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.
Z750 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 L ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celsius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) hour(s) liter(s) lb m min N Pa PS psi r rpm TDC TIR V W Ω pound(s) meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) per minute top dead center total indicator r
Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.
NOTE This note symbol indicates points of par○ ticular interest for more efficient and convenient operation. a procedural step or work to be • Indicates done. ○Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.
GENERAL INFORMATION 1-1 General Information 1 Table of Contents Before Servicing ..................................................................................................................... Model Identification................................................................................................................. General Specifications............................................................................................................ Technical Information – Air Inlet System ....
1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.
GENERAL INFORMATION 1-3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly. Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.
1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally. Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench.
GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out.
1-6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side). Electrical Wires A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.
GENERAL INFORMATION 1-7 Model Identification ZR750–J1 Left Side View: ZR750–J1 Right Side View:
1-8 GENERAL INFORMATION General Specifications Items Dimensions: Overall length Overall width Overall height Wheelbase Road clearance Seat height Dry mass Curb mass: ZR750–J1 Front Rear Fuel tank capacity 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 plug Cylinder numbering method Firing order Valve timing: Inlet Open C
GENERAL INFORMATION 1-9 General Specifications Items Viscosity Capacity Drive Train: Primary reduction system: Type Reduction ratio Clutch type Transmission: Type Gear ratios: 1st 2nd 3rd 4th 5th 6th Final drive system: Type Reduction ratio Overall drive ratio Frame: Type Caster (rake angle) Trail Front tire: Type Size Rear tire: Type Size Front suspension: Type Wheel travel Rear suspension: Type Wheel travel Brake Type: Front Rear Electrical Equipment: Battery Headlight: Type Bulb Tail/brake light Alternat
1-10 GENERAL INFORMATION Technical Information – Air Inlet System Subthrottle Control System The ZR750–J1 employs large bore throttle bodies to increase power output. However, sudden changes in throttle opening can cause hesitation and jerky throttle response with a single butterfly valve in a large bore. Therefore two throttle valves are placed in each inlet tract, the main throttle valve located closest to the cylinder and a subthrottle valve placed further up the inlet tract.
GENERAL INFORMATION 1-11 Technical Information – Air Inlet System Operation The subthrottle control system consists of the subthrottle valve, subthrottle valve actuator with a stepping motor built in it, ECU, and subthrottle sensor. The subthrottle valve is built in the each throttle body. The subthrottle control system operates on the signal supplied from the ECU.
1-12 GENERAL INFORMATION Technical Information – New Ignition Interlock Sidestand Outline The New Ignition Interlock Sidestand System applied to ZR750–J1 models that cannot function if gears are engaged and/or the sidestand is not lifted upward even though clutch lever pulled in, which differs from the traditional one. Refer to the tables below as to the engine starts and/or the driving at each condition.
GENERAL INFORMATION 1-13 Technical Information – Tail/Brake Lights Employing LED Outline This model employs a tail/brake light containing 21 Light Emitting Diodes (LED). The LED emits luminous beams over a longer life span than those emitted from a traditional electric heated bulb (more than 5 times longer), uses lower voltage, expends lower wattage (approx. 1/5), and is quicker responsing.
1-14 GENERAL INFORMATION Technical Information – Tail/Brake Lights Employing LED The emitting color differs according to the materials of semi-conductors.
GENERAL INFORMATION 1-15 Technical Information – KAWASAKI LOW EXHAUST EMISSION SYSTEM Since the emission regulations become more severe, Kawasaki has adopted a type of simplified KAWASAKI LOW EXHAUST EMISSION SYSTEM (KLEEN), which have no catalyst protection system, according to each regulation of different countries. The muffler with built-in catalyst has the same durability as the conventional muffler, however, do not use leaded gasoline and do not coast with the ignition system OFF.
1-16 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Prefix mega kilo centi milli micro Symbol M k c m µ Units of Length: × × × × × Power 1 000 000 1 000 0.01 0.001 0.000001 Units of Mass: kg g × × 2.205 0.03527 = = lb oz = = = = = = = = = gal (US) gal (imp) qt (US) qt (imp) pint (US) pint (imp) oz (US) oz (imp) cu in Units of Volume: L L L L L L mL mL mL × × × × × × × × × 0.2642 0.2200 1.057 0.8799 2.113 1.816 0.03381 0.02816 0.06102 km m mm × × × 0.6214 3.281 0.
PERIODIC MAINTENANCE 2-1 Periodic Maintenance 2 Table of Contents Periodic Maintenance Chart .............. Torque and Locking Agent................. Specifications .................................... Special Tools ..................................... Periodic Maintenance Procedures..... Fuel System (DFI)........................... Fuel Hose and Connection Inspection.................................. Throttle Control System Inspection.................................. Idle Speed Inspection .............
2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected.
PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever comes first * ODOMETER READING km × 1000 (mile × 1000) 1 INSPECTION Engine stop switch operation Every 6 12 • year Throttle control system (play, smooth return, no drag) - inspect year Choke operation - inspect year Engine vacuum synchronization - inspect • • 36 • • Fuel hoses leak - inspect Fuel hoses damage - inspect year Fuel hoses installation condition - inspect year • • • • • • 2–14 • • • • • • • • • • •
2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart Periodic Replacement Parts: FREQUENCY Whichever comes first * ODOMETER READING km × 1000 (mile × 1000) 1 CHANGE/REPLACE ITEM Every Brake hoses 4 years Brake fluid (front and rear) 2 years Rubber parts of master cylinder and caliper 4 years (0.6) (7.
PERIODIC MAINTENANCE 2-5 Torque and Locking Agent 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. The following tables list the tightening torque for the major fasteners requiring use of a non -permanent locking agent or liquid gasket.
2-6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Water pump drain bolt Water pipe bolts Thermostat housing ground bolt Thermostat bracket bolt Radiator upper bolts Radiator lower bolts Radiator screen bolt Coolant reserve tank screws Radiator fan switch Water temperature sensor Engine Top End: Air suction valve cover bolts Cylinder head cover bolts Camshaft cap bolts Camshaft chain guide bolts Cylinder head bolts (M10 new bolts) Cylinder head bolts (M10 used bolts) Cylinder head bolts (M6) Cylinde
PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Engine Lubrication: Oil filler plug Engine oil drain bolt Oil filter Holder mounting bolt Oil pan bolts Oil pipe holder bolts Oil pressure relief valve Oil pressure switch Oil pressure switch terminal bolt Water pump cover bolts Water pump impeller bolt Coolant drain plug (water pump) Oil passage plugs Engine Removal/Installation: Adjusting collar locknut Engine mounting bolts and nuts Front engine bracket bolts Rear engine bracket bolts Engine grou
2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Tie-rod locknuts Neutral switch Wheels/Tires: Front axle clamp bolt Front axle Rear axle nut Final Drive: Engine sprocket nut Engine sprocket cover bolts Speed sensor cover bolts Rear sprocket nuts Speed sensor bolt Brakes: Bleed valves Brake hose banjo bolts Brake lever pivot bolt Brake lever pivot bolt locknut Front brake reservoir cap screws Front brake light switch screws Front master cylinder clamp bolts Front caliper mounting bolts Front brake
PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Fastener Handlebar lower clamp nuts Switch housing screws Front fork clamp bolts (Upper) Front fork clamp bolts (Lower) Frame: Footpeg bracket bolts Side stand bolt Side stand switch bolt Front fender bracket bolts Front fender bolts Side stand bracket bolts Electrical System: Spark plugs Alternator rotor bolt Stator coil bolts Alternator lead holding plate bolt Engine ground cable terminal bolt Alternator cover bolts Crankshaft sensor cover bolts Crankshaft
2-10 PERIODIC MAINTENANCE Specifications Item Fuel System: Throttle grip free play Idle speed Bypass screws (turn out) Engine vacuum Air cleaner element Cooling System: Coolant: Type (recommended) Color Mixed ratio Freezing point Total amount Engine Top End: Valve clearance: Inlet Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) 1 100 ±50 r/min (rpm) 2 ±1/4 (for reference) 29.7 ±1.
PERIODIC MAINTENANCE 2-11 Specifications Item Air pressure: (when cold) Front Rear Final Drive: Drive chain slack Drive chain 20-link length Brakes: Brake fluid: Grade Brake pad lining thickness: Front Rear Brake light timing: Front Rear Electrical System: Spark plug gap Standard Up to 180 kg (397 lb) load: 250 kPa (2.5 kgf/cm², 36 psi) Up to 180 kg (397 lb) load: 290 kPa (2.9 kgf/cm², 42 psi) 25 ∼ 35 mm (1.0 ∼ 1.4 in.) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) DOT4 4.5 mm (0.18 in.) 5 mm (0.20 in.
2-12 PERIODIC MAINTENANCE Special Tools Steering Stem Nut Wrench: 57001–1100 Pilot Screw Adjuster, C: 57001–1292 Jack: 57001–1238 Hand Tester: 57001–1394 Oil Filter Wrench: 57001–1249 Spark Plug Wrench (Owner’s Tool): 92110–1146
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 (DFI) chapter) and check the fuel hoses. Replace the hose if any fraying, cracks [B] or bulges [C] are noticed.
2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Throttle Control System Inspection Throttle Grip Play Inspection Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cable. • Throttle Grip Free Play Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) that the throttle grip moves smoothly from close to • Check full open, and the throttle closes quickly and completely • • • • in all steering positions by the return spring.
PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Idle Speed Inspection the engine and warm it up thoroughly. • Start the engine idling, turn the handlebar to both sides. • With If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed or damaged. Be sure to correct any of these conditions before riding (see Cable, Wire, and Hose Routing section in the Appendix chapter).
2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures the fuel tank (see Fuel System (DFI) chapter). • Install Start the and warm it up thoroughly. • Check theengine • Tachometeridle[A]speed. If the idle speed is out of the specified range, adjust it. CAUTION Do not measure the idle speed by the tachometer of the meter unit. While idling the engine, inspect the engine vacuum, using the vacuum gauge [B]. Engine Vacuum Standard: 29.7 ±1.
PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures If any one vacuum measurement is out of the standard measurement after synchronization, adjust the bypass screws [A]. Front [B] Special Tool - Pilot Screw Adjuster, C: 57001–1292 the lowest vacuum between #1 and #2 to the high• Adjust est of #1 and #2. the lowest vacuum between #3 and #4 to the high• Adjust est of #3 and #4. and close the throttle valves after each measure• Open ment and adjust the idle speed as necessary. the vacuums as before.
2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures out the same number of turns counted when first • Back turned in. This is to set the screw to its original position. NOTE ○A throttle body has different “turns out” of the bypass screw for each individual unit. When setting the bypass screw, use the “turns out” determined during disassembly. Use the specifications in this manual only if the original number is unknown. the same procedure for other bypass screws. • Repeat Repeat the synchronization.
PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures the fuel tank (see Fuel System (DFI) chapter). • Remove Remove the fuel tank bracket bolts and bracket [A]. • • Remove: Air Cleaner Duct Holder Screws [A] • Remove the air cleaner duct holder [B] backward. the element by tapping it lightly to loosen dust. • Clean Blow away the remaining dust by applying compressed • air [A] from the outside to the inside (from the clean side • to the dirty side).
2-20 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 2-21 Periodic Maintenance Procedures filling the coolant, choose a suitable mixture ratio • When by referring to the coolant manufacturer’s directions. CAUTION Soft or distilled water must be used with the antifreeze in the cooling system. If hard water is used in the system, it causes scale accumulation in the water passages, and considerably reduces the efficiency of the cooling system.
2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Top End Air Suction Valve Inspection the air suction valve (see Engine Top End chap• Remove ter). inspect the reeds for cracks, folds, warps, heat • Visually damage or other damage. • • • If there is any doubt as to the condition of the reeds [A], replace the air suction valve as an assembly. Check the reed contact areas [B] of the valve holder for grooves, scratches, any signs of separation from the holder or heat damage.
PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures ○When positioning #4 piston TDC at the end of the compression stroke: Inlet valve clearance of #2 and #4 cylinders Exhaust valve clearance of #3 and #4 cylinders Measuring Valve [A] ○When positioning #1 piston TDC at the end of the compression stroke: Inlet valve clearance of #1 and #3 cylinders Exhaust valve clearance of #1 and #2 cylinders Measuring Valve [A] If the valve clearance is not within the specified range, first record the clearance,
2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures the dust cover [A] at the clutch cable lower end out • Slide of place. both adjusting nuts [B] at the clutch cover as far • Loosen as they will go. the clutch outer cable [C] tight and tighten the adjust• Pull ing nuts against the cover [D]. the rubber dust cover back onto place. • Slip Turn the adjuster at the clutch lever until the free play is • correct. the release lever [A] toward the front of the motor• Push cycle until it becomes hard to turn.
PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures 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. Oil Filter Change the engine oil (see Engine Oil Change). • Drain • Remove the oil filter [A] with the oil filter wrench [B]. Special Tool - Oil Filter Wrench: 57001–1249 the filter with a new one. • Replace Apply engine oil to the gasket [A] before installation.
2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tread Depth Front: Standard: 3.4 mm (0.13 in.) Service Limit: 1 mm (0.04 in.) 1.6 mm (0.06 in.) (AT, CH, DE) Rear: Standard: 5.8 mm (0.23 in.) Service Limit: 2 mm (0.08 in.) (Up to 130 km/h (80 mph)) 3 mm (0.12 in.) (Over 130 km/h (80 mph)) WARNING To ensure safe handling and stability, use only the recommended standard tires for replacement, inflated to the standard pressure.
PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Final Drive Drive Chain Slack Inspection NOTE ○Check the slack with the motorcycle setting on its side stand. ○Clean the chain if it is dirty, and lubricate it if it appears dry. the wheel alignment (see Wheel Alignment Inspec• Check tion). the rear wheel to find the position where the chain • Rotate is tightest. the vertical movement (chain slack) [A] midway • Measure between the sprockets. If the chain slack exceeds the standard, adjust it.
2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Bend the cotter pin [A] over the nut. WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condition may result. Drive Chain Wear Inspection • Remove: Chain Cover Screws [A] Chain Cover [B] Mud Guard [C] (see Frame chapter) the rear wheel to inspect the drive chain for dam• Rotate aged rollers, and loose pins and links. • • If there is any irregularity, replace the drive chain.
PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Drive Chain Lubrication a special lubricant is not available, a heavy oil such as • IfSAE 90 is preferred to a lighter oil because it will stay on • the chain longer and provide better lubrication. If the chain appears especially dirty, clean it before lubrication. CAUTION The O-rings between the side plates seal in the lubricant between the pin and the bushing.
2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures • If it does not, adjust and inspect the brake light switch. While holding the switch body, turn the adjusting nut [A] to adjust the switch. CAUTION To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. the right side cover (see Frame chapter). • Remove Disconnect connector [A].
PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Master Cylinder Inspection (Visual Inspection) the master cylinders (see Brakes chapter). • Remove 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].
2-32 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 level line [B]. NOTE ○Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C] in the reservoir. that the brake fluid level in the rear brake reservoir • Check [A] is above the lower level line [B].
PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures the brake fluid reservoir. • Level Remove reservoir cap and diaphragm. • Remove the • caliper. the rubber cap from the bleed valve [A] on the a clear plastic hose [B] to the bleed valve, and run • Attach the other end of the hose into a container. • Fill the reservoir with fresh specified brake fluid. the brake fluid: •○Change Repeat this operation until fresh brake fluid comes out 1. 2. 3. 4.
2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air enters the brake lines, brake lever or pedal movement will be partially used in compressing the air. This will make the lever or pedal feel spongy, and there will be a loss in braking power.
PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures the brake line and the caliper: •○Bleed Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A]. 2. Quickly open and close [B] the bleed valve while holding the brake applied. 3. Release the brake [C]. NOTE ○The fluid level must be checked often during the bleeding operation and replenished with fresh brake fluid as necessary.
2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING When working with the disc brake, observe the precautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types and brands of fluid for use in the brake. This lowers the brake fluid boiling point and could cause the brake to be ineffective. It may also cause the rubber brake parts to deteriorate. 4.
PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Suspension Front Fork Oil Leak Check inspect the front forks [A] for oil leakage, scoring • Visually or scratches on the inner surface of the inner tubes. Replace or repair any defective parts, if necessary. Rear Shock Absorber Oil Leak Check inspect the shock absorber [A] for oil leakage. • Visually If the oil leakage is found on it, replace the shock absorber with a new one.
