VULCAN 1600 MEAN STREAK VN1600 MEAN STREAK 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.
VULCAN 1600 MEAN STREAK VN1600 MEAN STREAK 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 & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
LIST OF ABBREVIATIONS A ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft g h kg kgf 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) (mass) hour(s) (mass) (force) liter(s) lb m min N Pa PS psi r r/min, 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 minu
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.
GENERAL INFORMATION 1-1 General Information 1 Table of Contents Before Servicing ..................................................................................................................... Model Identification................................................................................................................. General Specifications............................................................................................................ Unit Conversion Table .......................
1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a 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 VN1600-B1 (US, and Canada) Left Side View: VN1600-B1 (US, and Canada) Right Side View:
1-8 GENERAL INFORMATION Model Identification VN1600-B1 (Europe) Left Side View: VN1600-B1 (Europe) Right Side View:
GENERAL INFORMATION 1-9 General Specifications Items Dimensions: Overall length Overall width Overall height Wheelbase Road clearance Seat height Dry mass Curb mass: Front Rear Fuel tank capacity Fuel Performance: Minimum turning radius Engine: Type Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Carburetion system Starting system Ignition system Timing advance Ignition timing Spark plugs Cylinder numbering method Firing order Valve timing: Inlet Open Close
1-10 GENERAL INFORMATION General Specifications Items Capacity Drive Train: Primary reduction system: Type Reduction ratio Clutch type Transmission: Type Gear ratios: 1st 2nd 3rd 4th 5th 1st 2nd 3rd 4th 5th Final drive system: Type Reduction ratio Overall drive ratio Final gear case oil: Grade Viscosity Capacity Frame: Type Caster (rake angel) Trail Front tire: Type Size Rear tire: Type Size Front suspension: Type Wheel travel Rear suspension: Type Wheel travel Brake Type: Front Rear VN1600–B1 3.5 L (3.
GENERAL INFORMATION 1-11 General Specifications Items Electrical Equipment: Battery Capacity Headlight: Type Bulb Tail/brake light Alternator: Type Rated output VN1600–B1 12 V 18 Ah Semi-sealed beam 12 V 60/55 W (quartz-halogen) 12 V 5/21 W Three-phase AC 23 A × 14 V @6 000 r/min (rpm) Specifications subject to change without notice, and may not apply to every country.
1-12 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Prefix Units of Length: Symbol mega kilo centi milli micro M k c m µ Power × × × × × 1 000 000 1 000 0.01 0.001 0.000001 Units of Mass: kg g × × 2.205 0.03527 = = lb oz × × × × × × × × × 0.2642 0.2200 1.057 0.8799 2.113 1.816 0.03381 0.02816 0.06102 × × × 0.6214 3.281 0.03937 = = = mile ft in.
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 * ODOMETER READING km × 1000 (mile × 1000) 1 CHANGE/REPLACE ITEM Every (0.6) (7.
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. WL: Apply a soap and water solution or rubber lubricant. The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.
PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Fastener Radiator fan switch Radiator fan bolts Water temperature switch Water pump impeller bolt Water pump cover bolts Water pump air bleeder bolt Water pump drain bolt Water pipe bolts Radiator drain Bolt Engine Top End: Spark plugs Spark plug retainers Air suction valve cover bolts Chain tensioner mounting bolts Chain tensioner cap Chain tensioner lockbolt Timing inspection cap Rotor bolt cap Camshaft sprocket bolts Oil hose flange bolts Rocker shafts Ro
2-6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Starter lockout switch screws Push rod guide bolts Clutch cover bolts Clutch damper cover bolts Clutch damper plate bolts Clutch cover damper screws Clutch hub nut Engine Lubrication System: Oil filler cap Oil screen plug Engine oil drain plug Oil filter (cartridge type) Oil filter pipe Oil pressure relief valve Oil pressure switch terminal screw Oil pressure switch Oil pump mounting bolts Oil hose banjo bolts Oil hose flange bolt (outside) Oil pipe
PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Oil hose banjo bolts Primary gear bolt Water pump chain guide spring hook bolt Water pump chain guide bolt Idle shaft holder bolts Oil pressure switch terminal screw Oil pressure switch Oil return pipe bolts (inside) Oil pipe holder bolts (inside) Oil pipe clamp bolts (inside) Left balancer gear bolt Starter clutch bolt Starter clutch coupling bolts Gear set lever bolt Shift shaft return spring pin (bolt) Shift pedal clamp bolt Rear shift lever cla
2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Final gear case Studs Final gear case cover bolts: 8 mm 10 mm Pinion gear nut (final gear) Bearing retainer bolt Brakes: Caliper bleed valves Brake hose banjo bolts Brake lever pivot bolt Brake lever pivot bolt locknut Front brake reservoir cap screws Front brake light switch screw Front master cylinder clamp bolts Front brake pad spring bolts Front caliper mounting bolts Front caliper assembly bolts Rear caliper mounting bolts Rear caliper holder
PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Fastener Sidestand nut Electrical System: Spark plugs Crankshaft sensor screws Stator lead holder screw Crankshaft sensor lead holder bolt Alternator outer cover bolts Alternator outer cover joint bolts Alternator outer cover damper bolts Alternator outer cover assembly bolts Alternator cover bolts Alternator inner cover bolts Alternator rotor bolt Alternator stator bolts Regulator/rectifier bolts Timing inspection cap Rotor bolt cap Starter motor terminal l
2-10 PERIODIC MAINTENANCE Specifications Item Fuel System (DFI): Throttle grip free play Idle speed Air cleaner element Cooling System: Coolant: Type (recommended) Color Mixed ratio Freezing point Total amount Engine Top End: Valve clearance Clutch: Clutch fluid: Grade Clutch lever free play Engine Lubrication System: Engine oil: Type Viscosity Capacity Level Tires: Tread depth: Front Rear Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.
PERIODIC MAINTENANCE 2-11 Specifications Item Final Drive: Final gear case oil: Grade Viscosity Oil level Amount Propeller shaft joint grease Brakes: Brake fluid Grade Brake pad lining thickness: Front Rear Brake light timing: Front Rear Electrical System: Spark plug gap Standard Service Limit API Service Classification: GL-5 hypoid gear oil when above 5°C (41°F) SAE90 when below 5°C (41°F) SAE80 Filler opening bottom 200 mL (6.76 US oz) 20 mL (0.
2-12 PERIODIC MAINTENANCE Special Tools Steering Stem Nut Wrench: 57001–1100 Attachment Jack: 57001–1398 Jack: 57001–1238 Driver-Filler Cap: 57001–1454
PERIODIC MAINTENANCE 2-13 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 chapter) and check the fuel hose. Replace the fuel hose if any fraying, cracks [B] or bulges [C] are noticed.
2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Inspection the engine and warm it up thoroughly. •○Start At first the engine will run fast to decrease warm up time (fast idle). ○Gradually the fast idle will lower to a certain RPM auto- • • matically. This is the idle speed. Check the idle speed. Idle Speed Standard: 950 ±50 r/min (rpm) With the engine idling, turn the handlebar to both sides.
PERIODIC MAINTENANCE 2-15 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 inside to the outside (from the clean side • • to the dirty side). Visually check the element for no tears or no breaks and check the sponge gasket [B] also. If the element or gasket has any tears or breaks, replace the element. Install the left air cleaner cover. Torque - Left Air Cleaner Cover Allen Bolt: 16 N·m (1.
2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cooling System Radiator Hose and Connection Inspection ○The • high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen. Replace the hose if any fraying, cracks [B] or bulges [C] are noticed.
PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures : • Remove Right Side Cover (see Frame chapter) • • • Reserve Tank Bolts Turn over the reserve tank [A], remove the cap [B], and pour the coolant into a suitable container. Install the reserve tank. When filling the coolant, choose a suitable mixture ratio by referring to the coolant manufacturer’s directions. CAUTION Soft or distilled water must be used with the antifreeze (see Specifications in this chapter) in the cooling system.
2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures the radiator up to the filler neck [A] with coolant. • Fill Install cap. • Tightenthetheradiator air bleeder bolt [B]. • Torque - Thermostat Air Bleeder Bolt: 7.8 N·m (0.80 kgf·m, 69 in·lb) the reserve tank up to the “F” (full) level line [A] with • Fill coolant and install the cap. the fuel tank (see Fuel System (DFI) chapter). • Install Start the engine and warm it up thoroughly until the radi• ator fan turns on and then stop the engine.
PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Clutch Clutch Hose and Connection Inspection high pressure inside the clutch line can cause fluid • The to leak [A] or the hose to burst if the line is not properly • maintained. Bend and twist the rubber hose while examining it. Replace it if any fraying, cracks [B] or bulges [C] are noticed. Check that the hoses are securely connected and banjo bolts are tightened correctly. Torque - Clutch Hose Banjo Bolts: 25 N·m (2.
2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Fluid Change the clutch fluid reservoir and remove the reservoir • Level cap. the alternator outer cover (see Electrical System • Remove chapter.) and the rubber cap from the bleed valve on the clutch slave cylinder. Attach a clear plastic hose [A] to the bleed valve and run the other end of the hose into a container. Fill the reservoir with fresh fluid. Change the clutch fluid as follows. Open [B] the bleed valve, using a wrench.
PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Clutch Master Cylinder Cup and Dust Seal Replacement the clutch master cylinder (see Clutch chapter). • Remove Remove the reservoir cap [A] and diaphragm [B], and • pour the clutch fluid into a container. Unscrew the locknut • the clutch lever [E]. [C] and pivot bolt [D], and remove the dust cover [F] out of place, and remove the circlip • Pull [G].
2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Slave Cylinder Piston Seal Replacement the alternator outer cover (see Electrical System • Remove chapter) the banjo bolt [A] at the clutch pipe lower end, and • Loosen tighten it loosely. the slave cylinder bolts [B] and detach the slave • Unscrew cylinder with the pipe installed from the engine. the clutch lever until the piston comes out of the • Pump cylinder. • Unscrew the banjo bolt and remove the slave cylinder [C].
PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures • Remove: Oil Screen Plug [A] the oil screen [A], the spring [B], and the washer • Remove [C]. the oil screen with a high-flash point solvent and • Clean remove any particles stuck to it. the screen thoroughly whenever the engine oil is • Clean changed. WARNING Clean the screen in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area.
2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Oil Type: API SE, SF or SG class API SH or SJ class with JASO MA Viscosity: SAE 10W-40 Amount: 2.9 L (3.1 US qt, when filter is not removed) 3.1 L (3.3 US qt, when filter is removed) 3.5 L (3.7 US qt, when engine is completely disassembled and dry) NOTE ○Although 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area.
PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures the tread depth at the center of the tread with a • Measure depth gauge [A]. Since the tire may wear unevenly, take measurement at several places. If any measurement is less than the service limit, replace the tire (see Wheels/Tires chapter). Tread Depth Front: Standard: Service Limit: Rear: Standard: Service Limit: 4.4 mm (0.17 in.) 1 mm (0.04 in.) (DE, AT, CH) 1.6 mm (0.063 in.) 6.9 mm (0.27 in.) 2 mm (0.08 in.): Up to 130 km/h (80 mph) 3 mm (0.
2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures oil level [A] should come to the bottom of the filler • The opening. • If it is low, first check the final gear case for oil leakage, remedy it if necessary, and add oil through the filler opening. Use the same type and brand of oil that is already in the final gear case. Install the filler plug. Oil Change up the oil by running the motorcycle so that the • Warm oil will pick up any sediment and drain easily.
PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Brakes Brake Pad Wear Inspection the bolts [A] and remove the pad spring [B] • Unscrew (Front Brake Caliper) the bolts [A] and remove the caliper [B] (Rear • Unscrew Brake Caliper). 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 (see Brakes chapter). Pad Lining Thickness Standard: Front: 4.0 mm (0.157 in.) Rear: 7.
2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Level Inspection that the brake fluid level in the front brake reservoir • Check [A] is above the lower [B] level line. 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 [A] in the reservoir [B].
PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Brake Fluid Change NOTE ○The procedure to change the front brake fluid is as follows. Changing the rear brake fluid is almost the same as for the front brake. the brake fluid reservoir. • Level Remove the reservoir cap [A], plate [B] and diaphragm [C] • the rubber cap from the bleed valve [A] on the • Remove front caliper [B]. a clear plastic hose [C] to the bleed valve, and run • Attach the other end of the hose into a container.
2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures the clear plastic hose. • Remove Install the cap. • Follow the reservoir procedure • reservoir cap correctly.below to install the rear brake fluid ○First, tighten the rear brake fluid reservoir cap [B] clock- wise [C] by hand until the resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].
PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures • If it does not, adjust the brake light switch. While holding the switch body, turn the adjusting nut to adjust the switch. Switch Body [A] Adjusting Nut [B] Light sooner as the body rises [C] Light later as the body lowers [D] CAUTION To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment.
2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Stem Bearing Lubrication the steering stem. (see Steering chapter). • Remove Using a high-flash point solvent, wash the upper and • lower tapered roller bearings [A] in the cages, and wipe • • • the upper and lower outer races, which are press-fitted into the frame head pipe, clean of grease and dirt. Visually check the outer races and the rollers.
PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures the claw washer. • Remove Tighten the stem nut [A] firmly with the stem nut wrench • [B], and loosen it. Tighten the stem nut again with the specified torque. • Special Tool - Steering Stem Nut Wrench: 57001-1100 Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb) the stem head. • Install Tighten the following in the order listed. • Torque - Stem Head Nut: 88 N·m (9.0 kgf·m, 65 ft·lb) Upper Fork Clamp Bolts: 29 N·m (3.
2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Points: Lubricate with Grease. Throttle Inner Cable Upper Ends [A] Clutch Lever Pivot (Apply silicone grease) Brake Lever Pivot (Apply silicone grease) Brake Pedal Pivot Sidestand Cable: Lubricate with Cable Lubricant. Choke Cable Throttle Cables Lubricate the cables by seeping the oil between the cable and housing. ○The cable may be lubricated by using a commercially available pressure cable lubricator [A] with an aerosol cable lubricant [B].
PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Nut, Bolt and Fastener to be checked Wheels: Front Axle Front Axle Clamp Bolts Rear Axle Nut Rear Axle Nut Cotter Pin Final Drive: Final Gear Case Mounting Nuts Brakes: Front Master Cylinder Clamp Bolts Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Caliper Holder Bolt Brake Lever Pivot Nut Brake Pedal Clamp Bolt Brake Rod Joint Cotter Pin Suspension: Front Fork Clamp Bolts Front Fender Mounting Bolts Rear Shock Absorber Mounting Nut
FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View................................... DFI Parts Location............................. DFI System........................................ DFI Wiring Diagram ........................... Specifications .................................... Special Tools and Sealant ................. DFI Servicing Precautions ................. Troubleshooting the DFI System ....... Outline ............................................ Inquiries to Rider........
3-2 FUEL SYSTEM (DFI) Resistance Inspection.................. Fuel Line............................................ Fuel Pressure Inspection ............. Pressure Regulator Removal....... Fuel Flow Rate Inspection ........... Throttle Grip and Cables ................... Throttle Grip Free Play Inspection Throttle Grip Free Play Adjustment ................................ Choke Knob Operation ................ Choke Cable Free Play Inspection.................................. Cable Removal/Installation .....
3-4 FUEL SYSTEM (DFI) Exploded View
FUEL SYSTEM (DFI) 3-5 Exploded View No. 1 2 3 4 5 6 7 8 9 10 11 Fastener Water temperature sensor Left air cleaner cover Allen bolt Left air cleaner base bolts Left air cleaner base screws Right air cleaner base screws Right air cleaner base bolt Right air cleaner Allen bolts Right air cleaner cover Allen bolt Throttle body assy holder bolts Spark plug lead holder bolts Air cleaner duct holder bolts N·m 18 16 11 2.2 2.2 11 11 16 11 11 9.8 12. Air switching valve 13. Air cleaner element 14.
3-6 FUEL SYSTEM (DFI) Exploded View
FUEL SYSTEM (DFI) 3-7 Exploded View No. 1 2 3 4 5 6 7 8 9 10 11 12 Fastener Fuel pump bolts Inlet air temperature sensor nut ISC pipe bolts Throttle body assy holder bolts Spark plug lead holder bolts Choke cable plate screw Inlet manifold bolt High pressure fuel hose clamp screws Delivery joint screws Pressure regulator screws Throttle body flange bolts Return fuel check valve 13. Vehicle-down sensor 14. Atmospheric pressure sensor 15. Inlet air pressure sensor 16. Choke cable 17.
3-8 FUEL SYSTEM (DFI) DFI Parts Location
FUEL SYSTEM (DFI) 3-9 DFI Parts Location DFI: DFI parts (this chapter) F: Front 1. Atmospheric pressure sensor (DFI) 2. Water temperature sensor (DFI) 3. Ignition coils 4. Ignition switch 5. Starter motor 6. Water temperature switch 7. Regulator/rectifier 8. Crankshaft sensors 9. Alternator 10. Sidestand switch 11. Neutral switch 12. Oil pressure switch 13. Fuel pump (DFI) 14. Vehicle-down sensor (DFI) 15. ECU (DFI) 16. DFI fuse 15 A 17. Sealed battery 18. Junction box 19. Starter relay 20.
3-10 FUEL SYSTEM (DFI) DFI Parts Location
FUEL SYSTEM (DFI) 3-11 DFI Parts Location DFI: DFI Parts (this chapter) F: Front 1. Atmospheric pressure sensor (DFI) 2. Water temperature sensor (DFI) 3. Ignition coils 4. Ignition switch 5. Starter motor 6. Water temperature switch 7. Regulator/rectifier 8. Crankshaft sensors 9. Alternator 10. Sidestand switch 11. Neutral switch 12. Oil pressure switch 13. Fuel pump (DFI) 14. Vehicle-down sensor (DFI) 15. ECU (DFI) 16. DFI fuse 15 A 17. Sealed battery 18. Junction box 19. Starter relay 20.
3-12 FUEL SYSTEM (DFI) DFI System
FUEL SYSTEM (DFI) 3-13 DFI System #1: For front cylinder #2: For rear cylinder 1. ECU (electronic control unit) 2. Crankshaft sensor #1 3. Crankshaft sensor #2 4. Pressure regulator 5. Throttle sensor (front view) 6. Atmospheric pressure sensor 7. Inlet air pressure sensor 8. Water temperature sensor 9. Inlet air temperature sensor 10. FI indicator LED light 11. Fuel filter 12. Delivery joint 13. Injector #1 14. Injector #2 15. Fuel pump 16. ISC valve #1 (idle speed control valve #1, front side) 17.
3-14 FUEL SYSTEM (DFI) DFI Wiring Diagram
FUEL SYSTEM (DFI) 3-15 DFI Wiring Diagram DFI and Electrical Parts DFI: DFI parts A. ECU: electronic control unit (DFI) B. Engine stop switch C. Starter button D. Ignition coils E. Crankshaft sensors F. Junction box G. Starter circuit relay H. Interlock diodes J. Diode: (for water temperature warning LED light) K. Diode: (for fuel reserve warning light) L. FI indicator LED light: (DFI) M. Speedometer N. Ignition switch O. Starter relay P. Main fuse 30 A Q. Sealed battery R. Fuel injector #1: (DFI) S.
3-16 FUEL SYSTEM (DFI) DFI Wiring Diagram Terminal Numbers of ECU Connectors Terminal Names #1: Front cylinder, #2: Rear Cylinder 1. Starter lockout switch signal 2. Interlock circuit signal 3. Self-diagnosis signal (generated by grounding this terminal and shown by FI indicator LED light) 4. Tachometer signal 5. Electric starter button signal 6. Anti theft signal 7. Water temperature sensor (+) 8. Power source for diagnosis tool 9. — 10. ECU power source circuit ground to battery (–) terminal 11.
FUEL SYSTEM (DFI) 3-17 Specifications Item Throttle Grip Free Play: Air Cleaner Element: DFI (Digital Fuel Injection) System: Make: Idle speed: Throttle assy: Type × bore ECU (electronic control unit): Type Usable engine speed ISC valves: Maximum air flow rate Solenoid resistance Fuel Filter: Filtration area Rated flow Fuel pressure (high pressure line): Right after Ignition SW ON After pump runs 3 sec. and stops.
3-18 FUEL SYSTEM (DFI) Specifications Item Water temperature sensor: Resistance Vehicle-down sensor: Detection method Detection angle Detection time Fuel injectors: Type Injection timing Static injection quantity Nozzle type × diameter Resistance Fuel pump: Type Discharge Standard 2.162 ∼ 3.112 kΩ at 20° C (68° F) 0.785 ∼ 1.049 kΩ at 50° C (122° F) 0.207 ∼ 0.253 kΩ at 100° C (212° F) Magnetic flux detection method More than 45° ±5° for each bank Within 0.5 ∼ 1.0 sec.
FUEL SYSTEM (DFI) 3-19 Special Tools and Sealant Oil Pressure Gauge, 5 kg/cm² : 57001–125 Filler Cap Driver : 57001–1454 Fork Oil Level Gauge : 570101–1290 Needle Adapter Set : 57001–1457 Hand Tester : 57001–1394 Kawasaki Bond (Silicone Sealant) : 56019–120 Fuel Pressure Gauge Adapter : 57001–1417
3-20 FUEL SYSTEM (DFI) DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○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 cap [A] after filling the engine oil, using the driver-filler cap [B]. Clutch Cover [C] Front [D] Special Tool - Driver-Filler Cap: 57001–1454 Torque - Oil Filler Cap: 1.5 N·m (0.
FUEL SYSTEM (DFI) 3-21 DFI Servicing Precautions ○To prevent corrosion and deposits n the fuel system, do not add any fuel antifreeze chemicals to fuel. ○When any fuel hose is disconnected, do not turn on the ignition SW. Otherwise, the fuel pump will operate and fuel will spout from the fuel hose. ○Do not operate the fuel pump if the pump is completely dry. This is to prevent pump seizure. ○Before removing the fuel system parts, blow the outer surfaces of these parts clean with compressed air.
3-22 FUEL SYSTEM (DFI) DFI Servicing Precautions ○Fit the outlet hose joint #1 or #2 [A] onto the pipe until the joint clicks [B]. Front [C] ○Push and pull [A] the hose joint #1 or #2 [B] back and forth more than two times and make sure it is locked and doesn’t come off. When the hose joint is correctly installed, it should slide on the delivery pipe about 5 mm (0.2 in.).
FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System Outline When an abnormality in the system occurs, the FI indicator LED 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.
3-24 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○There are two ways to inspect the DFI system. One is Voltage Check Method and the other is Resistance Check Method. Voltage Check Method ○This method is conducted by measuring the input voltage [B] to a sensor [A] first, and then the output voltage [C] from the sensor. ○Sometime this method can detect a fault of the ECU. ○Refer to each Sensor Inspection section for detail in this chapter.
FUEL SYSTEM (DFI) 3-25 Troubleshooting the DFI System ○After measurement, remove the needle adapters and apply silicone sealant to the seals [A] of the connector [B] for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Connectors check battery condition before replacing the DFI • Always parts. A fully charged battery is a must for conducting accurate tests of the DFI system. Resistance Check Method ○This method is simple. No need for a fully charged battery and the needle adapter.
3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System If any wiring is deteriorated, replace the 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. 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.
FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider to the next sample diagnosis chart. •○Refer 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.
3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Year of initial registration: Registration No. (license plate No.): Frame No.: Model: Engine No.: Mileage: Date problem occurred: Environment when problem occurred.
FUEL SYSTEM (DFI) 3-29 Troubleshooting the DFI System Poor running or no power at high speed □choke knob left pulled out fully (push it in fully). □spark plug loose (tighten it). □spark plug dirty, broken, or gap maladjusted (remedy it). □spark plug incorrect (replace it). □knocking (fuel poor quality or incorrect, → use high-octane gasoline). □brake dragging. □clutch slipping. □engine overheating. □engine oil level too high. □engine oil viscosity too high.
3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide NOTE ○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. ○The ECU may be involved in the DFI electrical and ignition system troubles. If these parts and circuits checked out good, be sure to check the ECU for ground and power supply. If the ground and power supply are checked good, replace the ECU.
FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or Possible Causes No spark or spark weak: 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 but 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 or high tension wiring trouble Spark plu
3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Cylinder, piston worn Piston ring bad (worn, weak, broken or sticking) Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve guide worn Valve spring broken or weak Valve not seating properly (valve bent, worn or carbon accumulating on seating surface) KACR (compression release cam) sticks open (Engine stalls when moving off) HLA (hydraulic lash adjuster) damaged (worn, seizure or spri
FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Fuel injector trouble Throttle sensor trouble Inlet air temperature sensor trouble Water temperature sensor trouble Atmospheric pressure sensor trouble Fuel pressure too low or too high Battery voltage low Incorrect idle speed: Water temperature sensor trouble Throttle sensor trouble ISC valve trouble Engine stalls easily: Fuel pump trouble Fuel injector trouble Throttle sensor trouble (engine stops when opening the throttle
3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Inlet air temperature sensor trouble Throttle sensor malfunction Water temperature sensor trouble Atmospheric pressure sensor trouble Inlet air pressure sensor trouble Loose injector connectors Crankshaft sensor trouble Ignition coil trouble Loose terminal of battery (–) lead or engine ground lead Delay of ignition timing Poor acceleration: Choke knob left pulled out Too low fuel pressure Water or foreign matter in fuel Clog
FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Throttle sensor malfunction Inlet air temperature sensor trouble Water temperature sensor trouble Atmospheric pressure sensor trouble Inlet air pressure sensor trouble Air switching valve broken Air suction valve trouble After fire: Spark plug burned or gap maladjusted Crankshaft sensor trouble Inlet air temperature sensor trouble Water temperature sensor trouble Atmospheric pressure sensor trouble Inlet air pressure sensor
3-36 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 or high tension wiring trouble Actions (detailed reference) Clean spark plug and adjust plug gap (see chapter 2). Inspect plug cap and ignition coil (see chapter 16).
FUEL SYSTEM (DFI) 3-37 DFI System Troubleshooting Guide Symptoms or Possible Causes HLA (hydraulic lash adjuster) damaged (worn, seizure or spring broken) Knocking: Carbon buit up in combustion chamber Fuel poor quality or incorrect (Use high-octane gasoline recommended in the Owner’s Manual) Spark plug incorrect Ignition coil trouble IC igniter in ECU trouble Inlet air temperature sensor trouble Atmospheric pressure sensor trouble Miscellaneous: Throttle valves won’t fully open Brake dragging Clutch slippi
3-38 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Air cleaner O-ring damaged Too low fuel pressure Water temperature sensor trouble Inlet air temperature sensor trouble Actions (detailed reference) Replace (see chapter 3). Inspect (see chapter 3). Inspect and replace (see chapter 3). Inspect and replace (see chapter 3).
FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Self-diagnosis Conducting ○When a problem occurs with the DFI system, the DFI in- dicator LED light [A] goes on. Remove the seat (see Frame chapter). With the ECU connector joined, the self-diagnosis mode by grounding the self-diagnosis check female connector [C] (yellow lead from ECU [B]) to the battery (−) connector [D], using a wire [E]. The LED light blinks in 2 seconds after grounding. Battery [F] Count the blinks of the LED light to read the service code.
