0 43 4 Engine sprocket cover damper bolts 6.9 0.7 61 in·lb L 5 Speed sensor bolt 6.9 0.7 61 in·lb L 6 Rear axle nut 127 13 94 7. Drive chain joint (ZR1000–A2 ∼ ) G: Apply grease. HO: Apply heavy oil. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil.
11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain: Chain slack 20 ∼ 30 mm (0.8 ∼ 1.2 in.) 20-link length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) - - 323 mm (12.7 in.) Standard chain Make ENUMA - - - Type EK525UVXL2, Endless - - - Link 112 links - - - Sprockets: Rear sprocket warp 0.4 mm (0.016 in.) or less 0.5 mm (0.020 in.
FINAL DRIVE 11-5 Special Tools Bearing Driver Set: 57001–1129 Jack: 57001–1238
11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection to the Drive Chain Slack Inspection in the Periodic • Refer Maintenance chapter. Drive Chain Slack Adjustment to the Drive Chain Slack Adjustment in the Periodic • Refer Maintenance chapter. Wheel Alignment Inspection/Adjustment to the Wheel Alignment Inspection/Adjustment in • Refer the Periodic Maintenance chapter. Drive Chain Wear Inspection to the Drive Chain Wear Inspection in the Periodic • Refer Maintenance chapter.
FINAL DRIVE 11-7 Drive Chain EK JOINT TOOL #50 Body [A] Handlebar [B] Cutting and Riveting Pin [C] For Cutting [D] For Riveting [E] Plate Holder (A) [F] Plate Holder (B) [G] Gauge [H] [A] pin head to make it flat. • Grind Set cutting and riveting pin [B] as shown. • pin holder until it touches chain pin. • Screw Be sure that cutting pin hits center of chain pin. • handlebar [A] into body. • Screw Turn pin • pin. holder with wrench [B] clockwise to extract chain the link pin, link plate and grease seals.
11-8 FINAL DRIVE Drive Chain plate holder (A) [A] and plate holder (B) [B] on the • Set body. plate holder (A) to link plate. • Fit Turn holder by hand until plate holder (B) touches the • otherpin link plate. pin holder by wrench clockwise until two pins of link • Turn come into groove of plate holder (A). • Take off plate holder. plate holder (B) [A] and cutting and riveting pin [B] as • Set shown. • Turn pin holder until riveting pin touches link pin.
FINAL DRIVE 11-9 Drive Chain wrench clockwise until tip of riveting pin hits of link • Turn pin. it. • Rivet Some work for the other link pin. • staking, check the staked area of the link pin for • After cracks. the outside diameter [A] of the link pin and link • Measure plates outside width [B]. Link Pin Outside Diameter Standard: 5.6 ∼ 6.0 mm (0.22 ∼ 0.24 in.) Link Plates Outside Width Standard: 19.85 ∼ 20.00 mm (0.781 ∼ 0.787 in.
11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove: Speed Sensor [A] Connector Engine Sprocket Cover Bolts [B] Engine Sprocket Cover [C] with Speed Sensor out the bended washer [A]. • Flatten Remove the engine sprocket nut [B] and washer. • NOTE ○When loosening the engine sprocket nut, hold the rear brake on. • Using the jack, raise the rear wheel off the ground. Special Tool - Jack : 57001–1238 the drive chain (see Slack Adjustment). • Loosen Remove • right.
FINAL DRIVE 11-11 Sprocket, Coupling Rear Sprocket Removal • Remove the rear wheel (see Wheels/Tires chapter). CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. the rear sprocket nuts [A]. • Remove Remove the rear sprocket [B]. • Rear Sprocket Installation the sprocket facing the tooth number marking [A] • Install outward. • Tighten the rear sprocket nuts.
11-12 FINAL DRIVE Sprocket, Coupling the grease seal with a new one. • Replace Press in the seal so that the seal surface is flush • with the end grease of the hole. ○Apply high temperature grease to the grease seal lips. Special Tool - Bearing Driver Set : 57001–1129 Coupling Installation the following and install the coupling.
FINAL DRIVE 11-13 Sprocket, Coupling Sprocket Wear Inspection inspect the engine and rear sprocket teeth for • Visually wear and damage. If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see Drive Chain Wear Inspection). [A] Worn Tooth (Engine Sprocket) [B] Worn Tooth (Rear Sprocket) [C] Direction of Rotation NOTE ○If a sprocket requires replacement, the chain is probably worn also. When replacing a sprocket, inspect the chain.
BRAKES 12-1 Brakes Table of Contents Exploded View................................... Specifications .................................... Special Tool ....................................... Brake Lever, Brake Pedal.................. Brake Lever Position Adjustment. Brake Pedal Position Inspection .. Brake Pedal Position Adjustment. Calipers ............................................. Front Caliper Removal ................. Rear Caliper Removal.................. Caliper Installation .....................
12-2 BRAKES Exploded View
BRAKES 12-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Front caliper mounting bolts 25 2.5 18 2 Brake hose banjo bolt 25 2.5 18 3 Bleed valve 7.8 0.80 69 in·lb 4 Front caliper assembly bolts 22 2.2 16 5 Front brake pad pin bolt 17 1.7 12 6 Brake lever pivot bolt 1.0 0.10 9 in·lb 7 Brake lever pivot bolt locknut 5.9 0.60 52 in·lb 8 Brake disc mounting bolts 27 2.8 20 9 Front brake light switch screws 1.2 0.
12-4 BRAKES Exploded View
BRAKES 12-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Rear master cylinder push lod locknut 18 1.8 13 2 Rear caliper mounting bolts 25 2.5 18 3 Brake hose banjo bolts 25 2.5 18 4 Bleed valve 7.8 0.80 69 in·lb 5 Rear master cylinder mounting bolts 25 2.5 18 6 Brake disc mounting bolts 27 2.8 20 7. Gasket (Before Frame No. 005854) B: Apply brake fluid. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement parts Si: Apply silicone grease (ex.
12-6 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal: Brake lever position 5-way adjustable (to suit rider) - - - Brake lever free play Non-adjustable - - - Pedal free play Non-adjustable - - - Pedal position About 47 mm (1.85 in.) below footpeg top - - - DOT4 - - - Brake Fluid: Grade Brake Pads: Lining thickness: Front 4 mm (0.16 in.) 1 mm (0.04 in.) Rear 5 mm (0.20 in.) 1 mm (0.04 in.) Brake Discs: Thickness: Front 5.8 ∼ 6.2 mm (0.23 ∼ 0.24 in.) 5.
BRAKES 12-7 Special Tool Jack: 57001–1238
12-8 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator’s hand. Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder. ○The distance from the grip to the lever is minimum at number 5 and maximum at number 1. • Brake Pedal Position Inspection that the brake pedal [A] is in the correct position.
BRAKES 12-9 Calipers Front Caliper Removal 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. CAUTION Do not loosen the caliper assembly bolts [D]. Take out only the caliper mounting bolts for caliper removal. Loosening the caliper assembly bolts will cause brake fluid leakage. the banjo bolt and remove the brake hose [E] • Unscrew from the caliper (see Brake Hose Removal/Installation).
12-10 BRAKES Calipers Caliper Installation the caliper and brake hose lower end. •○Install Replace the washers on each side of hose fitting with new • ones. Tighten: Torque - Caliper Mounting Bolts (Front): 25 N·m (2.5 kgf·m, 18 ft·lb) Caliper Mounting Bolts (Rear): 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) the fluid level in the brake reservoirs. • Check Bleed the line (see Bleeding the Brake Line).
BRAKES 12-11 Calipers WARNING To avoid serious injury, never place your fingers or palm in front of the piston. If you apply compressed air into the caliper, the piston may crush your hand or fingers. ○Pull out the pistons by hand. the dust seals [A] and fluid seals [B]. • Remove Remove the bleed valve [C] and rubber cap [D]. • Repeat the previous step to remove the pistons from the • other side of the caliper body.
12-12 BRAKES Calipers the fluid seals [A] with new ones. •○Replace Apply brake fluid to the fluid seals, and install them into the cylinders by hand. Replace the dust seals [B] with new ones if they are damaged. ○Apply brake fluid to the dust seals, and install them into the cylinders by hand. • the O-rings [A] if they are damaged. • Replace Apply brake fluid to the outside of the pistons, and push • them into each cylinder by hand. sure to install the O-rings.