2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures the claw washer tabs [A]. • Bend Remove • [C]. the steering stem locknut [B] and claw washer • Adjust the steering. Special Tool - Steering Stem Nut Wrench: 57001–1100 [B] If the steering is too tight, loosen the stem nut [A] a fraction of a turn. If the steering is too loose, tighten the stem nut a fraction of a turn. NOTE ○Turn the stem nut 1/8 turn at time maximum.
PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Electrical System Spark Plug Inspection • Remove: Fuel Tank (see Fuel System (DFI) chapter) the thermostat bracket bolt [A]. • Unscrew Disconnect: • Water Temperature Sensor Connector [B] Left Switch Housing Connector [C] ○If removing the spark plug #2 or #3. • Disconnect: Stick Coil Connectors [A] out the stick coil #1 [B]. • Pull Take out the camshaft position sensor connector [C] from • the bracket. • Pull out the stick coil #2 [D].
2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures the spark plug, preferably in a sandblasting device, • Clean and then clean off any abrasive particles. The plug may • also be cleaned using a high-flash point solvent and a wire brush or other suitable tool. If the spark plug center electrode [A] and/or side electrode [B] are corrected or damaged, or if the insulator [C] is cracked, replace the plug. Use the standard spark plug or its equivalent.
PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures General Lubrication Lubrication lubricating each part, clean off any rusty spots with • Before rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. ○Whenever NOTE the vehicle has been operated under wet or rainy conditions, or especially after using a high-pressure water spray, perform the general lubrication.
2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Nut, Bolt, and Fastener Tightness Tightness Inspection the tightness of the bolts and nuts listed here. Also, • Check check to see that each cotter pin is in place and in good condition. NOTE ○For the engine fasteners, check the tightness of them when the engine is cold (at room temperature). If there are loose fasteners, retighten them to the specified torque, following the specified tightening sequence.
FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................................................................................................................ DFI Parts Location.................................................................................................................. DFI Wiring Diagram ................................................................................................................ Specifications .......................................
3-2 FUEL SYSTEM (DFI) Sensor Resistance Inspection .......................................................................................... Atmospheric Pressure Sensor (Service Code 15).................................................................. Removal............................................................................................................................ Input Voltage Inspection....................................................................................................
FUEL SYSTEM (DFI) 3-3 Fuel Pump Relay Removal ............................................................................................... Fuel Pump Relay Inspection ............................................................................................. Fuel Injectors .......................................................................................................................... Removal/Installation...........................................................................................
3-4 FUEL SYSTEM (DFI) Exploded View
FUEL SYSTEM (DFI) 3-5 Exploded View No. 1 2 3 4 5 6 7 Fastener Throttle cable plate bolt Throttle body assy holder clamp bolts Choke link holder screws Delivery pipe screws Fuel pump bolts Fuel level sensor bolts Bypass screws 8. Center adjusting screw 9. FI indicator LED light 10. Meter unit 11. Throttle cable (accelerator) 12. Throttle cable (decelerator) 13. Choke cable 14. Injector connectors 15. Main throttle sensor connector (grey) 16. Subthrottle sensor connector (black) 17.
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 Fastener Inlet air pressure sensor bolt Water temperature sensor Vehicle down sensor bolts Camshaft position sensor bolt Camshaft position sensor rotor bolt Air cleaner duct holder screws Air cleaner housing mounting bolts Air cleaner duct clamp bolts Air cleaner housing screws Air cleaner housing tapping screws Speed sensor bolt Torque N·m 12 25 2.0 12 12 3.8 9.8 2.0 1.2 1.2 6.9 12. Inlet air pressure sensor 13.
3-8 FUEL SYSTEM (DFI) DFI Parts Location DFI: DFI Parts (this chapter) 1. Water temperature Sensor (DFI) 2. Inlet Air Pressure Sensor (DFI) 3. Injectors (DFI) 4. Fuel Pump (DFI) 5. Inlet Air Temperature Sensor (DFI) 6. Sealed Battery 7. Junction Box 8. ECU Fuse 15 A 9. ECU (DFI) 10. Stick Coils 11. Throttle Body Assy 12. Self-diagnosis Terminal 13. Neutral Switch 14. Vehicle Down Sensor (DFI) 15. Atmospheric Pressure Sensor (DFI) 16. Delivery Pipe 17. ECU Main Relay 18. Fuel Pump Relay (DFI) 19.
FUEL SYSTEM (DFI) 3-9 DFI Parts Location [1], [2], [10], [13], [22] and [24] are not included.
3-10 FUEL SYSTEM (DFI) DFI Wiring Diagram
FUEL SYSTEM (DFI) 3-11 DFI Wiring Diagram Terminal Names 1. Power Supply to Sensors 2. Main Throttle Sensor Signal 3. Subthrottle Sensor Signal 4. Atmospheric Pressure Sensor Signal 5. Water Temperature Sensor Signal (+) 6. Unused 7. Ignition Switch Signal 8. Unused 9. Camshaft Position Sensor Signal (+) 10. Unused 11. Crankshaft Sensor Signal (+) 12. Unused 13. Power Supply to ECU, Injectors, and Fuel Pump 14. Ground to sensors 15. Unused 16. Vehicle-down Sensor Signal 17.
3-12 FUEL SYSTEM (DFI) Specifications Item Digital Fuel Injection System Idle Speed Throttle Assy: Type Bore ECU (Electronic Control Unit): Make Type Usable engine speed Fuel Pressure (high pressure line): Right after Ignition SW ON After 3 sec from Ignition SW ON With engine idling Fuel Pump: Type Discharge Fuel Injectors: Type Nozzle type Resistance Main Throttle Sensor: Input voltage Output voltage at idle throttle opening Output voltage at full throttle opening Resistance Inlet Air Pressure Sensor or At
FUEL SYSTEM (DFI) 3-13 Specifications Item Detection time Output voltage Subthrottle Sensor: Input voltage Output voltage at idle throttle opening Output voltage at full throttle opening Resistance Subthrottle Valve Actuator: Resistance Input voltage Throttle Grip and Cables Throttle grip free play Choke Cable Choke cable free play Standard Within 0.5 ∼ 1.0 sec. with the sensor tilted 60 ∼ 70° or more: 3.7 ∼ 4.4 V with sensor arrow mark pointed up: 0.4 ∼ 1.4 V Non-adjustable and non-removal 4.75 ∼ 5.
3-14 FUEL SYSTEM (DFI) Special Tools Oil Pressure Gauge: 57001–125 Needle Adapter Set: 57001–1457 Fork Oil Level Gauge: 57001–1290 Throttle Sensor Setting Adapter: 57001–1538 Hand Tester: 57001–1394 Sensor Harness Adapter: 57001–1561 Throttle Sensor Setting Adapter: 57001–1400 Kawasaki Bond (Silicone Sealant): 56019–120 Fuel Pressure Gauge Adapter: 57001–1417
FUEL SYSTEM (DFI) 3-15 DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source. ○Do not reverse the battery cable connections. This will damage the ECU.
3-16 FUEL SYSTEM (DFI) DFI Servicing Precautions ○Whenever the DFI electrical connections are to be discon- nected, first turn off the ignition SW (switch), and disconnect the battery (–) terminal. Do not pull the lead, only the connector. Conversely, make sure that all the DFI electrical connections are firmly reconnected before starting the engine. ○When disconnecting the vehicle-down sensor connector, raise the lock of the connector. Push the lock of the other connectors.
FUEL SYSTEM (DFI) 3-17 Troubleshooting the DFI System Outline Outline When an abnormality in the system occurs, the FI indicator LED (Light Emitting Diode) light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit). With the engine stopped and turned in the self-diagnosis mode, the service code [A] is indicated by the number of times the FI indicator LED light blinks.
3-18 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○The DFI part connectors [A] have seals [B], including the • ECU. Join the connector and insert the needle adapters (special tool) [C] inside the seals [B] from behind the connector until the adapter reaches the terminal. Special Tool - Needle Adapter Set: 57001–1457 CAUTION Insert the needle adapter straight along the terminal in the connector to prevent short-circuit between terminals.
FUEL SYSTEM (DFI) 3-19 Troubleshooting the DFI System each connector [A] apart and inspect it for corrosion, • Pull dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. Check the wiring for continuity. ○Use the wiring diagram to find the ends of the lead which is suspected of being a problem. ○Connect the hand tester between the ends of the leads. ○Set the tester to the × 1 Ω range, and read the tester.
3-20 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○There are two ways to inspect the DFI system. One is voltage Check Method and the other is Resistance Check Method. (Voltage Check Method) ○This method is conducted by measuring the input voltage [B] to a sensor [A] first, and then the output voltage [C] from the sensor. ○Sometimes this method can detect a fault of the ECU. Refer to each sensor inspection section for detail in this chapter.
FUEL SYSTEM (DFI) 3-21 Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider Inquiries to Rider ○Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.
3-22 FUEL SYSTEM (DFI) Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Model: Registration No. (license plate No.): Year of initial registration: Engine No.: Date problem occurred: Frame No.: Mileage: Environment when problem occurred.
FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System Poor running at low speed Poor running or no power at high speed □ choke lever pulled out fully (push it in fully) □ very low choke speed (adjust choke cable) □ very low idle speed, □ very high idle speed, □ rough idle speed □ battery voltage is low (charge the battery) □ spark plug loose (tighten it) □ spark plug dirty, broken, or gap maladjusted (remedy it) □ backfiring □ afterfiring □ hesitation when acceleration □ engine oil viscosity too high □ br
3-24 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide 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.
FUEL SYSTEM (DFI) 3-25 DFI System Troubleshooting Guide Symptoms or possible Causes Starting technique faulty 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, sidestand up and gear not in neutral Vehicle-down sensor coming off Vehicle-down sensor trouble ECU ground or power supply trouble Battery voltage low Spark plug dirty, broken or gap maladjusted Spark plug cap trouble Spark pl
3-26 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 No valve clearance Valve guide worn Valve spring broken or weak Valve not seating properly (valve bent, worn or carbon accumulating on seating surface) Actions (chapter) Inspect and replace (see chapter 5). Inspect and replace (see chapter 5).
FUEL SYSTEM (DFI) 3-27 DFI System Troubleshooting Guide Symptoms or Possible Causes 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 Main throttle sensor trouble Engine stalls easily : Fuel pump trouble Fuel injector trouble Main throttle sensor trouble Camshaft position sensor trouble Fuel pressure too low or too high Inlet air pressure senso
3-28 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Main throttle sensor trouble Subthrottle sensor trouble Subthrottle valve actuator trouble Water temperature sensor trouble Atmospheric pressure sensor trouble Inlet air pressure sensor trouble Loose injector connectors Crankshaft sensor trouble Stick coil trouble Actions (chapter) Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3).
FUEL SYSTEM (DFI) 3-29 DFI System Troubleshooting Guide Symptoms or Possible Causes Spark plug dirty, broken or gap maladjusted Too low fuel pressure Fuel pump trouble Main throttle sensor trouble Inlet air temperature sensor trouble Water temperature sensor trouble Atmospheric pressure sensor trouble Inlet air pressure sensor trouble Vacuum switch valve broken Air suction valve trouble After fire : Crankshaft sensor trouble Spark plug burned or gap maladjusted Inlet air temperature sensor trouble Water tem
3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Poor Running or No Power at High Speed: Symptoms or Possible Causes Firing incorrect : Spark plug dirty, broken or maladjusted Spark plug cap trouble Spark plug cap shorted or not in good contact Spark plug incorrect IC igniter in ECU trouble Crankshaft sensor trouble Stick coil trouble Fuel/air mixture incorrect : Choke lever pulled Air cleaner clogged, poorly sealed or missing Air cleaner duct loose Air cleaner O-ring damaged Water or foreign matter
FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or Possible Causes Fuel poor quality or incorrect (Use the gasoline recommended in the Owner’s Manual) Spark plug incorrect Stick coil trouble IC igniter in ECU trouble Inlet air temperature sensor trouble Atmospheric pressure sensor trouble Miscellaneous : Subthrottle sensor trouble Subthrottle valve actuator trouble Speed sensor trouble Actions (chapter) Change fuel (see chapter 3). Replace it with the correct plug (see chapter 16).
3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Too low fuel pressure Water temperature sensor trouble Inlet air temperature sensor trouble Actions (chapter) Inspect fuel line and fuel pump (see chapter 3). Inspect and replace (see chapter 3). Inspect and replace (see chapter 3).
FUEL SYSTEM (DFI) 3-33 Self-Diagnosis Self-diagnosis Outline Self-diagnosis Outline The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User Mode: The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator when DFI system and ignition system parts are faulty, and initiates fail-safe function. In case of serious troubles, the ECU stops the injection/ignition/starter motor operation.
3-34 FUEL SYSTEM (DFI) Self-Diagnosis enter the self-diagnosis dealer mode 2, open [B] and • To ground [A] the lead more than five times [F] within 2 seconds [C] after the lead is first grounded, and then keep it grounded continuously [D] for more than 2 seconds. ○Count the blinks of the LED light to read the service code. Keep the auxiliary lead ground until you finish reading the service code.
FUEL SYSTEM (DFI) 3-35 Self-Diagnosis
3-36 FUEL SYSTEM (DFI) Self-Diagnosis How to Read Service Codes How to Read Service Codes ○Service codes are shown by a series of long and short blinks of the FI indicator LED light as shown below. ○Read 10th digit and unit digit as the FI indicator LED light blinks. ○When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order.
FUEL SYSTEM (DFI) 3-37 Self-Diagnosis Service Code Table Service Code Table Service Code FI Indicator LED Light 11 Problems Main throttle sensor malfunction, wiring open or short Inlet air pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Atmospheric pressure sensor malfunction, wiring open or short 12 13 14 15 21 Crankshaft sensor malfunction, wiring open or short 23 Camshaft pos
3-38 FUEL SYSTEM (DFI) Self-Diagnosis Backups Backups ○The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service Codes Parts 11 Main Throttle Sensor 12 Inlet Air Pressure Sensor 13 14 15 21 23 Inlet Air Temperature Sensor Water Temperature Sensor Atmospheric Pressure Sensor Output Signal Usable Range or Criteria Main Throttle Sensor Output Voltage 0.2 ∼ 4.
FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Service Codes 32 51 52 53 54 62 Parts Output Signal Usable Range or Criteria Subthrottle Sensor Subthrottle Output Voltage sensor 0.15 ∼ 4.85 V Backups by ECU If the subthrottle sensor system fails (the signal is out of the usable range, wiring short or open), the actuator locks sub throttle valve at full open position.
3-40 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Removal/Adjustment CAUTION Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Main Throttle Sensor Connector (gray) [B] Input Voltage Inspection NOTE ○Be sure the battery is fully charged. the ignition switch OFF.
FUEL SYSTEM (DFI) 3-41 Main Throttle Sensor (Service Code 11) Output Voltage Inspection the output voltage at the main throttle sensor • Measure in the same way as input voltage inspection, Note the • following. Disconnect the main throttle sensor (gray) [A] and connect the harness adapter [B] between these connectors. Special Tool - Throttle Sensor 57001–1538 Harness Adapter : the engine and warm it up thoroughly. • Start Check idle speed to ensure the throttle opening is correct.
3-42 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Resistance Inspection the ignition switch OFF. • Turn the main throttle sensor connector. • Disconnect Connect a digital • connector [B]. meter [A] to the main throttle sensor • Measure the main throttle sensor resistance. Main Throttle Sensor Resistance Connections: BL lead [C] ←→ BR/BK lead [D] Standard: 4 ∼ 6 kΩ If the reading is out of the range, replace the throttle body assy.
FUEL SYSTEM (DFI) 3-43 Inlet Air Pressure Sensor (Service Code 12) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Removal • Remove: Fuel Tank (see Fuel System chapter) • Water Temperature Sensor Connector [A] Inlet Air Pressure Sensor Bolt [B] Raise the inlet air pressure sensor [C] and disconnect the inlet air pressure sensor connector and the vacuum hose.
3-44 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Output Voltage Inspection NOTE ○The output voltage changes according to the local atmospheric pressure. the output voltage at the ECU in the same way • Measure as input voltage inspection. Note the following. Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter (+) → Y/BL lead (terminal 17) Meter (–) → BR/BK lead (terminal 14) Usable Range: 3.74 ∼ 4.26 V DC at the standard atmospheric pressure (101.32 kPa, 76 cmHg abs.