3-40 FUEL SYSTEM (DFI) Self-Diagnosis
FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Service Code Reading ○Service codes are shown by a series of long and short blinks of the FI indicator LED light as shown below. ○Read 10th digit and unit digit as the FI indicator LED light blinks. ○When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order. Then after completing all codes, the display is repeated until the ignition SW is turned OFF.
3-42 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Table Service Code FI Indicator LED Light Problems (1) 11 Throttle sensor malfunction, wiring open or short 12 Inlet air pressure sensor malfunction, wiring open or short 13 Inlet air temperature sensor malfunction, wiring open or short 14 Water temperature sensor malfunction, wiring open or short 15 Atmospheric pressure sensor malfunction, wiring open or short 21 Crankshaft sensor #1 malfunction, wiring open or short 22 Crankshaft sensor #2
FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Backups ○The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles.
3-44 FUEL SYSTEM (DFI) Self-Diagnosis Service Codes Parts Output Signal Usable Range or Criteria 51 Ignition Coil #1 The ignition coil primary winding must send signals (output voltage) continuously to the ECU. 52 Ignition Coil #2 The ignition coil primary winding must send signals (output voltage) continuously to the ECU.
FUEL SYSTEM (DFI) 3-45 Throttle Sensor (Service Code 11) Throttle Sensor Removal/Adjustment CAUTION Do not remove or adjust the throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Front View [B] Input Voltage Inspection NOTE ○Be sure the battery is fully charged.
3-46 FUEL SYSTEM (DFI) Throttle Sensor (Service Code 11) the ECU (see this chapter). Do not disconnect • Remove the ECU connectors. a digital meter [A] to the connector [B], using the • Connect needle adapters [C]. Special Tool - Needle Adapter Set: 57001–1457 CAUTION Insert the needle adapter straight along the lead in the connector to prevent short circuit between terminals. the output voltage of the sensor with the engine • Measure stopped, and with the connector joined. • Turn the ignition SW ON.
FUEL SYSTEM (DFI) 3-47 Throttle Sensor (Service Code 11) A. ECU c.
3-48 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Removal CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. the fuel tank (see Fuel Tank section in this chap• Remove ter). the inlet air pressure sensor connector [A]. • Disconnect Unscrew the • the sensor. inlet air pressure sensor nut [B] and remove the vacuum hose from the sensor.
FUEL SYSTEM (DFI) 3-49 Inlet Air Pressure Sensor (Service Code 12) • Turn the ignition SW ON. Inlet Air Pressure Sensor Input Voltage Connections to ECU Meter (+) → BL/W lead (terminal 35) Meter (−) → BR/BK lead (terminal 11) Input Voltage at ECU Standard: 4.75 ∼ 5.25 V DC If the reading is less than the standard range, check the ECU for its ground, and power supply (see this chapter). If the ground and power supply are good, the ECU is suspect. Replace the ECU.
3-50 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) If the output voltage is normal, check the inlet air pressure sensor output voltage for vacuum other than 76 cmHg (abs) as follows. If the output voltage changes within the usable range as vacuum changes, the sensor is normal and the ECU is suspect. Replace the ECU. Remove the fuel tank (see this chapter). Remove the inlet air pressure sensor [D] and disconnect the vacuum hose from the sensor.
FUEL SYSTEM (DFI) 3-51 Inlet Air Pressure Sensor (Service Code 12) Suppose: Pg : Vacuum (gauge) of Throttle Assy Pl : Local Atmospheric Pressure (absolute) measured by a barometer Pv : Vacuum (absolute) of Throttle Assy Vv : Sensor Output Voltage (v) then Pv = Pl – Pg For example, suppose the following data is obtained in the chart of the next page. Pg = 8 cmHg (vacuum gauge reading) Pl = 70 cmHg (barometer reading) Vv = 3.
3-52 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Pv = 55 ∼ 86 cm Hg Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading) Pv: Throttle Vacuum (absolute) Ps: Standard Atmospheric Pressure (absolute) ID: Idling TO: Throttle Full Open ST: Standard of Sensor Output Voltage (v) UR: Usable Range of Sensor Output Voltage (v) A. ECU a.
FUEL SYSTEM (DFI) 3-53 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 right air cleaner base (see Right Air Cleaner • Remove Housing Removal in this chapter). the connector [A] from the inlet air tempera• Disconnect ture sensor, and unscrew the nut [B]. • Remove the inlet air temperature sensor. Torque - Inlet Air Temperature Sensor Nut: 7.8 N·m (0.
3-54 FUEL SYSTEM (DFI) 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 and threaded portion are • submerged. Suspend a thermometer [B] with the heat-sensitive portion [C] located in almost the same depth with the sensor. NOTE ○The sensor and thermometer must not touch the container side or bottom.
FUEL SYSTEM (DFI) 3-55 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 thermostat housing [A] (see Thermostat Re• Remove moval in the Cooling System chapter). the sensor connector, and unscrew the water • Disconnect temperature sensor [B]. Top [C] Silicone Sealant (Kawasaki Bond: 56019-120) - Threads of Water Temperature Sensor Torque - Water Temperature Sensor: 18 N·m (1.
3-56 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Sensor Resistance Inspection the water temperature sensor (see this section). • Remove Suspend the sensor [A] in a container of machine oil so • that the heat-sensitive portion and threaded portion are • submerged. Suspend a thermometer [B] with the heat-sensitive portion [C] located in almost the same depth with the sensor. NOTE ○The sensor and thermometer must not touch the container side or bottom.
FUEL SYSTEM (DFI) 3-57 Atmospheric Pressure Sensor (Service Code 15) Removal 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 section in this chap• Remove ter). the atmospheric pressure sensor connector • Disconnect [A]. the sensor nut [B]. • Remove Remove the • Front [D] atmospheric pressure sensor [C].
3-58 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) • • If the reading is within the standard range, check the wiring between the ECU and the atmospheric pressure sensor for continuity. If the wiring is good, check the output voltage. Remove the needle adapters. Apply silicone sealant to the seals of the connector for waterproofing.
FUEL SYSTEM (DFI) 3-59 Atmospheric Pressure Sensor (Service Code 15) A. ECU b. Atmospheric Pressure Sensor If you need to check the atmospheric pressure sensor for various altitudes other than sea level, check the output voltage as follows: ○Determine the local altitude (elevation). If you know the local atmospheric pressure using a barometer, substitute the atmospheric pressure for Pv (Throttle Vacuum) in the inlet air pressure sensor chart (see Inlet Air Pressure Sensor section in this chapter).
3-60 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) Va: Atmospheric Pressure Sensor Output Voltage (v) H: Altitude (m or feet) SL: Sea Level (0 m) ST: Standard of Sensor Output Voltage (v) UR: Usable Range of Sensor Output Voltage (v)
FUEL SYSTEM (DFI) 3-61 Crankshaft Sensors (#1, #2: Service Code 21, 22) Crankshaft Sensor #1: for Front Cylinder (Service Code 21) Crankshaft Sensor #2: for Rear Cylinder (Service Code 22) Crankshaft Sensor Removal/Installation Ignition System section in the Electrical System • See chapter. Crankshaft Sensor Inspection ○The crankshaft sensors have no power source, and when • • the engine stops, the crankshaft sensors generates no signals.
3-62 FUEL SYSTEM (DFI) 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. the seat (see Frame chapter). • Remove Remove the bolt [A] and take out the vehicle-down sensor • [B]. the connector lock, and disconnect the connector • Raise [C] to complete sensor removal. Front [D] Installation the vehicle-down sensor assy [A] in the original po• Install sition.
FUEL SYSTEM (DFI) 3-63 Vehicle-down Sensor (Service Code 31) If the power source is normal, check the output voltage of the sensor. Connect a digital volt meter [A] to the connector (natural, 3P), using two needle adapters [B]. Turn the ignition SW ON, and measure the output voltage with the connector joined. ○Tilt the sensor (40 ∼ 50°) or more [C] right or left, then hold the sensor almost vertical [D] with the arrow mark pointed up, and measure the output voltage.
3-64 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) A. ECU d. Vehicle-down Sensor F. Junction Box e. DFI Main Relay N. Ignition Switch O. Starter Relay P. Main Fuse 30 A Q. Sealed Battery f. Ignition Fuse 10 A V.
FUEL SYSTEM (DFI) 3-65 Fuel Injectors (#1, #2: Service Code 41, 42) Fuel Injector #1: Front Fuel Injector for Front Cylinder (Service Code 41) Fuel Injector #2: Rear Fuel Injector for Rear Cylinder (Service Code 42) CAUTION Never drop the injector, especially on a hard surface. Such a shock to the injector can damage it. Injector Removal WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Disconnect the battery (–) lead terminal.
3-66 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Service Code 41, 42) remove the screws [A] and the fuel hose [B], • Ifandnecessary, then take off the pressure regulator [C]. ○The screen [A] comes off from the pressure regulator [B]. • Delivery Joint [C] Front [D] Clean the screen with a high-flash point solvent to remove any particles. WARNING Clean the screen in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area.
FUEL SYSTEM (DFI) 3-67 Fuel Injectors (#1, #2: Service Code 41, 42) engine oil to the O-ring [A], and install each injector • Apply [B] into the delivery joint [C]. that there is no dirt or dust on the injector seating • Check surface [A] of the inlet manifold [B]. that the two dowel pins are in place in the inlet • Check manifold. the end of the injector into the delivery joint [C], and • Fit install them along with the joint screws [D], and the screw collar [E] onto the inlet manifold.
3-68 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Service Code 41, 42) the injector fuel line for leakage as follows: •○Check Connect a commercially available vacuum/pressure pump [C] and a rubber hose [I] to the fuel hose [B] of the delivery joint [A] as shown. ○Plug the outlet of the pressure regulator [G] with a rubber plug [J] (e.g. Plug: Part No. 92068–006). ○Bind the plug with a wire [K]. ○Apply a soap and water solution to the areas [D] shown.
FUEL SYSTEM (DFI) 3-69 Fuel Injectors (#1, #2: Service Code 41, 42) and pull [A] the fuel hose joint #2 [B] back and • Push forth more than two times and make sure it is locked and doesn’t come off. When the fuel hose joint #2 is correctly installed, it should slide on the delivery pipe about 5 mm (0.2 in.). WARNING Make sure the fuel hose joint is installed correctly on the delivery pipe by sliding the joint, or the fuel could leak.
3-70 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Service Code 41, 42) If the power source voltage is incorrect, check the DFI power source (see DFI Power Source in this chapter). If the DFI power source is good, check the ECU for its ground and power supply. If the ground and power supply of the ECU are good, the ECU is suspect. Replace the ECU. If the power source voltage is normal, check the output voltage of the injector. Output Voltage Inspection the ECU (see ECU section in this chapter).
FUEL SYSTEM (DFI) 3-71 Fuel Injectors (#1, #2: Service Code 41, 42) Injector Signal Test two test light sets with male terminals as shown. • Prepare Rating of Bulb [A]: 12 V × 3 ∼ 3.4 W Terminal Width [B]: 1.8 mm (0.07 in.) Terminal Thickness [C]: 0.8 mm (0.013 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.
3-72 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Service Code 41, 42) Injector Unit Test two wires [A] and the same test light set [B] as in • Use “Injector Signal Test”. Rating of Bulb [C]: 12 V × (3 ∼ 3.4) W 12 V Sealed Battery [D] CAUTION Be sure to connect the bulb in series. The bulb works as a current limiter to protect the solenoid in the injector from excessive current. the test light set to the injector [E] as shown.
FUEL SYSTEM (DFI) 3-73 Fuel Pump (Service Code 45) Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard surface. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF. Disconnect the battery (−) terminal.
3-74 FUEL SYSTEM (DFI) Fuel Pump (Service Code 45) Fuel Pump Installation the pump screen (see Pump Filter Cleaning). • Clean Remove dirt or dust from the fuel pump by lightly applying • compressed air. Replace the fuel gasket with a new one. • Install a new pumppump gasket • and right [D] (top view). [A] with its tab [B] facing back Front [C] the fuel pump [A] into the fuel tank [B] in the order • Install shown. Front [C] First [1] ∼ Last [4] that the fuel pump terminals are in place.
FUEL SYSTEM (DFI) 3-75 Fuel Pump (Service Code 45) the fuel pump leads [A] with the clamps [B]. • Secure Press the • tom. clamps flat by hands against the fuel tank botsure that the end of each clamp is covered with a • Make plastic cap [C] and touches the fuel tank bottom. the fuel pump leads and clamp on the fuel tank • Clamp bottom as shown with the strap [D]. portion of strap push in the fuel tank bottom side. • Connect Must not cut off the strap end.
3-76 FUEL SYSTEM (DFI) Fuel Pump (Service Code 45) If the reading is good, the power source voltage is normal. Inspect operating source voltage (see in this section).
FUEL SYSTEM (DFI) 3-77 Fuel Pump (Service Code 45) A. ECU F. Junction Box N. Ignition Switch O. Starter Relay P. Main Fuse 30 A Q. Sealed Battery U. Fuel Pump V. DFI Fuse 15 A e. DFI Main Relay f.
3-78 FUEL SYSTEM (DFI) Ignition Coils (#1, #2: Service Code 51, 52) Ignition Coil #1: Ignition Coil for Front Cylinder (Service Code 51) Ignition Coil #2: Ignition Coil for Rear Cylinder (Service Code 52) Removal/Installation CAUTION Never drop the ignition coils, especially on a hard surface. Such a shock to the ignition coil can damage it. Ignition Coil Removal/Installation of the Ignition Sys• See tem section in the Electrical System chapter.
FUEL SYSTEM (DFI) 3-79 FI Indicator LED Light Inspection Flow Chart
3-80 FUEL SYSTEM (DFI) FI Indicator LED Light The FI indicator LED light [A] goes ON when the ignition SW is turned ON and the LED light goes OFF 2 seconds later. This is to ensure that the FI indicator LED light has not burned out and the DFI system and the ignition system function properly. LED Light Inspection ○Refer to the Meter, Gauge section in the Electrical System chapter for LED Light Inspection. WARNING This inspection may produce sparks.
FUEL SYSTEM (DFI) 3-81 ECU ECU Identification ○Most countries have their own regulations, so each ECU has different characteristic of fuel injection according to each country. 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 emission regulation. ECU Identification Models CAL and US EU and AU Type [A] F8T97471 F8T97472 Part No.
3-82 FUEL SYSTEM (DFI) ECU ECU Power Supply Inspection inspect the terminals of the ECU connector. • Visually If the connector is clogged with mud or dust, blow it off with compressed air. Replace the main harness if the terminals [A] of the main harness connectors are cracked, bent, or otherwise damaged. Replace the ECU if the terminals of the ECU connector are cracked, bent, or otherwise damaged.
FUEL SYSTEM (DFI) 3-83 DFI Power Source DFI Fuse Removal the seat (see Frame chapter). • Remove Pull the lock [A] and open the lid [B]. • Pull out the DFI fuse [C] from the case with needle nose • pliers. Front [D] 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. DFI Fuse Inspection the fuse (see DFI Fuse Removal). • Remove Inspect the element. • If it is open,fuse replace the fuse.
3-84 FUEL SYSTEM (DFI) DFI Power Source DFI Power Source Circuit A. ECU F. Junction Box N. Ignition SW O. Starter Relay P. Main Fuse 30 A Q. Sealed Battery R. Fuel Injector #1 S. Fuel Injector #2 U. Fuel Pump V. DFI Fuse 15 A W. ISC Valve #2 X. ISC Valve #1 e. DFI Main Relay f. Ignition Fuse 10 A p.
FUEL SYSTEM (DFI) 3-85 ISC Valves Removal/Installation CAUTION Never drop the ISC valves, especially on a hard surface. Such a shock to the valve can damage it. ○The ISC valves are removed during right air cleaner housing removal (see this chapter). ○The ISC valve itself is the same for front and rear, but • wiring is different. Be careful not to reverse the leads. ISC Valve #1 [A] → G/Y, W/R leads [B] ISC Valve #2 [C] → G/BL, W/R leads [D] Front [E] Install the ISC hoses as shown.
3-86 FUEL SYSTEM (DFI) ISC Valves Output Voltage Inspection the output voltage at the connectors [A] of the ISC • Check Valves. • Remove the right air cleaner cover (see this chapter). Special Tool - Hand Tester [B] : 57001–1394 the output voltage with the engine stopped, and • Measure with the connector joined. • Turn the ignition SW ON.
FUEL SYSTEM (DFI) 3-87 ISC Valves A. ECU F. Junction Box N. Ignition Switch O. Starter Relay P. Main Fuse 30 A Q. Sealed Battery V. DFI Fuse 15 A W. ISC Valve #2 X. ISC Valve #1 e. DFI Main Relay f.
3-88 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○This inspection can detect the faults of the DFI fuel line other than the DFI electronic system. ○It is preferable to measure the fuel pressure while running the motorcycle when the trouble has occurred in order to know symptom well. ○Be sure the battery is fully charged. • Remove the fuel tank (see this chapter). the lock of the fuel hose joint #2 with fingers, dis• Pinch connect the joint [A] and take out the fuel hose assy [B].
FUEL SYSTEM (DFI) 3-89 Fuel Line the ignition SW ON. The fuel pump will turn for 3 • Turn seconds, and then stop. • Measure the fuel pressure with the engine stopped. Fuel Pressure right after Ignition SW ON, with pump running: Standard: 310 kPa (3.2 kgf/cm², 46 psi) after 3 seconds from Ignition SW ON, with pump stopped: Standard: 280 kPa (2.9 kgf/cm², 41 psi, residual fuel pressure) The system should hold the residual pressure about 30 seconds. the engine, and let it idle.
3-90 FUEL SYSTEM (DFI) Fuel Line the fuel hose joint #2 [A] onto the pipe (for delivery • Fit joint) until the joint clicks [B]. ○Insert the hose joint straight along the pipe. Front [C] and pull [A] the fuel hose joint #2 [B] back and • Push forth more than two times and make sure it is locked and doesn’t come off. When the fuel hose joint #2 is correctly installed, it should slide on the delivery pipe about 5 mm (0.2 in.
FUEL SYSTEM (DFI) 3-91 Fuel Line a plastic hose of the inside diameter 7.5 mm × L • Prepare about 400 mm and a measuring cylinder. • Remove: Seat (see Frame chapter) Indicator Unit (see Fuel Tank Removal in this chapter). Fuel Tank Bolts Raise the fuel tank. Stuff a clean shop towel around the fuel outlet hose joint. ○While pinching the locks of the hose joint #1 with fingers, disconnect the joint (see Fuel Tank Removal) and insert the plastic hose [A] quickly onto the tank outlet pipe.
3-92 FUEL SYSTEM (DFI) Throttle Grip and Cables Throttle Grip Free Play Inspection ○Refer to Throttle Control System Check in the Periodic Maintenance Chapter. Throttle Grip Free Play Adjustment the locknuts [A] and screw the adjusters [B] all the • Loosen way in so as to give the throttle grip plenty of play. out the adjuster of the decelerator cable [C] until • Turn there is no play. the locknut against the adjuster.
FUEL SYSTEM (DFI) 3-93 Throttle Body Assy Idle Speed Check ○Refer to Idle Speed Check in the Periodic Maintenance Chapter. Idle Speed Adjustment ○Refer to Idle Speed Check in the Periodic Maintenance Chapter. High Altitude Performance Adjustment ○Any modification is not necessary in this model since the atmospheric pressure sensor senses atmospheric pressure change due to high altitude and the ECU compensates the change. Throttle Body Assy Removal the fuel tank (see this chapter).
3-94 FUEL SYSTEM (DFI) Throttle Body Assy the following from the choke cable holder [A] (left • Remove -behind view). Screw [B] Choke Cable Plate [C] pushing the choke lever [A] forward, remove the • While cable housing from the choke cable holder [B] and the • inner cable out of the holder slit [C]. Take off the lower end [D] from the choke lever. Front [E] the screws and take off the right switch housing. • Remove Remove cable end [A] and decelerator • cable endthe[B] accelerator at the throttle grip.
FUEL SYSTEM (DFI) 3-95 Throttle Body Assy the decelerator cable end [A] from the throttle • Remove pulley [B]. needle nose pliers, move the accelerator inner ca• Using ble outside the engine, and remove the cable end [C] from the pulley. Front [D] the lock of the fuel hose joint #2 [A] with your fin• Pinch gers, pull the joint #2 out along the pipe (for delivery joint), and take out the fuel hose assy [B]. Front [C] the oil hose clamps [A]. • Remove Unscrew the inlet manifold bolts [B].
3-96 FUEL SYSTEM (DFI) Throttle Body Assy a piece of lint-free, clean cloth into the throttle body • Stuff assy, and the inlet ports of the cylinder heads to keep dirt out of the engine. WARNING If dirt or dust is allowed to pass through into the throttle bore, the throttle may become stuck, possibly causing an accident. CAUTION If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur. Throttle Body Assy Installation the lower air cleaner duct between cylinders.
FUEL SYSTEM (DFI) 3-97 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. • Install Fit the [A] of the right switch housing into the • hole [B]projection 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 in the Periodic Maintenance chapter).
3-98 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the three throttle body flange bolts [A]. the throttle body assy into the throttle body [A] and • Split the inlet manifold [B]. The gasket [C] comes off. • Discard the gasket. ○Do not remove or adjust the following parts. These parts are set at the factory and cannot be readjusted. CAUTION Adjustment of some of these parts could result in poor performance, requiring replacement of the throttle body.
FUEL SYSTEM (DFI) 3-99 Throttle Body Assy the delivery joint and injectors (see Injector sec• Remove tion in this chapter). the butterfly valves [A], and wipe any carbon off • Open the throttle bores [B] around the valves, using a piece of • • lint-free cloth penetrated with a high-flash point solvent. Clean the bores [C] of the inlet manifold [D] as well. Blow away dirt or dust from the throttle body and the inlet manifold by applying compressed air.
3-100 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Element Removal • Remove: Allen Bolt and Washer [A] Left Air Cleaner Cover [B] Front [C] the element [A]. • Remove Push a clean, towel into the lower air cleaner duct • to keep dirt orlint-free other foreign material from entering. WARNING If dirt or dust is allowed to pass through into the throttle assy, the throttle may become stuck, possibly causing an accident.
FUEL SYSTEM (DFI) 3-101 Air Cleaner Right Air Cleaner Housing Removal • Remove: Allen Bolt and Washer [A] Right Air Cleaner Cover [B] Front [C] • Remove: ISC Valve Hoses [A] ISC Valve Lead Connectors [B] Air Cleaner Allen Bolts [C] and Screws [D] Air Cleaner Base Bolt [E] • Remove: Air Cleaner Base [A] Inlet Air Temperature Sensor Connector [B] ISC Valve Leads [C] Crankcase Breather Hose [D] Air Cleaner Drain Hose [E] (separate from the base [A]) Vacuum Switch Valve Air Hose [F] ○Be careful not to lose
3-102 FUEL SYSTEM (DFI) Air Cleaner If the air cleaner drain hose [A] has been removed with it attached to the right air cleaner base, pull the drain hose off the right air cleaner base. Remove the left air cleaner base and insert the drain hose under the lower air cleaner duct. the inlet air temperature sensor [A], the ISC valve • Install #2 [B], ISC valve #1 [C], and the crankcase breather hose [D]. Torque - Inlet Air Temperature Sensor Nut [E]: 7.8 N·m (0.
FUEL SYSTEM (DFI) 3-103 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 and disconnect the battery (–) terminal. To avoid fire, do not remove the fuel tank when the engine is still hot. Wait until it cools down.
3-104 FUEL SYSTEM (DFI) Fuel Tank • Disconnect: Indicator Unit Connector [A] • Ignition Switch Connector [B] Remove: Ignition Switch [C] and Screws [D] Bracket [E] and Bolt [F] Front [G] the seat (see Frame chapter). • Remove Disconnect battery (−) terminal [A]. • Open the fuelthepump clamp [B]. • Raise the lock [C] andlead disconnect the fuel pump connector • [D] (black, 4p). ○The fuel pump connector has fuel pump leads and fuel • reserve switch leads.
FUEL SYSTEM (DFI) 3-105 Fuel Tank a 8 mm plug ( 7.8 ∼ 8.0 mm [A] × L 35 mm • Prepare [B] with a rounded end [C]), and a 7.3 ∼ 7.5 mm inside diameter fuel hose [D] (e.g. Part No. 92191–1264). 8 mm plug can be made by cutting the threaded portion off a 8 mm bolt [F] (e.g. Part No. 92151–1444). ○Make a plug hose × L about 100 mm of the fuel hose with one end tied with a wire [E]. Do not leave the threaded portion.
3-106 FUEL SYSTEM (DFI) Fuel Tank ○Be careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump. WARNING Store the fuel tank in an area which is well -ventilated and free from any source of flame or sparks. Do not smoke in this area. Place the fuel tank on a flat surface and plug the fuel pipes to prevent fuel leakage. Fuel Tank Installation the above WARNING (see Fuel Tank Removal). • Read Route hoses correctly (see Appendix chapter).
FUEL SYSTEM (DFI) 3-107 Fuel Tank the fuel return hose [A] onto the pipe fully and install • Fit the plate clamp [B] beyond the raised rib [C]. the fuel pump leads [A] with the clamps [B]. • Secure Press the • tom. clamps flat by hands against the fuel tank botsure that the end of each clamp is covered with a • Make plastic cap [C] and touches the fuel tank bottom. the fuel pump leads and clamp on the fuel tank • Clamp bottom as shown with the strap [D]. portion of strap push in the fuel tank bottom side.
3-108 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Cleaning WARNING Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvent to clean the tank. the fuel tank (see this chapter). • Remove Remove the fuel pump and the return fuel check valve • from the fuel tank (see In-tank Fuel Pump section in this • • • • • chapter).
FUEL SYSTEM (DFI) 3-109 Evaporative Emission Control System The Evaporative Emission Control System for California Model routes fuel vapors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart. Parts Removal/Installation WARNING Gasoline is extremely flammable and can be explosive under certain conditions.
3-110 FUEL SYSTEM (DFI) Evaporative Emission Control System Hose Inspection (Periodic Inspection) ○Refer to Evaporative Emission Control System Check in the Periodic Maintenance Chapter. Separator Operation Test 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.
COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................................................................................................................ Coolant Flow Chart................................................................................................................. Specifications ......................................................................................................................... Special Tools and Sealant ..............................
4-2 COOLING SYSTEM Exploded View
COOLING SYSTEM 4-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Water temperature sensor (DFI) 18 1.8 13 2 Water pipe bolts 11 1.1 97 in·lb 3 Radiator fan bolts 8.3 0.85 74 in·lb 4 Radiator drain bolt 2.2 0.22 19 in·lb 5 Water temperature switch 7.8 0.80 69 in·lb 6 Radiator fan switch 18 1.8 13 7 Water pump cover bolts 11 1.1 97 in·lb 8 Water pump impeller bolt 8.8 0.90 78 in·lb 9 Water pump drain bolt 11 1.