BRAKES 12-13 Calipers Rear Caliper Assembly • Clean the caliper parts except for the pads. CAUTION For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • Install the bleed valve and rubber cap. Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) the fluid seal [A] with a new one. •○Replace Apply brake fluid to the fluid seal, and install it into the cylinder by hand. Replace the dust seal [B] with a new one if it is damaged.
12-14 BRAKES Calipers Caliper Piston and Cylinder Damage inspect the piston [A] and cylinder surfaces. • Visually Replace the caliper if the cylinder and piston are badly scores or rusty. Front Caliper [B] Rear Caliper [C] Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shaft [D]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature.
BRAKES 12-15 Brake Pads Front Brake Pad Removal • Remove: Mounting Bolts [A] • Remove: Pad Pin Bolt [A] Pad Spring [B] Brake Pads [C] Front Brake Pad Installation the caliper pistons in by hand as far as they will go. • Push Apply • Install:silicone grease to the stopper ring [A]. • Brake Pads Pad Spring Pad Pin Bolts Torque - Front Brake Pad Pin Bolts: 17 N·m (1.
12-16 BRAKES Brake Pads Rear Brake Pad Installation the caliper piston in by hand as far as it will go. • Push • Install: Brake Pads • Pad Pin Clip Install the caliper (see Caliper Installation). WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc. The brake will not function on the first application of the pedal if this is not done.
BRAKES 12-17 Master Cylinder Front Master Cylinder Removal the front brake light switch connectors [A]. • Disconnect the banjo bolt [B] to disconnect the brake hose • Remove from the master cylinder [C] (see Brake Hose Removal/In- • stallation). Remove the rear view mirror (see Steering chapter). the clamp bolts [A], and take off the master cylin• Unscrew der as an assembly with the reservoir, brake lever, and brake switch installed.
12-18 BRAKES Master Cylinder Rear Master Cylinder Removal the brake hose banjo bolt [A] on the master cylin• Unscrew Brake Hose Removal/Installation). der (see off the reservoir hose lower end [B], and drain the • Pull brake fluid into a container. the master cylinder mounting bolts [C] lightly. • Loosen • Remove the cotter pin [D]. NOTE ○Pull off the joint pin while pressing down the brake pedal. the master cylinder mounting bolts, and remove • Unscrew the master cylinder.
BRAKES 12-19 Master Cylinder Rear Master Cylinder Disassembly NOTE ○Do not remove the push rod clevis for master cylinder disassembly since removal requires brake position adjustment. the rear master cylinder (see Rear Master Cylin• Remove der Removal). the dust cover on the push rod out of place, and • Slide remove the circlip. out the push rod with the piston stop. • Pull Take off the piston [A], secondary cup [B], primary cup [C], • and return spring [D].
12-20 BRAKES Brake Disc Brake Disc Removal the wheel (see Wheels/Tires chapter). • Remove • Unscrew the mounting bolts, and take off the disc. Brake Disc Installation the brake disc on the wheel so that the marked side • Install [A] faces out. a non-permanent locking agent to the threads of • Apply the front and rear brake disc mounting bolts [B]. • Tighten: Torque - Brake Disc Mounting Bolts: 27 N·m (2.
BRAKES 12-21 Brake Fluid Brake Fluid Level Inspection to the Brake Fluid Level in the Periodic Maintenance • Refer chapter. Brake Fluid Change to the Brake Fluid Change in the Periodic Mainte• Refer nance chapter. Brake Line Bleeding to the Brake Line Bleeding in the Periodic Mainte• Refer nance chapter.
12-22 BRAKES Brake Hose Brake Hose Removal/Installation CAUTION Brake fluid quickly ruins painted or plastic surfaces; any spilled fluid should be completely wiped up immediately with wet cloth. removing the brake hose, take care not to spill the • When brake fluid on the painted or plastic parts. removing the brake hose, temporarily secure the • When end of the brake hose to some high place to keep fluid • • • loss to a minimum. There are washers on each side of the brake hose fitting.
SUSPENSION 13-1 Suspension Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools .......................................................................................................................... Front Fork ...............................................
13-2 SUSPENSION Exploded View
SUSPENSION 13-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb Front fork clamp bolts (Upper) 8.8 0.90 78 in·lb Front fork clamp bolts (Upper): ZR1000–A2 ∼ 13 1.3 113 in·lb Front fork clamp bolts (Lower) 20 2.0 15 Front fork clamp bolts (Lower): ZR1000–A2 ∼ 30 3.1 22 3 Front fork top plugs 35 3.6 26 4 Piston rod nuts 20 2.0 15 5 Front fork bottom Allen bolts 20 2.0 15 6 Front axle clamp bolt 20 2.0 15 1 2 Remarks 7. Right fork leg 8.
13-4 SUSPENSION Exploded View
SUSPENSION 13-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Rear shock absorber nuts (upper and lower) 34 3.5 25 2 Swingarm pivot shaft nut 127 13 94 3 Swingarm pivot shaft locknut 98 10 72 4 Rocker arm nut 34 3.5 25 5 Tie-rod nuts 59 6.0 43 G: Apply or add grease.
13-6 SUSPENSION Specifications Item Standard Front Fork (per one unit): Fork inner tube outside diameter 41 mm (1.61 in.) Air Pressure Atmospheric pressure (Non-adjustable) Rebound damper setting 1 turns out from the fully clockwise position (only right fork leg) Fork spring preload setting (Usable Range: 0 ←→ 1 4/5 ∼ 2 2/5 turns out) Adjuster protrusion is 19 mm (0.75 in.) (Usable Range: 10 ∼ 25 mm (0.39 ∼ 0.98 in.
SUSPENSION 13-7 Special Tools Oil Seal and Bearing Remover: 57001–1058 Fork Piston Rod Puller, M10 × 1.
13-8 SUSPENSION Front Fork Rebound Damping Force Adjustment (Only Right Fork Leg) adjust the rebound damping force, turn the rebound • To damping adjuster [A] on top of the right front fork leg to the desired position. ○The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is 1 turns out of the fully clockwise position. ○The damping force can be left soft for average riding.
SUSPENSION 13-9 Front Fork Front Fork Removal (each fork leg) • Remove: Front Wheel (see Wheels/Tires chapter.) Front Fender (see Frame chapter.) Windshield and Bracket (see Frame chapter.) Inner Cover (see Frame chapter.) Fairing and Bracket (see Frame chapter.) Loosen the upper fork clamp bolts [A] and fork top plug [B] before-hand if the fork leg is to be disassembled. ○Loosen NOTE the top plug after loosening the upper fork clamp bolts.
13-10 SUSPENSION Front Fork Fork Oil Change the front fork (see Front Fork Removal). •○Remove spring preload adjuster [A] counterclockwise until Turn the • the fully position. Unscrew the top plug [B] out of the inner tube. the pins [A], set the front fork spring compressor • Avoiding set [B] on the washer [C]. Special Tool - Front Fork Spring Compressor: 57001–1338 • Compress the fork spring. the piston rod nut [A] with a wrench [B], remove • Holding the fork top plug from the piston rod.
SUSPENSION 13-11 Front Fork the fork oil into a suitable container. • Drain Remove fork spring [A]. •○Pump thethepiston rod [B] up and down at least ten times to expel the oil from the fork. the fork tube upright, press the inner tube and the • Hold piston rod all the way down. • Pour in the type and amount of fork oil specified. Fork Oil Viscosity: Amount (Right fork leg) When changing oil: After disassembly and completely dry: SHOWA SS-8 approx. 385 mL (13.01 US oz) 450 ± 2.5 mL (15.21 ± 0.
13-12 SUSPENSION Front Fork Oil Level (fully compressed, without spring) Standard: Right fork leg 62 ± 2 mm (2.44 ± 0.08 in.) Left fork leg 47 ± 2 mm (1.85 ± 0.08 in.) (from the top of the outer tube) NOTE ○Fork oil level may also be measured using the fork oil level gauge. Special Tool - Fork Oil Level Gauge: 57001–1290 [A] ○With the fork fully compressed and without fork spring, insert the gauge tube into the inner tube [B] and position the stopper across the top end [F] of the outer tube [C].