FUEL SYSTEM (DFI) 3-45 Inlet Air Pressure Sensor (Service Code 12) then Pv = Pl – Pg For example, suppose the following data is obtained: Pg = 8 cmHg (vacuum gauge reading) Pl = 70 cmHg (barometer reading) Vv = 3.2 V (digital volt meter reading) then Pv = 70 – 8 = 62 cmHg (abs) Plot this Pv (62 cmHg) at a point [1] on the chart and draw a vertical line through the point. Then, you can get the usable range [2] of the sensor output voltage. Usable range = 3.04 ∼ 3.49 V Plot Vv (3.2 V) on the vertical line.
3-46 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Pv = 55 ∼ 86 cmHg Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading) Pv: Throttle Vacuum Pressure (absolute) Ps: Standard Atmospheric Pressure (absolute) ID: Idling TO: Throttle Full Open ST: Standard of Sensor Output Voltage (v) UR: Usable Range of Sensor Output Voltage (v) A. ECU C.
FUEL SYSTEM (DFI) 3-47 Inlet Air Temperature Sensor (Service Code 13) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. the fuel tank (see Fuel Tank Removal). • Remove the connector [A] from the inlet air tempera• Disconnect ture sensor. out the inlet air temperature sensor. • Pull Put the inlet air temperature sensor into the grommet. • Output Voltage Inspection NOTE ○Be sure the battery is fully charged.
3-48 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 is submerged. a thermometer [B] with the heat-sensitive por• Suspend tion [C] located in almost the same depth with the sensor. NOTE ○The sensor and thermometer must not touch the container side or bottom.
FUEL SYSTEM (DFI) 3-49 Water Temperature Sensor (Service Code 14) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. the fuel tank (see Fuel Tank Removal). • Remove the coolant (see Cooling System chapter). • Drain Disconnect sensor connector, and unscrew the water • temperaturethesensor [A]. Torque - Water Temperature Sensor: 25 N·m (2.
3-50 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) A. ECU D. Water Temperature Sensor V. Coolant Temperature Gauge in Tachometer Sensor Resistance Inspection the water temperature sensor (see this section). • Remove Refer to the System chapter for water temper• ature sensorElectrical inspection.
FUEL SYSTEM (DFI) 3-51 Atmospheric Pressure Sensor (Service Code 15) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. NOTE ○The atmospheric pressure sensor is the same part as the inlet air pressure sensor except that the inlet air pressure sensor has the vacuum hose and different wiring. Removal the ignition switch off. • Turn the seat cover (see Frame chapter).
3-52 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) Output Voltage Inspection the output voltage at the ECU in the same way • Measure as input voltage inspection. Note the following. Digital Meter [A] ECU Connector [B] Atmospheric Pressure Sensor Output Voltage Connections to ECU Meter (+) → G/W lead (terminal 4) Meter (–) → BR/BK lead (terminal 14) Usable Range: 3.74 ~ 4.26 V DC at the standard atmospheric pressure (101.32 kPa, 76 cmHg abs.
FUEL SYSTEM (DFI) 3-53 Atmospheric Pressure Sensor (Service Code 15) Va: Atmospheric Pressure Sensor Output Voltage (v) H: Altitude (m or feet) A. ECU E.
3-54 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condition of the crankshaft sensor. In this case, turn off the ignition switch and turn it on again to enter the Dealer 2 mode.
FUEL SYSTEM (DFI) 3-55 Camshaft Position Sensor (Service Code 23) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condition of the camshaft position sensor. In this case, turn off the ignition switch and turn it on again to enter the Dealer 2 mode.
3-56 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) Speed Sensor Removal/Installation the Switches and Sensors section in the Electrical • See System chapter. Speed Sensor Inspection the Switches and Sensors section in the Electrical • See System chapter. Input Voltage Inspection NOTE ○Be sure the battery is fully charged. the ignition switch OFF. • Turn Disconnect speed sensor connector [A] and connect • the harnessthe adapter [B] between the harness connector • and speed sensor connector.
FUEL SYSTEM (DFI) 3-57 Speed Sensor (Service Code 24, 25) the speed sensor connector [A] and connect • Disconnect the harness adapter [B] between the harness connector • and speed sensor connector. Engine Sprocket Cover [C] Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Setting Adapter: 57001–1400 the sensor output voltage with • Measure stopped, and with the connector joined. • Turn the ignition switch ON.
3-58 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. • Remove: Connection and Vehicle-down Sensor [A] Bolts [B] Installation • The UP mark [A] of the sensor should face upward. Torque - Vehicle-down Sensor Bolts: 2.0 N·m (0.20 kgf·m, 17 in·lb) WARNING Incorrect installation of the vehicle-down sensor could cause sudden loss of engine power.
FUEL SYSTEM (DFI) 3-59 Vehicle-down Sensor (Service Code 31) the ignition switch OFF. • Turn Remove sensor. • Connect athedigital • dle adapter set [B].volt meter [A] to the connector with neeSpecial Tool - Needle Adapter Set: 57001–1457 Vehicle-down Sensor Output Voltage Connections to Sensor Meter (+) → Y/G lead [D] Meter (–) → BK/Y lead [E] the sensor vertically. • Hold Turn the switch ON, and measure the output volt• age with ignition the connector joined.
3-60 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) A. ECU S. ECU Main Relay T. Ignition Switch a. ECU Fuse 15 A b. Vehicle-down Sensor d. Starter Relay f. Sealed Battery j. Joint Connector B k.
FUEL SYSTEM (DFI) 3-61 Subthrottle Sensor (Service Code 32) Subthrottle Sensor Removal/Adjustment CAUTION Do not remove or adjust the subthrottle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Subthrottle Sensor Connector (black) [B] Input Voltage Inspection NOTE ○Be sure the battery is fully charged. the ignition switch OFF.
3-62 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Output Voltage Inspection the throttle body assy (see Throttle Body Assy • Remove Removal). the output voltage at the subthrottle sensor in • Measure the same way as input voltage inspection. Note the fol- • lowing. Disconnect the subthrottle sensor (black) [A] and (black) connect the harness adapter [B] between these connectors.
FUEL SYSTEM (DFI) 3-63 Subthrottle Sensor (Service Code 32) Resistance Inspection the ignition switch OFF. • Turn the subthrottle sensor connector. • Disconnect Connect a digital meter [A] to the subthrottle sensor con• nector [B]. • Measure the subthrottle sensor resistance. Throttle Sensor Resistance Connections: BL lead [C] ←→ BR/BK lead [D] Standard: 4 ∼ 6 kΩ If the reading is out of the range, replace the throttle body assy.
3-64 FUEL SYSTEM (DFI) Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) Stick Coil #1: Stick Coil #2: Stick Coil #3: Stick Coil #4: Ignition Ignition Ignition Ignition Coil (Service Code Coil (Service Code Coil (Service Code Coil (Service Code 51) 52) 53) 54) Removal/Installation CAUTION Never drop the stick coils, especially on a hard surface. Such a shock to the stick coil can damage it. the Ignition System section in the Electrical System • See chapter.
FUEL SYSTEM (DFI) 3-65 Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) A. ECU M. Stick Coils N. Engine Stop Switch T. Ignition Switch X. Ignition Fuse 10 A Y. Junction Box d. Starter Relay e. Joint Connector C f. Sealed Battery k.
3-66 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the actuator , especially on a hard surface. Such a shock to the actuator can damage it. Audible Inspection NOTE ○Be sure the battery is fully charged.
FUEL SYSTEM (DFI) 3-67 Subthrottle Valve Actuator (Service Code 62) Input Voltage Inspection NOTE ○Be sure the battery is fully charged. the ignition switch OFF. • Turn Remove • Removal).the throttle body assy (see Throttle Body Assy the peak voltage adapter [A] and a digital meter • Connect [B] to the connector [C], using the needle adapter set [D].
3-68 FUEL SYSTEM (DFI) FI Indicator LED Light Inspection Flow Chart
FUEL SYSTEM (DFI) 3-69 FI Indicator LED Light LED Light Inspection the meter unit (see Electrical System chapter). • Remove two auxiliary leads, supply battery power to the FI • Using indicator LED light [A]. 12 V Battery [B] FI Indicator LED Light Check Connector: Meter Connector [C] (disconnected) Connection: BR/W Lead Terminal [1] of the Meter → Battery (+) Terminal BR/R Lead Terminal [6] of the Meter → Battery (–) Terminal Criterion: The LED light should light.
3-70 FUEL SYSTEM (DFI) ECU CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Removal • Remove: Seats (see Frame chapter) Junction Box [A] the ECU [A] out along with the harness. • Take Disconnect the ECU lead connectors [B]. • ECU Installation the ECU connectors, noting the length of the • Connect locks. Longer Lock [A] Shorter Lock [B] ECU Power Supply Inspection inspect the terminals [A] of the ECU connectors.
FUEL SYSTEM (DFI) 3-71 ECU the ECU connectors [A] connected, check the fol• With lowing ground lead for continuity with the ignition switch OFF, using a tester and needle adapter set. ECU Grounding Inspection 26, 50, or 51 (BK/Y) ←→ Battery (–) Terminal: 0 Ω Terminal Engine Ground ←→ Battery (–) Terminal: 0 Ω If no continuity, check the connector, the engine ground lead, or main harness, and repair or replace them if necessary.
3-72 FUEL SYSTEM (DFI) ECU ECU Power Source Circuit A. ECU S. ECU Main Relay T. Ignition Switch a. ECU Fuse 15 A d. Starter Relay e. Joint Connector C f. Sealed Battery j. Joint Connector B k.
FUEL SYSTEM (DFI) 3-73 DFI Power Source ECU Fuse Removal to the Electrical System chapter for the ECU fuse • Refer removal. ECU Fuse Installation • If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage. Refer to the Electrical System chapter for the ECU fuse installation. ECU Fuse Inspection to the Electrical System chapter for the ECU fuse • Refer inspection.
3-74 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○This inspection can determine which trouble the DFI system has, mechanical or electrical trouble. ○It is preferable to measure the fuel pressure while running the motorcycle just when trouble occurred in order to know symptom well. ○Be sure the battery is fully charged. the fuel tank (see Fuel Tank Removal). • Remove Be sure to a piece of cloth around the pump outlet • pipe and theplace delivery pipe. Remove the fuel pump outlet hose [A].
FUEL SYSTEM (DFI) 3-75 Fuel Line the engine, and let it idle. • Start Measure the fuel pressure with the engine idling. • Fuel Pressure (idling) Standard: 310 kPa (3.2 kgf/cm², 46 psi) NOTE ○The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. • • If the fuel pressure is normal, the fuel circulation system (fuel pump, pressure regulator, and oil passage) is no faults.
3-76 FUEL SYSTEM (DFI) Fuel Line the fuel tank cap [A] to lower the pressure in the • Open tank. sure to place a piece of cloth around the fuel pump • Be outlet hose. the fuel pump outlet hose [A] from the fuel pump • Remove [B] and the delivery pipe [C] (see Fuel Pump Removal). Front [D] WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure.
FUEL SYSTEM (DFI) 3-77 Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard surface. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF. Disconnect the battery (–) terminal.
3-78 FUEL SYSTEM (DFI) Fuel Pump • Replace the fuel pump gasket [A] with a new one. that the fuel pump (–) terminal [A] and band [B] are • Check in place. • • • Front [C] Apply a non-permanent locking agent to the threads of the fuel pump bolts. Tighten the fuel pump bolts to a snug fit, following the tightening sequence shown. Following the tightening sequence, tighten the fuel pump bolts to the specified torque. Torque - Fuel Pump Bolts: 9.8 N·m (1.
FUEL SYSTEM (DFI) 3-79 Fuel Pump the hand tester (25 V DC) to the fuel pump con• Connect nector [A] with needle adapter set. Special Tools - Hand Tester: 57001–1394 Needle Adapter Set: 57001–1457 ○Measure the operating voltage with the engine stopped, and with the connector joined. Turn the ignition switch ON. ○The tester needle should indicate battery voltage for 3 seconds, and then 0 V.
3-80 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Relay Removal CAUTION Never drop the relay, especially on a hard surface. Such a shock to the relay can damage it. the seat cover (see Frame chapter). • Remove the fuel pump relay [A] from the tongue of the • Remove storage compartment. • Disconnect the connector. Fuel Pump Relay Inspection the fuel pump relay (see above). • Remove the hand tester [A] and one 12 V battery [B] to • Connect the relay connector [C] as shown.
FUEL SYSTEM (DFI) 3-81 Fuel Injectors Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Audible Inspection the engine. • Start Apply of a screwdriver [A] to the injector [C]. Put • the griptheendtiponto your ear, and listen whether the injector is clicking or not. ○A sound scope [B] can also be used. the same for the other injectors. • Do If all the injectors click at a regular intervals, the injectors are good.
3-82 FUEL SYSTEM (DFI) Fuel Injectors Output Voltage Inspection the ignition switch OFF. • Turn the ECU (see ECU section). • Remove Connect a digital voltmeter [A] to the ECU connector [B] • with the needle adapter set [C].
FUEL SYSTEM (DFI) 3-83 Fuel Injectors 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 (0.071 in.) Terminal Thickness [C]: 0.8 mm (0.031 in.) CAUTION Do not use larger terminals than specified above. A larger terminal could damage the injector main harness connector (female), leading to harness repair or replacement. Be sure to connect bulbs in series.
3-84 FUEL SYSTEM (DFI) Fuel Injectors Injector Resistance Inspection the fuel tank (see Fuel Tank Removal). • Remove the connector from the injector [A] (see Throt• Disconnect tle Body Assy Disassembly/Assembly). • Measure the injector resistance with the hand tester [B]. Special Tool - Hand Tester: 57001–1394 Injector Resistance Connections to Injector Meter (+) Meter (–) #1: W/R ←→ BL/R Terminal #2: W/R ←→ BL/G Terminal #3: W/R ←→ BL/BK Terminal #4: W/R ←→ BL/Y Terminal Standard: about 11.7 ∼ 12.
FUEL SYSTEM (DFI) 3-85 Fuel Injectors the injector fuel line for leakage as follows: •○Check Connect a commercially available vacuum/pressure pump [A] to the nipple of the delivery pipe [B] with a high-pressure fuel hose [C] (both ends connected with the clamps [D]) as shown. Torque - Fuel Hose Clamp Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb) ○Apply soap and water solution to the areas [E] as shown.
3-86 FUEL SYSTEM (DFI) Fuel Injectors A. ECU K. Fuel Injectors N. Engine Stop Switch T. Ignition Switch X. Ignition Fuse 10 A Y. Junction Box Z. Fuel Pump Relay (for fuel pump an injectors) d. Starter Relay e. Joint Connector C f. Sealed Battery j. Joint Connector B k.
FUEL SYSTEM (DFI) 3-87 Throttle Grip and Cables Throttle Grip Play Inspection/Adjustment to the Throttle Control System Inspection in the Pe• Refer riodic Maintenance chapter. Choke Lever Operation ○Do not use the choke lever except when the engine has a starting difficulty like in cold weather (10°C, 50°F or below) or at high altitude. The DFI system has an automatic choke system, using a water temperature sensor, and an atmospheric pressure sensor, which provide startability.
3-88 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection to the Idle Speed Inspection in the Periodic Main• Refer tenance chapter. Engine Vacuum Adjustment Synchronization Inspection/ to the Engine Vacuum Synchronization Inspection • Refer in the Periodic Maintenance chapter. High Altitude Performance Adjustment modification is not necessary in this model since the • Any atmospheric pressure sensor senses atmospheric pressure change due to high altitude and the ECU compensates the change.
FUEL SYSTEM (DFI) 3-89 Throttle Body Assy • Loosen: Throttle Assy Holder Clamp Bolts [A] Air Cleaner Duct Clamp Bolts [B] • Remove: Right and Left Side Covers (see Frame chapter) Coolant Reserve Tank (see Cooling System in the Periodic Maintenance chapter) Crankcase Breather Hose Right and Left Air Cleaner Housing Mounting Bolts [A] [A] the air cleaner housing backwards. • Move Pull [B] the throttle body assy out of the holders [C]. • • Slide [A] the throttle body assy [B] right and remove it.
3-90 FUEL SYSTEM (DFI) Throttle Body Assy the bolt [A] and the throttle cable plate [B] from • Remove the throttle body front side. the throttle cable lower ends from the throttle • Remove pulley. • Remove: Choke Cable Upper End (From choke lever) • Choke Cable Lower End [A] After removing the throttle body assy, stuff pieces of lint -free, clean cloth into the throttle body holders. CAUTION If dirt gets into the engine, excessive engine wear and possible engine damage will occur.