4-4 COOLING SYSTEM Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes as coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
COOLING SYSTEM 4-5 Coolant Flow Chart 1. Water Pump 2. Water Jacket 3. Cylinder Head 4. Water Pipe 5. Water Hose 6. Radiator Cap 7. Thermostat 8. Reserve Tank Hose 9. Radiator 10. Radiator Fan 11. Throttle Body Assy 12. Front 13. Cold Coolant 14. Hot Coolant 15. Reserve Tank 16.
4-6 COOLING SYSTEM Specifications Coolant provided when shipping: Type (recommended) Permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed ratio Soft water 50%, coolant 50% Freezing point − 35°C (− 31°F) Total amount 2.3 L (2.4 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 Tools and Sealant Bearing Driver Set : 57001–1129 Bearing Remover Head, φ10 x φ12 : 57001–1266 Bearing Remover Shaft : 57001–1265 Kawasaki Bond (Silicone Sealant) : 56019–120
4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection the right side cover (see Frame chapter). • Remove Visually inspect the coolant [A] in the reserve tank. • If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flash 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 chapter). • Remove Remove radiator cap, and install a cooling system • pressure the tester [A] on the radiator filler neck [B]. NOTE ○Wet the cap sealing surfaces with water or coolant to prevent pressure leakage. up pressure in the system carefully until the pres• Build sure reaches 123 kPa (1.25 kg/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 the coolant (see Coolant Change in the Periodic • Drain Maintenance chapter). • Remove: Water Hose Clamp [A] Water Hose [B] Front [C] • Remove: Water Pump Cover Bolts [A] Water Pump Cover [B] • Remove: Impeller Bolt [A] Impeller [B] NOTE ○The impeller bolt has left-hand threads. Turn the bolt clockwise and remove it. Water Pump Installation are aluminum washers [A] on rear side of the wa• There ter pump cover [B].
COOLING SYSTEM 4-11 Water Pump the clamp [A] so that the clamp end is about 16 • Install mm (0.63 in.) [B] apart from the pump inlet step. This • prevents coolant leakage from the hose end. Tighten the hose clamp screw securely. Water Pump Inspection the water pump drainage outlet hose [A] at the • Check bottom of the water pump for coolant leakage. If the mechanical seal is damaged, the coolant leaks through the seal and drain through the passage. Replace the mechanical seal. inspect the impeller [A].
4-12 COOLING SYSTEM Water Pump • • • • If the coolant still leaks through the drainage outlet hose, the seal and ball bearings is probably damaged. Replace the mechanical seal, ball bearings, and oil seal by splitting the crankcase. Split the crankcase (see Crankshaft/Transmission chapter). Remove the water pump impeller. Pull out the water pump shaft from the inside of the right crankcase. Take the bearing [A] out of the right crankcase, using the bearing remover.
COOLING SYSTEM 4-13 Water Pump both sliding surfaces of a new mechanical seal with • Clean a high-flash point solvent (e.g. ethyl alcohol), and apply a • • little coolant to the sliding surface to give the mechanical seal initial lubrication. Apply coolant to the surface of the rubber seal [A] and sealing seat [B], and press the rubber seal and sealing seat into the impeller by hand until the seat bottoms out. Tighten the water pump impeller bolt by turning the bolt counterclockwise.
4-14 COOLING SYSTEM Radiator 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. Radiator Removal the coolant (see Coolant Change in the Periodic • Drain Maintenance chapter). • Remove: Fuel Tank (see Fuel System chapter.) • Pry the plastic clamps [A].
COOLING SYSTEM 4-15 Radiator • Remove: Radiator Fan Bolts [A] Radiator Fan [B] Radiator Installation • Be sure to install the radiator fan ground lead terminal [A]. Torque - Radiator Fan Bolts and Fan Ground Lead Terminal Bolt: 8.3 N·m (0.85 kgf·m, 74 in·lb) the radiator stoppers [A] into the right and left grom• Fit mets [B]. the pump inlet hose and position the hose clamp • Install (see Water Pump Installation in this chapter). • Tighten the hose clamp screw securely.
4-16 COOLING SYSTEM Radiator Radiator Cap Inspection the condition of the top and bottom valve seals of • Check the radiator cap. If any one of them shows visible damage, replace the cap. Bottom Valve Seal [A] Top Valve Seal [B] Valve Spring [C] • Install the cap [A] on a cooling system pressure tester [B]. NOTE ○Wet the cap sealing surfaces with water or coolant to prevent pressure leakage.
COOLING SYSTEM 4-17 Thermostat Thermostat Removal • Remove: Coolant : Drain about 200 mL • Fuel Tank (see Fuel System chapter) Four Water Hoses [A] Bracket Bolts [B] Water Temperature Sensor Connector [C] Remove the thermostat housing [D] along with the bracket. 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.
4-18 COOLING SYSTEM Hoses and Pipes Hose Installation the hoses and pipes being careful to follow bend• Install ing direction. Avoid sharp bending, kinking, flattening, or twisting. Install the clamps [A] as near as possible to the hose end to clear the raised rib on the fitting. This will prevent the hoses from working loose. ○The clamp screws should be positioned correctly to prevent the clamps from contacting the other parts. • Torque - Water Hose Clamp Screws: 2.5 N·m (0.
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 Check............... Air Switching Valve Removal ....... Air Switching Valve Installation .... Air Switching Valve Operation Test...........................................
5-2 ENGINE TOP END Exploded View
ENGINE TOP END 5-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Rocker case cover bolts 8.8 0.90 78 in·lb 2 Air suction valve cover bolts 7.4 0.75 65 in·lb 3 Rocker case nuts φ 12 mm 78 8.0 58 S, MO 4 Rocker case nuts φ 8 mm 25 2.5 18 S 5 Rocker case bolts φ 6 mm 8.8 0.90 78 in·lb S 6 Spark plug retainers 12 1.2 106 in·lb 7 Plugs 20 2.0 15 8. Air switching valve 9. Air suction valves 10. HLA oil filters AD: Apply adhesive. EO: Apply engine oil.
5-4 ENGINE TOP END Exploded View
ENGINE TOP END 5-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Rocker shafts 25 2.5 18 2 Exhaust pipe cover clamp screws 6.9 0.70 61 in·lb 3 Premuffler chamber bolts 29 3.0 21 4 Upper muffler bracket nut 29 3.0 21 5 Muffler stay mounting bolts, φ 8 25 2.5 18 6 Upper muffler mounting nuts, φ 8 25 2.5 18 7. Rear exhaust pipe 8. Front exhaust pipe 9. Upper muffler 10. Lower muffler 11. Premuffler chamber 12.
5-6 ENGINE TOP END Exploded View
ENGINE TOP END 5-7 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Cylinder head nuts 25 2.5 18 S 2 Cylinder nuts 25 2.5 18 S 3 Chain tensioner cap 20 2.0 15 S 4 Chain tensioner lockbolt 4.9 0.50 43 in·lb S 5 Chain tensioner mounting bolts 11 1.1 97 in·lb S 6 Chain guide mounting bolts 11 1.1 97 in·lb L 7 Camshaft sprocket bolts 15 1.5 11 L 8. KACR unit 9. “R” marked side faces up. 10. “RN” marked side faces up. 11.
5-8 ENGINE TOP END Specifications Item Clean Air System: Air switching valve resistance: Camshafts: Cam height: Exhaust Inlet Camshaft/rocker case clearance φ25 φ17 Standard 18 ~ 22 Ω at 20° (68°F) 33.741 ~ (1.32839 33.928 ~ (1.33575 33.857 mm ~ 1.33295 in.) 34.044 mm ~ 1.34031 in.) Service Limit – – – 33.64 mm (1.3244 in.) 33.83 mm (1.3319 in.) 0.020 ~ 0.062 mm (0.000787 ~ 0.00244 in.) 0.016 ~ 0.055 mm (0.000630 ~ 0.00217 in.) 0.15 mm (0.00591 in.) 0.14 mm (0.00551 in.) 24.959 ~ 24.980 mm (0.
ENGINE TOP END 5-9 Specifications Item Valve stem diameter: Exhaust Inlet Valve guide inside diameter: Exhaust Inlet Valve/valve guide clearance Exhaust (wobble method): Inlet Cam Height Cam Height (maximum) [A] Valve Head Thickness Valve Head Thickness [A] Valve Stem Diameter [B] 45° [C] Standard 6.955 ~ 6.970 mm (0.27382 ~ 0.27441 in.) 6.965 ~ 6.980 mm (0.27421 ~ 0.27480 in.) Service Limit 6.94 mm (0.2732 in.) 7.000 ~ 7.015 mm (0.27559 ~ 0.27618 in.) 7.000 ~ 7.015 mm (0.27559 ~ 0.27618 in.) 7.
5-10 ENGINE TOP END Specifications Item Valve seat surface: Valve seat cutting angle Outside diameter: Standard Exhaust Inlet Width: Exhaust Inlet Valve spring free length: Outer (EX, IN) Inner (EX, IN) Cylinder, Piston: Cylinder inside diameter Piston diameter Piston/cylinder clearance Oversize piston and rings Piston ring/groove clearance: Top Second Piston ring groove width: Top Second Piston ring thickness: Top Second Piston ring end gap: Top Second Oil 45°, 32°, 55° 31.9 ~ 32.1 mm (1.
ENGINE TOP END 5-11 Special Tools and Sealant Valve Guide Reamer, φ7 : 57001–162 Piston Pin Puller Assembly : 57001–910 Valve Guide Arbor, φ7 : 57001–163 Compression Gauge Adapter, M12 x 1.25 : 57001–1018 Compression Gauge : 57001–221 Spark Plug Wrench, Hex 18 : 57001–1024 Valve Spring Compressor Assembly : 57001–241 Piston Ring Compressor Grip : 57001–1095 Valve Spring Compressor Adapter, φ28.
5-12 ENGINE TOP END Special Tools and Sealant Valve Seat Cutter, 32° – φ35 : 57001–1121 Piston Pin Puller Adapter : 57001–1211 Valve Seat Cutter, 32° – φ38.
ENGINE TOP END 5-13 Special Tools and Sealant Valve Seat Cutter 45° – φ40 : 57001–1496 Valve Seat Cutter 55° – φ38.5 : 57001–1497 Kawasaki Bond (Silicone Sealant) : 56019–120 ○Compression Gauge Adapter: 57001-1183 can also be used.
5-14 ENGINE TOP END Clean Air System Air Suction Valve Removal rear air suction valve removal, remove the rear ex• For haust pipe. the hose [A]. • Remove Unscrew the mounting bolts [B] and remove the rear air • suction valve cover [C]. Remove the rear air suction valve. • front air suction valve removal, remove the horn, the • For radiator mounting bolt and move the radiator forward. the hose [A]. • Remove Unscrew the mounting bolts [B] and remove the front air • suction valve cover [C].
ENGINE TOP END 5-15 Clean Air System Air Switching Valve Removal • Remove: Fuel Tank (see Fuel System Chapter) Pull off the hoses [A] and air switching valve connector • [B], and take out the air switching valve [C]. Air Switching Valve Installation the air switching valve [A] so that the connector [B] • Install faces forward. • Route the hoses correctly (see Appendix chapter). Air Switching Valve Operation Test the air switching hose [A] out of the right air cleaner • Pull base.
5-16 ENGINE TOP END Clean Air System the 12 V battery [A] to the air switching valve • Connect terminals as shown. the air to the inlet air duct [A], and make sure does • Blow not flow the blown air from the outlet air ducts [B]. the 12 V battery. • Disconnect Blow the air inlet air duct [A] again, and make sure • flow the blownto the air from the outlet air ducts [B]. If the air switching valve dose not operate as described, replace it with a new one.
ENGINE TOP END 5-17 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type cam chain tensioner. The push rod does not return to its original position once it moves out to take up 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.
5-18 ENGINE TOP END Camshaft Chain Tensioner the larger spring [A], and then the ball bearing assy • Install [B]. ○Fit the ball bearing assy into the body until it bottoms out, using a thin-bladed screwdriver. in the lockbolt [A] finger-tight to hold the ball bear• Screw ing assy temporarily. • Install the retainer [B]. the tensioner body [A] and tighten the mounting • Install bolts [B] to the specified torque. Torque - Chain Tensioner Mounting Bolts: 11 N·m (1.
ENGINE TOP END 5-19 Rocker Case Cover Rocker Case Cover Removal the engine (see Engine Removal/Installation • Remove chapter). the bolts [A] and take off the cover [B] from the • Remove rocker case. • Take out the oil filter springs [A] and HLA oil filters [B]. Rocker Case Cover Installation the HLA oil filters [A] with new ones. • Replace Install the oil filter springs [B] • After installing • engine oil. the rocker case, fill the oil reservoir [C] with the cover gasket [D] with a new one.
5-20 ENGINE TOP END Rocker Case Cover Rocker Case Cover Assembly adhesive to the rubber dampers [A] and install them • Apply on the rocker case cover as shown. ○Insert the projections [B] of the dampers to the holes [C] of the cover.
ENGINE TOP END 5-21 Rocker Case Rocker Case Removal the engine (see Engine Removal/Installation • Remove chapter). the throttle body assy (see Fuel System (DFI) • Remove chapter). the rocker case covers (see Rocker Case Cover • Remove Removal). the alternator outer cover (see Electrical System • Remove chapter). the timing inspection plug [A] and rotor bolt plug • Remove [B].
5-22 ENGINE TOP END Rocker Case the pry points [A], take the rocker case out of the • Using cylinder head. the rocker shafts [A], and take the rocker arms • Unscrew [B] out of the rocker case. out the oil filters if necessary. • Take Remove • moval). the lash adjuster if necessary (see HLA Re- CAUTION The cylinder head and rocker case are machined in the assembled state, so they must be used as a set. Be careful not to mix them up for front and rear cylinders.
ENGINE TOP END 5-23 Rocker Case molybdenum disulfide oil to the threads and seating • Apply surface of φ12 mm nuts and both sides of washers. the rocker case nuts and bolts temporarily follow• Tighten ing the tightening sequence shown, and then tighten them to the specified torque. Torque - Rocker Case Nuts φ12 mm: 78 N·m (8.0 kgf·m, 58 ft·lb) Rocker Case Nuts φ8 mm: 25 N·m (2.5 kgf·m, 18 ft·lb) Rocker Case Bolts φ6 mm: 8.8 N·m (0.
5-24 ENGINE TOP END Rocker Case Rocker Arm Assembly a flat-end bar [A] and a block [B] with a recess • Prepare [C]. the oil chamber [D] for the HLA into the rocker arm • Press end [E] until the chamber end is even with the step [F] of the hole. ○Install the oil chamber as shown so that the air bleed hole [G] is placed within 120 degrees [H]. This makes HLA bleeding easier. HLA Removal the rocker case (see Rocker Case Removal). • Remove Remove the rocker arms.
ENGINE TOP END 5-25 Rocker Case HLA Installation that the HLA plunger is not damaged. • Check If the plunger does damage, replace the HLA. HLA Body [A] O-ring [B] Plunger Spring [C] Pivot Plunger [D] Check Valve [E] Check Valve Spring [F] the HLA (see HLA Air Bleeding). • Air-bleed Soak a rocker [A] in engine oil, and then insert the • HLA [B] into thearm rocker arm. ○Be careful not to tip the rocker arm having the HLA, and not to allow engine oil to leak out of the HLA.
5-26 ENGINE TOP END Camshafts Camshaft Removal the timing inspection cap [A] and rotor bolt cap • Remove [B]. Special Tool - Driver-Filler Cap: 57001–1454 [C] Turn the crankshaft counterclockwise [A] and align the “F” • mark [B] (TDC mark for the front piston) with the middle • • of the notch [C]. Remove the front and rear rocker case covers (see Rocker Case Cover Removal). Remove the front and rear rocker cases (see Rocker Case Removal). the camshaft [B] along with the KACR [A].
ENGINE TOP END 5-27 Camshafts the KACR on each camshaft. •○Install The front KACR [A] and rear KACR [B] are different (inside view). Do not confuse these KACRs. the pin [A] into the notch [B], and install the KACR [C] • Fit onto the camshaft [D]. molybdenum disulfide oil to all cam parts, including • Apply their journals. ○The molybdenum disulfide oil is a mixture of engine oil • and molybdenum disulfide grease with a weight ratio (10 : 1).
5-28 ENGINE TOP END Camshafts the “R” mark [A] (TDC mark for the rear piston) with • Align the middle of the notch [B] (310° turn from the front piston TDC). the rear camshaft sprocket with the camshaft • Engage chain as shown. Timing Marks [A] and R Mark [B] Cylinder Head Upper Surface [C] Front [D] ○Pull the front side (inlet side) of the chain taut to install the camshaft. Install the rear chain tensioner and check the front/rear chain timing again.
ENGINE TOP END 5-29 Camshafts molybdenum disulfide oil to the threads and seating • Apply surface of φ12 mm nuts and both sides of washers. the rocker case nuts and bolts temporarily follow• Tighten ing the tightening sequence shown, and then tighten them to the specified torque. Torque - Rocker Case Nuts φ12 mm: 78 N·m (8.0 kgf·m, 58 ft·lb) Rocker Case Nuts φ8 mm: 25 N·m (2.5 kgf·m, 18 ft·lb) Rocker Case Bolts φ6 mm: 8.8 N·m (0.
5-30 ENGINE TOP END Camshafts • Remove: Alternator Rotor (see Electrical System chapter) • Lower Chain Guide Bolts [A] Lower Chain Guide [B] Take out the front camshaft chain [C].
ENGINE TOP END 5-31 Camshafts ○The cylinder compression is released while the engine is • running (abnormal): the pin [A] stays out the cam [B] and pushes up the exhaust rocker arm. Remove the spring [C] and move the weights [D] back and forth. If the weights do not move easily from the retracted position, replace the KACR unit. Also inspect the exhaust rocker arm for any damage, and replace the rocker arm if necessary.
5-32 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○Be sure the battery is fully charged. up the engine thoroughly. • Warm Stop the • Remove engine. spark plug and attach the compression • gauge andone adapter firmly into the spark plug hole. Do not • remove the other spark plug, only the plug lead. For the other cylinder, remove both spark plugs.
ENGINE TOP END 5-33 Cylinder Head The following table should be consulted if the obtainable compression reading is not within the usable range. Problem Diagnosis Carbon buildup on piston and in combustion chamber possibly due to damaged valve stem, valve guide, stem oil seal and/or damaged Cylinder piston oil rings (This may be indicated compression by white exhaust smoke). is higher than Incorrect cylinder head gasket thickness.
5-34 ENGINE TOP END Cylinder Head not remove the coolant drain plug [A] yet. • Do Remove cylinder head nuts [B]. • Take the the cylinder head off the cylinder. • Cylinder Head Installation ○The front cylinder head [A] has an F mark while the rear cylinder head [B] has an R mark. Be careful not to mix them up. Front [C] CAUTION The cylinder head and rocker case are machined in the assembled state, so they must be used as a set. the cylinder head gasket with a new one.
ENGINE TOP END 5-35 Cylinder Head Valve Clearance Adjustment NOTE ○Since the hydraulic lash adjusters constantly maintain zero clearance, it is not necessary to inspect or adjust the valve clearance. Valve Removal the cylinder head (see Cylinder Head Removal). • Remove Swing open the rocker arm. • Using the valve spring compressor assembly, remove the • valve. Special Tools - Valve Spring Compressor Assembly: 57001 -241 [A] Valve Spring Compressor Adapter, φ28.
5-36 ENGINE TOP END Cylinder Head Valve Guide Installation engine oil to the valve guide outer surface before • Apply installation. the area around the valve guide hole to about 120 ~ • Heat 150°C (248 ~ 302°F) in the engine oil. 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.
ENGINE TOP END 5-37 Cylinder Head Valve Seat Inspection the valve (see Valve Removal). • Remove Check the valve seat surface [A] between the valve [B] • and valve seat [C]. ○Measure the outside diameter [D] of the seating pattern on the valve seat with vernier calipers. If the outside diameter is too large or too small, repair the seat (see Valve Seat Repair). Valve Seat Surface Outside Diameter (Seat O.D.) Standard: Exhaust 31.9 ~ 32.1 mm (1.256 ~ 1.264 in.) Inlet 36.4 ~ 36.6 mm (1.433 ~ 1.441 in.
5-38 ENGINE TOP END Cylinder Head 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. Do not drop or shock the valve seat cutter, or the diamond particles may fall off. Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface. Also wash off ground particles sticking to the cutter with washing oil.
ENGINE TOP END 5-39 Cylinder Head ○To make the 32° grind, fit a 32° cutter into the holder, and slide it into the valve guide. ○Turn the holder one turn at a time while pressing down very lightly. Check the seat after each turn. CAUTION The 32° cutter removes material very quickly. Check the seat outside diameter frequently to prevent overgrinding. the seat at a 32° angle [A] until the seat O.D. [B] is • Grind within the specified range. • • • • If the seat O.D.
5-40 ENGINE TOP END Cylinder Head
ENGINE TOP END 5-41 Cylinders, Piston Cylinder Removal the cylinder head (see Cylinder Head Removal). • Remove Remove the coolant drain plug [A] and drain the coolant • from the cylinder. out the front camshaft chain guide [B]. • Pull Remove nuts [C]. • Tap lightlytheupcylinder the cylinder • from the crankcase. with a plastic mallet to separate • Remove the cylinder base gasket. Piston Removal the cylinder block (see Cylinder Removal).
5-42 ENGINE TOP END Cylinders, Piston not mix up the top ring and second ring. • Do Install the top ring [A] so that the “R” mark [B] faces up. • Install the second ring [C] so that the “RN” mark [D] faces • up. piston ring openings must be positioned as shown in • The the figure. The openings of the oil ring steel rails must be about 30 ~ 45° [F] of angle from the opening of the top ring.
ENGINE TOP END 5-43 Cylinders, Piston NOTE ○If a new piston or cylinder is used, check piston to cylinder clearance (see Piston/Cylinder Clearance), and use new piston ring. the cylinder base gasket [A] with a new one, and • Replace install the gaskets aligning the holes with the crankcase • water passages [B]. Be sure to install the dowel pins [C]. the piston ring compressor assembly [A] with the • Using chamfered side [B] upward, install the cylinder block [C].
5-44 ENGINE TOP END Cylinders, Piston the front cylinder in the same way. •○Install Position the front piston at TDC. ○Tighten the cylinder nuts temporarily (These nuts are tightened to the specified torque after rocker case installation). Cylinder Wear there is a difference in cylinder wear in different di• Since rections, take a side-to-side and a front-to-back measurement at each of the three locations (total of six measurements) shown in the figure.
ENGINE TOP END 5-45 Cylinders, Piston Cylinder Boring and Honing ○There is an oversize piston available. The oversize piston requires oversize rings. • Oversize Piston and Rings: 0.5 mm (0.02 in.) oversize Before boring a cylinder [A], first measure the exact diameter of the oversize piston, and then, according to the standard clearance in the Specifications, determine the rebore diameter. However, if the amount of boring necessary would make the inside diameter greater than 0.5 mm (0.02 in.
5-46 ENGINE TOP END Cylinders, Piston Piston Ring Thickness the thickness of the top [A] and second [B] rings. •○Measure Use a micrometer to measure at several points around the ring. Piston Ring Thickness Standard Top 1.17 ~ 1.19 mm (0.04606 ~ 0.04685 in.) Second 1.17 ~ 1.19 mm (0.04606 ~ 0.04685 in.) Service Limit 1.10 mm (0.0433 in.) 1.10 mm (0.0433 in.) If any of the measurements is less than the service limit on either of the rings, replace all the rings.
ENGINE TOP END 5-47 Mufflers Exhaust Pipe Removal WARNING To avoid a serious burn, do not remove the exhaust pipe or muffler when the engine is still hot. Wait until the muffler cools down. the upper muffler bracket bolt [A] for easy removal • Loosen or installation of exhaust pipes. the clamp screws [A]. • Loosen Detach the upper clamps [B] by sliding them up or for• ward. the lower clamp [C] by sliding it forward.
5-48 ENGINE TOP END Mufflers Lower Muffler Removal • Remove: Front and Rear Exhaust Pipe Covers (see above) • Chamber Flange Nuts [A] Muffler Bracket Bolts [B] Remove the lower muffler [C]. NOTE ○If the chamber flange nuts are difficult to remove, spray a penetrating oil on the studs and nuts. Upper Muffler Removal • Remove: Lower Muffler (see above) • Muffler Pipe Clamp Bolt [A] Upper Muffler Bracket Bolt [B] Remove the upper muffler [C].
ENGINE TOP END 5-49 Mufflers the front exhaust pipe cover clamp screw [A] with • Tighten its head inclined at 50° or less to horizontal as shown. This prevents the screw from touching ground when banking. Front Exhaust Pipe [B] Torque - Exhaust Pipe Cover Clamp Screws: 6.9 N·m (0.70 kgf·m, 61 in·lb) tighten all the bolts and nuts to a snug fit. • First, Secondary, tighten the exhaust pipe holder nuts evenly. • Finally, tighten • bolts securely.
5-50 ENGINE TOP END Mufflers Chamber Identification ○The all models have a premuffler chamber (Identification No. KHI M 092) with a honeycomb type catalytic converter and without any catalyst protection system. Do not mix up this chamber with the other type chamber (especially with a non-catalyst chamber). The motorcycle could not clear the emission regulation.
CLUTCH 6-1 Clutch Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools and Sealant ...................................................................................................... Clutch Fluid...............................................................
6-2 CLUTCH Exploded View
CLUTCH 6-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Clutch reservoir cap screws 1.5 0.15 13 in·lb 2 Clutch slave cylinder bleed valve 7.8 0.80 69 in·lb 3 Clutch master cylinder clamp bolts 9.8 1.0 87 in·lb 4 Clutch hose banjo bolt 25 2.5 18 5 Clutch slave cylinder bolts 6.9 0.70 61 in·lb 6 Clutch pipe banjo bolt 25 2.5 18 7 Clutch hub nut 147 15 108 8 Clutch cover bolts 11 1.1 97 in·lb 9 Clutch damper cover bolts 9.8 1.
6-4 CLUTCH Specifications Item Standard Service Limit Clutch Fluid Grade DOT4 (provided when shipping) Clutch Lever Position No. 1 (to suit rider) Clutch Lever Free Play Non-adjustable – – – 5-way adjustable – – – Clutch Clutch spring free height 4.3 mm (0.235 in.) 4 mm (0.16 in.) Spring plate gap (usable range) 1.95 ∼ 2.45 mm (0.0768 ~ 0.0965 in.) Friction plate thickness 3.3 ∼ 3.5 mm (0.130 ~ 0.138 in.) 3.1 mm (0.122 in.) Friction or steel plate warp 0.2 mm (0.0079 in.) or less 0.
CLUTCH 6-5 Special Tools and Sealant Inside Circlip Pliers : 57001–143 Clutch Spring Compressor : 57001–1162 Gear Holder: 57001–1557
6-6 CLUTCH Clutch Fluid Clutch Fluid Level Check ○Refer to Clutch Fluid Level Check in the Periodic Maintenance Chapter. Clutch Fluid Change ○Refer to Clutch Fluid Change in the Periodic Maintenance Chapter. Clutch Line Bleeding • Remove: Alternator Outer Cover (see Electrical System chapter) With reservoir cap off, slowly pump the clutch lever • severalthetimes until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir.