SUSPENSION 13-13 Front Fork the O-ring on the top plug and replace it with a new • Check one if damaged. the right fork leg, check the distance [C] between the • For bottom end [A] of the top plug and rebound damping adjuster [B] with a pair of vernier caliper. [C] 20 mm (0.79 in.) the top plug [A] with a wrench [B], tighten the • Holding piston rod nut [C] against the top plug. Torque - Piston Rod Nut: 20 N·m (2.
13-14 SUSPENSION Front Fork ○Holding the inner tube [A] by hand, pull the outer tube [B] several times to pull out the outer tube. the inner tube guide bushing [A], outer tube • Remove guide bushing [B], washer [C], oil seal [D] from the inner tube. Front Fork Assembly the following parts with new one. • Replace Oil Seal • Guide Bushings Bottom Allen Bolt Gasket Install the following parts onto the inner tube.
SUSPENSION 13-15 Front Fork the cente ring plate on the cylinder unit. • Install Insert the cente ring plate and cylinder unit as a set into • the inner tube. • • Cylinder Unit [A] and Center Ring Plate [C] for Right Fork Leg Cylinder Unit [B] and Center Ring Plate [C] for Left Fork Leg Hold the front fork in a vise. Torque the Allen bolt. Torque - Front Fork Bottom Allen Bolt: 20 N·m (2.0 kgf·m, 15 ft·lb) • Pour in the specified type of oil (see Fork Oil Change.
13-16 SUSPENSION Front Fork Spring Tension a spring becomes shorter as it weakens, check its • Since free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the remaining spring vary greatly, the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability. Spring Free Length Standard: 282.7 mm (11.13 in.) Service Limit: 277 mm (10.
SUSPENSION 13-17 Rear Shock Absorber Rebound Damping Force Adjustment adjust the rebound damping force, turn the rebound • To damping adjuster [A] to the desired position. ○The standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories 3/4 turns out of the fully clockwise position.
13-18 SUSPENSION Rear Shock Absorber Special Tools - Hook Wrench: 57001–1539 [A] Spring Adjustment Adjuster Position 193.4 mm (7.61 in.) ↑ ↓ 183.4 mm (7.22 in.) Damping Force Weak ↑ ↓ Strong Setting Load Road Speed Soft Light Good Low ↑ ↓ Hard ↑ ↓ Heavy ↑ ↓ Bad ↑ ↓ High Rear Shock Absorber Removal • Using the jack, raise the rear wheel off the ground. Special Tool - Jack: 57001–1238 the brake lever slowly and hold it with a band • Squeeze [A].
SUSPENSION 13-19 Rear Shock Absorber • Remove the shock absorber [A] from upside. Rear Shock Absorber Installation • Tighten: Torque - Rear Shock Absorber Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear Shock Absorber Inspection the rear shock absorber. • Remove Visually inspect • Smooth Strokethe following items. • Oil Leakage Crack or Dent If there is any damage to the rear shock absorber, replace it. Visually inspect the rubber bushing. If it show any signs of damage, replace it.
13-20 SUSPENSION Swingarm Swingarm Removal the muffler bodies (see Engine Top End chapter.) • Remove • Raise the rear wheel off the ground with jack. Special Tool - Jack: 57001–1238 • Remove: Rear Wheel (see Wheels/Tires chapter.) Chain Cover (see Final Drive chapter.) Mud Guard (see Frame chapter.) Brake Hose Clamp [A] Lower Shock Absorber Nut and Bolt [A] Upper Tie-Rod Nut and Bolt [B] the right frame cover (see Frame chapter). • Remove Loosen the shock absorber nut.
SUSPENSION 13-21 Swingarm Swingarm Installation plenty of grease to the ball bearing, needle bearings • Apply and grease seals, and add plenty of grease to the grease • nipple. Install the collars [A]. ○Place the right collar [A] on the • • • stopper [B] inside the frame [C]. Insert the pivot shaft into the frame from the right side. Tighten the pivot shaft so that the clearance [D] between the collar [A] and the frame [C] come to zero mm.
13-22 SUSPENSION Swingarm • Remove the ball bearing and needle bearings. Special Tool - Oil Seal and Bearing Remover: 57001–1058 [A] Swingarm Bearing Installation plenty of grease to the ball bearing and needle • Apply bearings. the needle bearings so that the manufacturer’s • Install marks face in. the ball bearing so that the manufacturer’s marks • Install faces out.
SUSPENSION 13-23 Tie-Rod, Rocker Arm Tie-Rod Removal the muffler bodies (see Engine Top End chapter.) • Remove the side stand (see Frame chapter.) • Remove Using the jack, raise the rear wheel off the ground. • Special Tool - Jack: 57001–1238 the brake lever slowly and hold it with a band • Squeeze [A]. • Remove: Lower Rear Shock Absorber Bolt and Nut [A] Upper and Lower Tie-Rod Bolts and Nuts [B] Tie-Rods [C] Tie-Rod Installation grease to the inside of the needle bearings and • Apply grease seals.
13-24 SUSPENSION Tie-Rod, Rocker Arm Rocker Arm Installation grease to the inside of the needle bearings and oil • Apply seal lips, and add grease to the grease nipple. • Tighten: Torque - Rocker Arm Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb) Tie-Rod Nut: 59 N·m (6.0 kgf·m, 43 ft·lb) Rear Shock Absorber Nut: 34 N·m (3.5 kgf·m, 25 ft·lb) Rocker Arm/Tie-Rod Bearing, Sleeve Inspection inspect the rocker arm/tie-rod sleeves and needle • Visually bearings.
STEERING 14-1 Steering Table of Contents Exploded View........................................................................................................................ Special Tools .......................................................................................................................... Steering .................................................................................................................................. Steering Inspection .......................................
14-2 STEERING Exploded View
STEERING 14-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Steering stem nut 27 2.75 20 2 Steering stem head bolt 108 11 80 3 Front fork clamp bolts (Upper) 8.8 0.90 78 in·lb Front fork clamp bolts (Upper): ZR1000–A2 ∼ 13 1.3 113 in·lb Front fork clamp bolts (Lower) 20 2.0 15 Front fork clamp bolts (Lower): ZR1000–A2 ∼ 30 3.1 22 5 Handlebar clamp bolts 25 2.5 18 6 Handlebar lower clamp nuts 34 3.5 25 7 Handlebar housing switch screws 3.4 0.
14-4 STEERING Special Tools Steering Stem Nut Wrench: 57001–1100 Steering Stem Bearing Driver: 57001–1344 Bearing Driver Set: 57001–1129 Steering Stem Bearing Driver Adapter: 57001–1345 Jack: 57001–1238
STEERING 14-5 Steering Steering Inspection to the Steering Inspection in the Periodic Mainte• Refer nance chapter. Steering Adjustment to the Steering Adjustment in the Periodic Mainte• Refer nance chapter.
14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Windshield and Bracket (see Frame chapter.) Inner Cover (see Frame chapter.) Fairing and Bracket (see Frame chapter.) Front Wheel (see Wheels/Tires chapter.) Handlebar (see Handlebar Removal.) Steering Stem Head Bolt Plug Steering Stem Head Bolt [A] and Washer Steering Stem Head the brake hose clamp bolt [A] and take the hose • Remove [B] off the steering stem [C]. • Remove the front fork (see Suspension chapter). the claw washer tabs [A].
STEERING 14-7 Steering Stem remove the bearing outer races [C] pressed into the • To head pipe [B], insert a bar [A] into the recesses [D] of head pipe, and applying it to both recess alternately hammer it to drive the race out. NOTE ○If either steering stem bearing is damaged, it is recommended that both the upper and lower bearings (including outer races) should be replaced with new ones.
14-8 STEERING Steering Stem grease the lower ball bearing [A] and install it onto • Apply the stem. grease to the upper ball bearing [B] and inner race • Apply [C]. the stem [A] through the head pipe and install the • Install ball bearing [B] and inner race [C] on it. • Install the stem cap [D] and steering stem nut [E]. the inner races in place as follows: •○Settle Tighten the steering stem nut with 39 N·m (4.0 kgf·m, 29 ft·lb) of torque first, and loosen it a fraction of a turn until it turns lightly.