FUEL SYSTEM (DFI) 3-91 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. 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).
3-92 FUEL SYSTEM (DFI) Throttle Body Assy CAUTION Never drop the injector, especially on a hard surface. Such a shock to the injector can damage it. out the injectors along with the delivery pipe [A]. • Pull If necessary, remove the injectors from the delivery pipe. Replace the O-rigs of the indicators. If necessary, cut straps and take the harness off the delivery pipe. Throttle Body Assy Assembly ○Replace the O-rings [A] of injectors and the seals [B] with • • • the new ones.
FUEL SYSTEM (DFI) 3-93 Air Cleaner Element Removal/Installation to the Air Cleaner Element Cleaning in the Periodic • Refer Maintenance chapter. Air Cleaner Oil Draining A drain hose is connected to the bottom of the air cleaner to drain water or oil accumulated in the cleaner part. Visually check the drain hose [A] if the water or oil accumulates. If any water or oil accumulates in the hose, remove the plug [B] from the drain hose and drain it.
3-94 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
FUEL SYSTEM (DFI) 3-95 Fuel Tank sure to place a piece of cloth [A] around the fuel hose • Be pump outlet joint [B]. pinching the hose joint locks [C] with fingers, pull • While the joint out along the delivery pipe. WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage.
3-96 FUEL SYSTEM (DFI) Fuel Tank the pump outlet hose joint [A] straight onto the de• Insert livery pipe [B] until the hose joint clicks [C]. Front [D] and pull [A] the hose joint [B] back and forth more • Push than two times and make sure it is locked and doesn’t come off. When the hose joint is correctly installed, it should slide on the delivery pipe about 5 mm (0.2 in.). WARNING Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint, or the fuel could leak.
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. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Fastener Radiator hose clamp screws Radiator fan bolts Water pump impeller bolt Water pump cover bolts Water pump drain bolt Water pipe bolts Thermostat housing ground bolt Thermostat bracket bolt Radiator upper bolts Radiator lower bolts Radiator screen bolt Coolant reserve tank screws Radiator fan switch Water temperature sensor 15. Mechanical seal 16. Oil pump rotor 17. Thermostat 18. To cylinder head 19. To cylinder G: Apply grease.
4-4 COOLING SYSTEM Coolant Flow Chart
COOLING SYSTEM 4-5 Coolant Flow Chart 1. Drain Bolt 2. Water Pump 3. Cylinder Jacket 4. Cylinder Head Jacket 5. Thermostat Housing 6. Radiator Cap 7. Radiator 8. Oil Filter 9. Reserve Tank 10. Reserve Tank Hose 11. Reserve Tank Overflow Hose 12. Radiator Fan 13. Water Temperature Sensor 14. Radiator Fan Switch 15. Hot Coolant 16. Cold Coolant 17. Front Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion.
4-6 COOLING SYSTEM Specifications Item Coolant provided when shipping: Type (recommended) Color Mixed ratio Freezing point Total amount Radiator cap Relief pressure: Thermostat: Valve opening temperature Valve full opening lift Standard Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Green Soft water 50%, coolant 50% –35°C (–31°F) 2.9 L (3.
COOLING SYSTEM 4-7 Special Tools and Sealant Bearing Driver: 57001–382 Bearing Driver Set: 57001–1129 Kawasaki Bond (Silicone Sealant): 56019–120
4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection the left side cover (see Frame chapter). • Remove inspect the coolant [A] in the reserve tank. • Visually If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system. If the coolant gives off an abnormal smell, check for a cooling system leak. It may be caused by exhaust gas leaking into the cooling system.
COOLING SYSTEM 4-9 Coolant Pressure Testing the fuel tank (see Fuel System (DFI) chapter). • Remove the radiator cap, and install a cooling system • Remove pressure tester [A] on the filler neck [B]. NOTE ○Wet the cap sealing surfaces with water or coolant to prevent pressure leaks. up pressure in the system carefully until the pres• Build sure reaches 123 kPa (1.25 kgf/cm², 17.8 psi). CAUTION During pressure testing, do not exceed the pressure for which the system is designed.
4-10 COOLING SYSTEM Water Pump Water Pump Removal to the Oil Pump Removal in the Engine Lubrication • Refer System chapter. Water Pump Installation to the Oil Pump Installation in the Engine Lubrica• Refer tion System chapter. Water Pump Inspection the drainage outlet passage [A] at the bottom of • Check the water pump body for coolant leaks. If the mechanical seal is damaged, the coolant leaks through the seal and drains through the passage. Replace the mechanical seal unit.
COOLING SYSTEM 4-11 Water Pump • Take the oil seal [A] out of the housing [B] with a hook [C]. Water Pump Housing Assembly CAUTION Do not reuse the mechanical seal and oil seal. high temperature grease to the oil seal lips [A]. • Apply Press the new oil seal into the housing with a bearing • driver [B] until it stops at the bottom surface [C] of the housing. Special Tool - Bearing Driver Set: 57001–1129 CAUTION Be careful not to damage the sealing surface of the mechanical seal.
4-12 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal WARNING The radiator fan is connected directly to the battery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DISCONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES. the coolant (see Cooling System in the Periodic • Drain Maintenance chapter).
COOLING SYSTEM 4-13 Radiator Radiator and Radiator Fan Installation is the reverse of removal. • Installation the radiator bracket collars [A] as shown. • Install Rubber Damper [B] • 30 ∼ 40° [C] Radiator [D] Bracket [E] Tighten: Torque - Radiator Lower Bolts [F]: 7.0 N·m (0.70 kgf·m, 61 in·lb) Radiator Upper Bolts [G]: 7.0 N·m (0.70 kgf·m, 61 in·lb) Radiator Inspection the radiator core. • Check If there are obstructions to air flow, remove them.
4-14 COOLING SYSTEM Radiator • Install the cap [A] on a cooling system pressure tester [B]. NOTE ○Wet the cap sealing surfaces with water or coolant to prevent pressure leaks. the pressure gauge, pump the pressure tester • Watching to build up the pressure until the relief valve opens: the gauge needle flicks downward. Stop pumping and measure leak time at once.
COOLING SYSTEM 4-15 Thermostat Thermostat Removal the coolant (see Cooling System in the Periodic • Drain Maintenance chapter). • Remove: Fuel Tank (see Fuel System (DFI) chapter) Thermostat Bracket Bolt [A] Ground Lead [B] Water Temperature Sensor Connector [C] Three Water Hoses [D] Remove the thermostat housing [E]. • the screws [A], take off the cap [B], and take out • Remove the thermostat.
4-16 COOLING SYSTEM Thermostat check valve opening temperature, suspend the ther• To mostat [A] in a container of water and raise the temperature of the water. ○The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an accurate thermometer [B] in the water so that the heat sensitive portions [C] are located in almost the same depth. It must not touch the container, either.
COOLING SYSTEM 4-17 Hoses and Pipes Hose Installation the hoses and pipes, being careful to follow bend• Install ing direction. Avoid sharp bending, kinking, flattening or twisting. Run the hoses in accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter. Install the clamp [A] as near as possible to the hose end to clear the raised rib of the fitting. This will prevent the hoses from working loose.
4-18 COOLING SYSTEM Radiator Fan Switch, Water Temperature Sensor CAUTION The fan switch or the water temperature sensor should never be allowed to fall on a hard surface. Such a shock to their parts can damage them. Radiator Fan Switch Removal the coolant (see Cooling System in the Periodic • Drain Maintenance chapter). • Remove: Radiator Fan Switch Lead Connector [A] Radiator Fan Switch [B] Radiator Fan Switch Installation • Tighten: Torque - Radiator Fan Switch : 18 N·m (1.
ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View................................... Specifications .................................... Special Tools and Sealant ................. Clean Air System............................... Air Suction Valve Removal........... Air Suction Valve Installation........ Air Suction Valve Inspection ........ Vacuum Switch Valve Removal ... Vacuum Switch Valve Installation Vacuum Switch Valve Test ........... Clean Air System Hose Inspection..................
5-2 ENGINE TOP END Exploded View
ENGINE TOP END 5-3 Exploded View No. 1 2 3 Fastener Air suction valve cover bolts Cylinder head cover bolts Torque N·m 9.8 9.8 12 kgf·m 1.0 1.0 1.2 ft·lb 87 in·lb 87 in·lb 104 in·lb 12 1.2 104 in·lb 4 Camshaft cap bolts Camshaft chain guide bolts 5 Cylinder head bolts (M10 new bolts) 54 5.5 40 5 Cylinder head bolts (M10 used bolts) 49 5.
5-4 ENGINE TOP END Exploded View
ENGINE TOP END 5-5 Exploded View No. 1 2 3 4 5 Fastener Coolant drain plug (cylinder) Exhaust pipe manifold holder nuts Muffler body clamp bolt Muffler body mounting bolt Crankshaft sensor cover bolts Torque N·m 9.8 17 17 30 11 kgf·m 1.0 1.7 1.7 3.0 1.1 ft·lb 87 in·lb 12 12 22 95 in·lb Remarks 6. "1T" marked side faces up. 7. "2T" marked side faces up. 8. Hollow mark faces forward. EO: Apply engine oil. R: Replacement Parts Exhaust System UK: U.K. Model Full: Full Power 78.2: Horsepower 78.
5-6 ENGINE TOP END Specifications Item Standard Service Limit Clean Air System: Vacuum switch valve closing Open → Close – – – pressure 41 ∼ 49 kPa (310 ∼ 370 mmHg, 6.0 ∼ 7.1 psi) Camshafts: Cam height: Exhaust 36.146 ∼ 36.254 mm (1.4231 ∼ 1.4273 in.) 36.05 mm (1.419 in.) Inlet 36.746 ∼ 36.854 mm (1.4467 ∼ 1.4509 in.) 36.65 mm (1.443 in.) Camshaft journal, camshaft 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.) 0.16 mm (0.0063 in.) cap clearance Camshaft journal diameter 23.950 ∼ 23.972 mm (0.9429 ∼ 0.9438 in.) 23.
ENGINE TOP END 5-7 Specifications Item Valve spring free length: Exhaust Inlet Cylinder, Pistons: Cylinder inside diameter: Piston diameter Piston/cylinder clearance Piston ring/groove clearance: Top Second Piston ring groove width: Top Second Piston ring thickness: Top Second Piston ring end gap: Top Second Standard 40.7 mm (1.602 in.) 40.7 mm (1.602 in.) Service Limit 38.9 mm (1.531 in.) 38.9 mm (1.531 in.) 68.400 ∼ 68.412 mm (2.6929 ∼ 2.6934 in.) 68.345 ∼ 68.360 mm (2.6907 ∼ 2.6913 in.) 0.040 ∼ 0.
5-8 ENGINE TOP END Special Tools and Sealant Compression Gauge: 57001–221 Valve Seat Cutter, 32° 57001–1118 25: Valve Spring Compressor Assembly: 57001–241 Valve Seat Cutter, 32° 57001–1119 28: Piston Pin Puller Assembly: 57001–910 Valve Seat Cutter Holder Bar: 57001–1128 Valve Seat Cutter, 45° 57001–1113 24: Valve Spring Compressor Adapter, 20: 57001–1154 Valve Seat Cutter, 45° 57001–1114 27.
ENGINE TOP END 5-9 Special Tools and Sealant Valve Guide Reamer, 57001–1274 4: Valve Seat Cutter Holder, 57001–1275 4: Valve Seat Cutter, 60° 57001–1328 25: Valve Seat Cutter, 60° 57001–1409 27: Fork Oil Level Gauge: 57001–1290 Spark Plug Wrench (Owner’s Tool): 92110–1146 Compression Gauge Adapter, M10 × 1.
5-10 ENGINE TOP END Clean Air System Air Suction Valve Removal • Remove: Fuel Tank (see Fuel System (DFI) chapter) Connector [A] (from Clamp [B]) Air Suction Valve Cover Bolts [C] and Clamp Air Suction Valve Cover [D] Air Suction Valve Air Suction Valve Installation the air suction valve [A] so that its wider side [B] of • Install the reed valve case faces the front. • Tighten: Torque - Air Suction Valve Cover Bolts: 9.8 N·m (1.
ENGINE TOP END 5-11 Clean Air System Vacuum Switch Valve Test • Remove: Vacuum Switch Valve (see Vacuum Switch Valve Re• moval) Connect a vacuum gauge [A] and syringe [B] or fork oil level gauge to the vacuum hoses as shown. Special Tool - Fork Oil Level Gauge: 57001–1290 Air Flow [C] raise the vacuum (lower the pressure) applied • Gradually to the vacuum switch valve, and check the valve operation. When the vacuum is low, the vacuum switch valve should permit air to flow.
5-12 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal • Remove: Fuel Tank (see Fuel System (DFI) chapter) Vacuum Switch Valve and Hoses Stick Coils (see Electrical System chapter) Air Suction Valve Covers [A] the cylinder head cover bolts [A] and take off the • Remove cover. Cylinder Head Cover Installation the head cover gasket with a new one. • Replace • Apply silicone sealant [A] to the cylinder head as shown.
ENGINE TOP END 5-13 Cylinder Head Cover the cover bolts following the specified tightening • Tighten sequence. Torque - Cylinder Head Cover Bolts [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the removed parts (see appropriate chapters).
5-14 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway. Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain.
ENGINE TOP END 5-15 Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re• moval) Pickup Coil Cover Position the crankshaft at #1, 4 piston TDC.
5-16 ENGINE TOP END Camshaft, Camshaft Chain the crankshaft at #1, 4 piston TDC. • Position Pull the tension side (exhaust side) [A] of the chain taut • to install the chain. the camshaft chain with the camshaft sprockets • Engage so that the timing marks on the sprockets are positioned as shown. ○The timing marks of #1, 4T must be aligned with the lower surface of crankcase of rear side [B]. ○The timing marks must be aligned with the cylinder head upper surface [C].
ENGINE TOP END 5-17 Camshaft, Camshaft Chain If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer. Camshaft Journal Diameter Standard: 23.950 ∼ 23.972 mm (0.9429 ∼ 0.9438 in.) Service Limit: 23.92 mm (0.942 in.) If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again. If the clearance still remains out of the limit, replace the cylinder head unit.
5-18 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○Use the battery which is fully charged. up the engine thoroughly. • Warm Stop the • Remove: engine. • Seats (see Frame chapter) Fuel Tank (see Fuel System (DFI) chapter) Stick Coils Spark Plugs Owner’s Tool - Spark Plug Wrench, 16 mm: 92110–1146 the compression gauge [A] and adapter [B] firmly • Attach into the spark plug hole.
ENGINE TOP END 5-19 Cylinder Head Cylinder Head Removal the coolant (see Cooling System chapter).
5-20 ENGINE TOP END Cylinder Head • Install: Front Camshaft Chain Guide [A] • O-ring [B] Collar [C] Tighten: Torque - Front Camshaft Chain Guide Bolt (Upper) [D]: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Camshaft Chain Guide Bolt (Lower) [E]: 12 N·m (1.2 kgf·m, 104 in·lb) • Install the removed parts (see appropriate chapters). Cylinder Head Warp the cylinder head. • Clean Lay a straightedge across the lower surface of the cylinder • head at several positions.
ENGINE TOP END 5-21 Valves Valve Clearance Inspection to the Engine Top End in the Periodic Maintenance • Refer chapter. Valve Removal the cylinder head (see Cylinder Head Removal). • Remove the valve lifter and shim. •○Remove Mark and record the valve lifter and shim locations so they • can be installed in their original positions. Using the valve spring compressor assembly, remove the valve.
5-22 ENGINE TOP END Valves Valve Guide Installation oil to the valve guide outer surface before installa• Apply tion. the area around the valve guide hole to about 120 ∼ • Heat 150°C (248 ∼ 302°F). the valve guide in from the top of the head using the • Drive valve guide arbor. The flange stops the guide from going in too far.
ENGINE TOP END 5-23 Valves Valve Seat Inspection the valve (see Valve Removal). • Remove the valve seating surface [A] between the valve [B] • Check and valve seat [C]. ○Measure the outside diameter [D] of the seating pattern on the valve seat. If the outside diameter is too large or too small, repair the seat (see Seat Repair). Valve Seating Surface Outside Diameter Standard: Inlet 26.4 ∼ 26.6 mm (1.0276 ∼ 1.0472 in.) Exhaust 21.6 ∼ 21.8 mm (0.850 ∼ 0.858 in.