CLUTCH 6-7 Clutch Master Cylinder Clutch Lever Adjustment The adjuster has 5 positions so that the clutch 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 (front view). ○The distance from the grip to the lever is minimum at number 5 and maximum at number 1. • Clutch Master Cylinder Removal the starter lockout switch connector [A].
6-8 CLUTCH Clutch Master Cylinder Clutch Master Cylinder Disassembly/Assembly ○Refer to Clutch Master Cylinder Cup and Dust Seal Replacement in the Periodic Maintenance Chapter. Clutch Master Cylinder Inspection the clutch master cylinder. • Disassemble Check that there no scratches, rust or pitting on the • inside of the masterarecylinder [A] and on the outside of the • piston [B]. If the master cylinder or piston shows any damage, replace them. Inspect the primary cup [C] and secondary cup [D].
CLUTCH 6-9 Clutch Slave Cylinder Clutch Slave Cylinder Removal • Remove: Alternator Outer Cover (see Electrical System chapter) Banjo Bolt [A] Clutch Slave Cylinder Bolts [B] Slave Cylinder [C] CAUTION Immediately wash away any clutch fluid that spills. It may damage painted surfaces. the following if the clutch slave cylinder is to be • Perform removed but not disassembled.
6-10 CLUTCH Clutch Slave Cylinder • Tighten the bolts [A]. Torque - Clutch Slave Cylinder Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb) ○Put the clamp [B] together the clutch slave cylinder bolt • • and bend along the slave cylinder with the end of the clamp straight to the engine side as shown in the figure. This clamp is to prevent the edge of the slave cylinder from damaging the wire, not to clamp the wire. Replace the washers on each side of the clutch hose fitting with new ones.
CLUTCH 6-11 Clutch Clutch Cover Removal • Raise the rear wheel off the ground. Special Tools - Jack: 57001–1238 Attachment Jack: 57001–1398 the engine oil (see Periodic Maintenance chapter). • Drain the engine with a suitable stand [A]. •○Support Put a plank [B] onto the stand. • Remove: Front Exhaust Pipe [A] (see Engine Top End chapter) Downtube [B] (see Frame chapter, but remove the downtube with the right footpeg and rear master cylinder left installed) the eighteen cover bolts [A].
6-12 CLUTCH Clutch the clutch hub nut [A] by using an air impact • Unscrew wrench. the clutch spring [B], and the clutch spring holder [C] • Take out of the clutch hub. the back torque limiter springs [A], and the clutch • Take spring plate out of the clutch housing. the friction/steel plate [A], and outer clutch hub [B] • Take out of the clutch housing. the inner clutch hub [A], collar [B], washer [C] and • Take clutch housing [D] out of the crankcase.
CLUTCH 6-13 Clutch Clutch Installation When replacing any one of the following parts, check the spring plate gap (see Spring Plate Gap Measurement). Spring Plate [A] Friction Plates [B] Steel Plates [C] installing the clutch housing, mesh the oil pump • When drive gear [A] with the oil pump gear [B] so that the pump gear turns smoothly. CAUTION If new dry steel or friction plates are installed, apply engine oil to the surfaces of each plate to avoid clutch plate seizure.
6-14 CLUTCH Clutch spring plate pusher [A] into the clutch hub. Squeeze • The the clutch lever slowly and hold it with a band. ○Install the needle bearing [B] and the washer onto the pusher. [A] the operating plate [B] into the clutch hub, and • Pushing insert the retaining ring [C] by hand. Inner Clutch Hub Disassembly a press [A], and the clutch spring compressor [B], • Using push the damper spring holder [C] to remove the retaining ring [D].
CLUTCH 6-15 Clutch sheet gum (chewing gum) or about 5 g clay [A]. • Prepare Make an about 2.5 mm (0.098 in.) thick sheet [B] of gum • or clay, using a press and two thickness gauges [C] which • are overlapped to about 2.5 mm (0.098 in.). Cut the sheet with scissors into four strips [D] of gum or clay as shown. unit: mm the clutch (see this chapter). • Remove Place the clutch hub, spring holder assy [A], the • outer clutchinner hub [B], and the clutch plates (friction and steel plates) [C] on blocks [D].
6-16 CLUTCH Clutch Spring Plate Gap Adjustment If the plate gap is out of the usable range, change one of the steel plates [A] to a thicker or thinner one to get the correct gap. ○Use the standard steel plates (2.0 mm (0.079 in.) thick) × (6 ∼ 7) plates, and the adjustment steel plate (1.6 or 2.3 mm (0.063 or 0.091 in.) thick) × (0 ∼ 1) plates: total 7 plates. Steel Plates Thickness (mm) 1.6 (0.063 in.) 2.0 (0.079 in.) 2.3 (0.091 in.) Part No.
CLUTCH 6-17 Clutch Clutch Spring Height Measurement the height [B] of the clutch spring [A]. • Measure If the spring height is less than the service limit, it must be replaced. Clutch Spring Height Standard: 4.3 mm (0.235 in.) Service Limit: 4 mm (0.16 in.) Clutch Housing Finger Inspection inspect the fingers [A] of the clutch housing where • Visually the tangs [B] of the friction plates hit them. If they are badly worn or if there are groove cuts where the tangs hit, replace the housing.
ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Engine Oil Flow Chart............................................................................................................. Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools and Sealant .........
7-2 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart
ENGINE LUBRICATION SYSTEM 7-3 Engine Oil Flow Chart →: Oil Flow (1 ∼ 30) --→: Blowby Gas 1. Oil Screen 2. Oil Pump 3. Relief Valve 4. Oil Filter 5. Bypass Valve 6. Oil Pressure Switch 7. Inside Oil Pipe 8. Banjo Bolts of Right Crankcase Rear 9. Outside Oil Hoses 10. HLA Oil Filter 11. Rocker Shafts 12. Rocker Arms 13. HLA (Hydraulic Lash Adjuster) 14. Camshafts 15. Outside Oil Pipe 16. Front Gear Case 17. Inside Oil Pipe 18. Crankshaft 19. Alternator Rotor 20. Oil Nozzle 21. Front Piston 22. Drive Shaft 23.
7-4 ENGINE LUBRICATION SYSTEM Exploded View
ENGINE LUBRICATION SYSTEM 7-5 Exploded View No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Fastener Oil pipe holder bolts Oil pipe clamp bolts Oil hose flange bolts Oil hose banjo bolt Relief valve Oil pump mounting bolts Oil pressure switch Oil pressure switch terminal screw Oil screen plug Oil filter Oil nozzles Oil nozzle Oil filter pipe Oil drain plug Oil baffle bolt Oil return pipe bolts N·m 11 11 9.8 9.8 15 11 15 1.5 20 18 2.9 2.9 25 20 11 11 Torque kgf·m 1.1 1.1 1.0 1.0 1.5 1.1 1.5 0.15 2.0 1.8 0.
7-6 ENGINE LUBRICATION SYSTEM Specifications Item Engine Oil: Type Viscosity Capacity Standard API Service Classification : SE, SF or SG class API Service Classification : SH or SJ class with JASO MA SAE 10W-40 2.9 L (3.1 US qt, when filter is not removed) 3.1 L (3.3 US qt, when filter is removed) 3.5 L (3.
ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Oil Pressure Gauge, 5 kg/cm² : 57001–125 Filler Cap Driver : 57001–1454 Oil Pressure Gauge Adapter, PT 1/8 : 57001–1033 Kawasaki Bond (Silicone Sealant) : 56019–120 Oil Filter Wrench : 57001–1249
7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury. Oil Level Inspection the motorcycle so that it is vertical. • Situate that the engine oil level is between the upper [A] • Check and lower [B] levels in the gauge. Clutch Cover [C] NOTE ○Situate the motorcycle so that it is perpendicular to the ground.
ENGINE LUBRICATION SYSTEM 7-9 Oil Pump and Oil Line Oil Pump Removal the engine (see Engine Removal/Installation • Remove chapter). the crankcase (see Crankshaft/Transmission chap• Split ter). the oil pump mounting bolts [A], and take off the • Remove pump [B] out of the right crankcase. • Unscrew the relief valve [C] if necessary.
7-10 ENGINE LUBRICATION SYSTEM Oil Pump and Oil Line Oil Hose Installation the front oil hose over the rear oil hose as shown. •○Run Insert the rear oil hose [A] first. ○Next insert the front oil hose [B]. ○Run both oil hoses between the rocker case and the rocker case cover. Torque - Oil Hose Flange Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) the clamps [C]. • Install Fit the clamp [D] as shown. • each bottom end of the oil hoses on the right • Install crankcase behind the rear cylinder as shown.
ENGINE LUBRICATION SYSTEM 7-11 Oil Pump and Oil Line • Remove the oil pipe clamp bolt [A], and oil return pipe [B]. • Remove the separator [A]. • Remove: Oil Pipe Clamp Bolt [A] Oil Pipe Holder Bolt [B] Remove the inside oil pipe [C] and the oil return pipe [D] from the left crankcase [E]. ○Pull out the large size fittings [F] first, and remove the small size fitting [G] upward. • • Remove the bolt [A] and the separator [B].
7-12 ENGINE LUBRICATION SYSTEM Oil Pump and Oil Line the inside oil pipe [A], separator [B] and the oil re• Install turn pipe [C] to left crankcase [D] as shown. ○Do not apply silicone sealant to the groove of the grommet and the mating surface of the grommet [E]. ○Apply silicone sealant to the crankcase mating surface [F] of the separator. ○Apply a non-permanent locking agent to the oil pipe holder bolt [H], oil return pipe clamp bolts [I], oil pipe clamp bolt [J] and oil baffle bolt [K].
ENGINE LUBRICATION SYSTEM 7-13 Oil Pump and Oil Line the inside oil pipe [A], separator [B], and the oil • Install return pipe [C] to the right crankcase [D]. ○Do not apply silicone sealant to the groove of the grommet and the mating surface of the grommet [E]. ○Install the separator so that it’s smaller side [F] faces inside. ○Apply a non-permanent locking agent to the oil pipe holder bolt [G], oil return pipe clamp bolts [H] and oil pipe clamp bolt [I]. ○If the oil nozzle [J] is removed, install it.
7-14 ENGINE LUBRICATION SYSTEM Oil Pump and Oil Line Breather Drain Cleaning ○The air cleaner drain hose is provided beneath the right • • • air cleaner housing, and catches the water or oil from the crankcase breather hose. Usually water or oil does not collect at the bottom. In the event that rain water is drawn in through the air cleaner or if engine oil is blown back, drain the housing. Remove the left air cleaner housing (see Fuel System chapter).
ENGINE LUBRICATION SYSTEM 7-15 Oil Pressure Oil Pressure Measurement out the rubber boot [A]. • Slide Disconnect oil pressure switch lead [B] from the ter• minal screwthe [C]. • Unscrew the oil pressure switch [D]. NOTE ○Measure the oil pressure after the engine is warmed up. the oil pressure gauge [B] and adapter [C] to the • Attach switch hole.
7-16 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Inspection the crankcase (see Crankshaft/Transmission chap• Split ter). the relief valve [A] from the oil pump [B]. • Remove Check to if the valve slides smoothly when pushing • it in with asee wooden or other soft rod, and see if it comes back to its seat by spring pressure. NOTE ○Inspect the valve in its assembled state. Disassembly and assembly may change the valve performance.
ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Engine Removal/Installation ................................................................................................... Engine Removal....................
8-2 ENGINE REMOVAL/INSTALLATION Exploded View
ENGINE REMOVAL/INSTALLATION 8-3 Exploded View No. 1 2 3 Fastener Downtube bolts and nuts Engine mounting bolts and nuts Engine mounting bracket bolts N·m 44 44 25 WL: Apply a soap and water solution or rubber lubricant. Torque kgf·m 4.5 4.5 2.
8-4 ENGINE REMOVAL/INSTALLATION Specifications Jack : 57001–1238 Attachment Jack : 57001–1398
ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal the rear part of the frame on the jack [A], and the • Support attachment jack [B]. ○Fit the ribs of the frame into the groove of the attachments. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398 the brake lever slowly and hold it with a band • Squeeze [A]. Front [B] 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.
8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Disconnect: Snap-on Clamps [A] (pry open) • Radiator Fan Motor Connector [B] Rear Brake Light Switch Connector [C] Spark Plug Leads [D] Front and Rear Exhaust Pipes [E] (see Engine Top End chapter) Remove: Shift Pedal (see Crankshaft/Transmission chapter) Alternator Outer Cover (see Electrical System chapter) • Disconnect: Speed Sensor Connector [A] • Starter Motor Terminal Alternator Connector [B] Crankshaft Sensor Lead Connector [C] Oil P
ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation the engine with a commercially available stand • Support [A]. • Remove: Right Spark Plug Lead Holder Front and Rear Exhaust Pipes (see Engine Top End chapter) Engine Mounting Bracket Bolts [B] Downtube Bolts [C] the downtube [A] with the right footpeg and rear • Remove master cylinder installed. • Remove: Engine Mounting Bracket Bolts [B] Engine Mounting Bolts and Nuts [C] the propeller shaft from the engine.
8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation a thin coat of high temperature grease to the driven • Apply gear joint and to the propeller shaft joint. on the lockpin [A] and move back the engine to en• Push gage the front bevel gear joint with the propeller shaft joint. the brake hose [A] and the clutch hose [B] inside the • Run frame [C] as shown. Clamps [D] Front [E] the rear mounting bolt from the left side of the en• Insert gine to set the engine into its original position in the frame.
ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation the removed parts (see appropriate chapters). • Install Adjust throttle cables (see Fuel System chapter). • Fill the the engine • chapter). with engine oil (see Periodic Maintenance the engine with coolant and bleed the air from the • Fill cooling system (see Periodic Maintenance chapter). the idling (see Periodic Maintenance chapter). • Adjust Check the clutch operation. • Check the brake effectiveness.
CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools and Sealants .................................................................................................... Crankcase ................................
9-2 CRANKSHAFT/TRANSMISSION Exploded View
CRANKSHAFT/TRANSMISSION 9-3 Exploded View No. Fastener 1 2 3 4 5 6 7 8 9 10 Connecting rod big end nuts Starter clutch bolt Left balancer gear bolt Camshaft chain guide bolts Starter clutch coupling bolts Oil nozzle 11 12 13 14 15 16 Crankcase bolts, φ8 Crankcase bolts, φ10 Crankcase bolts, φ6 Clutch push rod guide bolts Frame ground bracket bolt Oil return pipe bolts Oil nozzles Bearing retainer bolts Oil baffle bolt Primary gear bolt N·m 59 85 85 11 15 2.9 2.
9-4 CRANKSHAFT/TRANSMISSION Exploded View
CRANKSHAFT/TRANSMISSION 9-5 Exploded View No. Fastener 1 2 3 4 5 6 7 Shift shaft return spring pin Shift rod locknuts Rear shift lever clamp bolt Gear set lever bolt Shift drum cam bolt Shift pedal clamp bolt Damper cam nut N·m 39 9.8 12 11 15 30 195 8 9 10 11 Idle shaft holder bolts Water pump chain guide spring hook bolt Water pump impeller bolt Water pump chain guide bolt 8.3 2.9 8.8 8.3 12. Align the punch marks. 13. Align the punch mark with the slit. 14. Drive Shaft 15.
9-6 CRANKSHAFT/TRANSMISSION Specifications Item Crankshaft, Connecting Rods: Connecting rod bend Connecting rod twist Crankpin diameter: None ○ Connecting rod big end bore diameter: Marking Service Limit – – – TIR 0.2/100 mm (0.08/3.94 in.) TIR 0.2/100 mm (0.08/3.94 in.) 0.7 mm (0.028 in.) 0.10 mm – – – Connecting rod big end side clearance Connecting rod big end bearing insert/crankpin clearance Marking Standard None ○ 0.16 ∼ 0.46 mm (0.0062 ∼ 0.0181 in.) 0.026 ∼ 0.057 mm (0.001024 ∼ 0.0022 in.
CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Crankshaft main bearing/journal clearance Crankshaft main journal diameter Crankcase main bearing bore diameter Transmission Shift fork ear thickness Gear shift fork groove width Shift fork guide pin diameter Shift drum groove width Standard 0.025 ∼ 0.052 mm (0.00098 ∼ 0.00205 in.) 54.986 ∼ 55.000 mm (2.1648 ∼ 2.1654 in.) 55.025 ∼ 55.038 mm (2.1663 ∼ 2.1669 in.) Service Limit 0.10 mm (0.00394 in.) 54.96 mm (2.1638 in.) 55.07 mm (2.1681 in.) 5.9 ∼ 6.0 mm 5.
9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealants Outside Circlip Pliers : 57001–144 Flywheel Holder : 57001–1410 Damper Cam Holder : 57001–1025 Gear Holder : 57001–1557 Bearing Driver Set : 57001–1129 Kawasaki Bond (Silicone Sealant) : 56019–120 Flywheel Holder : 57001–1313 Kawasaki Bond (Liquid Gasket – Black) : 92104–1003
CRANKSHAFT/TRANSMISSION 9-9 Crankcase Disassembly • Remove: Engine (see Engine Removal/Installation chapter) • • Cylinder Blocks (see Engine Top End chapter) Pistons (see Engine Top End chapter) Clutch (see Clutch chapter) Front Gear Case (see Final Drive chapter) Alternator Inner Cover (see Electrical System chapter) Remove the shift shaft [A] while pushing [B] the shift mechanism arm [C] towards the shift shaft. Unscrew the bolt [D] and remove the gear set lever [E] and its spring [F].
9-10 CRANKSHAFT/TRANSMISSION Crankcase the starter clutch bolt [A] while holding the primary • Loosen gear bolt [B]. • Take out the torque limiter [C]. the following from the right end of the balancer • Remove shaft. Starter Clutch Bolt [A] Washer [B] Collar [C] Needle Bearing [D] Copper Washer [E] Starter Clutch [F] the primary gear bolt [A] while holding the alter• Loosen nator rotor steady with the flywheel holder (The primary gear can be removed with the engine in the frame).
CRANKSHAFT/TRANSMISSION 9-11 Crankcase the following from the left crankcase with the • Remove cylinder head removed. Front Chain Holder [A] Lower Chain Guide [B] Rear Chain Guide [C] Front Camshaft Chain [D] Front [E] the end of the spring [A] off the hook and unscrew • Take the bolts [B]. the idle shaft holder [C] and chain guide [D] from • Remove the right crankcase (The idle shaft holder can be removed with the engine in the frame).
9-12 CRANKSHAFT/TRANSMISSION Crankcase the starter motor bolts [B] and the motor [A] from • Remove the crankcase. the water pump sprocket [A] with it’s chain [B] and • Pull shaft [C]. • Remove the oil banjo bolt [A] with the hoses [B]. • Remove the oil filter [A] with the oil filter wrench [B]. Special Tool - Oil Filter Wrench: 57001–1249 • Remove the oil pressure switch [C]. the right crankcase bolts.
CRANKSHAFT/TRANSMISSION 9-13 Crankcase all the left crankcase bolts in the order listed. • Remove 6 mm Bolts (14) [A] 8 mm Bolt (1) [B] 10 mm Bolts (3) [C] ○Turn the left crankcase down. ○Lift up the right crankcase. ○Using the pry points, split the crankcase halves. • Pry Point (Front) [A] Pry Point (Rear) [B] Remove the following from the left crankcase.
9-14 CRANKSHAFT/TRANSMISSION Crankcase • Install the bearing retainers. Special Tool - Bearing Driver Set: 57001-1129 Bearings [A] Bearing Retainer [B] Left Crankcase [C] Non-permanent Locking Agent Bearing Retainer Bolts Torque - Bearing Retainer Bolts: 11 N·m (1.1 kgf·m, 97 in·lb) silicone sealant [A] to the step of the oil separating • Apply chamber [B] in the left crankcase [C]. Sealant - Silicone Sealant: 56019–120 the oil baffle [D] on the chamber.
CRANKSHAFT/TRANSMISSION 9-15 Crankcase the transmission assy as a set (see this chapter). • Install Set the gear set lever to the neutral position. • Shift Drum Cam [A] Gear Set Lever [B] Neutral Position [C] engine oil to the transmission gears, ball bearings, • Apply shift drum, and crankshaft main bearing. • Install: Oil Pipe and Oil Return Pipes (see Engine Lubrication System chapter) ○The left shaft [B] of the crankshaft [A] is longer than the right shaft [C].
9-16 CRANKSHAFT/TRANSMISSION Crankcase the water pump chain guide [A]. •○Install Be sure to install the collar [B] in the bolt hole. Torque - Water Pump Chain Guide Bolt: 8.3 N·m (0.85 kgf·m, 73 in·lb) to see that the following parts are in place in the • Check right crankcase. Oil Oil Oil Oil Pipe [A] Pump [B] Separator [C] Return Pipe [D] liquid gasket [A] to the mating surface of the right • Apply crankcase [B].
CRANKSHAFT/TRANSMISSION 9-17 Crankcase tightening all the crankcase bolts, check the follow• After ing items. ○Wipe up the liquid gasket that seeps out around the crankcase mating surface. ○Turn the right crankcase down, and check that the drive shaft and output shaft turn freely. ○Check that the positive neutral finder operates properly: While spinning [C] the output shaft [A] using an air impact wrench, gears shift smoothly from the 1st, 2nd · · · 5th gear, and 5th, 4th · · · 1st.
9-18 CRANKSHAFT/TRANSMISSION Crankcase the alternator rotor [A] while fitting the alignment • Install notch [B] of the splines onto the alignment tooth [C]. ○Be sure to align the balancer gear mark with the alternator mark (shorter line mark) [A] while keeping the front piston on its top dead center.
CRANKSHAFT/TRANSMISSION 9-19 Crankcase • Install: Water Pump Sprocket [A] with Shaft [B] Chain [C] • Install: Washer [A] Idle Shaft Sprocket [B] ○Fit the pin [C] into the slots [D] of the idle shaft sprocket. the primary gear [A] with the boss [B] facing toward • Install the engine inside. • Install: Idle Shaft Sprocket [A] and Pin Water Pump Drive Sprocket [B] and Chain [C] Washer [D] Dowel Pins [E] • Install: Idle Shaft Holder [A] and Water Pump Chain Guide [B].
9-20 CRANKSHAFT/TRANSMISSION Crankcase the alignment tooth [A] of the splines of the right bal• Fit ancer [B] onto the alignment notch of the balancer shaft. the starter torque limiter [A] and washer [B]. • Install Install the collar [C], copper washer [D], and needle bear• ing [E] in the order listed. ○The copper washer must be on the collar. the starter clutch gear [A] in and turn it clockwise [B] • Push and install it.
CRANKSHAFT/TRANSMISSION 9-21 Crankcase Starter Clutch Disassembly the starter clutch assy (see Crankcase Disas• Remove sembly). the Allen bolts [A] with the balancer mass [B] • Remove held with the flywheel holder [C] (special tool). Special Tool - Flywheel Holder: 57001-1313 the coupling [A] out of the right balancer [B]. • Pull Take • the one-way clutch [C] out of the coupling.
9-22 CRANKSHAFT/TRANSMISSION Crankcase Sliding Surface [A] of Coupling Starter Torque Limiter Check the torque limiter (see Crankcase Disassembly) • Remove and visually inspect it. If the limiter has wear, discoloration, or other damage, replace it as a set.
CRANKSHAFT/TRANSMISSION 9-23 Crankshaft/Connecting Rods Connecting Rod Removal the crankshaft. • Remove Remove the connecting rod big end nuts, and take off • the rod and cap along with the bearing inserts from the crankshaft [A]. NOTE ○Mark and record the locations of the connecting rods [B] and their big end caps [C] with the bearing inserts left attached so that they can be installed in their original positions.
9-24 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods ○When installing the inserts [A], be careful not to damage • • • • the insert surface with the edge of the connecting rod [B] or the cap [C]. One way to install inserts is as follows: Installation [D] to Cap Installation [E] to Connecting Rod Push [F] Dowel Pin [G] Connecting Rod Bolts [H] Install the cap on the connecting rod, aligning the weight and diameter marks. Remove debris and clean the surface of inserts.
CRANKSHAFT/TRANSMISSION 9-25 Crankshaft/Connecting Rods Connecting Rod Big End Side Clearance the side clearance [B] of the connecting rod big • Measure end [A]. ○Insert a thickness gauge between the big end and either crank web to determine clearance. Connecting Rod Big End Side Clearance 0.16 ∼ 0.46 mm Standard: (0.0062 ∼ 0.0181 in.) Service Limit: 0.7 mm (0.028 in.) If the clearance exceeds the service limit, replace the connecting rod with new one and then check clearance again.
9-26 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods If the clearance exceeds the service limit, measure the diameter of the crankpin [A]. Crankpin Diameter Standard: 54.981 ∼ 55.000 mm (2.1646 ∼ 2.1654 in.) 54.97 mm (2.1642 in.) Service Limit: If the crankpin has worn past the service limit, replace the crankshaft with a new one. If the measured crankpin diameter is not less than the service limit, but does not coincide with the original diameter marking on the crankshaft, make a new mark on it.
CRANKSHAFT/TRANSMISSION 9-27 Crankshaft/Connecting Rods Crankshaft Runout the crankshaft runout. • Measure If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: Service Limit: TIR 0.02 mm (0.0008 in.) or less TIR 0.05 mm (0.0020 in.) Crankshaft Main Bearing/Journal Wear • Measure the diameter [A] of the crankshaft main journal. Crankshaft Main Journal Diameter Standard: 54.986 ∼ 55.000 mm (2.1648 ∼ 2.1654 in.) Service Limit: 54.96 mm (2.1638 in.
9-28 CRANKSHAFT/TRANSMISSION Primary Gear Primary Gear Removal • Remove: Clutch Cover (see Clutch chapter) • Starter Clutch Gear (see Crankcase Disassembly) Using the gear holder [A] to loosen the primary gear bolt [B]. Special Tool - Gear Holder: 57001–1557 • Remove: Clutch (see Clutch chapter) • Bolts [A] Remove the water pump chain guide [B] and water pump idle shaft holder [C] from the right crankcase.
CRANKSHAFT/TRANSMISSION 9-29 Primary Gear the pin [A] into the slot [B] of the water pump drive • Fit sprocket boss and install the sprockets. • Install: Dowel Pins [A] • • Washer [B] Pulling the chain guide [C] and install the idle shaft holder [D]. Install the clutch (see Clutch chapter). Torque - Idle Shaft Holder Bolts: 8.3 N·m (0.
9-30 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal the footpeg bracket bolts [A] and take off the left • Unscrew front footpeg [B]. Front [C] • Unscrew the clamp bolt [B] and pull out the shift pedal [A]. Shift Pedal Installation the shift pedal [A] so that the punched mark on the • Install shaft is aligned [B] with the punched mark on the pedal. • Tighten the clamp bolt (the head is numbered 10). Torque - Shift Pedal Clamp Bolt: 30 N·m (3.