STEERING 14-9 Steering Stem NOTE ○Tighten the fork upper clamp bolts first, next the stem head nut, last the fork lower clamp bolts. Torque - Steering Stem Head Bolt : 108 N·m (11 kgf·m, 80 ft·lb) Front Fork Clamp Bolts (Upper): 8.8 N·m (0.90 kgf·m, 78 in·lb) 13 N·m (1.3 kgf·m, 113 in·lb): ZR1000–A2 ∼ Front Fork Clamp Bolts (Lower): 20 N·m (2.0 kgf·m, 15 ft·lb) 30 N·m (3.1 kgf·m, 22 ft·lb): ZR1000–A2 ∼ NOTE ○Tighten the two clamp bolts alternately two times to ensure even tightening torque.
14-10 STEERING Handlebar Handlebar Removal • Remove: Clutch Lever Assembly [A] • Left Handlebar Switch Housing [B] Front Brake Master Cylinder [C] Right Handlebar Switch Housing [D] Handlebar Holder Bolts [E] Remove the handlebar holders [F] and then pull out the handlebar [G]. the cotter pins [A]. • Remove Unscrew the mounting nuts [B] and remove the handlebar • lower clamps [C]. Handlebar Installation the handlebar lower clamps [A], noting the letters • Install “L” [B] and “R” [C].
STEERING 14-11 Handlebar Rear View Mirrors Removal the lower hexagonal area [A] for tightening to re• Loosen move the rear view mirror from the holder. CAUTION Do not force to tighten and/or loosen the upper hexagonal area (Adapter) [B] with a pair of spanners. Disassembly of this area is Not Available. Non-permanent locking agent [D] is already applied to the threads of this inner area. Forcible loosening may damage the adapter and/or the turning mechanism of the stay [C].
FRAME 15-1 Frame Table of Contents Exploded View........................................................................................................................ Seats ...................................................................................................................................... Rear Seat Removal........................................................................................................... Rear Seat Installation......................................................
15-2 FRAME Exploded View
FRAME 15-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Footpeg holder bolts 34 3.5 25 2 Muffler mounting nuts 29 3.0 22 3 Side stand bolt 44 4.5 33 4 Side stand switch bolt 8.8 0.9 78 in·lb G: Apply grease.
15-4 FRAME Exploded View
FRAME 15-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Windshield screws 0.35 ∼ 0.50 0.035 ∼ 0.050 3 ∼4 in·lb 2 Front fender bolts 3.9 0.4 34.
15-6 FRAME Exploded View
FRAME 15-7 Seats Rear Seat Removal the ignition switch key into the seat lock [A], turning • Insert the key counterclockwise, pulling up on the rear of the seat [B], and pulling the seat backward. WARNING The muffler surface is hot once the engine has been started. When operating the seat lock be careful not to touch the muffler or you may be burned.
15-8 FRAME Side Covers Side Cover Removal the bolt [A]. • Remove side cover [B] evenly outward to clear the stopthe • Pull pers. Side Cover Installation the tabs [A] into the holes [B]. • Insert Install the bolt.
FRAME 15-9 Fairings Windshield Removal • Remove: Bolts [A] Windshield [B] Windshield Installation • Windshield Installation is the reverse of removal. Torque - Windshield Screw: 0.35 ∼ 0.50 N·m (0.035 ∼ 0.050 kgf·m, 3 ∼ 4 in·lb) Inner Cover Removal • Remove: Inner Cover Screws [A] (both side) Inner Cover [B] Inner Cover Installation the projections [A] on the inner cover [B] into the holes • Fit [C] in the firing bracket. • Install the inner cover screws.
15-10 FRAME Fairings • Remove: Fairing Mounting Bolts [A] (both side) Headlight Connectors Fairing Installation • Fairing installation is the reverse of removal.
FRAME 15-11 Seat Covers Seat Cover Removal • Remove: Seats Screws [A] • Push the central pin, and then remove the quick rivets [A]. the front portions [A] of the seat cover outside [B], • Pull and then remove the seat cover backward. Seat Cover Installation is reverse of removal. • Installation • Put the projections [A] into the grommets [B] on the frame.
15-12 FRAME Mud Guard Mud Guard Removal • Remove: Chain Cover (see Final Drive chapter) Bolt [A] Clamp [B] • Lift up the mud guard [A], and then pull it out backward. Mud Guard Installation • Put the projections [A] into the grommets [B].
FRAME 15-13 Fenders Front Fender Removal • Remove: Brake Hose Clamps [A] • Bolts [B] (both side) Remove the front fender [C]. Front Fender Installation • Install the brake hose clamps to the front fender holes.
15-14 FRAME Fenders • Remove: Quick Rivets [A] Rear Fender Rear [B] Rear Fender Rear Installation • Put the projection [A] into the hole [B]. the projections [A] into the holes [B]. • Put Installation is reverse of removal.
FRAME 15-15 Frame Cover Frame Cover Removal • Remove: Bolts [A] Frame Cover [B] (both side)
15-16 FRAME Battery Case Battery Case Removal • Remove: Seats • Seat Cover Rear Fender Assy Side Covers Battery Left Side Screw [A] (with reserver tank) Pull out the battery case [B] backward [C]. Battery Case Installation the battery case attachments [A] at the projections [B] • Put on the frame.
FRAME 15-17 Side Stand Side Stand Removal the rear wheel off the ground with the stand. • Raise • Remove: Muffler (both side) Exhaust pipe Side Stand Switch Bolt [A] Side Stand Switch [B] Spring [C] Side Stand Nut [D] Side Stand Bolt [E] Side Stand [F] Side Stand Installation grease to the sliding area [B] of the side stand [A]. • Apply Tighten the bolt and lock them with the nut. • Torque - Side Stand Bolt: 44 N·m (4.5 kgf·m, 32 ft·lb) the spring • Hook the side stand switch.
15-18 FRAME Frame Frame Inspection inspect the frame for cracks, dents, bending, or • Visually warp. ○If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Parts Location.................................... Exploded View................................... Specifications .................................... Special Tools and Sealant ................. Wiring Diagram (U.S.A. and Canada) Wiring Diagram (Australia) ................ Wiring Diagram (Other than U.S.A., Canada, Australia, and Malaysia)... Wiring Diagram (Malaysia) ................ Precautions........................................
16-2 ELECTRICAL SYSTEM Fan Motor Inspection ................... Meter, Gauge, Indicator Unit.............. Meter Unit Removal ..................... Meter, Gauge Disassembly.......... Electronic Combination Meter Unit Inspection .......................... Switches and Sensors ....................... Brake Light Timing Inspection...... Brake Light Timing Adjustment .... Switch Inspection ......................... Radiator Fan Switch Inspection ... Water Temperature Sensor Inspection...........................
ELECTRICAL SYSTEM 16-3 Parts Location [A] Starter Lockout Switch [B] Camshaft Position Sensor [C] Radiator Fan Switch [D] Starter Motor [E] Alternator [F] Speed Sensor [G] Neutral Switch [H] Side Stand Switch [I] Water Temperature Sensor [J] Battery [K] Junction Box [L] Front Brake Light Switch [M] Stick Coils [N] Crankshaft Sensor [O] Rear Brake Light Switch [P] Starter Relay and Main Fuse [Q] ECU Fuse [R] Turn Signal Relay [S] Diode (Rectifier) [T] ECU (Electronic Control Unit) [U] Oil Pressure Switch
16-4 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 16-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Meter mounting screws 1.2 0.12 11 in·lb 2 Tail/brake light mounting screws 1.2 0.12 11 in·lb 3 License plate light mounting screws 1.2 0.12 11 in·lb 4 Front brake light switch screw 1.2 0.12 11 in·lb 5 Starter locknut switch screws - - - 6 Left switch housing screws 3.4 0.35 30 in·lb 7 Right switch housing screws 3.4 0.35 30 in·lb 8 Headlight mounting bolts 5.9 0.6 53 in·lb 9.
16-6 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 16-7 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Water temperature sensor 25 2.5 18 2 Spark plugs 13 1.3 115 in·lb 3 Alternator lead holding plate bolts 11 1.1 95 in·lb 4 Starter motor mounting bolts 11 1.1 95 in·lb 5 Stator motor coil bolts 11 1.1 95 in·lb 6 Alternator rotor bolt 110 11 80 7 Starter clutch bolts 12 1.2 104 in·lb 8 Alternator cover bolts 11 1.1 95 in·lb 9 Crankshaft sensor bolts 5.9 0.