5-24 ENGINE TOP END Valves Seat Cutter Operation Care: 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the diamond particles may fall off. 3. Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface. Also wash off ground particles sticking to the cutter with washing oil.
ENGINE TOP END 5-25 Valves the outside diameter of the seating surface with • Measure a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the specified range. Widened Width [A] of engagement by machining with 45° cutter Ground Volume [B] by 32° cutter 32° [C] Correct Width [D] Ground Volume [E] by 60° cutter 60° [F] the outside diameter of the seating surface with • Measure a vernier caliper.
5-26 ENGINE TOP END Valves If the seat width is too wide, make the 60° [A] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. Grind the seat at a 60° angle until the seat width is within the specified range. ○To make the 60° grind, fit 60° cutter into the holder, and slide it into the valve guide. ○Turn the holder, while pressing down lightly. ○After making the 60° grind, return to the seat width measurement step above.
ENGINE TOP END 5-27 Valves
5-28 ENGINE TOP END Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) • Water Hose [A] Remove the cylinder [B]. Cylinder Installation NOTE ○If a new cylinder is used, use new piston ring. the dowel pins [A] and new cylinder gasket [B]. • Install Apply engine oil to the cylinder bore. • piston ring openings must be positioned as shown in • The the figure. The openings of the oil ring steel rails must be about 30 – 40° of angle from the opening of the top ring.
ENGINE TOP END 5-29 Cylinder, Pistons • Remove the piston pins. Special Tool - Piston Pin Puller Assembly: 57001–910 [A] • Remove the pistons. spread the ring opening with your thumbs and • Carefully then push up on the opposite side of the ring [A] to remove • it. Remove the 3-piece oil ring with your thumbs in the same manner.
5-30 ENGINE TOP END Cylinder, Pistons NOTE ○If a new piston is used, use new piston ring. the piston with its marking hollow facing forward. • Install Fit a new pin snap ring into the side of the piston • so that thepiston ring opening [A] does not coincide with the slit [B] of the piston pin hole. ○Apply molybdenum disulfide oil solution to the piston pins and piston journals. ○When installing the piston pin snap ring, compress it only enough to install it and no more.
ENGINE TOP END 5-31 Cylinder, Pistons Piston Ring, Piston Ring Groove Wear for uneven groove wear by inspecting the ring seat• Check ing. • The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. With the piston rings in their grooves, make several measurements with a thickness gauge [A] to determine piston ring/groove clearance. Piston Ring/Groove Clearance Top Standard: 0.04 ∼ 0.08 mm (0.0016 ∼ 0.0031 in.) Service Limit: 0.18 mm (0.0071 in.
5-32 ENGINE TOP END Cylinder, Pistons Piston Ring End Gap the piston ring [A] inside the cylinder, using the pis• Place ton to locate the ring squarely in place. Set it close to the • bottom of the cylinder, where cylinder wear is low. Measure the gap [B] between the ends of the ring with a thickness gauge. Piston Ring End Gap Top Standard: 0.30 ∼ 0.40 mm (0.0118 ∼ 0.0157 in.) Service Limit: 0.7 mm (0.028 in.) Second Standard: 0.45 ∼ 0.55 mm (0.0177 ∼ 0.0217 in.) Service Limit: 0.8 mm (0.031 in.
ENGINE TOP END 5-33 Throttle Body Holder Throttle Body Holder Installation sure to install the O-rings [A]. • Be the clamps [B] as shown and so that its hole fit on • Install the projection [C] of the holder. • Tighten: Torque - Throttle Body Holder Bolts [D]: 13 N·m (1.3 kgf·m, 113 in·lb) Throttle Body Assy Holder Clamp Bolts [E]: 2.0 N·m (0.
5-34 ENGINE TOP END Muffler WARNING To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. Muffler Body Removal • Remove: Muffler Body Clamp Bolt [A] • Muffler Body Mounting Bolt [B] Pull the muffler body backward.
ENGINE TOP END 5-35 Muffler ○Install the muffler body clamp bolt as shown. Upper Side [H] Outside [I] warm up the engine, wait until the engine • Thoroughly cools down, and retighten all the bolts and nuts.
CLUTCH 6-1 Clutch Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tool and Sealant ........................................................................................................ Clutch Lever and Cable ...................................................
6-2 CLUTCH Exploded View
CLUTCH 6-3 Exploded View No. 1 2 3 4 5 Fastener Clutch lever clamp bolts Clutch cover mounting bolts Oil filler plug Clutch spring bolts Clutch hub nut CL: Apply cable lubricant. EO: Apply engine oil. G: Apply grease. M: Apply molybdenum disulfide grease. R: Replacement Parts S: Follow the specific tightening sequence. W: Apply water. N·m 7.8 11 1.5 8.8 Torque kgf·m 0.80 1.1 0.15 0.
6-4 CLUTCH Specifications Item Clutch Lever Free Play Clutch: Clutch plate assembly Friction plate thickness Friction and steel plate warp Clutch spring free length Standard 2 ∼ 3 mm (0.08 ∼ 0.12 in.) 37.7 ∼ 38.3 mm (1.48 ∼ 1.51 in.) 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) 0.2 mm (0.008 in.) or less 80.6 mm (3.17 in.) Service Limit – – – – – – 2.4 mm (0.094 in.) 0.3 mm (0.012 in.) 76.6 mm (3.02 in.
CLUTCH 6-5 Special Tool and Sealant Clutch Holder: 57001–1243 Kawasaki Bond (Silicone Sealant): 56019–120
6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment • Refer to the Clutch in the Periodic Maintenance chapter. Cable Removal the dust cover [A] at the clutch cable lower end out • Slide of place. the nuts [B], and slide the lower end of the clutch • Loosen cable to give the cable plenty of play. in the adjuster.
CLUTCH 6-7 Clutch Lever and Cable 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. ○The distance from the grip to the lever is minimum at number 5 and maximum at number 1.
6-8 CLUTCH Clutch Cover Clutch Cover Removal • Remove: Engine Oil (drain, see Engine Lubrication System in the Periodic Maintenance chapter) Clutch Cable Lower End [A] Clutch Cover Mounting Bolts [B] the release lever [A] toward the rear as shown, and • Turn remove the clutch cover [B]. About 90° [C] Clutch Cover Installation silicone sealant to the area [A] where the mating • Apply surface of the crankcase touches the clutch cover gasket.
CLUTCH 6-9 Clutch Cover the spring [A] as shown. • FitViewed from Rear [B] Release Shaft [C] Clutch Cover [D] Clutch Cover Disassembly • Remove: Oil Seal [A] Needle Bearings • Remove: Circlip [A] Oil Level Gauge [B] Clutch Cover Assembly • Replace the needle bearings and oil seal with new ones. NOTE ○Install the needle bearings so that the manufacture’s mark face out. the needle bearings [A] and oil seal [B] position as • Install shown. Press the bearing until the bottom [C].
6-10 CLUTCH Clutch Clutch Removal • Remove: Engine Oil (drain, see Engine Lubrication System in the Periodic Maintenance chapter) Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with thrust bearing and pusher [C], spring and washer) • Remove: Friction Plates, Steel Plates Spring, Spring Seat Clutch Hub Nut [A] ○Holding the clutch hub [B], remove the nut and washer.
CLUTCH 6-11 Clutch ○Install the spacer [A] so that the tapered side [B] faces inward. ○Install the washer [A] so that the OUTSIDE mark faces outward. ○Replace the clutch hub nut with a new one. ○Holding the clutch hub, tighten the clutch hub nut. Special Tool - Clutch Holder: 57001–1243 Torque - Clutch Hub Nut: 135 N·m (14 kgf·m, 100 ft·lb) the spring seat [A] and spring [B] as shown.
6-12 CLUTCH Clutch molybdenum disulfide grease to the pusher ends • Apply [A] and install the bearing [B], pusher [C], spring [D] and washer [E] in the clutch spring plate [F]. ○Apply engine oil to the needle bearing. the clutch spring plate, springs and spring holders, • Install and tighten the clutch spring bolts. Torque - Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Install the clutch cover (see Clutch Cover Installation).
CLUTCH 6-13 Clutch Clutch Plate, Wear, Damage Inspection inspect the friction and steel plates for signs of • Visually seizure, overheating (discoloration), or uneven wear. the thickness of each friction plate [A] at several • Measure points. If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones. Friction Plate Thickness Standard: 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) Service Limit: 2.4 mm (0.094 in.
ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................................................................................................................ Engine Oil Flow Chart............................................................................................................. Specifications ......................................................................................................................... Special Tools and Sealant .........
7-2 ENGINE LUBRICATION SYSTEM Exploded View
ENGINE LUBRICATION SYSTEM 7-3 Exploded View No. 1 2 3 4 5 6 7 Fastener Oil filler plug Engine oil drain bolt Oil filter Holder mounting bolt Oil pan bolts Oil pipe holder bolts Oil pressure relief valve 8 Oil pressure switch 9 Oil pressure switch terminal bolt 10 Water pump cover bolts 11 Water pump impeller bolt 12 Coolant drain plug (water pump) 13 Oil passage plugs N·m 1.5 20 31 76 11 13 15 15 1.5 11 9.8 11 20 Torque kgf·m ft·lb 0.15 13 in·lb 2.0 14 3.2 23 7.8 56 1.1 95 in·lb 1.3 113 in·lb 1.5 11 1.
7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart
ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart 1. Camshaft Oil Passage 2. Oil Passage Hole in Alternator Rotor Bolt 3. Starter Clutch Oil Passage Hole 4. Main Oil Passage 5. Crankshaft Oil Passage 6. Oil Filter 7. Oil Pressure Switch 8. Oil Pipe 9. Oil Pump 10. To Drive Shaft 11. Oil Pipe 12. To Output Shaft 13. Drive Shaft Oil Passage Hole 14. Output Shaft Oil Passage Hole 15. Inlet Camshaft 16. Exhaust Camshaft 17. To Air Cleaner 18. Drive Shaft 19. Relief Valve 20. Oil Screen 21.
7-6 ENGINE LUBRICATION SYSTEM Specifications Item Engine Oil: Type Viscosity Capacity: Level Oil Pressure Measurement: Oil pressure @4 000 r/min (rpm), oil temp. 90°C (194°F) Standard API SE, SF or SG API SH or SJ with JASO MA SAE 10W-40 3.1 L (3.3 US gt) (when filter is not removed) 3.3 L (3.5 US gt) (when filter is removed) 3.8 L (4.0 US gt) (when engine is completely dry) Between upper and lower level lines 255 ∼ 314 kPa (2.6 ∼ 3.
ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: 57001–164 Oil Filter Wrench: 57001–1249 Oil Pressure Gauge Adapter, PT3/8: 57001–1233 Kawasaki Bond (Silicone Sealant): 56019–120
7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury. Oil Level Inspection that the engine oil level is between the upper [A] • Check and lower [B] levels in the gauge. NOTE ○Situate the motorcycle so that it is perpendicular to the ground.
ENGINE LUBRICATION SYSTEM 7-9 Oil Pan Oil Pan Removal • Remove: Engine Oil (drain, see Engine Lubrication System in the Periodic Maintenance chapter) Exhaust Pipe Assy and Muffler Body (see Engine Top End chapter) Oil Pan Bolts [A] Oil Pan [B] Oil Pan Installation the oil screen [A]. • Clean the oil screen so that the crankcase rib [B] fits the • Install slot [C] of the oil screen. engine oil to the O-rings on the oil pipe. • Apply If the oil pressure relief valve was removed, install it.
7-10 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • See Oil Pan Removal. Oil Pressure Relief Valve Installation • See Oil Pan Installation. Oil Pressure Relief Valve Inspection to see if the valve [A] slides smoothly when push• Check ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure. NOTE ○Inspect the valve in its assembled state. Disassembly and assembly may change the valve performance.
ENGINE LUBRICATION SYSTEM 7-11 Oil Pump Oil Pump Removal • Drain: Coolant (see Cooling System in the Periodic Mainte• nance chapter) Engine Oil (see Engine Lubrication System in the Periodic Maintenance chapter) Remove: Water Pipe Bolts [A] Water Pipes [B] • Remove: Water Pump Cover Bolts [A] Clamp [B] Water Pump Cover [C] • Remove: Impeller Bolt [A] Washer Impeller [B] Water Pump Body Oil Pump Cover Oil (Water) Pump Shaft Outer Rotor and Inner Rotor Oil Pump Installation the outer rotor [A] into the
7-12 ENGINE LUBRICATION SYSTEM Oil Pump • Install: Pins [A] Water Pump Body [B] • Install: Impeller [A], Washer and Bolt [B] • Tighten: Torque - Water Pump Impeller Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install: Pins [C] Water Pump Cover and Bolts Torque - Water Pump Cover Bolts: 11 N·m (1.1 kgf·m, 95 in·lb) • Install: Water Pipes [A] Tighten: • Torque - Water Pipe Bolts [B]: 11 N·m (1.
ENGINE LUBRICATION SYSTEM 7-13 Oil Pressure Measurement Oil Pressure Measurement the oil passage plug, and attach the adapter [A] • Remove and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001–164 Oil Pressure Gauge Adapter, PT 3/8: 57001–1233 the engine and warm up the engine. • Start Run the at the specified speed, and read the oil • pressureengine gauge.
7-14 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal • Remove: Engine Oil (drain, see Engine Lubrication System in the Periodic Maintenance chapter) Switch Cover [A] Switch Terminal [B] Oil Pressure Switch [C] Oil Pressure Switch Installation silicone sealant to the threads of the oil pressure • Apply switch and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019–120 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb) the switch lead direction upward.
ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................................................................................................................ Special Tool ............................................................................................................................ Engine Removal/Installation ................................................................................................... Engine Removal...................
8-2 ENGINE REMOVAL/INSTALLATION Exploded View
ENGINE REMOVAL/INSTALLATION 8-3 Exploded View No. Fastener 1 2 3 4 Adjusting collar locknut Upper engine mounting bolts Rear engine bracket bolts Front engine bracket bolts N·m 49 44 25 44 5 6 7 Middle engine mounting nut Lower engine mounting nut Engine ground cable terminal bolt 44 44 9.8 8. Adjusting Collar 9. Middle Engine Mounting Bolt 10. Lower Engine Mounting Bolt S: Follow the specific tightening sequence. Torque kgf·m 5.0 4.5 2.5 4.5 ft·lb 36 33 18 33 4.5 4.5 1.
8-4 ENGINE REMOVAL/INSTALLATION Special Tool Engine Mount Nut Wrench: 57001–1450
ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal the rear part of the swingarm with a stand. • Support the brake lever slowly and hold it with a band • Squeeze [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It could cause an accident and injury. CAUTION Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. The engine or the motorcycle could be damaged.
8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Camshaft Position Sensor Connector [A] • Injector Harness Connector [B] Remove the vacuum switch valve hose from the air cleaner housing. • Remove: Breather Hose End [A] Engine Ground Cable Terminal Bolt [B] the engine with a suitable stand [A]. •○Support Put a plank [B] onto the suitable stand for engine balance.
ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation the middle and lower engine mounting nuts [A] • Remove and bolts. • Remove: Rear Engine Bracket Bolts [B] Rear Engine Bracket [C] • Using the nut wrench [A], loosen the locknut [B]. Special Tool - Engine Mount Nut Wrench: 57001–1450 the Hexagon Wrench, turn the adjusting collar [A] • Using counter clockwise to mark the gap between the engine and frame adjusting collar. the drive chain [A] from the output shaft [B].
8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation the engine mounting bolts and nuts, following the • Install specified installing sequence. ○First, hang the drive chain over the output shaft just before moving the engine into its final position in the frame. ○Second, insert the lower engine mounting bolt [A]. ○Third, insert the middle engine mounting bolt [B]. ○Fourth, install the rear engine bracket [C] temporarily. ○Fifth, install the left upper engine mounting bolt [A] and tighten it.
ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation ○Tenth, temporarily install: Front Engine Bracket [C] Right Upper Engine Mounting Bolt [A] Front Engine Bracket Bolts [B] ○Eleventh, tighten the right upper engine mounting bolt. ○Lastly, tighten the front engine bracket bolts. Torque - Right Upper Engine Mounting Bolt : 44 N·m (4.5 kgf·m, 33 ft·lb) Front Engine Bracket Bolts: 44 N·m (4.
CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View................................... Specifications .................................... Special Tools and Sealant ................. Crankcase Splitting............................ Crankcase Splitting ...................... Crankcase Assembly ................... Crankshaft and Connecting Rods...... Crankshaft Removal .................... Crankshaft Installation ................. Connecting Rod Removal ............