CRANKSHAFT/TRANSMISSION 9-31 Transmission External Shift Mechanism Installation the gear set lever [A] and the spring [B] in the • Install crankcase and tighten the bolt [C]. Torque - Gear Set Lever Bolt: 11 N·m (1.1 kgf·m, 97 in·lb) the shift mechanism arm assy. Be sure to install • Install the washer onto the shift shaft. the front gear case (see Final Drive chapter). • Install Install the front shift lever and the rear shift lever.
9-32 CRANKSHAFT/TRANSMISSION Transmission Transmission Removal the engine (see Engine Removal/Installation • Remove chapter). the crankcase (see this chapter). • Split Remove the crankshaft. • First, remove pipe [A] (see Engine Lubrication Sys• tem chapter),theandoilthen remove the shift drum bearing • holder bolts and holder [B]. Pull out the shift rod [C] and take the shift fork [D] out of the output shaft 4th gear.
CRANKSHAFT/TRANSMISSION 9-33 Transmission ○Each output shaft shift fork has an identification number. • Do not confuse them. Install the shift forks with each number faced left as shown. Shift Fork (No. 270, 5th gear) [A] Shift Fork (No. 293, 4th gear) [B] Front [C]. a non-permanent locking agent to the shift drum • Apply bearing holder bolts. Torque - Shift Drum Bearing Holder Bolts: 11 N·m (1.
9-34 CRANKSHAFT/TRANSMISSION Transmission Transmission Disassembly Remove the transmission shafts (see this chapter). •Using the circlip pliers (special tool), remove the circlips, and disassemble the transmission shaft. Special Tool - Outside Circlip Pliers: 57001-144 The 4th gear [A] on the output shaft has three steel balls for the positive neutral finder mechanism. Remove the 4th gear as follows. ○Set the output shaft in a vertical position holding the 3rd gear [B].
CRANKSHAFT/TRANSMISSION 9-35 Transmission Shift Fork Bending inspect the shift forks, and replace any fork that • Visually is bend. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear under load. 90° [A] Shift Fork/Gear Groove Wear the thickness of the shift fork ears [A], and mea• Measure sure the width [B] of the gear grooves. If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced.
9-36 CRANKSHAFT/TRANSMISSION Transmission 1. Circlip ( 20 × 25.5 × t 1.2) 2. Needle Bearing 3. Thrust Washer ( 22.3 × 35 × t 1.6) 4. Three Circlips ( 28) 5. 2nd Gear 6. 5th (top) Gear 7. Bushing (5th gear) 8. Two Splined Washers ( 28.5 × 34 × t 1.5) 9. 3rd Gear 10. 4th Gear 11. 1st Gear (drive shaft) 12. Output Shaft 13. 2nd Gear 14. Three Splined Washers ( 30.3 × 40 × t 1.5) 15. Three Circlips ( 29) 16. 5th (top) Gear 17. 3rd Gear 18. Bushing (3rd gear) 19. Steel Balls 20. 4th Gear 21. Washer ( 25.
CRANKSHAFT/TRANSMISSION 9-37 Ball Bearing, Needle Bearing, and Oil Seal Ball Bearing and Outer Race Replacement CAUTION Do not remove the ball bearing or needle bearing outer race unless it is necessary. Removal may damage them. a press or puller, remove the ball bearing and/or • Using needle bearing outer race. NOTE ○In the absence of the above mentioned tools, satisfac- tory results may be obtained by heating the case to approximately 93°C (200°F) max., and tapping the bearing in or out.
9-38 CRANKSHAFT/TRANSMISSION Ball Bearing, Needle Bearing, and Oil Seal Oil Seal Inspection the oil seal. • Inspect Replace it if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened or otherwise damaged.
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 Tire air valve stem nuts 1.5 0.15 13 in·lb 2 Air valve cores 0.3 0.03 2.6 in·lb 3 Tire air valve caps 0.15 0.015 1.3 in·lb 4 Front axle clamp bolts 29 3.0 21 5 Front axle 108 11 79.6 6 Rear axle nut 108 11 79.6 Remarks G: Apply grease. R: Replacement Parts AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. WL: Apply soap and water solution or rubber lubricant.
10-4 WHEELS/TIRES Specifications Item Wheels (Rims): Rim runout: Axial Radial Axle runout/100 mm Wheel balance Balance weights Tires: Air pressure (when cold): Front Rear Standard TIR 0.05 mm (0.002 in.) or less 10 g (0.35 oz.) or less 10 g (0.35 oz.), 20 g (0.71 oz.), 30 g (1.1 oz.) Service Limit TIR 0.5 mm (0.02 in.) TIR 0.8 mm (0.03 in.) TIR 0.2 mm (0.008 in.) – – – Up to 184 kg (405 lb) load: 250 kPa (2.50 kg/cm², 36 psi) Up to 184 kg (405 lb) load: 250 kPa (2.
WHEELS/TIRES 10-5 Special Tools Inside Circlip Pliers : 57001–143 Bearing Remover Head, φ25 x φ28 : 57001–1346 Bearing Driver Set : 57001–1129 Bearing Remover Shaft, φ13 : 57001–1377 Jack : 57001–1238 Attachment Jack : 57001–1398 Bearing Remover Head, φ20 x φ22 : 57001–1293
10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal the front brake caliper mounting bolts [A] and • Unscrew remove the brake calipers [B] with the hose installed. the European Model, remove the cap. • For Loosen: • Front Axle Clamp Bolts [A] Front Axle [B] ○Using the jack [A] and the attachment jack [B] under the frame pipe ribs [C], and a commercially available jack [D] under the engine [E], lift the front wheel [F] OFF the ground until the rear wheel [G] touches the ground.
WHEELS/TIRES 10-7 Wheels (Rims) Front Wheel Installation grease to the seal lips. • Apply Fit the collars [A] on the both side of the hub. •○The collars are identical. the axle from the right side of the wheel. • Insert Tighten the axle. • Torque - Front Axle: 108 N·m (11 kgf·m, 79.6 ft·lb) tightening the clamp bolts on the right fork leg, • Before pump the forks up and down [A] 4 or 5 times to allow the right fork leg to find a neutral position on the front axle.
10-8 WHEELS/TIRES Wheels (Rims) Rear Wheel Removal the jack [A] and attachment jack [B] under the frame • Using pipe ribs [C], lift the rear wheel [D] off the ground until the front wheel [E] touches the ground. CAUTION Be sure to put the front wheel ON the ground when removing the rear wheel, or the motorcycle may fall over. The motorcycle could be damaged. WARNING Be sure to put the front wheel ON the ground when removing the rear wheel, or the motorcycle may fall over.
WHEELS/TIRES 10-9 Wheels (Rims) out the axle, and slide the rear wheel [A] toward the • Pull right [B] to disengage the wheel from the final gear case. • Move the rear wheel back [C] and remove it. CAUTION Do not lay the wheel directly 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 grease to the grease seal of the wheel.
10-10 WHEELS/TIRES Wheels (Rims) • Bend the cotter pin [A] over the nut as shown. inspect the tire for stuck any grease [A]. • Visually If any grease have stuck to the surface of the tire, wash the tire clean with soap and water solution. • Check the rear brake effectiveness. WARNING Do not attempt to ride the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc.
WHEELS/TIRES 10-11 Wheels (Rims) Wheel Inspection • Raise the front or rear wheel off the ground. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398 [A] the wheel lightly, and check for roughness or • Spin binding. • • If roughness or binding is found, replace the hub bearings. Inspect the front and rear axles for damage (see Axle Inspection). If the axle is damaged or bent, replace it. Inspect the wheel for small cracks, dents, bending, or warp.
10-12 WHEELS/TIRES Wheels (Rims) Balance Inspection the wheel. • Remove Support the wheel so that it can be spun freely. • Spin the wheel and mark [A] the wheel at the top • when the wheellightly, stops. ○Repeat this procedure several times. If the wheel stops of its own accord in various positions, it is well balanced. If the wheel always stops in one position, adjust the wheel balance.
WHEELS/TIRES 10-13 Wheels (Rims) Balance Weight Removal • • (a) When the tire is not on the rim. Push [A] the blade portion toward the outside with a regular tip screw driver, and slip the weight off the rim flange. Discard the used balance weight. (b) When the tire is on the rim. Pry [A] the balance weight off the rim flange using a regular tip screw driver as shown in the figure.
10-14 WHEELS/TIRES Wheels (Rims) that the blade [A] seat fully on the rim flange [B], • Check and that the weight bottom [C] reaches rim flat portion. required total weight exceeds 20 g (0.71 oz.), install • When balance weight at both sides of rim flange as shown. Required Weight Selection Total Weight One Side [A] 10 g (0.35 oz.) 10 g (0.35 oz.) Other Side [B] – 20 g (0.71 oz.) 10 g (0.35 oz.) 10 g (0.35 oz.) 30 g (1.1 oz.) 20 g (0.71 oz.) 10 g (0.35 oz.) 40 g (1.4 oz.) 20 g (0.71 oz.
WHEELS/TIRES 10-15 Tires Air Pressure Inspection/Adjustment to Tire Inspection in the Periodic Maintenance chap• Refer ter. Tire Inspection to Tire Inspection in the Periodic Maintenance chap• Refer ter. Tire Removal the following. • Remove Wheel (see Front/Rear Wheel Removal) • Brake Disc (see Brakes chapter) 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.
10-16 WHEELS/TIRES Tires the new air valve in the front wheel rim. • Insert Valve Cap [A] Valve Body [B] Valve Nuts [C] Valve Washer [D] Rim [E] Valve Grommet [F] Remove the valve cap, valve nuts, valve washer and in○ sert the valve body through the rim from the inside out. Torque - Tire Air Valve Nuts: 1.5 N·m (0.15 kgf·m, 13 in·lb) Air Valve Cap: 0.15 N·m (0.015 kgf·m, 13 in·lb) Air Valve core: 0.3 N·m (0.03 kgf·m, 2.6 in·lb) the new air valve in the rear wheel rim.
WHEELS/TIRES 10-17 Tires the tire on the rim so that the valve [A] is at the tire • Position balance mark [B] (the chalk mark made during removal, • • • or the yellow paint mark on a new tire). Install the tire bead over the rim flange using a commercially available tire changer. Lubricate the tire beads and rim flanges with a soap and water solution or rubber lubricant to help seat the tire beads in the sealing surfaces of the rim while inflating the tire.
10-18 WHEELS/TIRES Tires Tire Repair Currently two types of repair for tubeless tires have come into wide use. One type is called a temporary (external) repair which can be carried out without removing the tire from the rim, and the other type is called permanent (internal) repair which requires tire removal. It is generally understood that higher running durability is obtained by permanent (internal) repairs than by temporary (external) ones.
WHEELS/TIRES 10-19 Hub Bearings (Wheel Bearings) Hub Bearings Removal the wheel, and take out the following. • Remove Collars Grease Seals [A] Circlips [B] Coupling [C] (Out of Rear Hub) Front Hub [D] Rear Hub [E] Special Tool - Inside Circlip Pliers: 57001-143 • Use the bearing remover to remove the hub bearings [A]. CAUTION Do not lay the wheel directly 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.
10-20 WHEELS/TIRES Hub Bearings (Wheel Bearings) ○Replace the circlips with new ones. Special Tool - Inside Circlip Pliers: 57001-143 the grease seals with new ones. • Replace Press in the grease seals [A] so that the seal surface is • flush [B] with the end of the hole. ○Apply high temperature grease to the grease seal lips. Special Tool - Bearing Driver Set: 57001-1129 [C] Hub Bearings Inspection ○Since the hub bearings are made to extremely close tolerance, the clearance cannot normally be measured.
FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View................................... Specifications .................................... Special Tools ..................................... Final Gear Case and Oil .................... Oil Level Inspection...................... Oil Change ................................... Final Gear Case Removal............ Final Gear Case Installation......... Final Gear Case Disassembly ..... Final Gear Case Assembly .......... Pinion Gear Removal.............
11-2 FINAL DRIVE Exploded View
FINAL DRIVE 11-3 Exploded View Front Gear Case No. 1 2 3 4 5 6 7 8 9 10 11 12 Fastener Oil pipe banjo bolts (front gear) Front gear case bolts 6 mm Neutral switch Oil nozzle (front gear) Oil nozzle (front gear) Speed sensor bolt Bearing retainer bolts (front gear) Drive gear nut (front gear) Driven gear assy mounting bolts Front gear case bolts 8 mm Driven gear bolt (front gear) Damper cam nut (front gear) EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent.
11-4 FINAL DRIVE Exploded View
FINAL DRIVE 11-5 Exploded View Final Gear Case No. 1 2 3 4 5 6 7 Fastener Final gear case mounting nuts Pinion gear nut (final gear) Final gear case cover bolts 10 mm Final gear case cover bolts 8 mm Bearing retainer bolt Final gear case drain plug Final gear case studs G: Apply grease. HO: Apply hypoid gear oil. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil. R: Replacement parts St: Stake the fasteners. N·m 34 127 34 23 6.9 8.8 – Torque kgf·m 3.5 13 3.5 2.3 0.70 0.
11-6 FINAL DRIVE Specifications Item Final Gear Case Oil: Grade Viscosity Oil level Amount Final Bevel Gear Backlash Preload for Pinion Gear Bearing: Torque wrench Spring seal Propeller Shaft Joint Grease Front Bevel Gear Backlash Preload for Front Bevel Gear Bearing: Torque wrench Spring scale Standard API Service Classification: GL-5 hypoid gear oil When above 5°C (41°F) SAE90 When below 5°C (41°F) SAE80 Filler opening bottom 200 mL (6.76 US oz.) 0.06 ∼ 0.09 mm (0.0024 ∼ 0.0035 in.
FINAL DRIVE 11-7 Special Tools Outside Circlip Pliers: 57001–144 Driven Gear Holder: 57001–1027 Bearing Puller: 57001–158 Oil Seal & Bearing Remover: 57001–1058 Bearing Puller Adapter: 57001–317 Bearing Driver Set: 57001–1129 Bearing Driver: 57001–382 Pinion Gear Holder: 57001–1165 Damper Cam Holder: 57001–1025 Final Gear Case Holder: 57001–1250
11-8 FINAL DRIVE Special Tools Drive Shaft Holder: 57001–1407
FINAL DRIVE 11-9 Final Gear Case and Oil Oil Level Inspection to Oil Level Inspection in Periodic Maintenance • Refer chapter. Oil Change • Refer to Oil Change in Periodic Maintenance chapter. Final Gear Case Removal • • • • If the final gear case is to be disassembled, drain the final gear case oil. Remove the rear wheel (see Wheels/Tires chapter). Remove the left shock absorber [A] from its studs by taking off the nuts. Remove the swingarm cover (see Suspension chapter).
11-10 FINAL DRIVE Final Gear Case and Oil the final gear case cover bolts [A]. • Remove Use three tapped holes [B] to lift the ring gear assy from • the gear case. The shim(s) comes off with the assy. NOTE ○Do not disassemble the ring gear assy (ring gear, ring gear hub, and final gear case cover), but the oil seal can be removed. remove the ring gear oil seal [A], heat the ring gear • To assy in an oil bath to 120 ∼ 150°C (248 ∼ 302°F), then pry out the oil seal with an awl or other tool.
FINAL DRIVE 11-11 Final Gear Case and Oil Final Gear Case 1. Pinion Gear Nut 2. Washer 3. Shim(s) for Preload 4. Pinion Gear Joint 5. O-ring 6. Ring Gear Hub 7. Ring Gear Oil Seal 8. Ball Bearing 9. Final Gear Case Cover 10. Cover Mounting Bolts 11. Ring Gear Shim(s) 12. Ring Gear Final Gear Case Assembly ○The ring gear and pinion gear are lapped as a set in the • • factory to get the best tooth contact. They must be installed as a pair, and never replace one without the other.
11-12 FINAL DRIVE Final Gear Case and Oil the needle bearings [A] with new ones. • Replace Apply a hypoid gear oil to the roller parts of the needle • bearings. NOTE ○Install the bearing so that the marked side faces out. ○Press in the bearings until they are bottomed. Special Tool - Bearing Driver Set: 57001–1129 the snap ring [B] secure. • Install Apply a locking agent to the bearing re• tainer boltnon-permanent [C]. • Install the washer [D] and the bearing retainer bolt.
FINAL DRIVE 11-13 Final Gear Case and Oil Pinion Gear Removal • Pry open the staking [A] on the pinion gear nut [B]. the nut [A] while holding the pinion gear assem• Unscrew bly [B] with the pinion gear holder [C]. Special Tool - Pinion Gear Holder: 57001–1165 • Remove: Washer [A] Shim(s) [B] Pinion gear joint [C] with the O-ring [D]. Pinion gear [E] with the Tapered Roller Bearing [F] out the bearing outer race from the bearing housing • Drive [A].
11-14 FINAL DRIVE Final Gear Case and Oil Pinion Gear Installation pinion gear and ring gear are lapped as a set in the • The factory to get the best tooth contact. They must be replaced as a set. Check the tapered roller bearing (see this chapter). Apply a hypoid gear oil to the roller bearings. • • the tapered roller bearing [A] into the pinion gear • Drive housing [B] using the bearing driver set [C].
FINAL DRIVE 11-15 Final Gear Case and Oil the oil seal with a new one. • Replace Drive the oil seal [A] using the bearing driver set [B]. • Special Tool - Bearing Driver Set: 57001–1129 [C] the above removed parts. •○Reinstall Stake [A] the pinion gear nut with a punch. CAUTION When staking the nut, be careful not to apply shock to the pinion gear and its bearing. Such a shock could damage the pinion gear and/or bearing.
11-16 FINAL DRIVE Final Gear Case and Oil a little hypoid gear oil to the bearings, and turn the • Apply gear shaft more than 5 turns to allow the bearings to seat. the bearing preload. Bearing preload is defined • Measure as the force or torque which is needed to start the gear shaft turning. Preload for Pinion Gear Bearing Using Spring Scale: 3.0 ∼ 5.0 N (0.30 ∼ 0.50 kg, 0.7 ∼ 1.1 lb) Using Torque Wrench: 0.6 ∼ 1.0 N·m (0.06 ∼ 0.10 kgf·m, 5.2 ∼ 8.
FINAL DRIVE 11-17 Final Gear Case and Oil 1. Washer 2. Shim(s) 3. Pinion Gear Joint 4. Bearing Housing 5. Tapered Roller Bearing 6. Tapered Roller Bearing A. Before Tightening B. After Tightening Bevel Gear Inspection check the bevel gears [A] for scoring, chipping, • Visually or other damage. Replace the bevel gears as a set if either gear is damaged. Pinion Gear Joint Inspection inspect the splines [A] of the pinion gear joint.
11-18 FINAL DRIVE Final Gear Case and Oil Final Bevel Gear Adjustment ○The backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged. After replacing any of the backlash-related parts, be sure to check and adjust the backlash and tooth contact of the bevel gears. First, adjust backlash, and then tooth contact by replacing shims. ○The amount of backlash is influenced by the ring gear position more than by the pinion gear position.
FINAL DRIVE 11-19 Final Gear Case and Oil Ring Gear Shims for Backlash Adjustment Thickness (mm) 0.15 (0.0059 in.) 0.5 (0.02 in.) 0.6 (0.023 in.) 0.7 (0.028 in.) 0.8 (0.031 in.) 0.9 (0.035 in.) 1.0 (0.039 in.) 1.2 (0.047 in.) Parts Number 92025-1783 92025-1784 92025-1785 92025-1786 92025-1787 92025-1788 92025-1789 92025-1790 Pinion Gear Shims for Tooth Contact Adjustment Thickness (mm) Parts Number 0.15 (0.0059 in.) 92180-0009 0.5 (0.02 in.) 92180-0010 0.6 (0.023 in.) 92180-0011 92180-0012 0.7 (0.028 in.
11-20 FINAL DRIVE Final Gear Case and Oil a dial gage [D] on a vise so that the tip of the gage • Mount is against the splines of the ring gear hub. measure the backlash, turn the ring gear hub [B] back • To and forth [C] while holding the pinion gear steady with the pinion gear holder [A]. The difference between the highest and the lowest gage reading is the amount of backlash. ○Measure backlash at three locations equally spaced on the splines. Final Bevel Gear Backlash: 0.10 ∼ 0.20 mm (0.0039 ∼ 0.0079 in.
FINAL DRIVE 11-21 Final Gear Case and Oil the pinion gear assembly with the final gear case • Hold holder [A]. Special Tool - Final Gear Case Holder: 57001–1250 Torque - Final Gear Case Mounting Nuts: kgf·m, 25 ft·lb) 34 N·m (3.5 the pinion gear for one revolution [B] back and forth, • Turn while creating a drag on the ring gear hub [C]. the ring gear assy and pinion gear assy to check • Remove the drive pattern and coast pattern of the bevel gear teeth.
11-22 FINAL DRIVE Final Gear Case and Oil Correct Tooth Contact Pattern: No adjustment is required. A. Heel B. Bottom C. Top D. Toe Incorrect Tooth Contact Patterns (Example 1) ○Decrease the thickness of the pinion gear shim(s) by 0.05 mm (0.002 in.) to correct the pattern shown above. A. Heel B. Bottom C. Top D. Toe Incorrect Tooth Contact Patterns (Example 2) ○Increase the thickness of the pinion gear shim(s) by 0.05 mm (0.002 in.) to correct the pattern shown above. A. Heel B.
FINAL DRIVE 11-23 Propeller Shaft Propeller Shaft Removal • Remove: Final Gear Case (see this chapter) Swingarm (see Suspension chapter) Remove the propeller shaft from the front driven gear joint. ○Turn the propeller shaft so that the lockpin access hole [A] in the propeller shaft comes outside. • ○Move back the propeller shaft and slip the propeller shaft off the driven gear joint while pushing on the lockpin.
11-24 FINAL DRIVE Propeller Shaft Propeller Shaft Joint Lubrication the final gear case and propeller shaft joint (see • Remove Final Drive chapter). the old grease off the propeller shaft sliding joint and • Wipe pinion joint. the propeller shaft sliding joint with 20 mL (16 • Pack grams) of high temperature grease [A]. Propeller Shaft Inspection that the universal joint [A] works smoothly without • Check rattling or sticking.
FINAL DRIVE 11-25 Front Bevel Gears Front Gear Case Removal • Remove: Engine (see Engine Removal/Installation chapter) Rear Shift Lever [A] ○The speed sensor connector [B] is disconnected during • engine removal. Unscrew the front gear case bolts [C] and remove the front gear case [D]. ○The cam follower [A] and the damper spring [B] come off • with the gear case. Check that the shift shaft oil seal and replace it if damaged. Front Gear Case Installation the front gear case bolts as follows.
11-26 FINAL DRIVE Front Bevel Gears ○Raise the driven gear, using the following pry points [A]. the drive gear assy as follows. •○Remove Pry off the gear case cap [A] with a tool. ○Pry open the drive gear nut [A] with a small chisel. ○Install: Damper Spring Cam Follower [B] ○Unscrew the drive gear nut while holding the drive gear shaft with the drive shaft holder [C] (special tool).
FINAL DRIVE 11-27 Front Bevel Gears Front Gear Case Assembly ○The drive and driven gear are lapped as a set in the fac- • tory to get the best tooth contact. They must be replaced as a set. Press the drive gear [B] slowly with the bearing driver [A] onto the shaft [C]. Special Tool - Bearing Driver: 57001-382 a non-permanent locking agent to the bearing re• Apply tainer bolts. • Tighten: Torque - Bearing Retainer Bolts: 8.8 N·m (0.
11-28 FINAL DRIVE Front Bevel Gears Driven Gear Disassembly the driven gear joint with the driven gear holder • Holding [A] in a vise, unscrew the driven gear bolt [B]. Special Tool - Driven Gear Holder: 57001–1027 the driven gear joint [A] with the O-ring [B]. • Remove Remove driven gear from the bearing housing. • Remove the the oil seal from the housing with a hook, and • pull the tapered roller bearing out of the housing.
FINAL DRIVE 11-29 Front Bevel Gears Damper Cam Removal the front gear case (see this chapter). • Remove Remove • shaft. the retainer and needle bearing of the output the clutch push rod guide [A] and bolts, and • Remove crankcase bearing upper retainer and bolts. a bolt ( 12 mm, L100 mm, 0.47 in., L3.94 in.) [B] • Insert into the engine mounting bolt hole. the damper cam nut [C] using a damper cam • Unscrew holder [D] (special tool) and deep socket wrench.
11-30 FINAL DRIVE Front Bevel Gears Front Bevel Gear Adjustment In order to prevent one gear from moving away from the other gear under load, the tapered roller bearings must be properly preloaded. Also the backlash (the distance one gear will move back and forth without moving the other gear) and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged.
FINAL DRIVE 11-31 Front Bevel Gears Front Bevel Gear Adjustment ○When any of the backlash-related parts are replaced, or the driven gear bolt is loosened; even if the purpose is not to replace the parts, be sure to check and adjust the bearing preload, the bevel gear backlash, and tooth contact by replacing shims. Preload Adjustment the driven gear assy, and tighten the driven gear • Install nut to the specified torque.
11-32 FINAL DRIVE Front Bevel Gears Preload Measurement with Spring Scale the bearing housing in a vise so that the gear shaft • Hold axis is vertical. [C] the spring scale [B] on the driven gear holder [A] • Hook at a point 200 mm (7.87 in.) [D] apart from the center of • the gear shaft. Apply force to the handle horizontally and at a right angle to it. Special Tool - Driven Gear Holder: 57001–1027 • If the preload is out of specified range, replace the bearing collar and/or spacer.
FINAL DRIVE 11-33 Front Bevel Gears Bearing Preloading Mechanism 1. Bearing Housing 2. Tapered Roller Bearing A. Before Tightening B. After Tightening 3. Spacer 4. Collar C. Under No Preload D. Initial Clearance Backlash Adjustment any dirt and oil off bevel gear teeth with a high-flash • Clean point solvent. the drive gear with the primary shim (1.0 mm, 0.04 • Install in., thickness), and tighten the nut to the specified torque.
11-34 FINAL DRIVE Front Bevel Gears a holder [A] with 6 mm bolts and nuts on the front • Install gear case to mount a dial gage. up a dial gage against a drive gear tooth to check • Set gear backlash. The gage stem must be in line with the • • direction of tooth travel. To measure the backlash, move the drive gear back and forth [C] while holding [B] the driven gear steady with a tool. The difference between the highest and lowest gage readings is the amount of backlash.
FINAL DRIVE 11-35 Front Bevel Gears the driven gear for 3 or 4 revolutions in the drive and • Turn reverse (coast) directions, while creating a drag on the • drive gear. Check the drive pattern and coast pattern of the bevel gear teeth. The tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth, and little closer to the toe of the tooth.