16-8 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 16-9 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Regulator/rectifier bolts 6.9 0.7 62 in·lb 2 Fuel level sensor bolts 6.9 0.7 62 in·lb 3 Side stand switch bolt 8.8 0.9 78 in·lb 4 Neutral switch 15 1.5 11 5 Speed sensor bolt 6.9 0.7 62 in·lb L 6 Speed sensor cover bolts 6.9 0.7 62 in·lb L 7 Regulator/rectifier bracket bolts 6.9 0.7 62 in·lb 8 Engine ground cable terminal bolt 9.8 1.0 87 in·lb 9. Turn signal relay 10.
16-10 ELECTRICAL SYSTEM Specifications Item Battery: Type Capacity Voltage Charging System: Type Alternator output voltage Stator coil resistance Charging voltage (regulator/rectifier output voltage) Ignition System: Crankshaft sensor resistance Crankshaft sensor peak voltage Camshaft Position Sensor resistance Camshaft Position Sensor peak voltage Stick coil: Primary winding resistance Secondary winding resistance Primary peak voltage Spark plug: Spark plug gap IC igniter inspection: Electric Starter Syste
ELECTRICAL SYSTEM 16-11 Special Tools and Sealant Hand Tester: 57001–1394 Rotor Puller, M16/M18/M20/M22 × 1.5: 57001–1216 Flywheel Puller, M38 × 1.
16-12 ELECTRICAL SYSTEM Wiring Diagram (U.S.A.
ELECTRICAL SYSTEM 16-13 Wiring Diagram (U.S.A.
16-14 ELECTRICAL SYSTEM Wiring Diagram (Australia)
ELECTRICAL SYSTEM 16-15 Wiring Diagram (Australia)
16-16 ELECTRICAL SYSTEM Wiring Diagram (Other than U.S.A.
ELECTRICAL SYSTEM 16-17 Wiring Diagram (Other than U.S.A.
16-18 ELECTRICAL SYSTEM Wiring Diagram (Malaysia)
ELECTRICAL SYSTEM 16-19 Wiring Diagram (Malaysia)
16-20 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below. ○Do not reverse the battery lead connections. This will burn out the diodes on the electrical parts. ○Always check battery condition before condemning other parts of an electrical system. A fully charged battery is a must for conducting accurate electrical system tests.
ELECTRICAL SYSTEM 16-21 Precautions Male Connectors [B]
16-22 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection inspect the wiring for signs of burning, fraying, • Visually etc. If any wiring is poor, replace the damaged wiring. Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Check the wiring for continuity. ○Use the wiring diagram to find the ends of the lead which is suspected of being a problem.
ELECTRICAL SYSTEM 16-23 Battery Battery Removal CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is ON, as this could damage the ECU (Electronic Control Unit). Never reverse the connections of the battery, this could damage the ECU. • Remove: Seats (see Frame Chapter) Disconnect negative (–) cable [A]. • Slide out thethe positive (+) terminal cap [B] and then discon• nect the positive (+) cable.
16-24 ELECTRICAL SYSTEM Battery CAUTION Do not remove the aluminum seal sheet [A] sealing the filler ports [B] until just before use. to see that there is no peeling, tears or holes in the • Check seal sheet on the top of the battery. the battery on a level surface. • Place Remove the seal sheet. • NOTE ○A battery whose sealing sheet has any peeling, tears, holes, or from which the air–sucking sound was not heard requires a refreshing charge (initial charge).
ELECTRICAL SYSTEM 16-25 Battery the seal caps [A] tightly into the filler ports until the seal • Fit caps are at the same level as the top of the battery. NOTE ○Do not hammer. Press down evenly with both hands. CAUTION Once you installed the seal caps after filling the battery, never remove it, nor add any water or electrolyte.
16-26 ELECTRICAL SYSTEM Battery Precautions 1) No need of topping–up No topping–up is necessary in this battery until it ends its life under normal use. Forcibly prying off the sealing plug to add water is very dangerous. Never do that. 2) Refreshing charge 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 the this chapter).
ELECTRICAL SYSTEM 16-27 Battery Interchange The sealed battery can fully display its performance only when combined with a proper vehicle electric system. Therefore, replace the sealed battery only on a motorcycle which was originally equipped with the sealed battery. Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original equipment, the sealed battery’s life will be shortened.
16-28 ELECTRICAL SYSTEM Battery Terminal Voltage: 11.5 ∼ less than 12.6 V Standard Charge 0.9 A × 5 ∼ 10 h Quick Charge 4.0 A × 1.0 h Battery Terminal Voltage (V) [A] Charge Time (h) [B] CAUTION If possible, do not quick charge. If the quick charge is done due to unavoidable circumstances, do standard charge later on. Terminal Voltage : less than 11.5 V Charging Method : 0.9 A × 20 h NOTE ○Increase the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially.
ELECTRICAL SYSTEM 16-29 Charging System Alternator Cover Removal • Remove: Frame Cover Bolts [A] Left Frame Cover [B] Clamp (open) [A] Alternator Lead Connector [B] For ○ California model, remove the separator. a suitable container under the alternator cover [A], • Place and remove the cover bolts [B]. • Pull the alternator cover outside.
16-30 ELECTRICAL SYSTEM Charging System Stator Coil Installation a non-permanent locking agent to the stator coil • Apply bolts and tighten it. Torque - Stator Coil Bolts: 11 N·m (1.1 kgf·m, 95 in·lb) the alternator • Secure tighten the bolt. lead with a holding plate, and ○Apply a non-permanent locking agent to the plate bolt. Torque - Alternator Lead Holding Plate Bolt: 11 N·m (1.
ELECTRICAL SYSTEM 16-31 Charging System the starter gear [A]. • Install Again, • there. clean the crankshaft tapered portion [B] and dry the woodruff key [C] securely in the slot in the crank• Fit shaft before installing the alternator rotor. the alternator rotor [A] while turning [B] the starter • Install clutch gear [C]. the washer [A] so that the chamfer side [B] faces • Install outward. NOTE ○Confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque.
16-32 ELECTRICAL SYSTEM Charging System a thin coat of molybdenum disulfide grease to the • Apply shaft [A], and install it and starter idle gear [B]. the alternator cover (see Alternator Cover Installa• Install tion). Alternator Inspection There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all.
ELECTRICAL SYSTEM 16-33 Charging System • If there is more resistance than shown in the table, or no hand tester reading (infinity) for any two leads, the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced. Using the highest resistance range of the hand tester, measure the resistance between each of the black leads and chassis ground.
16-34 ELECTRICAL SYSTEM Charging System the 1st step regulator circuit test: •○Do Connect the test light and the 12 V battery to the regulator/rectifier as shown. ○Check BK1, BK2, and BK3 terminal respectively. If the test light turns on, the regulator/rectifier is defective. Replace it. If the test light does not turn on, continue the test. the 2nd step regulator circuit test: •○Do Connect the test light and the 12 V battery in the same manner as specified in the "Regulator Circuit Test–1st Step".
ELECTRICAL SYSTEM 16-35 Charging System Charging Voltage Inspection the battery condition (see Battery section). • Check up the engine to obtain actual alternator operating • Warm conditions. the seats (see Frame chapter). • Remove Check that the ignition switch is turned off, and connect • the hand tester [A] to the battery terminals [B]. Special Tool - Hand Tester: 57001–1394 [A] the engine, and note the voltage readings at various • Start engine speeds with the headlight turned on and then turned off.
16-36 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 2. To Starter Circuit Relay 3. Alternator 4. Regulator/Rectifier 5. Joint Connector C 6. Battery 12 V 8 Ah 7. Main Fuse 30A 8.
ELECTRICAL SYSTEM 16-37 Ignition System WARNING The ignition system produces extremely high voltage. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running. This is to prevent ECU (Electrical Control Unit) damage. Do not install the battery backwards. The negative side is grounded.
16-38 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Installation the crankshaft sensor lead correctly (see Cable, • Route Wire, and Hose Routing in Appendix chapter). • Tighten: Torque - Crankshaft Sensor Bolts: 5.9 N·m (0.6 kgf·m, 53 in·lb) silicone sealant [A] to the crankshaft sensor lead • Apply grommet and crankcase halves mating surface on the front and rear sides of the crankshaft sensor cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 56019–120 the clamps [A] direction as shown.