9-2 CRANKSHAFT/TRANSMISSION Exploded View
CRANKSHAFT/TRANSMISSION 9-3 Exploded View No.
9-4 CRANKSHAFT/TRANSMISSION Exploded View
CRANKSHAFT/TRANSMISSION 9-5 Exploded View No. 1 2 3 4 5 6 7 8 Fastener Shift pedal mounting bolt Gear positioning lever bolt Shift shaft return spring pin Shift drum cam holder bolt Footpeg bracket bolts Shift lever bolt Tie-rod locknuts Neutral switch EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts Torque N·m 34 12 29 12 34 6.9 6.9 15 kgf·m 3.5 1.2 3.0 1.2 3.5 0.70 0.70 1.
9-6 CRANKSHAFT/TRANSMISSION Specifications Item Crankshaft, Connecting Rods: Connecting rod bend Standard Service Limit – – – 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.) 0.041 ∼ 0.071 mm (0.0016 ∼ 0.0028 in.) 34.984 ∼ 35.000 mm TIR 0.2/100 mm (0.008/3.94 in.) TIR 0.2/100 mm (0.008/3.94 in.) 0.58 mm (0.023 in.) 0.11 mm (0.0043 in.) 34.97 mm None (1.3773 ∼ 1.3780 in.) 34.984 ∼ 34.992 mm (1.3768 in.) – – – Connecting rod big end inside diameter: (1.3773 ∼ 1.3776 in.) 34.993 ∼ 35.000 mm (1.3777 ∼ 1.3780 in.
CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard 0.05 ∼ 0.20 mm Crankshaft side clearance (0.0020 ∼ 0.0079 in.) Crankshaft runout TIR 0.02 mm (0.0008 in.) or less Crankshaft main bearing insert/journal clearance 0.020 ∼ 0.044 mm (0.0008 ∼ 0.0017 in.) Crankshaft main journal diameter: 32.984 ∼ 33.000 mm (1.2986 ∼ 1.2992 in.) Marking None 32.984 ∼ 32.992 mm (1.2986 ∼ 1.2989 in.) 1 32.993 ∼ 33.000 mm (1.2989 ∼ 1.2992 in.) Crankcase main bearing inside diameter: 36.000 ∼ 36.016 mm (1.4173 ∼ 1.
9-8 CRANKSHAFT/TRANSMISSION Specifications Item Shift fork guide pin diameter Shift drum groove width Standard 6.9 ∼ 7.0 mm (0.272 ∼ 0.276 in.) 7.05 ∼ 7.20 mm (0.278 ∼ 0.283 in.) Service Limit 6.8 mm (0.268 in.) 7.3 mm (0.287 in.
CRANKSHAFT/TRANSMISSION 9-9 Special Tools and Sealant Bearing Puller: 57001–135 Kawasaki Bond (Silicone Sealant): 56019–120 Bearing Puller Adapter: 57001–317 Kawasaki Bond (Silicone Sealant): 92104–1066
9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Splitting the engine (see Engine Removal/Installation • Remove chapter). the engine on a clean surface and hold the engine • Set steady while parts are being removed.
CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting liquid gasket to the breather plate mating surface • Apply [A] 1 to 1.5 mm (0.04 to 0.06 in.) thick, and then install the breather plate. Sealant - Three Bond: 1207B a non-permanent locking agent to the threads and • Apply tighten the bolts [A]. Torque - Breather Plate Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) the breather hose [A]. •○Install Align the white mark on the hose with the white mark on the pipe.
9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting liquid gasket [A] to the mating surface of the lower • Apply crankcase half. Sealant - Kawasaki Bond (Silicone Sealant): 92104–1066 CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts, and oil passage holes. • Fit the lower crankcase to the upper crankcase. molybdenum disulfide oil to the seating surface [A] • Apply on the lower crankcase for the M9 bolts [B].
CRANKSHAFT/TRANSMISSION 9-13 Crankshaft and Connecting Rods Crankshaft Removal the crankcase (see Crankcase Splitting). • Split • Remove the crankshaft [A]. Crankshaft Installation CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bearing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.
9-14 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods molybdenum disulfide grease [A] to the outer sur• Apply face of the upper insert and the inner surface of the connecting rod big end. Apply molybdenum disulfide oil [B] to the inner surfaces of upper and lower bearing inserts. ○The molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease with a weight ratio (10:1). ○Do not apply any grease or oil [C] to the cap inside and cap insert outside.
CRANKSHAFT/TRANSMISSION 9-15 Crankshaft and Connecting Rods (1) Bolt Length Measurement Method Be sure to clean the bolts, nuts, and connecting rods thoroughly with a high-flash point solvent, because the new connecting rods, bolts, and nuts are treated with an anti-rust solution. • WARNING Clean the bolts, nuts, and connecting rods in a well -ventilated area, and take care that there is no spark or flame anywhere near the working area. This includes any appliance with a pilot light.
9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods (2) Rotation Angle Method If you don’t have a point micrometer, you may tighten the nuts using the “Rotation Angle Method”. Be sure to clean the bolts and nuts thoroughly with a high -flash point solvent, because the new bolts and nuts are treated with an anti-rust solution. • WARNING Clean the bolts and nuts in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area.
CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods Connecting Rod Bend the connecting rod big end bearing inserts, and • Remove reinstall the connecting rod big end cap. an arbor [A] of the same diameter as the connect• Select ing rod big end, and insert the arbor through the connect- • • • ing rod big end. Select an arbor of the same diameter as the piston pin and at least 100 mm (3.94 in.) long, and insert the arbor [B] through the connecting rod small end.
9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert/Crankpin Wear the bearing insert/crankpin [B] clearance with • Measure plastigage [A]. the big end nuts to the specified torque (see Con• Tighten necting Rod Installation). NOTE ○Do not move the connecting rod and crankshaft during clearance measurement. CAUTION After measurement, replace the connecting rod bolts. Connecting Rod Big End Bearing Insert/Crankpin Clearance Standard: 0.041 ∼ 0.071 mm (0.0016 ∼ 0.
CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods the connecting rod big end inside diameter, and • Measure mark each connecting rod big end in accordance with the • inside diameter. Tighten the connecting rod big end nuts to the specified torque (see Connecting Rod Installation). NOTE ○The mark already on the big end should almost coincide with the measurement. Connecting Rod Big End Inside Diameter Marks None 38.000 ∼ 38.008 mm (1.4961 ∼ 1.4964 in.) 38.009 ∼ 38.016 mm (1.4964 ∼ 1.4967 in.
9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Runout the crankshaft runout. • Measure If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: TIR 0.02 mm (0.0008 in.) or less Service Limit: TIR 0.05 mm (0.0020 in.) Crankshaft Main Bearing Insert/Journal Wear a plastigage (press gauge) [A], measure the bear• Using ing insert/journal [B] clearance. NOTE ○Tighten the crankcase bolts to the specified torque (see Crankcase Assembly).
CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods the main bearing inside diameter, and mark the • Measure upper crankcase half in accordance with the inside diam- • eter. Crankcase Main Bearing Inside Diameter Marks : " " or no mark. Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). NOTE ○The mark already on the upper crankcase half should almost coincide with the measurement. Crankcase Main Bearing Inside Diameter Marks 36.000 ∼ 36.008 mm (1.4173 ∼ 1.4176 in.
9-22 CRANKSHAFT/TRANSMISSION Starter Motor Clutch Starter Motor Clutch Removal/Installation to the Alternator Rotor Removal and Installation in • Refer the Electrical System chapter. Starter Motor Clutch Inspection • Remove: Alternator Cover (see Electrical System chapter) • • Starter Idle Gear Turn the starter motor clutch gear [A] by hand. The starter motor clutch gear should turn clockwise [B] freely, but should not turn counterclockwise [C].
CRANKSHAFT/TRANSMISSION 9-23 Transmission Shift Pedal Removal [A] the position of the shift lever [B] on the shift shaft • Mark so that it can be installed later in the same position. • Remove: Shift Lever Bolt [C] Shift Lever • Remove: Footpeg Bracket Bolts [A] Footpeg Bracket [B] • Remove the bolt [A], footpeg [B] and shift pedal [C]. Shift Pedal Installation grease to the oil seal lip.
9-24 CRANKSHAFT/TRANSMISSION Transmission the footpeg bracket [A]. • Install Tighten: • Torque - Footpeg Bracket Bolts [B]: 34 N·m (3.5 kgf·m, 25 ft·lb) the shift lever [A], aligning the mark (previously • Install marked). • Tighten: Torque - Shift Lever Bolt: 6.9 N·m (0.70 kgf·m, 61 in·lb) the shift pedal [B] as shown. • Install About 90° [C] ○To adjust the pedal position, loosen the front locknut [D] • (left-hand threads) and rear locknut [E] and then turn the tie-rod [F].
CRANKSHAFT/TRANSMISSION 9-25 Transmission • Remove: Gear Positioning Lever Bolt [A] Gear Positioning Lever [B], Collar and Spring External Shift Mechanism Installation the gear positioning lever [A] as shown. • Install Spring [B] • Collar [C] Bolt [D] Tighten: Torque - Gear Positioning Lever Bolt: 12 N·m (1.2 kgf·m, 104 in·lb) grease to the O-rings on the oil pipe ends. • Apply Apply a locking agent to the oil pipe holder • bolts andnon-permanent tighten them.
9-26 CRANKSHAFT/TRANSMISSION Transmission Transmission Shaft Removal the crankcase (see Crankcase Splitting). • Split • Remove the drive shaft [A] and output shaft [B]. Transmission Shaft Installation to see that the set pins [A] and set rings [B] are in • Check place. the drive shaft and output shaft into the upper • Install crankcase half. engine oil to the bearings. •○Apply The bearing set pins and rings must match properly with the holes or grooves in the bearing outer races.
CRANKSHAFT/TRANSMISSION 9-27 Transmission • Remove the ball bearing [A] from each shafts. Special Tools - Bearing Puller: 57001–135 [B] Bearing Puller Adapter: 57001–317 [C] • Discard the bearing. Transmission Shaft Assembly engine oil to the bushings, ball bearings and shafts. • Apply the gear bushings [A] on the shaft with their holes • Install [B] aligned. any circlips removed with new ones. • Replace Install the [A] so that the opening [B] is aligned • with a splinecirclips groove [C].
9-28 CRANKSHAFT/TRANSMISSION Transmission NOTE ○When the toothed washers [28] [29] are assembled onto the output shaft, note the following. ○When the tangs [A] of the toothed washer [29] shall be assembled, they should be installed into the notch [B] of the toothed washer [28] (see Page 9–29). the steel balls into the 5th gear holes in the output • Fit shaft, aligning three oil holes [D]. 5th Gear [A] Output Shaft [B] Steel Balls [C] CAUTION Do not apply grease to the balls to hold them in place.
CRANKSHAFT/TRANSMISSION 9-29 Transmission 1. 1st Gear 2. 2nd Gear 3. 3rd Gear 4. 4th Gear 5. 5th Gear 6. 6th (Top) Gear 7. Toothed Washer, 31 mm (1.22 in.) 8. Thrust Washer, 30 mm (1.18 in.) 9. Circlip 10. Circlip 11. Bushing 12. Bushing 13. Needle Bearing 14. Needle Bearing 15. Bearing Outer Race 16. Steel Ball 17. Nut 18. Bushing 19. Bushing 20. Circlip 21. Ball Bearing 22. Collar 23. Washer 24. Toothed Washer 25. Oil Seal 26. Thrust Washer, 31 mm (1.22 in.) 27. Thrust Washer, 33 mm (1.30 in.) 28.
9-30 CRANKSHAFT/TRANSMISSION Transmission Shift Drum and Fork Removal • Remove: Lower Crankcase Half (see Crankcase Splitting) • • Transmission Shafts External Shift Mechanism (see External Shift Mechanism Removal) Bolt [A] and Screw [B] Shift Drum Bearing Holder [C] Pull out the shift rods [D], and take off the shift forks. Pull out the shift drum [E]. Shift Drum and Fork Installation the shift rods [A], noting the groove position. The • Install rods are identical.
CRANKSHAFT/TRANSMISSION 9-31 Transmission Shift Fork Bending inspect the shift forks, and replace any fork that is • Visually bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 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.
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. 1 2 3 Fastener Front axle clamp bolt Front axle Rear axle nut G: Apply grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant. Torque N·m 34 108 108 kgf·m 3.
10-4 WHEELS/TIRES Specifications Item Wheels (Rims): Rim runout: Axial Radial Axle runout/ 100 mm (3.94 in.) Wheel balance Balance weights Tires: Front Air pressure: (when cold) Rear Tread depth: Front Standard Service Limit – – – TIR 0.5 mm (0.020 in.) TIR 0.8 mm (0.031 in.) TIR 0.2 mm (0.008 in.) – – – – – – – – – – – – TIR 0.05 mm (0.0020 in.) or less 10 g (0.35 oz.) or less 10 g (0.35 oz.), 20 g (0.71 oz.), 30 g (1.06 oz.) 250 kPa (2.5 kgf/cm², 36 psi) Up to 180 kg (397 lb) load: 290 kPa (2.
WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: 57001–1129 Bearing Remover Head, 57001–1293 20 × Jack: 57001–1238 Bearing Remover Shaft, 57001–1377 13: 22:
10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Brake Caliper Mounting Bolts [A] the front axle clamp bolt [A]. • Loosen Remove the front axle [B]. • • Raise the front wheel off the ground. Special Tool - Jack: 57001–1238 out the axle to the right and drop the front wheel out • Pull of the forks. CAUTION Do not lay the wheel down on one of the discs. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.
WHEELS/TIRES 10-7 Wheels (Rims) • Tighten the front axle. Torque - Front Axle: 108 N·m (11 kgf·m, 80 ft·lb) tightening the clamp bolt on the right front fork leg, • Before pump the front fork up and down 4 or 5 times to allow the right front fork leg to seat on the front axle. NOTE ○Put a block in front of the front wheel to stop moving. • Tighten the axle clamp bolt [A]. Torque - Front Axle Clamp Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb) the front brake calipers (see Brakes chapter).
10-8 WHEELS/TIRES Wheels (Rims) • Remove: Caliper Mounting Bolts [A] Caliper [B] the drive chain [A] from the rear sprocket toward • Remove the left. the rear wheel back and remove the wheel from the • Move rear caliper. • Remove the rear wheel. CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. Rear Wheel Installation the caliper bracket [A] onto the swingarm stop [B].
WHEELS/TIRES 10-9 Wheels (Rims) • Bend the cotter pin [A] over the nut. WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condition may result. the drive chain slack after installation (see Final • Adjust Drive chapter). • Check the rear brake effectiveness. WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc.
10-10 WHEELS/TIRES Wheels (Rims) Axle Inspection the front and rear axles. • Remove inspect the front and rear axle for damages. • Visually If the axle is damaged or bent, replace it. the axle in V blocks that are 100 mm (3.94 in.) [A] • Place apart, and set a dial gauge [B] on the axle at a point halfway between the blocks. Turn [C] the axle to measure the runout. The difference between the highest and lowest dial readings is the amount of runout.
WHEELS/TIRES 10-11 Wheels (Rims) CAUTION When removing the balance weight, do not touch the brake disc. The disc could be damaged. Do not tap the screwdrivers. The rim could be damaged. Balance Weight Installation if the weight portion has any play on the clip. • Check If it does, discard it. WARNING If the balance weight has any play on the rim, the clip of the weight have been stretched. Replace the loose balance weight. Do not reuse used balance weight.
10-12 WHEELS/TIRES Tires Air Pressure Inspection to the Air Pressure Inspection in the Periodic Main• Refer tenance chapter. Tire Inspection to the Tire Wear Inspection in the Periodic Mainte• Refer nance chapter. Tire Removal • Remove: Wheel (see Front Wheel Removal, • Rear Wheel Re- moval) Disc(s) Valve Core (let out the air) To maintain wheel balance, mark the valve stem position on the tire with chalk so that the tire can be reinstalled in the same position.
WHEELS/TIRES 10-13 Tires a new valve in the rim. •○Install Remove the valve cap, lubricate the stem seal with a soap and water solution or rubber lubricant, and pull [B] the valve stem [A] through the rim from the inside out until it snaps into place. CAUTION Do not use engine oil or petroleum distillates to lubricate the stem because they will deteriorate the rubber. a soap and water solution, or rubber lubricant to the • Apply rim flange and tire beads. ○The air valve is shown in the figure.