11-36 FINAL DRIVE Front Bevel Gears Incorrect Tooth Contact Patterns (Example 2): Decrease the thickness of the drive gear shim(s) by 0.05 mm (0.002 in.), and/or decrease the thickness of the driven gear shim(s) by 0.05 mm (0.002 in.) to correct the pattern shown below. Repeat in 0.05 mm (0.002 in.) steps if necessary. Heel [A] Bottom [B] Top [C] Toe [D] Drive Gear [E] Driven Gear [F] • Bevel Gear Inspection check the bevel gears for scoring, chipping, or • Visually other damage.
FINAL DRIVE 11-37 Bearing and Oil Seal Ball or Needle Bearing Replacement the bearing driver set or the oil seal & bearing re• Using mover, remove the bearings. Special Tools - Oil Seal & Bearing Remover: 57001–1058 Bearing Driver Set: 57001–1129 NOTE ○In the absence of the above mentioned tools, satisfac- tory results may be obtained by heating the case to approximately 93°C (200°F) max., and tapping the bearing in or out. CAUTION Do not heat the case with a blowtorch. This will warp the case.
11-38 FINAL DRIVE Bearing and Oil Seal Tapered Roller Bearing Inspection CAUTION Do not remove the tapered roller bearing for inspection. Removal may damage them. inspect the bearing in the front and final gear • Visually cases for abrasion, color change, or other damage. If there is any doubt as to the condition of the bearing, replace it. Needle Bearing Inspection CAUTION Do not remove the needle bearing in the final gear case for inspection. Removal may damage them.
BRAKES 12-1 Brakes Table of Contents Exploded View................................... Specifications .................................... Special Tool ....................................... Brake Lever, Brake Pedal.................. Brake Lever Position Adjustment. Brake Pedal Position Adjustment. Brake Pedal Removal .................. Brake Pedal Installation ............... Calipers ............................................. Front Caliper Removal ................. Rear Caliper Removal................
12-2 BRAKES Exploded View
BRAKES 12-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Brake hose banjo bolts 25 2.5 18 2 Front brake reservoir cap screws 1.5 0.15 13 in·lb 3 Brake lever pivot bolt 1.0 0.10 8.9 in·lb 4 Brake lever pivot bolt locknut 5.9 0.60 52 in·lb 5 Front master cylinder clamp bolts 8.8 0.90 78 in·lb 6 Front brake light switch screw 1.2 0.12 11 in·lb 7 Caliper bleed valves 7.8 0.80 69 in·lb 8 Front caliper mounting bolts 34 3.5 25 9 Brake disc bolts 27 2.
12-4 BRAKES Exploded View
BRAKES 12-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Rear master cylinder mounting bolts 25 2.5 18 2 Brake hose banjo bolts 25 2.5 18 3 Rear master cylinder push rod locknut 18 1.8 13 4 Brake pedal clamp bolt 25 2.5 18 5 Caliper bleed valves 7.8 0.80 69 in·lb 6 Rear caliper mounting bolts 34 3.5 25 7 Rear caliper holder bolt 64 6.5 47 8 Brake disc bolts 27 2.8 20 B: Apply brake fluid. G: Apply grease. L: Apply a non-permanent locking agent.
12-6 BRAKES Specifications Item Brake Lever, Brake Pedal: Brake lever position Brake lever free play Pedal free play Pedal position Brake Fluid: Grade Brake Pads: Pad lining thickness: Brake Discs: Thickness: Runout Standard Service Limit No.1 Non-adjustable Non-adjustable About 110 mm (4.33 in.) (height from pedal top to footpeg top) 5-way adjustable – – – – – – – – – DOT4 Front Rear 4.0 mm (0.157 in.) 7.5 mm (0.295 in.) Front Rear 4.8 ∼ 5.1 mm (0.19 ~ 0.20 in.) 6.8 ∼ 7.2 mm (0.268 ~ 0.283 in.
BRAKES 12-7 Special Tool Inside Circlip Pliers: 57001–143
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 Adjustment • Check that the brake pedal [A] is in the correct position.
BRAKES 12-9 Brake Lever, Brake Pedal the right front footpeg bracket bolts [A] and turn • Remove over the footpeg [B]. the locknut [A] and turn the push rod with the hex • Loosen head [B] to achieve the correct pedal position. • If the length [C] is 80 ±1 mm (3.1 ±0.04 in.), the pedal position will be within the standard range. Tighten: Torque - Push Rod Locknut: 18 N·m (1.8 kgf·m, 13 ft·lb) Brake Pedal Removal the brake fluid reservoir [A] (see Brake Pedal • Remove Position Adjustment).
12-10 BRAKES Brake Lever, Brake Pedal out the brake pedal [B] from the right footpeg bracket • Pull [A]. Brake Pedal Installation grease to the brake pedal shaft. • Apply Install pedal shaft [A] so that the punched mark on the • shaft isthealigned [B] with the punched mark on the brake • • lever [C]. Install: Brake Pedal Return Spring Brake Switch Return Spring Tighten: Torque - Brake Pedal Clamp Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) Rear Master Cylinder Mounting Bolts: 25 N·m (2.
BRAKES 12-11 Calipers Front Caliper Removal the banjo bolt [A] at the brake hose lower end, • Loosen and tighten it loosely. • Unscrew the caliper mounting bolts [B]. CAUTION Do not loosen the caliper assembly bolts [C]. Take out only the caliper mounting bolts for caliper removal. Loosening the caliper assembly bolts will cause brake fluid leakage. Immediately wash away any brake fluid that spills. off the caliper. • Take Unscrew • the caliper.
12-12 BRAKES Calipers Front Caliper Disassembly the pad spring and brake pads (see Front Brake • Remove Pad Removal). the U.S.A. and Canadian Models, remove the bolt [A] • For and reflector [B]. the front upper caliper mounting bolt [C] and • Unscrew loosen the front lower caliper mounting bolt [D]. [A] the front caliper little. • Move Loosen the front caliper assembly bolts [B] and front • caliper banjo bolt [C] and tighten them loosely. Remove the front caliper [D] and banjo bolt.
BRAKES 12-13 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. Be sure to install O-rings. • Tighten the calipertheassembly bolts.
12-14 BRAKES Calipers the board and pull out the pistons [A] by hand. •○Remove These pistons can also be removed by disconnecting the hose and applying compressed air to the hose joint opening using the same wooden board. But be careful not to put your fingers or palm inside the caliper opening during work. WARNING To avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply compressed air into the caliper, the pistons may crush your hand or fingers.
BRAKES 12-15 Calipers the caliper holder shaft rubber friction boot [A] • Replace and dust boot [B] if they are damaged. a thin coat of silicone or PBC grease to the caliper • Apply holder shafts [C] and holder holes (Silicone or PBC • grease is a special high temperature, water-resistance grease). Install the pads (see Rear Brake Pad Installation). Caliper Fluid Seal Damage The fluid seals [A] around the piston maintain the proper pad/disc clearance.
12-16 BRAKES Brake Pads Front Brake Pad Removal the pad spring bolts [A], and remove the pad • Unscrew spring [B]. out the snap pin [A], and take off the pad pin [B]. • Draw Remove the brake pads [C]. • Front Brake Pad Installation the caliper pistons in by hand as far as they will go. • Push Install the brake pads. • Install the and snap pin [A]. The snap pin must be • “outside” ofpadthepinpads. • Install the pad spring. Torque - Front Brake Pad Spring Bolts: 2.9 N·m (0.
BRAKES 12-17 Brake Pads the jaw side pad [A], and then remove the piston • Remove side pad [B]. Jaw [C] Rear Brake Pad Installation installation, clean the pads with a high-flash point • Before solvent. [A] the caliper pistons in by hand as far as they will • Push go. • Be sure to install the snap pin for the caliper. WARNING Do not attempt to ride the motorcycle until a full pedal is obtained by pumping the brake lever or pedal until the pads are against the disc.
12-18 BRAKES Master Cylinder Front Master Cylinder Removal the front brake light switch connectors [A]. • Disconnect Draw out the fluid from the reservoir with a means • like the fork oilbrake level gage. • Pull the bolt caps [B] out. the banjo bolt [A] to disconnect the brake hose • Remove from the master cylinder (see Brake Hose Removal/In- • stallation). Unscrew the clamp bolts [B], and take off the master cylinder [C] as an assembly with the reservoir, brake lever, and brake switch installed.
BRAKES 12-19 Master Cylinder Rear Master Cylinder Removal the brake fluid reservoir cover (see Brake Pedal • Remove Position Adjustment). out the brake fluid from the reservoir with a means • Draw like the fork oil level gage. the brake fluid reservoir (see Brake Pedal Posi• Remove tion Adjustment). the brake hose banjo bolt [A] on the master cylin• Unscrew der. the master cylinder mounting bolts [B]. • Loosen Unscrew • Remove: the footpeg bracket bolts [C].
12-20 BRAKES Master Cylinder Rear Master Cylinder Installation the cotter pin with a new one. • Replace Insert the cotter pin [A] to the hole of the joint pin [B] and • separate [C] the cotter pin ends. Use a new flat washer on each side of the brake hose • fitting. • Tighten: Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) the brake line (see Brake Line Bleeding).
BRAKES 12-21 Master Cylinder Rear Master Cylinder Disassembly NOTE ○Do not remove the push rod clevis [A] for master cylinder disassembly since removal requires brake pedal 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. Special Tool - Inside Circlip Pliers: 57001-143 out the push rod with the piston stop. • Pull off the piston assy [B], primary cup [C], and return • Take spring [D].
12-22 BRAKES Master Cylinder Master Cylinder Inspection the front and rear master cylinders. • Disassemble Check that there are no scratches, rust or pitting on the • inner wall [A] of each master cylinder and on the outside • of each piston [B]. If a master cylinder or piston shows any damage, replace them. Inspect the primary cup [C] and secondary cup [D]. If a cup is worn, damaged softened (rotted), or swollen, the piston assy should be replaced to renew the cups.
BRAKES 12-23 Brake Discs Brake Disc Removal the wheel (see Wheels/Tires chapter). • Remove Unscrew the mounting bolts [A], and take off the disc. • Brake Disc Installation the brake disc [A] on the wheel so that the marked • Install side [B] faces out. a non-permanent locking agent to the threads of • Apply the brake disc bolts [C]. • Tighten: Torque - Brake Disc Bolts: 27 N·m (2.8 kgf·m, 20 ft·lb) Brake Disc Wear the thickness of each disc [A] at the point where • Measure it has worn the most.
12-24 BRAKES Brake Fluid Brake Fluid Level Inspection to the Brake Fluid Level Inspection in Periodic Main• Refer tenance chapter. Brake Fluid Change to the Brake Fluid Change in Periodic Maintenance • Refer chapter. 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.
BRAKES 12-25 Brake Fluid the rubber cap from the bleed valve on the • Remove caliper. a clear plastic hose to the bleed valve, and run the • Attach other end of the hose into a container. the brake line and the caliper as follows: •○Bleed Repeat this operation until no more air can be seen coming out into the plastic hose. Pump the brake lever until it becomes hard, and apply the brake lever and hold it [A]. Quickly open and close [B] the bleed valve while holding the brake lever applied.
12-26 BRAKES Brake Fluid the fluid level. • Check After bleeding done, check the brake for good braking • power, no brakeis drag, and no fluid leakage. 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.
BRAKES 12-27 Brake Hoses Brake Hose Removal/Installation CAUTION Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately. removing the brake hose, take care not to spill the • When brake fluid on the painted or plastic parts. removing the brake hose [A], temporarily secure • When the end of the brake hose to some high place to keep • • • fluid loss to a minimum. Immediately wash away any brake fluid that spills.
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. 1 2 3 4 5 6 7 8 9 Fastener Upper front fork clamp bolts Lower front fork clamp bolts Front fork top plugs Front fork bottom Allen bolt Front axle clamp bolts Inner fork bolt Piston rod nut Joint rod nut Protector screws N·m 29 29 34 20 29 98 20 20 5.9 Torque kgf·m 3.0 3.0 3.5 2.0 3.0 10 2.0 2.0 0.60 ft·lb 21 21 25 15 21 72 15 15 52 in·lb G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts M: Apply molybdenum disulfide grease.
13-4 SUSPENSION Exploded View
SUSPENSION 13-5 Exploded View No. 1 2 3 Fastener Rear shock absorber nuts Swingarm pivot shaft Shock absorber air valves N·m 34 108 5.4 G: Apply grease. L: Apply a non-permanent locking agent. WL: Apply a soap and water solution or rubber lubricant. Torque kgf·m 3.5 11 0.55 ft·lb 25 79.
13-6 SUSPENSION Specifications Item Front Fork (per one unit): Fork inner tube diameter Fork spring setting Air pressure Rebound damper setting Fork oil viscosity Fork oil capacity: Right Fork Leg Standard 43 mm ( 1.7 in.) Non-adjustable Atmospheric pressure (Non-adjustable) Non-adjustable SAE 10W-20 507 ±2.5 mL (17.1 ±0.085 US oz.) (completely disassembled and dry) approx. 430 mL (14.5 US oz.) (when changing oil) Left Fork Leg 601 ±2.5 mL (20.3 ±0.085 US oz.
SUSPENSION 13-7 Special Tools Oil Seal & Bearing Remover : 57001–1058 Attachment Jack : 57001–1398 Bearing Driver Set : 57001–1129 Fork Cylinder Holder : 57001–1502 Jack : 57001–1238 Fork Oil Seal Driver, 57001–1530 Fork Piston Rod Puller, M12 × 1.
13-8 SUSPENSION Front Fork Fork Oil Change the front fork (see Front Fork Removal). • Remove Unscrew top plug out of the outer tube. •Right Forkthe Leg: the wrenches on the top plug [A] and piston rod nut • Use [B] loosen the piston rod nut. • Remove the top plug from the piston rod. • Remove: Piston Rod Nut [A] Washer [B] Collar [C] Spring Seat [D] Fork Spring [E] the fork oil into a suitable container.
SUSPENSION 13-9 Front Fork • Pull out the joint rod assy [A] together with the spring [B]. and extend [B] the fork [A] upside down to draw • Compress out the fork oil into a suitable container [C], then drop out the collar [D], washer [E] and fork spring [F]. Both Fork Legs: Hold the fork tube upright, press the outer tube [A] and the piston rod (Right Fork Leg) all the way down. Pour in the type and amount of fork oil specified.
13-10 SUSPENSION Front Fork ○Pump the outer tube several times to expel air bubbles. ○Wait until the oil level settles. ○With the fork fully compressed and the piston rod fully pushed in (Right Fork Leg), insert a tape measure or rod into the inner tube, and measure the distance from the top of the outer tube to the oil. Oil Level (fully compressed, without spring) Standard: Right fork leg 142 ±2 mm (5.59 ±0.08 in.) Left fork leg 136 ±2 mm (5.35 ±0.08 in.
SUSPENSION 13-11 Front Fork • Install: Spring Seat [A] • Collar [B] Washer [C] Screw the piston rod nut [D] stopped on to the piston rod. Left Fork Leg: Install the fork spring [A] with the smaller end facing upward [B]. Install: Washer Collar Joint Rod Assy together with the spring Install the inner fork bolt using the fork cylinder holder.
13-12 SUSPENSION Front Fork Front Fork Removal (each fork leg) the front axle nut (see wheels/Tires chapter). • Loosen Using the jack [A] and attachment jack [B] under the frame • pipe ribs [C], and a commercially available jack [D] under the engine [E], lift the front wheel [F] OFF the ground until the rear wheel [G] touches the ground.
SUSPENSION 13-13 Front Fork Front Fork Installation (each fork leg) the fork so that the top end [A] of the outer tube is • Install flush with the upper surface [B] of the steering stem head • bracket. Tighten the lower fork clamp bolts and fork top bolt. Torque - Front Fork Clamp Bolts (Lower): 29 N·m (3.0 kgf·m, 21 ft·lb) • Tighten the upper fork clamp bolt. Torque - Front Fork Clamp Bolt (Upper): 29 N·m (3.0 kgf·m, 21 ft·lb) NOTE ○Tighten the top plug before tightening the upper fork clamp bolt.
13-14 SUSPENSION Front Fork the fork leg with a vise [A]. • Hold Loosen the Allen bolt [B] and tighten it loosely. • • Remove: Piston Rod Nut [A] Stopper [B] Coller [C] Spring Joint [D] Fork Spring [E] the fork oil into a suitable container. •○Drain Using the piston rod puller [A], pump the piston rod up and down at least ten times to expel the oil from the fork. the bottom Allen bolt, then take the bolt [A] and • Unscrew gasket [B] out of the bottom of the inner tube.
SUSPENSION 13-15 Front Fork Left Fork Leg: ○Refer to the Fork Oil Change for the Left Fork Leg disassembly. Remove: Joint Rod Nut [A] Rubber Stopper [B] Inner Fork Bolt [C] Joint Rod Assy [D] with Spring • Special Tool - Fork Cylinder Holder: 57001–1502 the fork oil into a suitable container [A]. • Drain Remove: • Coller [B] Washer [C] Fork Spring [D] Both Fork Legs: Separate the inner tube from the outer tube as follows: ○Pull out the dust seal [A] from the outer tube.
13-16 SUSPENSION Front Fork Front Fork Assembly the following parts with new ones after removal. • Replace Retaining Ring [A] Oil Seal [B] Slide Bushing [C] Guide Bushing [D] Bottom Allen Bolt Gasket [E] (Right Fork Leg) Right Fork Leg: Install the centering plate [A] onto the bottom end of the cylinder unit [B]. Put the cylinder unit with the centering plate into the inner tube [C]. Apply a non-permanent locking agent to the bottom Allen bolt. Temporarily tighten the bottom Allen bolt.
SUSPENSION 13-17 Front Fork Right Fork: Hold the front fork with a vise [A]. Tighten the Allen bolt [B]. • • Torque - Bottom Allen Bolt: 20 N·m (2.0 kgf·m, 15 ft·lb) Inner Tube, Outer Tube Inspection inspect the inner tube [A] and repair any damage. • Visually Nick or rust can sometimes be repaired by using • a wet-stone damage to remove sharp edges or raised areas which cause seal damage. If the damage is not repairable, replace the inner tube.
13-18 SUSPENSION Front Fork Spring Inspection the fork spring becomes shorter as it weakens, • Since check its 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 the 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. Fork Spring Free Length Standard: 333.7 mm (13.14 in.
SUSPENSION 13-19 Rear Shock Absorber (Air Type) Rebound Damping Adjustment The rebound damping force adjuster on each rear shock absorber has 4 positions so that the rebound damping force can be adjusted for different road and loading conditions. The numbers on the adjuster show the setting position. Turn the adjuster [A] until the desired number [B]. ○The standard adjuster setting is No.II for an average-build rider of 68 kg (150 lb) with no passenger and no accessories.
13-20 SUSPENSION Rear Shock Absorber (Air Type) ○Raise the rear wheel [A] off the ground, using the jack [B], and the attachment jack [C]. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398 ○Take off each air valve cap [A] on the right and left shock absorbers. Front [B] ○Check the air pressure with the air pressure gauge. NOTE ○Do not use tire gauges for checking air pressure.
SUSPENSION 13-21 Rear Shock Absorber (Air Type) Rear Shock Absorber Removal the rear wheel off the ground, using the jack and the • Lift attachment jack. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398 the brake lever slowly and hold it with a band • Squeeze [A]. CAUTION Be sure to hold the front brake when removing the shock absorber, or the motorcycle may fall over. The motorcycle could be damaged.
13-22 SUSPENSION Rear Shock Absorber (Air Type) inspect the shock absorber sleeves [A] and nee• Visually dle bearings [B]. roller in a needle bearing normally wear very little, • The and wear is difficult to measure. Instead of measuring, inspect the bearing in the shock absorber for abrasion, color change, or other damage. If there is any doubt as to the condition of any of the needle bearings or sleeves, replace the sleeves, and needle bearings as a set.
SUSPENSION 13-23 Swingarm Swingarm Removal • Remove: Bolts [A] and Washers Swingarm Cover [B] the rear exhaust pipe (see Engine Top End chap• Remove ter). • Loosen: Right Muffler Chamber Bolt [A] • Front Exhaust Pipe Clamp Bolt [B] Remove: Swingarm Pivot Cap [C] removing the swingarm, unscrew the banjo bolt [A] • Before on the rear caliper [B]. ○Temporarily secure the end of the brake hose to some • • • high place to keep fluid loss to a minimum. Immediately wash away any brake fluid that spills.
13-24 SUSPENSION Swingarm • Remove: Rear Wheel (see Wheels/Tires chapter) • • • Final Gear Case (see Final Drive chapter) Remove the right rear shock absorber. Unscrew the pivot shaft [A], and pull it out while turning. Pull the swingarm [B] rearward, and take it off. CAUTION Do not tap the swingarm pivot shaft when removing or installing. Push or pull the pivot shaft while turning the shaft. Tapping on the shaft could damage the needle bearings in the swingarm.
SUSPENSION 13-25 Swingarm Swingarm Bearing Removal • Remove: Swingarm (see Swingarm Removal) Propeller Shaft (see Final Drive chapter) Right and Left Sleeves [A] Right and Left Grease Seals [B] the needle bearings, using the oil seal & bearing • Remove remover [A]. Special Tool - Oil Seal & Bearing Remover: 57001-1058 the bearings and sleeves with new ones. • Replace Remove the other side bearing in the same manner. • Swingarm Bearing Installation plenty of grease to the needle bearings, and sleeve.
13-26 SUSPENSION Swingarm Grease Seal and Needle Bearing Lubrication to the Swingarm Pivot Lubrication in the Periodic • Refer Maintenance chapter.
STEERING 14-1 Steering Table of Contents Exploded View........................................................................................................................ Special Tools .......................................................................................................................... Handlebar ............................................................................................................................... Handlebar Removal ...........................................
14-2 STEERING Exploded View
STEERING 14-3 Exploded View No. 1 2 3 4 5 Fastener Handlebar nuts Steering stem head nut Steering stem nut Upper front fork clamp bolts Lower front fork clamp bolts N·m 34 88 4.9 29 29 Torque kgf·m 3.5 9.0 0.50 3.0 3.0 ft·lb 25 65 43 in·lb 21 21 AD: Apply adhesive. AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease. S: Follow the specific tightening sequence.
14-4 STEERING Special Tools Head Pipe Outer Race Press Shaft: 57001–1075 Jack: 57001–1238 Head Pipe Outer Race Driver: 57001–1077 Steering Stem Bearing Driver: 57001–1344 Steering Stem Nut Wrench: 57001–1100 Steering Stem Bearing Driver Adapter: 57001–1345 Head Pipe Outer Race Remover: 57001–1107 Attachment Jack: 57001–1398
STEERING 14-5 Handlebar Handlebar Removal • Remove: Clutch Master Cylinder [A] Left Handlebar Switch Housing [B] Front Brake Master Cylinder [A] Right Handlebar Switch Housing [B] Throttle Grip [C] the nuts [A] and remove the handlebar [B] from • Unscrew the stem head. Handlebar Installation • Tighten the handlebar nuts. Torque - Handlebar Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) front half of the right handlebar switch housing [A] • The has a small projection [B].
14-6 STEERING Handlebar adhesive the inside the left grip [A]. • Apply Insert the grip until punched mark [B] in the handlebar. • Check andleftadjust the throttle cables and rear view mirrors.
STEERING 14-7 Steering Steering Check to the Steering Check in the Periodic Maintenance • Refer chapter. Steering Adjustment to the Steering Adjustment in the Periodic Mainte• Refer nance chapter.
14-8 STEERING Steering Stem Steering Stem Removal the jack [A] and attachment jack [B] under the frame • Using pipe ribs [C], and a commercially available jack [D] under the engine [E], lift the front wheel [F] OFF the ground until the rear wheel [G] touches the ground. Special Tools - Jack: 57001–1238 Attachment Jack: 57001–1398 • Remove the front wheel (see Tires/Wheels chapter). CAUTION Be sure to put the rear wheel on the ground when removing the steering, or the motorcycle may fall over.
STEERING 14-9 Steering Stem • Remove: O-ring [A] • Take off the steering stem head [A] with the handlebar [B]. CAUTION Cover the fuel tank with a thick towel [C] or cloth to protect the painted surface of the fuel tank. • Loosen: Lower Fork Clamp Bolts [A] Remove: • Front Fork Legs [B] with Front Fender • Remove: Claw Washer [A] Steering Stem Nut [B] Stem Cap [C] O-ring [D] Special Tool - Steering Stem Nut Wrench: 57001–1100 NOTE ○Be sure to remove the O-ring for removal of the steering stem.
14-10 STEERING Steering Stem Steering Stem Installation • Install: Steering Stem [A] • Bearing [B] New O-ring [C] (I.D. 34.5 × 2 mm) Stem Cap [D] Tighten the stem nut [E] firmly, and loosen it. Special Tool - Steering Stem Nut Wrench: 57001–1100 the stem nut again with the specified torque (see • Tighten Stem Bearing Installation). Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb) • Install the claw washer [F]. the fork leg [A] and push [B] it up tightly against the • Install stem bottom.
STEERING 14-11 Steering Stem the removed parts. • Install Headlight Body Front Brake Hose Joint Front Wheel (see Wheels/Tires chapter) Install the turn signal lights [A]. ○Run the signal light leads [B] to the clamp portion [C] of the signal light. ○Clamp the signal light leads onto the headlight body clamps [D]. Install the headlight unit (see Electrical System chapter). Check and adjust the following items after installation.
14-12 STEERING Steering Stem Bearing Stem Bearing Removal the steering stem (see Steering Stem Removal). • Remove Drive out the bearing outer races from the head pipe. • Special Tool - Head Pipe Outer Race Remover: -1107 [A] 57001 NOTE ○If either steering stem bearing is damaged, it is recommended that both the upper and lower bearings (including outer races) be replaced with new ones. the lower inner race [A] which is pressed onto • Remove the steering stem, using a chisel.
STEERING 14-13 Steering Stem Bearing ○Check that there is no play and the steering stem turns • • smoothly without rattles. If not, the steering stem bearings may be damaged. Remove the stem nut. Install the O-rings and adjust the steering (see Periodic Maintenance chapter). Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb) Stem Bearing Lubrication In accordance with the Periodic Maintenance Chart, lubricate the steering stem bearings.
FRAME 15-1 Frame Table of Contents Exploded View........................................................................................................................ Special Tools .......................................................................................................................... Seat ........................................................................................................................................ Seat Removal ..................................................
15-2 FRAME Exploded View
FRAME 15-3 Exploded View 1.
15-4 FRAME Exploded View
FRAME 15-5 Exploded View No. 1 2 3 Fastener Rear footpeg bracket bolts Sidestand nut Downtube bolts G: Apply grease. L: Apply a non-permanent locking agent. N·m 25 44 44 Torque kgf·m 2.5 4.5 4.
15-6 FRAME Special Tools Jack: 57001–1238 Attachment Jack: 57001–1398
FRAME 15-7 Seat Seat Removal the seat bolts [A]. • Remove Pull the seat backward [B], then remove it. • Seat Installation the seat hook [A] under the brace [B] on the frame. • Slip Tighten the seat bolts.
15-8 FRAME Side Covers Left Side Cover Removal the ignition switch key [A] into the left side cover, • Insert and turn the key clockwise until the key slot is vertical. [B] the rear part of the left side cover towards you, • Pull push [C] the left side cover slightly forward, and remove it. Left Side Cover Installation the front stoppers [A] into the grommets [B] first, then • Put put the rear stopper into the grommet.