ELECTRICAL SYSTEM 16-39 Ignition System Crankshaft Sensor Resistance: 375 ∼ 565 Ω the highest resistance range of the tester, measure • Using the resistance between the crankshaft sensor leads and chassis ground. Any tester reading less than infinity (∞) indicates a short, necessitating replacement of the crankshaft sensor assembly. Crankshaft Sensor Peak Voltage Inspection NOTE ○Be sure the battery is fully charged.
16-40 ELECTRICAL SYSTEM Ignition System Camshaft Position Sensor Removal • Remove: Fuel Tank (see Fuel System (DFI) chapter) Camshaft Position Sensor Lead Connector [A] (disconnect) ○Push the tongue [B] upside and take out the connector from the bracket. • Remove: Camshaft Position Sensor Bolt [A] Camshaft Position Sensor [B] Camshaft Position Sensor Installation grease or engine oil to the O-ring on the camshaft • Apply position sensor. a non-parmanent locking agent to the sensor bolt.
ELECTRICAL SYSTEM 16-41 Ignition System Camshaft Position Sensor Peak Voltage Inspection • Remove: Fuel Tank (see Fuel System (DFI) chapter) • • Camshaft Position Sensor Lead Connector [A] (disconnect) Set the hand tester [B] to the 10 V DC range. Connect the peak voltage adapter [C] to the hand tester and Camshaft Position Sensor leads in the connector.
16-42 ELECTRICAL SYSTEM Ignition System the stick coil harness [A] from the bracket. • Remove Remove: • Stick Coil Connector #4 [B] (disconnect) Stick Coil #4 [C] Stick Coil Connector #3 [D] (disconnect) • Disconnect: Water Temperature Sensor Connector [A] • Left Switch Housing Connector [B] Pull the main harness [C] upward and remove the stick coil #3 [D]. Stick Coil (Ignition Coil together with Spark Plug Cap) Installation the coil using the following steps.
ELECTRICAL SYSTEM 16-43 Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection the stick coils (see this chapter). • Remove Measure the primary winding resistance [A] as follows. •○Connect the hand tester between the coil terminals. ○Set the tester to the × 1 Ω range, and read the tester. the secondary winding resistance [B] as follows. •○Measure Connect the tester between the plug terminal and (–) coil terminal. ○Set the tester to the × 1 kΩ range and read the tester.
16-44 ELECTRICAL SYSTEM Ignition System WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. the ignition switch and the engine stop switch ON. • Turn Pushing starter button, turn the engine 4 ∼ 5 seconds • with the the transmission in neutral to measure the primary • peak voltage. Repeat the measurements 5 times for one stick coil. Stick Coil Primary Peak Voltage 88 V or more Standard: the test for the other stick coil.
ELECTRICAL SYSTEM 16-45 Ignition System Interlock Operation Inspection • Remove: Seats (see Frame chapter) Junction Box (see this chapter) ○Do not disconnect the connectors. 1st Check Measure the terminal voltage of the G/BK lead in the junction box connector [A] in accordance with the following procedure. ○Insert the needle adapter [B] in the Green/Black lead terminal. ○Set the tester [C] to the 25 V DC range, connect it to the needle adapter and frame ground [D].
16-46 ELECTRICAL SYSTEM Ignition System IC Igniter Inspection ○The IC Igniter is built in the ECU [A]. to the Interlock Operation Inspection, Ignition • Refer System Troubleshooting Chapter and Fuel System (DFI) chapter for ECU Inspection.
ELECTRICAL SYSTEM 16-47 Ignition System
16-48 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Spark Plugs 5. Stick Coils 6. Side Stand Switch 7. Crankshaft Sensor 8. Camshaft Position Sensor 9. Throttle Sensor 10. Neutral Switch 11. Junction Box 12. Ignition Fuse 10A 13. Starter Lockout Switch 14. Diode 15. ECU Main Relay 16. ECU Fuse 15A 17. Vehicle-down Sensor 18. Main Fuse 30A 19. Battery 12 V 8 Ah 20. ECU (Electrical Control Unit) 21. Joint Connector A 22.
ELECTRICAL SYSTEM 16-49 Electric Starter System Starter Motor Removal CAUTION Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. the mounting bolts [A]. • Remove • Pull out the starter motor [B]. back the rubber cap [A]. • Slide Remove the starter motor terminal nut [B]. • Starter Motor Installation CAUTION Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor.
16-50 ELECTRICAL SYSTEM Electric Starter System ○The brush plate [A] and brushes come off with the right–hand end cover [B]. the terminal locknut [A] and terminal bolt [B], and • Remove then remove the brush with the brush plate [C] from the right–hand end cover. Starter Motor Assembly the brush plate and brushes [A], and then put the • Install armature [B] among the brushes. • Install the O-rings [A] as shown.
ELECTRICAL SYSTEM 16-51 Electric Starter System the line [A] marked on the yoke with the through bolt • Align hole [B]. Brush Inspection the length [A] of each brush. • Measure If any is worn down to the service limit, replace the carbon brush holder assembly [B] and the terminal bolt assembly [C]. Starter Motor Brush Length Standard: 12 mm (0.47 in.) Service Limit: 8.5 mm (0.33 in.
16-52 ELECTRICAL SYSTEM Electric Starter System NOTE ○Even if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with the hand tester. If all other starter motor and starter motor circuit components check good, but the starter motor still does not turn over or only turns over weakly, replace the starter motor with a new one. Brush Lead Inspection the × 1 Ω hand tester range, measure the resis• Using tance as shown.
ELECTRICAL SYSTEM 16-53 Electric Starter System the hand tester [A] and 12 V battery [B] to the • Connect starter relay [C] as shown. Special Tool - Hand Tester: 57001–1394 If the relay does not work as specified, the relay is defective. Replace the relay. Testing Relay Tester Range: Criteria: × 1 Ω range When battery is connected → 0 Ω When battery is disconnected → ∞ Ω Electric Starter Circuit 1. Ignition Switch 2. Joint Connector D 3. Engine Stop Switch 4. Starter Button 5. Junction Box 6.
16-54 ELECTRICAL SYSTEM Lighting System This models adopt the daylight system and have a headlight relay in the junction box. In these models, the headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off. The headlight will go out momentarily whenever the starter button is pressed and come back on when the button is released.
ELECTRICAL SYSTEM 16-55 Lighting System Headlight Bulb Replacement • Remove: Headlight Connector [A] Headlight Bulb Dust Cover [B] • Remove: Hook [A] Headlight Bulb [B] CAUTION When handling the quartz–halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode. NOTE ○Clean off any contamination that inadvertently gets on the bulb with alcohol or soap and water solution.
16-56 ELECTRICAL SYSTEM Lighting System the dust cover [A] with the arrow mark upward onto the • Fit bulb [B] firmly as shown. • Good [C] Bad [D] Arrow Mark [E] After installation, adjust the headlight aim (see this chapter). Headlight Removal/Installation • Remove: Fairing (see Frame chapter) Disconnect the headlight connectors [A]. •○For the european model disconnect the city light connector [B]. • Remove: Bolts [A] • Headlight Assy [B] Headlight installation is revers of removal.
ELECTRICAL SYSTEM 16-57 Lighting System • Pull the bulb [A] out of the socket [B]. CAUTION Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage then the specified valve. • Replace the bulb with a new one.
16-58 ELECTRICAL SYSTEM Lighting System Headlight/Tail Light Circuit (US, CA, AS) Headlight/Tail Light Circuit (Other than US, CA, AS) US: United States of America CA: Canada AS: Australia 1. Ignition Switch 2. Meter Ground 3. Alternator 4. Headlight Diodes 5. Taillight Fuse 10A 6. Headlight Fuse 10A 7. Junction Box 8. High Beam Indicator Light (LED) 9. Joint Connector D 10. City Light (European Model) 11. Headlight (High) 12. Headlight (Low) 13. Joint Connector A 14. Dimmer Switch 15.
ELECTRICAL SYSTEM 16-59 Lighting System Turn Signal Light Circuit US: U.S.A. model CA: Canada model MY: Malaysia model 1. Joint Connector D 2. Meter Unit 3. Right Turn Signal Indicator Light (LED) 4. Left Turn Signal Indicator Light (LED) 5. Front Right Turn Signal Light 6. Front Left Turn Signal Light 7. Joint Connector A 8. Frame Ground 9. Hazard Button Turn Signal Light Bulb Replacement For the European, Malaysian and Australian Models: Unscrew the screw [A] and remove the lens [B]. • 10.