10-14 WHEELS/TIRES Tires to see that the rim lines [A] on both sides of the tire • Check sidewalls are parallel with the rim flanges. If the rim flanges and tire sidewall rim lines are not parallel, remove the valve core. Lubricate the rim flanges and tire beads. Install the valve core and inflate the tire again. After the tire beads seat in the rim flanges, check for air leakage. ○Inflate the tire slightly above standard inflation.
WHEELS/TIRES 10-15 Hub Bearing Hub Bearing Removal the wheel, and take out the following. • Remove Collars • Coupling (out of rear hub) Grease Seals Circlip Use the bearing remover to remove the hub bearings [A]. CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Please blocks under the wheel so that the disc does not touch the ground.
FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools .......................................................................................................................... Drive Chain.............................................
11-2 FINAL DRIVE Exploded View
FINAL DRIVE 11-3 Exploded View No. 1 2 3 4 5 6 Fastener Engine sprocket cover bolts Engine sprocket nut Rear sprocket nuts Speed sensor cover bolts Speed sensor bolt Rear axle nut G: Apply grease. HO: Apply heavy oil. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil. R: Replacement Parts N·m 9.8 125 59 6.9 6.9 108 Torque kgf·m ft·lb 1.0 87 in·lb 13 92 6.0 43 0.70 61 in·lb 0.
11-4 FINAL DRIVE Specifications Item Drive Chain: Chain slack 20-link length Standard chain Make Type Link Sprockets: Rear sprocket warp Standard 25 ∼ 35 mm (1.0 ∼ 1.4 in.) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) ENUMA EK520MVXL 112 links 0.4 mm (0.016 in.) or less Service Limit – – – 323 mm (12.7 in.) – – – – – – – – – 0.5 mm (0.020 in.
FINAL DRIVE 11-5 Special Tools Bearing Driver Set: 57001–1129 Jack: 57001–1238
11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection to the Drive Chain Slack Inspection in the Periodic • Refer Maintenance chapter. Drive Chain Slack Adjustment to the Drive Chain Slack Adjustment in the Periodic • Refer Maintenance chapter. Drive Chain Wear Inspection to the Drive Chain Wear Inspection in the Periodic • Refer Maintenance chapter. Drive Chain Lubrication to the Drive Chain Lubrication in the Periodic Main• Refer tenance chapter.
FINAL DRIVE 11-7 Drive Chain Drive Chain Replacement • Remove: Chain Cover (see Drive Chain Removal) Engine Sprocket Cover (see Engine Sprocket Removal) EK JOINT TOOL #50 Body [A] Handlebar [B] Cutting & Riveting Pin [C] For Cutting [D] For Riveting [E] Plate Holder (A) [F] Plate Holder (B) [G] Gauge [H] [A] pin head to make it flat. • Grind • Set cutting & riveting pin [B] as shown. pin holder until it touches chain pin. • Screw Be sure that cutting pin hits center of chain pin.
11-8 FINAL DRIVE Drive Chain the link pin, link plate and grease seals. • Replace Apply grease to the link pins [A] and grease seals [B] [C]. • Engage the drive on the engine and rear sprockets. • Insert the link pinschain in the drive chain ends. • Install the grease seals [C]. • Install the link plate so that the mark [D] faces out. • Push link plate by hand or plier to fix it. • In case of O-ring chain, be sure to set O-rings correctly. • plate holder (A) [A] and plate holder (B) [B] on the • Set body.
FINAL DRIVE 11-9 Drive Chain • Turn pin holder until riveting pin touches link pin. wrench clockwise until tip of riveting pin hits of link • Turn pin. it. • Rivet Some work for the other link pin. • staking, check the staked area of the link pin for • After cracks. the outside diameter [A] of the link pin and link • Measure plates width [B]. Link Pin Outside Diameter Standard: 5.6 ∼ 6.0 mm (0.22 ∼ 0.24 in.) Link Plates Outside Width Standard: 17.45 ∼ 17.60 mm (0.687 ∼ 0.693 in.
11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove: Speed Sensor Connector [A] Engine Sprocket Cover Bolts [B] Engine Sprocket Cover [C] with Speed Sensor out the bended washer [A]. • Flatten Remove the engine sprocket nut [B] and washer. • NOTE ○When loosening the engine sprocket nut, hold the rear brake on. • Using the jack, raise the rear wheel off the ground. Special Tool - Jack : 57001–1238 the drive chain (see Slack Adjustment). • Loosen Remove • right.
FINAL DRIVE 11-11 Sprocket, Coupling Rear Sprocket Removal • Remove the rear wheel (see Wheels/Tires chapter). CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. the rear sprocket nuts [A]. • Remove Remove the rear sprocket [B]. • Rear Sprocket Installation the sprocket facing the tooth number marking [A] • Install outward. • Tighten the rear sprocket nuts.
11-12 FINAL DRIVE Sprocket, Coupling the grease seal with a new one. • Replace Press in the seal so that the seal surface is flush • with the end grease of the hole. ○Apply high temperature grease to the grease seal lips. Special Tool - Bearing Driver Set: 57001–1129 Coupling Installation the following and install the coupling.
FINAL DRIVE 11-13 Sprocket, Coupling Sprocket Wear Inspection inspect the engine and rear sprocket teeth for • Visually wear and damage. If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see Drive Chain Wear Inspection). Worn Tooth (Engine Sprocket) [A] Worn Tooth (Rear Sprocket) [B] Direction of Rotation [C] NOTE ○If a sprocket requires replacement, the chain is probably worn also. When replacing a sprocket, inspect the chain.
BRAKES 12-1 Brakes Table of Contents Exploded View................................... Specifications .................................... Special Tool ....................................... Brake Lever, Brake Pedal.................. Brake Lever Position Adjustment. Brake Pedal Position Inspection .. Brake Pedal Position Adjustment. Calipers ............................................. Front Caliper Removal ................. Rear Caliper Removal.................. Caliper Installation .....................
12-2 BRAKES Exploded View
BRAKES 12-3 Exploded View No. 1 2 3 4 5 6 7 8 9 Fastener Front caliper mounting bolts Brake hose banjo bolts Bleed valve Brake lever pivot bolt Brake lever pivot bolt locknut Front brake disc mounting bolts Front brake light switch screws Front brake reservoir cap screws Front master cylinder clamp bolts B: Apply brake fluid. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specific tightening sequence. Si: Apply silicone grease (ex. PBC grease). Torque N·m 34 25 7.8 1.0 5.
12-4 BRAKES Exploded View
BRAKES 12-5 Exploded View No. 1 2 3 4 5 6 Fastener Rear master cylinder push rod locknut Rear caliper mounting bolts Brake hose banjo bolts Bleed valve Rear master cylinder mounting bolts Rear brake disc mounting bolts B: Apply brake fluid. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts Si: Apply silicone grease (ex. PBC grease). Torque N·m 18 25 25 7.8 25 27 kgf·m 1.8 2.5 2.5 0.80 2.5 2.
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: Lining thickness: Front Rear Brake Discs: Thickness: Front Rear Runout Standard Service Limit 5-way adjustable (to suit rider) Non-adjustable Non-adjustable About 47 mm (1.85 in.) below footpeg top – – – – DOT4 – – – 4.5 mm (0.18 in.) 5 mm (0.20 in.) 4.3 ∼ 4.5 mm (0.17 ∼ 0.18 in.) 4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.) Not more than 0.2 mm (0.
BRAKES 12-7 Special Tool Jack: 57001–1238
12-8 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator’s hand. Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder. ○The distance from the grip to the lever is minimum at number 5 and maximum at number 1. • Brake Pedal Position Inspection that the brake pedal [A] is in the correct position.
BRAKES 12-9 Calipers Front Caliper Removal the banjo bolt [A] at the brake hose lower end, • Loosen and tighten it loosely. the caliper mounting bolts [B], and detach the • Unscrew caliper [C] from the disc. the banjo bolt and remove the brake hoses [D] • Unscrew from the caliper (see Brake Hose Removal/Installation). CAUTION Immediately wash away any brake fluid that spills.
12-10 BRAKES Calipers Front Caliper Disassembly • Remove: Front Caliper (see Caliper Removal) Brake Pads and Springs (see Brake Pad Removal) compressed air, remove the pistons. •○Using Cover the piston area with a clean, thick cloth [A]. ○Blow compressed air [B] into the hole for the banjo bolt to remove the piston. WARNING To avoid serious injury, never place your fingers or palm in front of the piston. If you apply compressed air into the caliper, the piston may crush your hand or fingers.
BRAKES 12-11 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. • brake fluid to the outside of the pistons, and push • Apply them into each cylinder by hand. the shaft rubber friction boot [A] and the dust cover • Check [B] replace them with new ones if they are damaged.
12-12 BRAKES Calipers Rear Caliper Assembly • Clean the caliper parts except for the pads. CAUTION For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • Install the bleed valve and rubber cap. Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) the fluid seal [A] with a new one. •○Replace Apply brake fluid to the fluid seal, and install it into the cylinder by hand. Replace the dust seal [B] with a new one if it is damaged.
BRAKES 12-13 Calipers Caliper Piston and Cylinder Damage inspect the piston [E] and cylinder surfaces. • Visually Replace the caliper if the cylinder and piston are badly scores or rusty. Fluid Seal [A] Dust Seal [B] Rubber Boot [C] Front Caliper [J] Rear Caliper [K] Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shaft [F].
12-14 BRAKES Brake Pads Front Brake Pad Removal the caliper from the disc. • Remove out the holder shaft pin [A], and take off the holder • Draw shaft [B]. the pad [C] on the piston side. • Remove Push the [D] towards the piston, and remove the • pad of theholder other side [E] from the holder shaft [F]. Front Brake Pad Installation the caliper pistons in by hand as far as they will go. • Push the anti-rattle spring in its correct position.
BRAKES 12-15 Master Cylinder Front Master Cylinder Removal the front brake light switch connectors [A]. • Disconnect the banjo bolt [B] to disconnect the brake hose • Remove from the master cylinder [C] (see Brake Hose Removal/Installation). the clamp bolts [A], and take off the master cylin• Unscrew der as an assembly with the reservoir, brake lever, and brake switch installed.
12-16 BRAKES Master Cylinder Rear Master Cylinder Removal the brake hose banjo bolt [A] on the master cylin• Unscrew der (see Brake Hose Removal/Installation). off the reservoir hose lower end [B], and drain the • Pull brake fluid into a container. the master cylinder mounting bolts [C] lightly. • Loosen • Remove the cotter pin [D]. ○Pull NOTE off the joint pin while pressing down the brake pedal. the master cylinder mounting bolts, and remove • Unscrew the master cylinder.
BRAKES 12-17 Master Cylinder Rear Master Cylinder Disassembly NOTE ○Do not remove the push rod clevis for master cylinder disassembly since removal requires brake position adjustment. the rear master cylinder (see Rear Master Cylin• Remove der Removal). the dust cover on the push rod out of place, and • Slide remove the circlip. out the push rod with the piston stop. • Pull off the piston [A], secondary cup [B], primary cup [C], • Take and return spring [D].
12-18 BRAKES Brake Disc Brake Disc Removal the wheel (see Wheels/Tires chapter). • Remove • Unscrew the mounting bolts, and take off the disc. Brake Disc Installation the brake disc on the wheel so that the marked side • Install [A] faces out. a non-permanent locking agent to the threads of • Apply the front and rear brake disc mounting bolts [B]. • Tighten: Torque - Brake Disc Mounting Bolts: 27 N·m (2.
BRAKES 12-19 Brake Fluid Brake Fluid Level Inspection • Refer to the Brakes in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brakes in the Periodic Maintenance chapter. Brake Line Bleeding • Refer to the Brakes in the Periodic Maintenance chapter.
12-20 BRAKES Brake Hose Brake Hose Removal/Installation CAUTION Brake fluid quickly ruins painted or plastic surfaces; any spilled fluid should be completely wiped up immediately with wet cloth. removing the brake hose, take care not to spill the • When brake fluid on the painted or plastic parts. removing the brake hose, temporarily secure the • When end of the brake hose to some high place to keep fluid • • • loss to a minimum. There are washers on each side of the brake hose fitting.
SUSPENSION 13-1 Suspension Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools .......................................................................................................................... Front Fork ...............................................
13-2 SUSPENSION Exploded View
SUSPENSION 13-3 Exploded View No. 1 2 3 4 5 Fastener Front Front Front Front Front fork clamp bolts (Upper) fork clamp bolts (Lower) fork top plugs fork bottom Allen bolts axle clamp bolt Torque N·m 20 20 25 30 34 kgf·m 2.0 2.0 2.5 3.1 3.5 ft·lb 14 14 18 22 25 Remarks 6. Right fork leg 7. Left fork leg AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. L: Apply a non-permanent locking agent.
13-4 SUSPENSION Exploded View
SUSPENSION 13-5 Exploded View No. 1 2 3 4 5 Fastener Rear shock absorber nuts (upper and lower) Swingarm pivot shaft nut Swingarm pivot shaft locknut Rocker arm nut Tie-rod bolts Torque N·m 34 108 98 34 59 kgf·m 3.5 11 10 3.5 6.
13-6 SUSPENSION Specifications Item Front Fork (per one unit): Fork inner tube outside diameter Air Pressure Fork spring setting Damper setting Fork oil viscosity Fork oil capacity Fork oil level Fork spring free length Rear Shock Absorber: Rebound damping force Spring preload Gas pressure Standard 41 mm (1.61 in.) Atmospheric pressure (Non-adjustable) Non-adjustable Non-adjustable KAYABA KHL34-G10 452 ±4 mL (15.28 ±0.135 US oz.) (completely dry) approx. 385 mL (13.01 US oz.
SUSPENSION 13-7 Special Tools Fork Cylinder Holder Handle: 57001–183 Fork Oil Seal Driver: 57001–1288 Fork Cylinder Holder Adapter: 57001–1057 Fork Oil Level Gauge: 57001–1290 Oil Seal & Bearing Remover: 57001–1058 Hook Wrench: 57001–1539 Bearing Driver Set: 57001–1129 Swingarm pivot Nut Wrench: 57001–1541 Jack: 57001–1238
13-8 SUSPENSION Front Fork Front Fork Removal • Remove: Front Wheel (see Tires/Wheels chapter) Front Fender (see Frame chapter) Fairing (see Frame chapter) Loosen the handlebar bolt, upper fork clamp bolt and fork top plug before-hand if the fork leg is to be disassembled. ○Loosen NOTE the top plug after loosening the upper fork clamp bolt. the upper fork clamp bolt and lower fork clamp • Loosen bolts [A]. • With a twisting motion, work the fork leg down and out.
SUSPENSION 13-9 Front Fork the outer tube vertically in a vise and compress the • Hold fork completely. until the oil level stabilizes. • Wait Use the oil level gauge [A] to measure the distance • betweenfork the top of the inner tube to the oil level. Special Tool - Fork Oil Level Gauge: 57001–1290 ○Set the oil level gauge stopper [B] so that the distance [C] from the bottom of the stopper to the lower end of the pipe is the standard oil level distance.
13-10 SUSPENSION Front Fork the cylinder unit [A], washer, and the spring [B] • Remove from the inner tube. the following from the top of the outer tube: • Remove Dust Seal [A] Retaining Ring [B] • Separate the inner tube [A] from the outer tube [B]. NOTE ○From the compressed state, firmly pull down the outer tube a few times towards the direction of elongation.
SUSPENSION 13-11 Front Fork Front Fork Assembly the top plug O-ring and replace it with a new one. • Check the following parts with new ones: • Replace Retaining Ring [A] Dust Seal [B] Oil Seal [C] Inner Guide Bushing [D] Outer Guide Bushing [E] Fork Bottom Allen Bolt Gasket [F] the guide bushing on the end of the inner tube. • Install Insert the unit and the spring into the inner tube, • and installcylinder the cylinder base [B] onto the cylinder end [A] that protrudes from the bottom.
13-12 SUSPENSION Front Fork Inner Tube/Outer Tube Inspection inspect the inner tube [A] and repair any nicks or • Visually rust by using an oil stone. If the damage is not repairable, replace the inner tube. Since damage to the inner tube damages the oil seal slip, replace the oil seal whenever the inner tube is repaired or replaced. CAUTION If the inner tube is badly nicked or bent, replace it. Excessive bending, followed by subsequent straightening, can weaken the inner tube.