FRAME 15-9 Fenders Front Fender Removal CAUTION Be careful not to scratch the painted surface during removal or installation. the mounting bolts [A] on both sides to separate • Remove the front fender [B] from the front fork [C]. the brake hose clamps [D]. • Remove Remove the front fender. • Rear Fender Removal CAUTION Be careful not to scratch the painted surface during removal or installation. the seat (see this chapter). • Remove Unscrew the rear fender stay bolts [A] on both side.
15-10 FRAME Battery Case Battery Case Removal • Remove: Seat (see this chapter) Bolts [A] and Battery Holder [B] Battery [C] (see Electrical System chapter) ECU [D] (see Fuel System chapter) Vehicle-down Sensor [E] (see Fuel System chapter) Rear Fender (see this chapter) • Remove: Oil Pressure Light Delay Unit [A] DFI Main Relay [B] Turn Signal Control Relay [C] Starter Relay [D] • Remove the bolts [A]. • Remove the battery case [A] from the rear [B].
FRAME 15-11 Tool Box Tool Box Removal the left side cover (see this chapter). • Remove For California model; remove the band [A] and canister • [B]. the bolts [C]. • Unscrew Pull the tool box [D] out.
15-12 FRAME Downtube Removal the jack and the attachment jack, raise the rear • Using wheel off the ground (see Wheels/Tires chapter). Special Tools - Jack: 57001–1238 Attachment Jack: 57001–1398 Remove: Brake Reservoir Cover [A] Brake Reservoir (see Brakes chapter) Open the lead clamps [B] Remove the right front footpeg bracket [C] by taking off the bolts [D] with the brake pedal and rear master cylinder installed. Remove the front exhaust pipe [E] (see Engine Top End chapter).
FRAME 15-13 Sidestand Sidestand Installation • Tighten: Torque - Sidestand Nut: 44 N·m (4.5 kgf·m, 32 ft·lb) the sidestand spring [A], noting the direction of the • Install hooks [B].
15-14 FRAME Rear View Mirrors Rear View Mirror Removal (Other than European Model) the locknut [A]. • Loosen Turn the view mirror stay [B] counterclockwise to re• move therear rear view mirror from the holder [C]. Rear View Mirror Removal (European Model) the lower hexagonal area [A]. • Loosen Turn the view mirror stay [B] counterclockwise to re• move therear rear view mirror from the holder [C].
FRAME 15-15 Rear View Mirrors Rear View Mirror Installation (European Model) the mounting area of the rear view mirror [A] into • Screw the holder [B] all the way, and tighten the lower hexagonal area [C] securely. CAUTION Do not force to tighten and/or loosen the upper hexagonal area (adapter) [A] with a pair of spanners or wrench. Disassembly of this area is not possible. Non-permanent locking agent [B] is already applied to the threads of this inner area.
15-16 FRAME Frame Frame Inspection inspect the frame [A] for cracks, dents, bending, • Visually or warp. If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Electrical Parts Location .................... Exploded View................................... Wiring Diagram (United States of America and Canada)..................... Wiring Diagram (Other Than United States of America, Canada and Australia)......................................... Wiring Diagram (Australia) ................ Specifications .................................... Special Tools and Sealant ................. Servicing Precautions.....
16-2 ELECTRICAL SYSTEM Oil Pressure Light Delay Unit Inspection.................................. Meter, Gauge..................................... Meter Unit Removal ..................... Meter Unit Installation .................. Meter Unit Disassemble............... Meter Unit Assembly.................... Meter Unit Inspection ................... Indicator Panel Bulb Replacement ............................. Water Temperature Warning System. Water Temperature Warning System Check ........................
ELECTRICAL SYSTEM 16-3 Electrical Parts Location DFI: DFI Parts (see Fuel System chapter) 1. Speedometer 2. Tachometer 3. Ignition Switch 4. Front Brake Light Switch 5. Starter Lockout Switch 6. Fuel Pump (DFI) with Fuel Reserve Switch 7. Indicator Light Cover 8. Atmospheric Pressure Sensor (DFI) 9. Water Temperature Sensor (DFI) 10. Ignition Coil #1 11. Ignition Coil #2 12. Diodes (Rectifiers) 13. Injector #1 (DFI) 14. Injector #2 (DFI) 15. Vacuum Sensor (DFI) 16. Throttle Sensor 17. Spark Plugs 18.
16-4 ELECTRICAL SYSTEM Electrical Parts Location 33. Vehicle-down Sensor (DFI) 34. ECU (DFI, Electronic Control Unit) 35. Sealed Battery 36. Starter Relay and Main Fuse 30A 37. DFI Fuse 20A 38. Junction Box 39. Turn Signal Control Relay 40. DFI Main Relay 41.
16-6 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 16-7 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Starter lockout switch screw 1.2 0.12 11 in·lb 2 Front brake light switch screw 1.2 0.12 11 in·lb 3 Headlight mounting screws 2.9 0.30 26 in·lb 4 Headlight rim screws 1.4 0.14 12 in·lb 5 Headlight body bracket screws 1.2 0.12 11 in·lb 6 Headlight body mounting nuts 7.8 0.80 69 in·lb 7 Front turn signal light mounting nuts 5.9 0.60 52 in·lb 8. Starter lockout switch 9.
16-8 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 16-9 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Spark plugs 18 1.8 13 2 Water temperature switch 7.8 0.80 69 in·lb 3 Radiator fan switch 18 1.8 13 4 Sidestand switch bolt 8.8 0.90 78 in·lb 5 Rear turn signal light mounting nuts 6.9 0.70 61 in·lb 6 License plate lens screws 1.0 0.10 8.9 in·lb 7 License plate light mounting screws 1.2 0.12 11 in·lb 8. Rear Brake Light Switch 9. Sealed Battery 12 V 18 Ah 10. Oil Pressure Light Delay Unit 11.
16-10 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 16-11 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Alternator stator bolts 13 1.3 115 in·lb L 2 Alternator rotor bolt 78 8.0 58 MO 3 Stator lead holder screw 9.8 1.0 87 in·lb L 4 Rotor bolt cap 1.5 0.15 13 in·lb 5 Timing inspection cap 1.5 0.15 13 in·lb 6 Alternator cover bolts 11 1.1 97 in·lb 7 Alternator inner cover bolts 11 1.1 97 in·lb 8 Crankshaft sensor screws 2.9 0.30 26 in·lb 9 Crankshaft sensor lead holder bolt 2.
16-12 ELECTRICAL SYSTEM Wiring Diagram (United States of America and Canada)
ELECTRICAL SYSTEM 16-13 Wiring Diagram (United States of America and Canada)
16-14 ELECTRICAL SYSTEM Wiring Diagram (Other Than United States of America, Canada and Australia)
ELECTRICAL SYSTEM 16-15 Wiring Diagram (Other Than United States of America, Canada and Australia)
16-16 ELECTRICAL SYSTEM Wiring Diagram (Australia)
ELECTRICAL SYSTEM 16-17 Wiring Diagram (Australia)
16-18 ELECTRICAL SYSTEM Specifications Item Standard Battery: Type Model name Capacity Voltage Charging System: Alternator type Sealed Battery FTZ16-BS 12 V 18 Ah 12.
ELECTRICAL SYSTEM 16-19 Specifications Item Water temperature switch resistance (Rising temperature) Fuel level switch resistance Standard From OFF to ON: 113 ∼ 117°C (235 ∼ 243°F) From ON to OFF: 108°C (226°F) ∼ temperature less than ON temperature FULL position: 4 ∼ 10 Ω EMPTY position: 90 ∼ 100 Ω ○Refer to Fuel System chapter for specifications of DFI parts.
16-20 ELECTRICAL SYSTEM Special Tools and Sealant Spark Plug Wrench, Hex 18 : 57001–1024 Attachment Jack : 57001–1398 Jack : 57001–1238 Flywheel Holder : 57001–1410 Hand Tester : 57001–1394 Kawasaki Bond (Silicone Sealant) : 56019–120
ELECTRICAL SYSTEM 16-21 Servicing Precautions There are a number of important precautions that should be followed servicing electrical systems. ○Do not reverse the battery cable 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.
16-22 ELECTRICAL SYSTEM Servicing Precautions Male Connectors [B]
ELECTRICAL SYSTEM 16-23 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 that the connectors are not loose. Check the wiring for continuity. ○Use the wiring diagram to find the ends of the wire which is suspected of being a problem.
16-24 ELECTRICAL SYSTEM Battery Battery Removal CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch in ON, as this could damage the ECU (Electronic Control Unit). Never reverse the connections of the battery, this could damage the ECU. off the ignition switch. • Turn Remove the seat (see Frame chapter).
ELECTRICAL SYSTEM 16-25 Battery the battery holder [A] on the battery. • Put Tighten securely. • Connectthethebolts sub harness [B], fuel pump [C] and battery • (−) lead [D] connectors. • Install the seat (see Frame chapter). Electrolyte Filling sure that the model name [A] of the electrolyte con• Make tainer matches the model name [B] of the battery. These names must be the same.
16-26 ELECTRICAL SYSTEM Battery the electrolyte container upside down aligning the • Place six seals with the six battery filler ports. the container down strongly enough to break the • Push seals. Now the electrolyte should start to flow into the battery. NOTE ○Do not tilt the container as the electrolyte flow may be interrupted. sure air bubbles [A] are coming up from all six filler • Make ports. ○Leave the container this way for 5 minutes or longer.
ELECTRICAL SYSTEM 16-27 Battery Initial Charge While a Sealed battery can be used after only filling with electrolyte, a battery may not be able to sufficiently move a starter motor to start an engine in the cases shown in the table below, where an initial charge is required before use. However, if a battery shows a terminal voltage of 12.6 V or more, using a digital volt meter, after 10 minutes of filling, no initial charge is necessary. Kawasaki-recommended chargers: OptiMate III Yuasa 1.
16-28 ELECTRICAL SYSTEM Battery WARNING Keep the battery away from sparks and open flames during charging, since the battery gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases. No fire should be drawn near the battery, or no terminals should have the tightening loosened. The electrolyte contains sulfuric acid.
ELECTRICAL SYSTEM 16-29 Battery Terminal Voltage: 11.5 ∼ less than 12.6 V 1.8 A × 5 ∼ 10 h Standard Charge (see following chart) 9.0 A × 1.0 h Quick Charge CAUTION If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on. Terminal Voltage: less than 11.5 V 1.8 A × 20 h Charging Method: NOTE ○Increase the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially.
16-30 ELECTRICAL SYSTEM Charging System Alternator Outer Cover Removal (left side view): • Remove Left Front Footpeg [A] (see Crankshaft/Transmission chapter) Shift Pedal [B] (see Crankshaft/Transmission chapter) the bolts [A] and take off the alternator outer • Unscrew cover [B]. Alternator Outer Cover Installation insert the upper edge [A] of the alternator outer • First, cover under the left crankcase ribs [B]. This prevents the • rib failure.
ELECTRICAL SYSTEM 16-31 Charging System • Unscrew the bolts [A] and take off the alternator cover [B]. and replace the gasket with a new one. • Discard Apply silicone sealant to the area [A] to the crankshaft • sensor wire grommet [B]. Stator Lead Grommet [C] Sealant - Kawasaki Bond (Silicone Sealant): 56019–120 • Tighten the cover bolts. Torque - Alternator Cover Bolts: 11 N·m (1.
16-32 ELECTRICAL SYSTEM Charging System the front engine mounting bolt [A]. • Remove Loosen the rear engine mounting bolt [B]. • up [A] the front part of the engine, using the jack until • Lift the lower part of the alternator inner cover clears the lower frame [B]. NOTE ○Turn the propeller shaft so that the engine can be raised as high as possible. the bolts [C] and take off the alternator inner • Unscrew cover [D]. Alternator Inner Cover Installation the gasket with a new one.
ELECTRICAL SYSTEM 16-33 Charging System the alternator rotor [A] while fitting the alignment • Install notch [B] of the splines onto the alignment tooth [C]. ○Be sure to align the balancer gear mark (shorter) with the alternator mark (line marks) [A] while keeping the front position on its top dead center. Top Mark for Rear Piston [B] (longer mark) Top Mark for Front Piston [C] (longer mark) molybdenum disulfide oil to the threads of the alter• Apply nator rotor bolt.
16-34 ELECTRICAL SYSTEM Charging System up the dampers [A] and crankshaft sensor holders [B] • Set to the pickup coils [C]. the crankshaft sensors as shown. • Install Crankshaft sensor [A] with shorter leads (BK and BK/Y) for #1 (front) Crankshaft sensor [B] with longer leads (BK/W and BK/R) for #2 (rear) Torque - Crankshaft Sensor Screws: 2.9 N·m (0.30 kgf·m, 26 in·lb) ○Run the longer crankshaft sensor leads over the shorter crankshaft sensor leads above the alternator leads.
ELECTRICAL SYSTEM 16-35 Charging System Charging Voltage Inspection the battery condition. • Check Warm up • conditions.the engine to obtain actual alternator operating the seat (see Frame chapter). • Remove Check that the ignition switch is turned off, and connect • the hand tester to the battery as shown in the table. Regulator/Rectifier Output Voltage Tester Connections Reading Range Tester (+) to Tester (−) to @3 000 rpm 25 V DC Battery (+) Battery (−) 14.2 ∼ 15.
16-36 ELECTRICAL SYSTEM Charging System Alternator Output Voltage Tester Range 250 V AC Connections Tester (+) to Tester (−) to One yellow wire Another yellow wire Reading @3 000 rpm 64 ∼ 96 V If the output voltage shows the value in the table, the alternator operates properly and the regulator/rectifier is damaged. A much lower reading than the value in the table indicates that the alternator is defective. ○Repeat the test for the other yellow wires.
ELECTRICAL SYSTEM 16-37 Charging System ○Open the clamp [A] with (−) screw driver [B]. the regulator/rectifier bolts [A] and take off the • Remove regulator/rectifier [B]. Regulator/Rectifier Inspection the alternator outer cover (see this chapter). • Remove Disconnect • connectors. the regulator/rectifier [A] and alternator [B] Set the hand tester to the × 1 kΩ range and make the • measurements shown in the table. Special Tool - Hand Tester: 57001-1394 the hand tester to the regulator/rectifier.
16-38 ELECTRICAL SYSTEM Charging System Regulator/Rectifier Internal Resistance Tester (+) Lead Connection (−)* Terminal BR W/R1 W/R2 Y1 Y2 Y3 Y4 BK1 BK2 BR — ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ W/R1 ∞ — 0 ∞ ∞ ∞ ∞ ∞ ∞ W/R2 ∞ 0 — ∞ ∞ ∞ ∞ ∞ ∞ Y1 ∞ 2 ∼ 20 2 ∼ 20 — ∞ ∞ 0 ∞ ∞ Y2 ∞ 2 ∼ 20 2 ∼ 20 ∞ — ∞ ∞ ∞ ∞ Y3 ∞ 2 ∼ 20 2 ∼ 20 ∞ ∞ — ∞ ∞ ∞ Y4 ∞ 2 ∼ 20 2 ∼ 20 0 ∞ ∞ — ∞ ∞ BK1 1 ∼ 20 5 ∼ 100 5 ∼ 100 2 ∼ 20 2 ∼ 20 2 ∼ 20 2 ∼ 20 — 0 BK2 1 ∼ 20 5 ∼ 10
ELECTRICAL SYSTEM 16-39 Charging System Charging System 1. Alternator 2. Regulator/Rectifier 3. Ignition Switch 4. Load 5. Main Fuse 30 A 6. Starter Relay 7. Sealed Battery 12 V 18 Ah 8.
16-40 ELECTRICAL SYSTEM Ignition System Ignition System Circuit #1: For Front Cylinder #2: For Rear Cylinder 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Spark Plugs 5. Ignition Coil #1 6. Ignition Coil #2 7. Vehicle-down Sensor (DFI) 8. Junction Box 9. Ignition Fuse 10 A 10. Throttle Sensor (DFI) 11. Main Fuse 30 A 12. Sealed Batter 12 V 18 Ah 13. ECU (DFI) 14. Crankshaft Sensor #2 15. Crankshaft Sensor #1 16. Neutral Switch 17. Starter Lockout Switch 18. Sidestand Switch 19.
ELECTRICAL SYSTEM 16-41 Ignition System
16-42 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high voltage. Do not touch the spark plugs, ignition coils, or spark plug high-tension cables 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 IC igniter damage in the ECU. Do not install the battery backwards.
ELECTRICAL SYSTEM 16-43 Ignition System the mounting nuts [A] and connector bracket [B]. • Remove Take out the #1 ignition coil. • the right handlebar switch, fan motor and rear • Disconnect brake switch connectors [A]. the mounting nuts [B] and connector bracket [C]. • Remove Take on the #2 ignition coil. • Disconnect the primary wires.
16-44 ELECTRICAL SYSTEM Ignition System WARNING To avoid extremely high voltage shocks, do not touch the coil body or leads. • If the distance reading is less than the specified value, the ignition coil or spark plug caps are defective. To determine which part is defective, measure the arcing distance again with the spark plug caps removed from the ignition coil. Remove the caps by turning them counterclockwise. If the arcing distance is subnormal as before, the trouble is with the ignition coil itself.
ELECTRICAL SYSTEM 16-45 Ignition System Ignition Coil Primary Peak Voltage NOTE ○Be sure the battery is fully charged. the fuel tank (see Fuel System chapter). • Remove Remove all the spark plug caps but do not remove the • spark plugs. new spark plugs into all the spark plug caps, and • Install ground them onto the engine. a commercially available peak voltage adapter [A] • Install into the hand tester [B].
16-46 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Removal the alternator cover [A] (see this chapter). • Remove Unscrew holder bolt [B] and take off the crankshaft • sensor leadtheholder [C]. Unscrew the screws • sors with the grommet[D][E].and take off the crankshaft sen- Crankshaft Sensor Installation ○Refer to Alternator Stator Installation in this chapter. Crankshaft Sensor Inspection the alternator outer cover (see this chapter).
ELECTRICAL SYSTEM 16-47 Ignition System NOTE ○Be sure the battery is fully charged. • • • • Hand Tester Range: × DC 10 V Turn the ignition switch and the engine stop switch ON. Pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measure the crankshaft sensor peak voltage. Repeat the measurements 5 or more times for one crankshaft sensor. Repeat the test for the other crankshaft sensor. Crankshaft Sensor Peak Voltage Standard: Front: 2.2 V or more Rear: 2.
16-48 ELECTRICAL SYSTEM Ignition System Interlock Operation Inspection • Remove: Side Cover (see Frame chapter) ○Do not disconnect the connectors. 1st Check Measure the terminal voltage of the R/W wire in the junction box connector [A] in accordance with the following procedure. ○Set the tester [B] to the 10 V DC range, connect it to the R/W wire and frame ground [C].
ELECTRICAL SYSTEM 16-49 Ignition System IC Igniter Inspection ○The IC igniter is built in the ECU [A]. Damper [B] Battery Case [C] Groove [D] Front [E] ○Refer to Fuel System chapter for ECU Inspection.
16-50 ELECTRICAL SYSTEM Ignition System
ELECTRICAL SYSTEM 16-51 Starter Motor Starter Motor Removal out the cap [A] • Slide Remove: • Starter Motor Terminal Nut [B] Cable [C] Starter Motor Bolts [D] • Pull the starter motor [A] toward the left and remove it. CAUTION Never drop the starter motor, especial on a hard surface. Such a shock to the motor can damage it. Starter Motor Installation CAUTION Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor.
16-52 ELECTRICAL SYSTEM Starter Motor Disassembly the starter motor (see Starter Motor Removal). • Remove Take off the starter motor assy bolts [A] and remove both • end covers [B] and pull the armature out of the yoke. the positive carbon brushes [B] out of the brush hold• Take ers [A]. • Take off the brush plate [C] with brush wire from the yoke. the terminal locknut [B] and remove the terminal • Unscrew bolt [A]. the positive carbon brushes and wire assy [C] out of • Take the yoke.
ELECTRICAL SYSTEM 16-53 Starter Motor the armature [A] among the brushes, and remove the • Put plastic washers [B]. the tang [A] of the brush plate into the left end cover • Fit groove [B]. a thin coat of grease to the oil seal [B] in the right • Apply end cover [A]. a thin coat of grease to the left bearing [A]. • Apply Fit shims onto the right end cover. • ○The line on the yoke should align [A] with the line on the left cover. Torque - Starter Motor Assembly Bolts: kgf·m, 43 in·lb) 4.9 N·m (0.
16-54 ELECTRICAL SYSTEM Starter Motor Brush Inspection the length [A] of each brush. • Measure If any is worn down to the service limit, replace the carbon brush holder assy [B] and the terminal bolt assy [C]. Starter Motor Brush Length Standard: 12 mm (0.47 in.) Service Limit: 8.5 mm (0.33 in.) Commutator Cleaning and Inspection the commutator surface [A] if necessary with fine • Smooth emery cloth [B], and clean out the grooves. the diameter [A] of the commutator [B].
ELECTRICAL SYSTEM 16-55 Starter Motor Brush Assy Inspection the × 1 Ω hand tester range, measure the resis• Using tance as follows. Terminal Bolt and Positive Brushes [A] Brush Plate and Negative Brushes [B] Plastic [C] ○The reading should be zero. If there is not close to zero ohms, the brush lead has an open. Replace the terminal bolt assembly and the brush holder assembly. Brush Plate and Terminal Bolt Inspection the highest hand tester range, measure the resis• Using tance as shown.
16-56 ELECTRICAL SYSTEM Starter Motor Electric Starter Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Junction Box 5. Starter Circuit Relay 6. Ignition Fuse 10 A 7. Starter Lockout Switch 8. Side Stand Switch 9. Diode 10. Neutral Switch 11. Starter Motor 12. Starter Relay 13. Main Fuse 30 A 14.
ELECTRICAL SYSTEM 16-57 Lighting System This model adopts the daylight system and has a head light relay in the junction box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on when the engine starts running and stays on even if the engine stalls. The headlight goes out when the ignition switch is turned off. It also goes out while the starter button is depressed.
16-58 ELECTRICAL SYSTEM Lighting System the headlight unit and drop it out. • Pull Pull the headlight connector [A]. • Remove the headlight dust cover [B]. • • Push the hook [A] to unlock. • Take out the bulb [A]. 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.
ELECTRICAL SYSTEM 16-59 Lighting System Headlight Body Removal the headlight rim screws [A]. • Remove Pull the headlight unit and drop it out. • the wiring connectors [A]. • Disconnect Remove the • body [C]. headlight body nuts [B], then take off the City Light Bulb Replacement (other than US, CA and AU) the headlight unit (see Headlight Body Re• Remove moval). out the socket [A] together with the bulb. • Pull Pull the • bly).
16-60 ELECTRICAL SYSTEM Lighting System the bulb in [A], turn it counterclockwise [B], and pull • Push it out. • Replace the bulb with a new one. the front pin [A] up and the rear pin [B] down, insert • With the new bulb by aligning the front pin with the left groove • [C] in the walls of the socket [D]. Push the bulb in, turn it clockwise, and release it. It should lock in position. the hooks [A] to the edge [B] of the tail/brake light • Put cover. the lens screws.
ELECTRICAL SYSTEM 16-61 Lighting System Headlight/Tail Light Circuit 1. Ignition Switch 2. Alternator 3. Junction Box 4. Headlight Relay 5. Headlight Fuse 10 A 6. Taillight Fuse 10 A 7. License Plate Light 8. Tail/Brake Light 9. Sealed Battery 12 V 18 Ah 10. Main Fuse 30 A 11. Starter Relay 12. Dimmer Switch 13. City Light (Other than United States of America, Canada and Australia) 14. Headlight 15.
16-62 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System Automobiles use a turn signal canceling system actuated by steering wheel turn. But, motorcycles turn with a bank additionally, and so have a smaller steer angle. This makes difficult to adopt an automobile type turn signal canceling system because of inaccurate operation in motorcycles. So, motorcycles adopt time & distance counting system.
ELECTRICAL SYSTEM 16-63 Automatic Turn Signal Canceling System Turn Signal Cancelling System [ ]: Other Than Canada and United States of America 1. Right Turn Signal Indicator Light 2. Left Turn Signal Indicator Light 3. Distance Sensor 4. Meter Unit 5. Front Right Turn Signal Light 6. Front Left Turn Signal Light 7. Rear Right Turn Signal Light 8. Rear Left Turn Signal Light 9. Junction Box 10. Main Fuse 30 A in Starter Relay 11. Turn Signal Control Relay 12. Ignition Switch 13. Turn Signal Switch 14.
16-64 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System Wiring Inspection all the connectors. • Connect Remove the side cover (see Frame chapter). • Remove the right coolant reserve tank bolts and hanging the • reserve tank. the turn signal control relay [A]. • Remove Pull off the 6-pin connector of the unit, the 9-pin and 4-pin • meter connectors in the headlight housing, and the 9-pin left handlebar switch connector under the fuel tank.
ELECTRICAL SYSTEM 16-65 Automatic Turn Signal Canceling System the hand tester to the DC25 V range and connect it • Set to the LB wire terminal [A] and battery (−) terminal [B] as shown. Connections Hand Tester (+) → LB Wire Terminal Hand Tester (−) → Battery (−) Terminal all the spark plugs and shift the gear into 1st. • Remove Turn the rear wheel slowly to see that the tester’s pointer • fluctuates repeated by reading 0.5 V and 12 V. If the tester’s pointer fluctuates, distance sensor is normal.
16-66 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System Turn Signal Control Relay Inspection CAUTION Never drop the turn signal control relay, especially on a hard surface. Such a shock to the unit can damage it. the right side cover (see Frame chapter). • Remove Connect one 12 V battery and turn signal lights as indi• cated in the figure, and count how many times the lights flash for one minute.
ELECTRICAL SYSTEM 16-67 Automatic Turn Signal Canceling System the bulb [A] in the socket and turn the bulb counter• Push clockwise [B]. • Replace the bulb. the new bulb [A] by aligning the pins [B] with the • Insert groove in the walls of the socket [C].
16-68 ELECTRICAL SYSTEM Radiator Fan System WARNING The radiator fan is connected directly to the battery. The 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. Fan System Circuit Inspection the wires from the radiator fan switch [A]. • Disconnect Using an auxiliary wire [B], connect the radiator fan switch • wires.
ELECTRICAL SYSTEM 16-69 Radiator Fan System Radiator Fan Circuit 1. Radiator Fan 2. Radiator Fan Switch 3. Junction Box 4. Fan Fuse 15 A 5. Main Fuse 30 A 6.
16-70 ELECTRICAL SYSTEM Oil Pressure Warning System Motorcycle operation with low engine oil level, even if it is higher than the lower level line, will cause oil level change when sudden acceleration, or deceleration, and may lead flicker of the oil pressure warning light because of too rapid response of the oil pressure switch. To improve this operation, the oil pressure light delay unit is adopted, which prevents flicker of the oil pressure warning light by delaying its lighting.