16-60 ELECTRICAL SYSTEM Lighting System and turn the bulb [A] counterclockwise and remove • Push it. the new bulb [A] by aligning its upper and lower pins • Insert [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise. ○Turn the bulb about 15° degrees. For the U.S.A. and Canadian Models: Unscrew the screw [A]. • • Unscrew the screws [A]. and turn the bulb [A] counter clockwise and remove • Push it.
ELECTRICAL SYSTEM 16-61 Lighting System the new bulb [A] by aligning its upper and lower pins • Insert [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise. CAUTION The front turn signal/running position lights use a vibration resistant bulb. Replacement of the front turn signal/running position bulbs with a non-vibration resistant bulb may result in premature bulb failure.
16-62 ELECTRICAL SYSTEM Lighting System the bolts [A]. • Unscrew Loosen the bolts [B]. • the mounting screws [A]. • Unscrew Remove the tail/brake light (LED) [B]. •○Pull out the mount portion [C]. Tail/Brake Light (LED) Installation • Tighten the tail/brake light mounting screws. Torque - Tail/Brake Light Mounting Screws: 1.2 N·m (0.
ELECTRICAL SYSTEM 16-63 Radiator Fan System Fan System Circuit Inspection the lead connector [A] from the radiator fan • Disconnect switch. an auxiliary wire [A], connect the radiator fan switch • Using leads. If the fan rotates, inspect the fan switch. If the fan does not rotate, inspect the following. Leads and Connectors Main Fuse and Fan Fuse Fan Motor Fan Motor Inspection the fuel tank (see Fuel System (DFI) chapter). • Remove Disconnect connector [A] in the fan motor leads.
16-64 ELECTRICAL SYSTEM Radiator Fan System Radiator Fan Circuit 1. Radiator Fan 2. Radiator Fan Switch 3. Joint Connector A 4. Joint Connector D 5. Meter Ground 6. Frame Ground 7. Joint Connector B 8. Junction Box 9. Fan Fuse 10A 10. Main Fuse 30A 11.
ELECTRICAL SYSTEM 16-65 Meter, Gauge, Indicator Unit Meter Unit Removal • Remove: Wind Sealed (see Frame chapter) Slide • [B]. the dust cover [A] and remove the wiring connector the meter unit by taking off the mounting screws • Remove [C] with the washers. CAUTION Place the meter or gauge so that the face is up. If a meter or gauge is left upside down or sideways for any length of time, it will malfunction.
16-66 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Electronic Combination Meter Unit Inspection • Remove the meter unit [A].
ELECTRICAL SYSTEM 16-67 Meter, Gauge, Indicator Unit MODE AND RESET BUTTON Operation Check: Connect the 12 V battery and terminals in the same manner as specified in the "Liquid Crystal Display (LCD) Segments Check". Check that the display change to the ODO, TRIP, and CLOCK displays each time the MODE button [A] is pressed. ○If the fuel level gauge flashed, display change to ODO, TRIP, CLOCK and FUEL. If the display function does not work, replace the meter assembly. • • the clock mode.
16-68 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit the HOUR setting mode, press the RESET button to • Ineffect the MINUTE setting mode. ○The minute display flashes on the display. • Press the MODE button to set the minute. the MINUTE setting mode, press the RESET button to • Inreturn to the HOUR/MINUTE setting mode. Press • process.the MODE button to complete the time setting ○The clock starts counting the seconds as soon as the MODE button is pressed. the ODO mode.
ELECTRICAL SYSTEM 16-69 Meter, Gauge, Indicator Unit the oscillator is not available, the speedometer can be • Ifchecked as follows. ○Install the meter unit. ○Raise the rear wheel off the ground, using the jack. ○Turn on the ignition switch. ○Rotate the rear wheel by hand. ○Check that the speedometer shows the speed. If the speedometer does not work, check the speed sensor electric source voltage and speed sensor. The electric source voltage and speed sensor are normal, replace the meter assembly.
16-70 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Water Temperature Meter Check: Connect the 12 V battery and terminals in the same manner as specified in the "Liquid Crystal Display (LCD) Segments Check". Connect the variable rheostat [A] to the terminal [8] as shown. Check that the number of segments matches the resistance value of the variable rheostat. • • • Resistance Value (Ω) 209.8 69.1 21.
ELECTRICAL SYSTEM 16-71 Meter, Gauge, Indicator Unit Fuel Level Gauge Inspection: Connect the 12 V battery and terminals in the same manner as specified in the “Liquid Crystal Display (LCD) Segments Check”. Connect a variable rheostat [A] to terminal [4] and [9] as shown. Check that the number of segment [B] matches the resistance value of the variable rheostat. • • • Resistance (Ω) 0 ∼ 16.5 Number of Segments F 8 11.5 ∼ 28.5 7 21.5 ∼ 40.5 6 31.5 ∼ 52.5 5 41.5 ∼ 64.5 4 51.5 ∼ 76.5 3 61.
16-72 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit the oscillator is not available, the tachometer can be • Ifchecked as follows. ○Connect the 12 V battery and terminals in the same man- ner as specified in the "Liquid Crystal Display (LCD) Segments Check". ○Using an auxiliary wire, quick open and connect the terminal [1] to the terminal [7] repeatedly. ○Then the tachometer segment [A] should flick [B]. If the segment does not flick, replace the meter assembly.
ELECTRICAL SYSTEM 16-73 Meter, Gauge, Indicator Unit Right and Left Turn Signal Indicator Light (LED): For Right Turn Signal Indicator Light (LED) Battery Positive (+) Terminal to Terminal [13] For Left Turn Signal Indicator Light (LED) Battery Positive (+) Terminal to Terminal [14] High Beam Indicator Light: Battery Positive (+) Terminal to Terminal [15] each LED lights does not go on, replace the meter as• Ifsembly.
16-74 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Circuit 1. Right Turn Signal Indicator Light (LED) 2. High Beam Indicator Light (LED) 3. Neutral Indicator Light (LED) 4. Oil Pressure Warning Indicator Light (LED) 5. FI Indicator Light (LED) 6. Odometer/Trip Meter/Clock/Fuel Indicator 7. Water Temperature Gauge 8. Fuel Level Gauge 9. Tachometer 10. Speedometer 11. Meter Light (LED) 12. Left Turn Signal Indicator Light (LED) 13. Meter Unit 14. Joint Connector D 15. Frame Ground 16.
ELECTRICAL SYSTEM 16-75 Switches and Sensors Brake Light Timing Inspection • Refer to the Brakes in the Periodic Maintenance chapter. Brake Light Timing Adjustment • Refer to the Brakes in the Periodic Maintenance chapter. Switch Inspection a hand tester, check to see that only the con• Using nections shown in the table have continuity (about zero ohms). ○For the handlebar switches and the ignition switch, refer to the tables in the Wiring Diagram.
16-76 ELECTRICAL SYSTEM Switches and Sensors the connector [A]. • Disconnect Remove the fan switch [B]. • the switch [A] in a container of coolant so that • Suspend the temperature–sensing projection and threaded portion • are submerged. Suspend an accurate thermometer [B] in the coolant so that the sensitive portions are located in almost the same depth. NOTE ○The switch and thermometer must not touch the container sides or bottom.
ELECTRICAL SYSTEM 16-77 Switches and Sensors the sensor [A] in a container of coolant so that • Suspend the temperature-sensing projection [E] and threaded por- • tion [E] are submerged. Suspend an accurate thermometer [B] in the coolant. NOTE ○The sensor and thermometer must not touch the container side or bottom. the container over a source of heat and gradu• Place ally raise the temperature of the coolant while stirring the coolant gently.
16-78 ELECTRICAL SYSTEM Switches and Sensors • Remove: Bolts [A] Speed Sensor Cover • Remove: Bolt [A] Take • out the speed sensor [B]. the speed sensor connector [A] with the battery • Connect [B], 10 kΩ resistor [C] and hand tester [D] as shown. • Set the tester to the DC 25 V range. Special Tool - Hand Tester: 57001–1394 [A] each side of the speed sensor surface with the • Trace screw driver. ○Then the tester indicator should flick [B].
ELECTRICAL SYSTEM 16-79 Switches and Sensors Fuel Level Sensor Inspection • Remove: Fuel Tank (see Fuel System (DFI) chapter) Open the clamps [A]. • Remove: • Bolts [B] Fuel Level Sensor [C] that the float moves up and down smoothly without • Check binding. It should go down under its own weight. If the float does not move smoothly, replace the sensor. Float in Full Position [A] Float in Empty Position [B] Float Arm Stoppers [C] 105.2 ∼ 112.2 mm (4.142 ∼ 4.417 in.) from the Sensor Base Line [D] 33.6 ∼ 40.
16-80 ELECTRICAL SYSTEM Switches and Sensors the test light [A] (12 V 3.4 W bulb a socket with • Connect leads) and the 12 V battery [B] to the fuel level sensor connector [C]. Connections: Battery (+) → 12 V 3.4 W Bulb (one side) 12 V 3.4 W Bulb (other side) → Blue Lead Terminal Battery (–) → BK/Y Lead Terminal If the test light turn on, the reverse switch is defective. Replace the fuel level sensor. • Remove: Fuel Level Sensor (see Fuel Level Sensor Inspection) Connect (12 V 3.
ELECTRICAL SYSTEM 16-81 Junction Box The junction box [A] has fuses [B], relays, and diodes. The relays and diodes can not be removed. Junction Box Fuse Circuit Inspection the seats (see Frame chapter). • Remove Remove the junction box [A]. • off the connectors [A] from the junction box [B]. • Pull Make all connector terminals are clean and tight, and • none ofsurethem have been bent. Clean the dirty terminals, and straighten slightly–bent terminals.
16-82 ELECTRICAL SYSTEM Junction Box Starter Circuit/Headlight Relay Inspection the junction box (see Junction Box Fuse Circuit • Remove Inspection). conductivity of the following numbered terminals • Check by connecting the hand tester and one 12 V battery to the junction box as shown. ○Refer to the Junction Box Internal Circuit. If the tester does not read as specified, replace the junction box.
ELECTRICAL SYSTEM 16-83 Junction Box Diode Circuit Inspection the junction box. • Remove • Check conductivity of the following pairs of terminals. Diode Circuit Inspection Tester Connection 13–8, 13–9, 12–11, 12–14, 15–14, 16–14 The resistance should be low in one direction and more than ten times as much in the other direction. If any diode shows low or high in both directions, the diode is defective and the junction box must be replaced.
16-84 ELECTRICAL SYSTEM Fuse 30A Main Fuse Removal • Remove: Right Side Cover (see Frame chapter) • 30A Main Fuse Connector [A] Pull out the main fuse [B] from the starter relay with needle nose pliers. Junction Box Fuse Removal the seats (see Frame chapter). • Remove Unlock the to lift up the lid [A]. • Pull the fuseshook • dle nose pliers.
APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing .............................................................................................. Troubleshooting Guide ...........................................................................................................
17-2 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Fixes by the left side clamp of the tank. 2. Tank drain hose passes the side cover installation under the bracket. 3. Air cleaner drain hose 4. Fuel tank drain hose 5. Cooling reserve tank hose 6. Fixes by the swingarm clamp 7. Fuel level sensor 8. Fixes by the right side clamps two places of the tank. 9. The outside of the frame passed 10.
17-4 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Clutch cable 2. Meter ground 3. Clamp (Ignition switch connector) 4. Ignition switch connector 5. Inlet air pressure sensor 6. To ignition coil 7. Fan motor connector (Connect the connector on the inlet air pressure sensor.) 8. Clamp 9. To fuel pump 10. To fuel level gauge and fuel reserve switch 11. To pickup coil and oil pressure switch 12. Insert the clamp of mainharness into the flame hole. 13. Mainharness 14. Starter relay 15. To rear brake switch 16.
17-6 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Run the main harness through lower and right side of the thermostat. 2. Frame ground (with thermostat bracket) 3. Ignition switch connector 4. Meter ground (with thermostat) 5. Engine harness (Connect the harness on the cross pipe.) 6. Water temperature sensor 7. Inlet air pressure sensor 8. Clamp 9. To pickup coil and oil pressure switch 10. To fuel level gauge and fuel reserve switch 11. To fuel pump 12. Bracket 13.
17-8 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Tail light 2. Clamp 3. Atmospheric pressure sensor 4. To ECU fuse 5. Junction Box 6. To self-diagnosis indicator terminal 7. Pickup coil and oil pressure switch 8. Fuel pump 9. Fuel level gauge and fuel reserve switch 10. To inlet air temperature sensor 11. Fan motor connector 12. Inlet air pressure sensor 13. Water temperature sensor 14. Engine harness 15. Meter ground 16. Ignition switch 17. Frame ground (with thermostat) 18. Right switch housing lead 19.
17-10 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Clamp all the wires as shown in the encircled area. 2. Meter 3. Take out the lead of the meter from the right side of the tie lap to connect with the meter. 4. Clutch cable 5. Starter cable 6. To front left turn signal light (Run the harness above the bolt for fairing installation.) 7. Run the ignition switch lead front the clutch cable and starter cable. 8. To left switch housing 9.
17-12 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Clamp 2. Brake hose 3. Punch mark 4. Run the brake hose through the inside of the frame. 5. Tight the bolt to the specified torque with the stopper (for turning prevention) applied.
17-14 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Cam sensor lead (Run the lead between the convex area of cap center and bolt head to secure the coupler.) 2. Radiator fan switch lead (Run the lead through into the water hose.) 3. Cap 4. Catch cable (Run the cable through forward the water hose.) 5. Air suction valve 6. Water hose (Thermostat – Radiator) 7. Water hose (Head – Thermostat) 8. Inlet air pressure sensor 9.
17-16 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Bend the bracket as shown to secure the lead. 2. Bend the bracket. 3. Run the lead end till it touches the boss of the crankcase. 4. Install the exterior of the lead with staking area facing downward.
17-18 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-19 Cable, Wire, and Hose Routing 1. Run the hose (cap – reserve) through upside of the throttle cable. 2. Run the hose (white) through into the throttle cables. 3. Run the throttle body harness throttle upside of the hose (white) and hose (throttle – fitting). 4. Run the harness through upside of the hose. 5. Throttle cables 6. Hose (fitting – throttle body #2 right) 7. Hose (canister – fitting) (green) 8. Hose (throttle body #3 right – under the separator) (white) 9.
17-20 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 17-21 Troubleshooting Guide Air cleaner duct loose Compression low: Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head warped Cylinder head gasket damaged Valve spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface) Other: IC igniter in ECU trouble Throttle body assy not synchronizing E
17-22 APPENDIX Troubleshooting Guide Muffler overheating: For KLEEN, do not run the engine even if with only one cylinder misfiring or poor running (Request the nearest service facility to correct it) For KLEEN, do not push-start with a dead battery (Connect another full-charged battery with jumper cables, and start the engine using the electric starter) For KLEEN, do not start the engine under misfire due to spark plug fouling or poor connection of the stick coil For KLEEN, do not coast the motorcycle with
APPENDIX 17-23 Troubleshooting Guide Abnormal Engine Noise: Knocking: IC igniter in ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap: Cylinder/piston clearance excessive Cylinder, piston worn Connecting rod bent Piston pin, piston pin hole worn Valve noise: Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Valve lifter worn Other noise: Connecting rod small end clearance excessive Connecting rod big end cl
17-24 APPENDIX Troubleshooting Guide Handling and/or Stability Unsatisfactory: Handlebar hard to turn: Cable routing incorrect Hose routing incorrect Wiring routing incorrect Steering stem nut too tight Steering stem bearing damaged Steering stem bearing lubrication inadequate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates: Tire worn Swingarm pivot bearing worn Rim warped, or not balanced Wheel bearing worn Handlebar clamp bolt loose Steering stem nut loose Front, rear
MODEL APPLICATION Year Model 2003 ZR1000–A1 2004 ZR1000–A2 Beginning Frame No. JKAZRCA1□3A000001 ZRT00A–000001 JKAZRT00AAA000001 JKAZRCA1□ 4A015001 JKAZRT00AAA015001 ZRT00A–015001 □:This digit in the frame number changes from one machine to another. Part No.