ELECTRICAL SYSTEM 16-71 Oil Pressure Warning System Oil Pressure Light Delay Unit Removal the right side cover (see Frame chapter). • Remove Remove the coolant reserve tank bolts and hanging the • reserve tank [A]. Pull the connectors out of the oil pressure light delay unit • [B]. Oil Pressure Light Delay Unit Inspection the wire [A] of the oil pressure switch [B] and • Disconnect ground [C] it to the engine, using an auxiliary wire. the ignition switch [D] ON.
16-72 ELECTRICAL SYSTEM Meter, Gauge Meter Unit Removal the headlight unit (see Headlight Body Re• Remove moval). the clamp [A] and disconnect the meter connectors • Open [B]. • Unscrew the bolts [A] and take the meter unit [B]. the screws [A] and remove the meter cover [B] • Unscrew from the meter unit. the nuts [A] and remove the meter unit [B] from • Unscrew the meter bracket [C]. CAUTION Never drop the meter unit, especially on a hard surface. Such a shock to the unit can damage it.
ELECTRICAL SYSTEM 16-73 Meter, Gauge Meter Unit Disassemble the meter unit (see this chapter). • Remove Remove: • Screws [A] • Separate the upper meter cover [B]. the screw [A], meter light sockets [B] and rubber • Remove lid [C]. the screws [D] on the lower cover [E] to free the • Remove digital meter assembly. • Disconnect the meter harness connectors [A]. out the fuel level indicator light socket [A] counter• Turn clockwise.
16-74 ELECTRICAL SYSTEM Meter, Gauge Meter Unit Assembly the connectors of the meter harness. • Connect Put on the lid [A] on the lower cover [B]. •○Tighten therubber screw together with the harness clamp [C] as shown. Meter Unit Inspection Mode Select and Reset Button Checks: When the ignition switch is turned ON, all the LCD segments (the letters and numbers of the liquid crystal display) [A] appear for 3 seconds on the meter. If they do not appear, check the LCD segments.
ELECTRICAL SYSTEM 16-75 Meter, Gauge Clock Setting: In the HOUR/MINUTE setting mode, push the reset button [A] again to effect the HOUR setting mode. ○The hour display flashes [B] on the display. Push the mode select button to set the hour. • • HOUR setting mode, push the reset button [A] once • Into the effect the MINUTE setting mode. ○The minute display flashes [B] on the display. • Push the mode select button to set the minute.
16-76 ELECTRICAL SYSTEM Meter, Gauge the auxiliary wires, connect a 12 V battery to the • Using meter unit connector terminals. First Connections: Battery Positive Terminal (+) → Terminal [7] Battery Negative Terminal (−) → Terminal [3] Next Connections: Battery Positive Terminal (+) → Terminal [1] that all the LCD segments (the letters and numbers • Verify of the liquid crystal display) to appear for 3 seconds. Then • the clock or meters normally depending on the mode selected.
ELECTRICAL SYSTEM 16-77 Meter, Gauge an oscillator is available, check the speedometer as fol• Iflows. ○Connect the terminals in the same way as in the LCD segment inspection. ○Connect the oscillator [A] to the terminal [11]. The vehicle speed that corresponds to the input frequency will be displayed when a short wave form such as the one show in the diagram is input. Example: An input frequency of 310 Hz will display about 40 km/h. An input frequency of 247 Hz will display about 20 mph.
16-78 ELECTRICAL SYSTEM Meter, Gauge ODO Meter Inspection: Turn the display [A] into ODO. During the speedometer inspection with an oscillator, verify that the digital meter reading increases. If it does not increase, replace the digital meter assembly. • TRIP Meter Inspection: Turn the display [A] into TRIP. During the speedometer inspection with an oscillator, verify that the trip meter reading increases.
ELECTRICAL SYSTEM 16-79 Meter, Gauge an oscillation is unavailable, check that the distance • Ifsensor as follows. ○Remove the right side cover (see Frame chapter). ○Remove the turn signal control relay [A], but do not disconnect the connectors [B]. ○Use the jack and the attachment jack to lift the rear wheel.
16-80 ELECTRICAL SYSTEM Meter, Gauge Water Temperature Warning LED Light Connections: Battery Negative Wire (−) to Terminal [6] the terminal [6]. •○Connect The water temperature warning LED light. the terminal [6]. •○Disconnect The water temperature warning LED light disappears. If there is any problem, replace the digital meter assembly. Fuel Level Indicator Light Connections: Battery Negative Wire (−) to Terminal [13] the terminal [13]. •○Connect The fuel level warning light lights. the terminal [13].
ELECTRICAL SYSTEM 16-81 Meter, Gauge out the indicator light socket [B] backward and then • Pull pull out the lens [A] from the socket . over the socket rubber. • Turn Remove type bulb [A], pull the bulb • straight outtheof wedge-base 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 value. the bulb, and insert the lens to the socket. • Replace Install the socket into the indicator panel.
16-82 ELECTRICAL SYSTEM Meter, Gauge 1. Oil Pressure Warning Light Delay Unit 2. Speed Sensor 3. Speedometer 4. Tachometer 5. Odo/Trip/Clock Indicator 6. FI Indicator LED Light 7. Water Temperature Warning LED Light 8. Oil Pressure Warning LED Light 9. Fuel Level Indicator Light 10. Speedometer Light 11. Tachometer Light 12. Ignition Switch 13. Water Temperature Switch 14. E.C.U. (Electronic Control Unit) 15. Junction Box 16. Ignition Fuse 10 A 17. Oil Pressure Switch 18. Turn Signal Control Relay 19.
ELECTRICAL SYSTEM 16-83 Water Temperature Warning System Water Temperature Warning System Check The water temperature warning LED light goes on when the ignition switch is turned on and goes off soon to ensure that its circuit functions properly and the warning LED light has not burned out. The warning LED light also goes on whenever the coolant temperature rises to 113 ~ 117° (235 ~ 243°F) when the motorcycle is in operation.
16-84 ELECTRICAL SYSTEM Switch and Sensors Fuel Reserve Switch Inspection the fuel tank with fuel. • Fill Close the fuel tank cap surely. • Remove: • Seat (see Frame chapter) Fuel Pump Connector (see Fuel System chapter) Connect the test light (12 V 3.4 W bulb a socket with wires) [B] and 12 V battery and the 12 V battery [A] to the fuel pump connector [C]. Connections: Battery (+) → 12 V 3.4 W Bulb (one side) 12 V 3.
ELECTRICAL SYSTEM 16-85 Switch and Sensors Speed Sensor Inspection • Remove: Speed Sensor (see Speed Sensor Removal) Connect speed sensor connector [A] with a battery • [B], 10 kΩtheresistor [C] and hand tester [D] as shown. Set the tester to the DC 25 V range. • Special Tool - Hand Tester : 57001–1394 [A] the speed sensor surface with the screw driver. •○Trace Then the tester indicator should flick [B]. If the tester indicator does not flick, replace the speed sensor.
16-86 ELECTRICAL SYSTEM Switch and Sensors Radiator Fan Switch Removal CAUTION Never drop the fan switch, especially on a hard surface. Such a shock to the part can damage it. the coolant (see Cooling System chapter). • Drain Disconnect fan switch connector. • Unscrew thetheradiator fan switch [A] from the radiator. • Radiator Fan Switch Installation Torque - Radiator Fan Switch: 18 N·m (1.8 kgf·m, 13 ft·lb) the coolant and bleed the air from the cooling system • Fill (see Periodic Maintenance chapter).
ELECTRICAL SYSTEM 16-87 Switch and Sensors Water Temperature Switch Installation silicone sealant to the threads of the water temper• Apply ature switch. Sealant - Kawasaki Bond: 59019–120 Torque - Water Temperature Switch: 7.8 N·m (0.8 kgf·m, 69 in·lb) the engine with coolant and bleed the air from the • Fill cooling system (see Periodic Maintenance chapter). Water Temperature Switch Inspection the water temperature switch.
16-88 ELECTRICAL SYSTEM Switch and Sensors • Set the hand tester to the × 100 Ω range. Special Tool - Hand Tester: 57001–1394 Check the continuity between the diode terminals in both directions. If there is continuity in one direction (forward direction) but no continuity (infinity) in the reverse direction, the diode is normal. The diode is defective if there is continuity after changing the direction, or if it remains with no continuity.
ELECTRICAL SYSTEM 16-89 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 right side cover (see Frame chapter). • Remove Remove junction box. • Pull off thetheconnectors the junction box. • Make sure all connectorfrom terminals • none of them have been bent. are clean and tight, and • Clean the dirty terminals, and straighten slightly-bent terminals.
16-90 ELECTRICAL SYSTEM Junction Box Starter Circuit/Headlight Relay Inspection the junction box. • Remove Check conductivity of the following numbered terminals • by connecting the hand tester and one 12 V battery to the junction box as shown (see Junction Box Internal Circuit). If the tester does not read as specified, replace the junction box.
ELECTRICAL SYSTEM 16-91 Junction Box Junction Box Internal Circuit Accessory Fuse 10 A [A] Fan Fuse 15 A [B] Turn Signal Fuse 10 A [C] Horn Fuse 10 A [D] Ignition Fuse 10 A [E] Headlight Fuse 10 A [F] Headlight Relay [G] Headlight Diodes [H] Starter Diode [I] Starter Circuit Relay [J] Interlock Diodes [K] Taillight Fuse 10 A [L]
16-92 ELECTRICAL SYSTEM Fuse Main Fuse Removal the right side cover (see Frame chapter). • Remove Remove the coolant reserve tank bolts and hanging the • reserve tank. the starter relay [A]. • Remove Pull out the • nose pliers.main fuse [B] from the starter relay with needle Junction Box Fuse Removal the right side cover (see Frame chapter). • Remove Unlock the to lift up the lid [A]. • Pull the fuseshook [B] • dle nose pliers.
APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing .............................................................................................. Troubleshooting Guide (except DFI) ......................................................................................
17-2 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-3 Cable, Wire, and Hose Routing F: Front 1. Indicator Lights 2. Fuel Tank 3. Fuel Pump Base 4. Two Clamps (fuel pump leads) 5. Plastic Caps 6. Snap-on Plastic Clamps 7. Fuel Tank Breather Hose 8. Fuel Pump Harness 9. Run the harness [8] under the hose [7]. 10. Indicator Light Connector: Insert the main harness side connector into the connector hole of the bracket [13] and join the connector. 11. Main Harness 12.
17-4 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-5 Cable, Wire, and Hose Routing F: Front 1. Front Right Spark Plug Cap 2. Rear Right Spark Plug Cap 3. 2nd Lead from the left ignition coil lower side 4. 2nd Lead from the right ignition coil lower side 5. Ignition Coil for Rear Spark Plugs 6. Ignition Coil for Front Spark Plugs 7. 2nd Lead from the left ignition coil upper side 8. 2nd Lead form the right ignition coil upper side 9. Front Left Spark Plug Cap 10. Rear Left Spark Plug Cap 11. Clutch Hose 12. Plastic Snap-on Clamps 13. Strap 14.
17-6 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-7 Cable, Wire, and Hose Routing →: Inlet Air Flow 1. Rear View 2. Air Inlet 3. Left Rubber Gasket 4. Left Air Cleaner Cover 5. Air Cleaner Element 6. Left Air Cleaner Base 7. Lower Air Cleaner Duct 8. Air Switching Valve Hose 9. To Air Switching Valve 10. Right Rubber Gasket 11. Right Rubber Gasket 12. Right Air Cleaner Cover 13. Locate the glued joint of the gasket within the angle. 14. Elbow Joint: connected to crankcase breather hose 15. Top 16.
17-8 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-9 Cable, Wire, and Hose Routing →: Bypass Air Flow F: Front 1. Rear View 2. Throttle Body Assy 3. Air Cleaner Base Seal 4. Spark Plug Lead Holder 5. Right Side View 6. Harness of Inlet Air Temperature Sensor & ISC Valves 7. T-Joint 8. Vacuum Hose from Throttle Body 9. Inlet Air Pressure Sensor and Pressure Regulator 10. Clamp 11. Air Switching Valve Hose 12. Right Air Cleaner Base Bolts 13. Right Air Cleaner Base 14. O-rings 15. ISC Valve Hose #2 (red) 16. ISC Valve Hose #1 (blue) 17.
17-10 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-11 Cable, Wire, and Hose Routing - - →: Vacuum Pulsation →: Fuel Flow F: Front #1. For Front Cylinder #2. For Rear Cylinder. 1. Fuel Tank (left view) 2. Return Fuel Check Valve 3. High Pressure Fuel Hoses 4. Delivery Joint 5. Fuel Injector #1 6. Fuel Injector #2 7. Pressure Regulator 8. Throttle Body 9. Inlet Manifold 10. Throttle Body Assy (top view) 11. Throttle Pulley 12. Throttle Sensor 13. Low Pressure (Return) Fuel Hose 14. Vacuum Hoses from Throttle Body 15.
17-12 APPENDIX Cable, Wire, and Hose Routing F: Front 1. Face the white marks top. 2. Air Switching Valve 3. Choke Cable 4. Face the clamp knob as shown. 5. Front Cylinder Coolant Hose 6. Breather Hose: Run the upper the air switching valve. 7. To the Right Air Cleaner Base 8.
APPENDIX 17-13 Cable, Wire, and Hose Routing F: Front 1. Air Switching Valve 2. Front Air Suction Valve Hose 3. Breather Hose 4. Rear Air Suction Valve Hose 5. Idle Adjusting Screw 6. Rear Cylinder Coolant Hose 7. Run the rear air suction valve hose under the pressure regulator on the throttle body assembly. 8. Hold the idle adjusting screw to the hook on the right air cleaner base.
17-14 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-15 Cable, Wire, and Hose Routing F: Front ←→: Vacuum Pulsation →: Bypass Air Flow #1: For Front Cylinder #2: For Rear Cylinder 1. Top View 2. Rear View 3. Bottom View 4. Pressure Regulator 5. Delivery Joint 6. Fuel Injector #2 7. Fuel Injector #1 8. Vacuum Hoses from Throttle Body 9. ISC Hose #1 10. T-Joint 11. Throttle Sensor 12. Vacuum Hose to Inlet Air Pressure Sensor 13. Inlet Manifold 14. ISC Hose #2 15. ISC Pipe #1 16. ISC Pipe #2 17. Throttle Cable Holder 18. Choke Lever Stop Screw 19.
17-16 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-17 Cable, Wire, and Hose Routing F: Front 1. Clips 2. Air Switching Valve 3. Air Switching Valve Hose (for front air suction valve) 4. White Mark (Face it upwards.) 5. Air Switching Valve Hose (for right air cleaner base) 6. Air Switching Valve Hose (for rear air suction valve): Run the hose under the vacuum hose of the pressure regulator and choke cable. 7. They will be almost the same in height by aligning punch marks. 8. Align these punch marks. 9. Left-hand Threads 10.
17-18 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-19 Cable, Wire, and Hose Routing F: Front 1. White Marks on the hose [2] and [7] : The marks faces forwards. 2. Front Coolant Hose 3. Reserve Tank Hose 4. Clip 5. Rear Cylinder Coolant Hose 6. White Marks on the hose face backwards. 7. Radiator Hose 8. Water Pump 9. Clamp 10. Water Pump Drainage Outlet Hose 11. Distance between pump inlet step and clamp end: about 16 mm (0.63 in.) 12. Clamps: Position each screw head as shown. 13. Insert the hose until the end touches the water pump inlet step.
17-20 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-21 Cable, Wire, and Hose Routing F: Front →: Fuel Flow ←→: Vacuum Pulsation 1. Atmospheric Pressure Sensor 2. Inlet Air Pressure Sensor 3. Inlet Air Pressure Sensor Hose 4. Rear Cylinder Coolant Hose 5. Injector Harness 6. Low Pressure Fuel Hose (return) 7. Fuel Hose Joint #2 8. Yellow Mark: Face the yellow mark upwards and forwards, aligning with the yellow marks. 9. Face the screw head left. 10. Install the hose with its mark up. 11. Fuel Hose Joint #1 12. Outlet Fuel from fuel tank 13.
17-22 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-23 Cable, Wire, and Hose Routing →: Fuel Flow F: Front 1. Fuel Pump Connector (outside the fuel tank) 2. Bottom of Fuel Tank 3. Outlet Fuel Pipe 4. Fuel Pump Body (DFI) 5. Fuel Reserve Switch (thermistor) 6. Pump Motor (−) BK/W Lead 7. Pump Motor (+) W/R Lead 8. Fuel Reserve Switch R/BK (+) Lead 9. Fuel Reserve Switch BK/Y (−) Lead 10. Pump Base Plate 11. Base Plate Gasket 12. Outlet Fuel Pipe Joint 13. Fuel Pump Screen (Pump Inlet) 14. Inlet Fuel Hose 15. Top 16. Bottom View 17. Fuel Filter 18.
17-24 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-25 Cable, Wire, and Hose Routing F: Front 1. Rubber Boot 2. Starter Motor Lead 3. Clutch Hose 4. Upper Washer ( 14 × 8.2 mm) 5. Lower Washer ( 25 × 8.2 mm) 6. Engine Oil Pipe 7. Clamp (For harness protection since edge of the clutch slave cylinder) 8. Clutch Slave Cylinder Bleed Valve 9. Bolt 10. Crankshaft Sensor Connector 11. Speed Sensor Connector 12. Holder 13. Speed Sensor 14. Strap (speed sensor lead) 15. Oil Pressure/Neutral Switch Lead Connector 16.
17-26 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-27 Cable, Wire, and Hose Routing F: Front 1. Fuel Tank Fill Opening (top view) 2. Fuel Tank 3. Fuel Tank Breather Pipe 4. Filler Drainpipe 5. Fuel Tank Filler Drain Hose 6. Clip (Face the tab rightwards.) 7. Fuel Tank Breather Hose (except for California Model) 8. Clip 9. Hole of Bracket (Run the hose [7] into this hole.) 10. Holder (hose [7], [5], coolant reserve tank hose, clutch hose) 11. Swingarm Pivot 12. Cross Pipe 13. Run these hoses in front of [11] and [12]. 14. Clamp 15.
17-28 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-29 Cable, Wire, and Hose Routing F: Front 1. Rear View 2. Rear Fender 3. Grommets 4. Six Clamps 5. Rear Fender Harness 6. Plastic Cover 7. Run the harness [5] into the cut of the plastic cover [6] 8. Connector of [9] (Fit the connector of [5] into the welded clamp.) 9. License Plate Light Lead (Run this lead between the ribs of the flap [18].) 10. Tail/Brake Light Leads (Clamp the connector of the rear harness with the welded clamp.) 11. Run the harness [5] between the ribs of the flap [18]. 12.
17-30 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-31 Cable, Wire, and Hose Routing F: Front T: Top ○ Install the plastic snap-on clamps [11] [16], nothing the position of the opening as shown. 1. Meter Connectors 2. Headlight Connector 3. Plate Clamp in [6] (lead [1] [4] [5]) 4. Front Turn Signal Light Lead Connector (right) 5. Front Turn Signal Light Lead Connector (left) 6. Headlight Body (front view and left side view) 7. Left Handlebar Switch Harness 8. Clutch Hose 9. Connector of Harness [7] 10.
17-32 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-33 Cable, Wire, and Hose Routing F: Front T: Top ○: Install the plastic snap-on clamps [3][17][18], noting the position of the opening as shown. 1. Clutch Hose 2. Starter Motor Lead 3. Plastic Snap-on Clamp ( 17 mm, rear view) 4. Left Fame Pipe 5. Holder (Run the clutch hose [8]). 6. ECU Connector 7. Rear Harness Connector 8. Rear Fender 9. Rear Harness 10.
17-34 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-35 Cable, Wire, and Hose Routing F: Front 1. Ignition Coil #2 (for rear cylinder) 2. Ignition Switch Connector (onto the fuel tank) 3. Throttle Cables (decelerator up and accelerator down, under the main harness [19]) 4. Right Handlebar Switch Harness 5. Holders 6. Plastic Snap-on Clamps ( 15 mm) 7. Main Harness Ground Terminal on the Frame 8.
17-36 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-37 Cable, Wire, and Hose Routing F: Front 1. Fit the clamp pin attached the main harness into the frame. 2. Plastic Snap-on Clamp (fuel pump harness) 3. Battery (−) Lead or Engine Ground Lead (to the engine ground terminal) 4. Oil Pressure Light Delay Unit 5. DFI Main Relay 6. Battery (+) Lead 7. Junction Box (installed on the coolant reserve tank) 8. Turn Signal Control Unit 9. Starter Relay 10. Vehicle-down Sensor Connector (installed on the battery case) 11. Vehicle-down Sensor 12.
17-38 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-39 Cable, Wire, and Hose Routing F: Front 1. Fuel Tank Filler Drain Hose 2. Starter Motor Lead 3. Holder 4. Engine Ground Lead (Run it downward) 5. Main Harness 6. Coolant Reserve Tank Hose (from the radiator cap to the coolant reserve tank) 7. To the inside of the alternator outer cover 8. Through the alternator outer cover to the starter motor 9. Clutch Hose 10. Crankcase 11. Fuel Tank Breather Hose (except CA, Run the hose through the right hole of the bracket.) 12. Coolant Reserve Tank 13.
17-40 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-41 Cable, Wire, and Hose Routing F: Front T: Top 1. Main Harness 2. Rear Coolant Hose 3. Right Handlebar Switch Connector 4. Holder 5. Frame Ground Lead 6. Ignition Coil #2 (for rear cylinder) 7. Throttle Cables 8. Radiator Fan Connector 9. Rear Brake Light Switch Connector 10. Throttle Pulley 11. Throttle Body Assy 12. Right Handlebar Switch Harness 13. Guides (For Rear Brake Hose) 14. Right Frame Pipe 15. Plastic Snap-on Clamps ( 15 mm) 16. Plastic Snap-on Clamp ( 10 mm) 17.
17-42 APPENDIX Cable, Wire, and Hose Routing F: Front 1. Rear Brake Caliper 2. Hose Holders 3. Rear Brake Hose 4. Hose White Marks (Position here.) 5. Hose Clamps 6. Run the brake hose between the engine mounting bracket bosses and the oil filter, and then along the downtube towards the front. 7.
APPENDIX 17-43 Cable, Wire, and Hose Routing 8. Rear Brake Reservoir 9. Rear Master Cylinder 10. Brake Pedal 11. Bend both ends of the cotter pin [16] as shown. 12. Clevis 13. Rear Brake Reservoir Cover 14. Downtube 15. Swingarm 16. Cotter Pin 17.
17-44 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-45 Cable, Wire, and Hose Routing F: Front 1. Throttle Cable (accelerator) 2. Throttle Cable (decelerator) 3. Front Brake Hose Assembly 4. Meter Bracket 5. Right Handlebar Switch Harness 6. Tachometer 7. Speedometer 8. Front Turn Signal Leads (Connect them in the headlight body.) 9. Clutch Hose 10. Clamps (leads [8]) 11. Plastic Snap-on Strap (harness [5]) 12. Holders 13. Main Harness 14. Left Handlebar Switch Harness 15. Punch Mark: Insert the grip until its end aligns with the mark. 16.
17-46 APPENDIX Cable, Wire, and Hose Routing Evaporative Emission Control System (California Model) with fuel line - - →: Vapor Flow →: Fuel Flow ←→: Vacuum Pulsation 1. Fuel Return Hose 2. Fuel Tank Breather Hose 3. Separator Breather Hose 4. Canister Purge Hose 5. Vacuum Hose 6. High Pressure Fuel Hoses (supply fuel) 7.
APPENDIX 17-47 Cable, Wire, and Hose Routing Evaporative Emission Control System (California Model) F: Front 1. Fuel Tank 2. Left Air Cleaner Base 3. Canister Purge Hose (Green) 4. Canister (Rear View) 5. Fuel Tank Breather Hose (right, blue) 6. Throttle Body Assy (Top View) 7. Fuel Tank Return Hose (left, red) 8. Separator 9. Fitting 10. Separator Breather Hose (blue) 11.
17-48 APPENDIX Cable, Wire, and Hose Routing Evaporative Emission Control System (California Model)
APPENDIX 17-49 Cable, Wire, and Hose Routing F: Front 1. Fuel Tank 2. Filler Drainpipe 3. Fuel Filler 4. Fuel Tank Breather Pipe 5. Coolant Reserve Tank Hose 6. Separator Vacuum Hose (white): Run it over the throttle cables and choke cable. 7. Rear Cylinder Coolant Hose: Run it leftward the hose [6]. 8. Fitting of the hose [6] 9. Radiator Cap 10. Clips 11. Throttle Body Assy 12. Left Air Cleaner Base 13. Canister Purge Hose (green) 14. Fuel Tank Breather Hose (blue, right) 15.
17-50 APPENDIX Cable, Wire, and Hose Routing Evaporative Emission Control System
APPENDIX 17-51 Cable, Wire, and Hose Routing R: Rear View 1. Fuel Tank 2. Filler Drainpipe 3. Fuel Tank Breather Pipe 4. Separator Vacuum Hose (white): Run it over the throttle cables and choke cable. 5. Clips 6. Canister Purge Hose (green) 7. Starter Motor Lead: Run the lead on the left of the separator [12] and all the evaporative hoses. 8. Fuel Tank Breather Hose (blue, right): Run the hose between [16] and [17]. 9. Separator Breather Hose (blue): Run the hose between [16] and [17]. 10.
17-52 APPENDIX Troubleshooting Guide (except DFI) NOTE ○Refer to Fuel System chapter for most of DFI troubleshooting 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 17-53 Troubleshooting Guide (except DFI) Choke knob left pulled out (DFI) Throttle body assy O-ring damage Air cleaner duct loose Air cleaner O-ring damaged Fuel pump (DFI) trouble Compression low: Spark plug loose Cylinder head not sufficiently tightened down 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 carb
17-54 APPENDIX Troubleshooting Guide (except DFI) 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 spark plug For KLEEN, do not coast the motorcycle with the ignition switch off (Turn the ignition switch ON and run the engine) IC igniter in ECU trouble Fuel/air mixture incorrect: Throttle body assy loose Throttle body assy O-ring damage Air cleaner duct loose Air cleaner poorly s
APPENDIX 17-55 Troubleshooting Guide (except DFI) Piston slap: Cylinder/piston clearance excessive Cylinder, piston worn Connecting rod bent Piston pin, piston pin hole worn Valve noise: Engine not sufficiently warmed up after HLA installation HLA damaged (worn, seizure, or spring broken) HLA aeration due to low oil level Air in HLA Metal chips or dust jammed in HLA Engine operated in red zone Valve spring broken or weak Camshaft bearing portion worn Other noise: Connecting rod small end clearance excessive
17-56 APPENDIX Troubleshooting Guide (except DFI) 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 sleeve or pivot bearings worn Wheel rim warped, or not balanced Wheel bearing worn Handlebar nuts loose Steering st
MODEL APPLICATION Year Model 2004 VN1600-B1 Beginning Frame No. JKBVNKB1□4A000001 or JKBVNT60BBA000001 □:This digit in the frame number changes from one machine to another. Part No.