SUSPENSION 13-13 Rear Shock Absorber Rebound Damping Force Adjustment the damper adjuster [A] to adjust the rebound damp• Turn ing. ○Align the numbered mark [B] of the adjuster. ○The standard adjuster setting for average-build rider of 68 kg (150 Ib) with no passenger and no accessories is position "2". If the damper’s effectiveness is not suited to the operating conditions, adjust it to an appropriate position by referring to the table below.
13-14 SUSPENSION Rear Shock Absorber • Remove: Lower Shock Absorber Nut [A] Lower Shock Absorber Bolt [B] • Remove: Upper Shock Absorber Nut [A] Upper Shock Absorber Bolt [B] • Remove the shock absorber [A] from upside. Rear Shock Absorber Installation • Tighten: Torque - Rear Shock Absorber Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear Shock Absorber Inspection the rear shock absorber. • Remove Visually inspect • Smooth Strokethe following items.
SUSPENSION 13-15 Swingarm Swingarm Removal • Raise the rear wheel off the ground with jack. Special Tool - Jack: 57001–1238 • Remove: Chain Cover (see Final Drive chapter) Mud Guard (see Frame chapter) Brake Hose Clamp [A] Rear Wheel (see Wheels/Tires chapter) Lower Shock Absorber Nut and Bolt [A] Upper Tie-rod Nut and Bolt [B] the both frame cover (see Frame chapter). • Remove Unscrew • wrench [B].
13-16 SUSPENSION Swingarm Swingarm Installation ○Place the collar [A] on the stopper [B] inside the frame [C]. the pivot shaft into the frame from the right side. • Insert Tighten shaft so that the clearance [D] between • the collartheandpivot the frame come to zero mm. • Tighten: Torque - Swingarm Pivot Shaft Nut: 108 N·m (11 kgf·m, 80 ft·lb) • Tighten the pivot locknut, using the socket wrench.
SUSPENSION 13-17 Swingarm Swingarm Bearing Installation the needle bearings so that the manufacturer’s • Install marks face in. the ball bearing so that the manufacturer’s marks • Install faces out. Special Tool - Bearing Driver Set: 57001–1129 [A] Swingarm Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection. Remove may damage them. the needle bearings [A] and ball bearing [B] in• Inspect stalled in the swingarm.
13-18 SUSPENSION Tie-rod, Rocker Arm Tie-rod Removal the side stand (see Frame chapter). • Remove • Using the jack, raise the rear wheel off the ground. Special Tool - Jack: 57001–1238 the brake lever slowly and hold it with a band • Squeeze [A]. • Remove: Lower Rear Shock Absorber Bolt and Nut [A] Upper and Lower Tie-rod Nuts and Bolts [B] Tie-rods [C] Tie-rod Installation the tie-rods so that the marked side faces the bolts • Install and nuts. • Tighten: Torque - Tie-rod Nuts: 59 N·m (6.
SUSPENSION 13-19 Tie-rod, Rocker Arm Rocker Arm/Tie-rod Bearing, Sleeve Inspection inspect the rocker arm/tie-rod sleeves and needle • Visually bearings. rollers in a needle bearing normally wear very little, • The and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage. If there is any doubt as to the condition of any of the needle bearings or sleeve, replace the sleeve, and needle bearings as a set.
STEERING 14-1 Steering Table of Contents Exploded View........................................................................................................................ Special Tools .......................................................................................................................... Steering .................................................................................................................................. Steering Inspection .......................................
14-2 STEERING Exploded View
STEERING 14-3 Exploded View No. 1 2 3 4 5 6 7 Fastener Steering stem nut Steering stem head bolt Front fork clamp bolts (Upper) Front fork clamp bolts (Lower) Handlebar clamp bolts Handlebar lower clamp nuts Switch housing screws Torque N·m 27 108 20 20 25 34 3.5 kgf·m 2.8 11 2.0 2.0 2.5 3.5 0.36 ft·lb 20 80 14 14 18 25 31 in·lb 8. Steering stem head bolt plug AD: Apply adhesive. AL: Tighten the two clamp bolts alternately two times to ensure even tighten torque. G: Apply grease.
14-4 STEERING Special Tools Steering Stem Nut Wrench: 57001–1100 Steering Stem Bearing Driver: 57001–1344 Bearing Driver Set: 57001–1129 Steering Stem Bearing Driver Adapter: 57001–1345 Jack: 57001–1238
STEERING 14-5 Steering Steering Inspection • Refer to the Steering in the Periodic Maintenance chapter. Steering Adjustment • Refer to the Steering in the Periodic Maintenance chapter.
14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Inner Cover (see Frame chapter) Fairing and Bracket (see Frame chapter) Front Wheel (see Wheels/Tires chapter) Handlebar (see Handlebar Removal) Steering Stem Head Bolt Plug Steering Stem Head Bolt [A] and Washer Front Fork Clamp Bolts (Lower) (Loosen) Steering Stem Head the brake hose clamp bolt [A] and take the hose • Remove [B] off the steering stem [C]. • Remove the front fork (see Suspension chapter). the claw washer tabs [A].
STEERING 14-7 Steering Stem Stem, Stem Bearing Installation the bearing outer races with new ones. • Replace grease to the outer races, and drive them into the • Apply head pipe at the same time. Special Tool - Bearing Driver Set: 57001–1129 [A] the bearing inner races and oil seal with new • Replace ones. grease to the oil seal. • Apply Drive the lower ball bearing inner race applied the grease • onto the stem.
14-8 STEERING Steering Stem the claw washer [A] so that its bent side [B] faces • Install upward, and engage the bent claws with the grooves of • • • • • • stem locknut [C]. Hand tighten the stem locknut until it touches the claw washer. Tighten the stem locknut clockwise until the claws are aligned with the grooves (ranging from 2nd to 4th) of stem nut [D], and bend the 2 claws downward [E]. Install the stem head. Install the washer, and tighten the stem head bolt with specified torque.
STEERING 14-9 Handlebar Handlebar Removal • Remove: Handlebar Holder Plugs • Clutch Lever Assembly [A] Left Handlebar Switch Housing [B] Front Brake Master Cylinder [C] Right Handlebar Switch Housing [D] Handlebar Holder Bolts [E] Remove the handlebar holder [F] and then pull out the handlebar. the cotter pins [A]. • Remove Remove the mounting nuts [B], washers and handlebar • lower clamps [C]. Handlebar Installation the handlebar lower clamps [A], noting the letters • Install “L” [B] and “R” [C].
FRAME 15-1 Frame Table of Contents Exploded View........................................................................................................................ Seats ...................................................................................................................................... Rear Seat Removal........................................................................................................... Rear Seat Installation......................................................
15-2 FRAME Exploded View
FRAME 15-3 Exploded View No. 1 2 3 4 Fastener Footpeg bracket bolts Side stand bracket bolts Side stand bolt Side stand switch bolt G: Apply grease. L: Apply a non-permanent locking agent. Torque N·m 34 49 44 kgf·m 3.5 5.0 4.5 ft·lb 25 36 33 8.8 0.
15-4 FRAME Exploded View
FRAME 15-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Front fender bracket bolts 8.8 0.90 78 in·lb 2 Front fender bolts 3.9 0.
15-6 FRAME Exploded View
FRAME 15-7 Seats Rear Seat Removal the ignition switch key into the seat lock [A], turning • Insert the key clockwise, pulling up on the rear of the seat [B], and pulling the seat backward. Rear Seat Installation the rear seat hooks [A] into the hollow-cubic bracket • Slip [B] on the frame. the seat latch [C] into the latch hole [D]. • Insert Push down the rear part of the seat until the lock clicks.
15-8 FRAME Side Covers Side Cover Removal the bolt [A]. • Remove the side cover [B] evenly outward to clear the stop• Pull pers. Side Cover Installation the tabs [A] into the holes [B]. • Insert • Install the bolt.
FRAME 15-9 Fairings Inner Cover Removal • Remove: Inner Cover Screws [A] and Washers Inner Cover [B] Inner Cover Installation the projection [A] on the inner cover [B] into the hole • Fit [C] in the fairing. • Install the washers and inner cover screws. Fairing Removal • Remove: Fairing Mounting Bolts [A] (both side) Headlight Connectors Fairing Installation the headlight connectors. • Install Fit the projections [A] on the fairing bracket into the holes • [B] in the fairing.
15-10 FRAME Seat Covers Seat Cover Removal • Remove: Seats Screws [A] • Push the central pin, and then remove the quick rivets [A]. the front portions [A] of the seat cover outside [B], • Pull and then remove the seat cover backward. Seat Cover Installation is reverse of removal. • Installation Put the projections [A] into the grommets [B] on the frame.
FRAME 15-11 Mud Guard Mud Guard Removal • Remove: Chain Cover (see Final Drive chapter) Bolt [A] Clamp [B] • Lift up the mud guard [A], and then pull it out backward. Mud Guard Installation • Put the projections [A] into the grommets [B].
15-12 FRAME Fenders Front Fender Removal • Remove: Front Wheel (see Wheels/Tires chapter) • Brake Hose Clamps Front Reflector Bolts [A] Bolts [B] (both side) Remove the front fender [C]. Front Fender Installation a non-permanent locking agent to the threads of • Apply the bracket bolts. • Tighten: Torque - Front Fender Bracket Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) Front Fender Bolts: 3.9 N·m (0.40 kgf·m, 35 in·lb) the brake hose clamps to the front fender holes.
FRAME 15-13 Fenders • Remove: Quick Rivets [A] Rear Fender Rear [B] Rear Fender Rear Installation • Put the projection [A] into the hole [B]. the projections [A] into the holes [B]. • Put Installation is reverse of removal.
15-14 FRAME Frame Cover Frame Cover Removal • Remove: Bolts [A] Frame Cover [B] (both side)
FRAME 15-15 Battery Case Battery Case Removal • Remove: Seats • Seat Cover Rear Fender Assy Side Covers Battery Reserver Tank Screws Pull out the battery case [A] backward. Battery Case Installation the battery case attachments [A] at the projections [B] • Put on the frame.
15-16 FRAME Side Stand Side Stand Removal the rear wheel off the ground with the stand. • Raise • Remove: Side Stand Switch Bolt [A] Side Stand Switch [B] Spring [C] Side Stand Nut [D] Side Stand Bolt [E] Side Stand [F] Side Stand Installation grease to the sliding area [B] of the side stand [A]. • Apply • Tighten the bolt and lock them with the nut. Torque - Side Stand Bolt: 44 N·m (4.5 kgf·m, 33 ft·lb) the spring • Hook Install side stand switch.
FRAME 15-17 Rear View Mirrors Rear View Mirrors Removal the lower hexagonal area [A] for tightening to re• Loosen move the rear view mirror from the holder. CAUTION Do not force to tighten and/or loosen the upper hexagonal area (Adapter) [B] with a pair of spanners. Disassembly of this area is Not Available. Non-permanent locking agent [D] is already applied to the threads of this inner area. Forcible loosening may damage the adapter and/or the turning mechanism of the stay [C].
15-18 FRAME Frame Frame Inspection inspect the frame for cracks, dents, bending, or • Visually warp. ○If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Parts Location......................................................................................................................... Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools and Sealant ...................
16-2 ELECTRICAL SYSTEM Spark Plug Installation ...................................................................................................... Spark Plug Inspection ....................................................................................................... Spark Plug Gap Inspection ............................................................................................... Interlock Operation Inspection ...................................................................................
ELECTRICAL SYSTEM 16-3 Parts Location 1. Starter Lockout Switch 2. Camshaft Position Sensor 3. Radiator Fan Switch 4. Starter Motor 5. Alternator 6. Speed Sensor 7. Neutral Switch 8. Side Stand Switch 9. Water Temperature Sensor 10. Battery 11. Junction Box 12. Front Brake Light Switch 13. Stick Coils 14. Crankshaft Sensor 15. Rear Brake Light Switch 16. Starter Relay and Main Fuse 17. ECU Fuse 18. Turn Signal Relay 19. Diode (Rectifier) 20. ECU (Electronic Control Unit) 21. Oil Pressure Switch 22.
16-4 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 16-5 Exploded View No. 1 2 3 4 5 6 7 8 Fastener Meter mounting screws Tail/brake light mounting screws License plate light mounting screws Front brake light switch screw Starter locknut switch screws Left switch housing screws Right switch housing screws Headlight mounting bolts 9. Tail/brake lights (LED) 10. Vibration Resistance Bulb 11. Install the rear brake spring as shown. Longer Side [A] L: Apply a non–permanent locking agent.
16-6 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 16-7 Exploded View No. 1 2 3 4 5 6 7 8 9 Fastener Water temperature sensor Spark plugs Alternator lead holding plate bolt Starter motor mounting bolts Stator coil bolts Alternator rotor bolt Starter motor clutch bolts Alternator cover bolts Crankshaft sensor bolts 10 Crankshaft sensor cover bolts 11 Timing rotor bolt 12 Camshaft position sensor bolt 13 14 15 16 Radiator fan switch Starter relay cable terminal bolts Oil pressure switch terminal bolt Oil pressure switch 17.
16-8 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 16-9 Exploded View No. 1 2 3 4 5 6 7 8 Fastener Regulator/rectifier bolts Fuel level sensor bolts Side stand switch bolt Neutral switch Speed sensor bolt Speed sensor cover bolts Regulator/rectifier bracket bolts Engine ground cable terminal bolt 9. Turn signal relay 10. Junction box 11. ECU (Electrical Unit Control) 12. 15 A ECU fuse 13. Fuel reserve switch 14. Diode (Rectifier) 15. Speed sensor 16. Regulator/rectifier 17. Battery 12 V 8 Ah L: Apply a non-permanent locking agent.
16-10 ELECTRICAL SYSTEM Specifications Item Battery: Type Capacity Voltage Charging System: Type Alternator output voltage Stator coil resistance Charging voltage (regulator/rectifier output voltage) Ignition System: Crankshaft sensor resistance Crankshaft sensor peak voltage Camshaft Position Sensor resistance Camshaft Position Sensor peak voltage Interlock Operation Voltage Stick coil: Primary winding resistance Secondary winding resistance Primary peak voltage Spark plug: Spark plug gap Electric Starter
ELECTRICAL SYSTEM 16-11 Special Tools and Sealant Rotor Puller, M16/M18/M20/M22 × 1.5 : 57001–1216 Needle Adapter : 57001–1457 Flywheel & Pulley Holder : 57001–1343 Harness Adapter : 57001–1542 Hand Tester : 57001–1394 Rotor Holder : 57001–1543 Flywheel Puller, M38 × 1.
16-12 ELECTRICAL SYSTEM Wiring Diagram (Canada)
ELECTRICAL SYSTEM 16-13 Wiring Diagram (Canada)
16-14 ELECTRICAL SYSTEM Wiring Diagram (Australia)
ELECTRICAL SYSTEM 16-15 Wiring Diagram (Australia)
16-16 ELECTRICAL SYSTEM Wiring Diagram (Other than Canada, Australia and Malaysia)
ELECTRICAL SYSTEM 16-17 Wiring Diagram (Other than Canada, Australia and Malaysia)
16-18 ELECTRICAL SYSTEM Wiring Diagram (Malaysia)
ELECTRICAL SYSTEM 16-19 Wiring Diagram (Malaysia)
16-20 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below. ○Do not reverse the battery lead connections. This will burn out the diodes on the electrical parts. ○Always check battery condition before condemning other parts of an electrical system. A fully charged battery is a must for conducting accurate electrical system tests.
ELECTRICAL SYSTEM 16-21 Precautions Male Connectors [B]
16-22 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection inspect the wiring for signs of burning, fraying, • Visually etc. If any wiring is poor, replace the damaged wiring. Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Check the wiring for continuity. ○Use the wiring diagram to find the ends of the lead which is suspected of being a problem.
ELECTRICAL SYSTEM 16-23 Battery Battery Removal CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is ON, as this could damage the ECU (Electronic Control Unit). Never reverse the connections of the battery, this could damage the ECU. • Remove: Seats (see Frame Chapter) Disconnect negative (–) cable [A]. • Slide out thethe positive (+) terminal cap [B] and then discon• nect the positive (+) cable.
16-24 ELECTRICAL SYSTEM Battery CAUTION Do not remove the aluminum seal sheet [A] sealing the filler ports [B] until just before use. to see that there is no peeling, tears or holes in the • Check seal sheet on the top of the battery. the battery on a level surface. • Place Remove the seal sheet. • NOTE ○A battery whose seal sheet has any peeling, tears or holes, requires a refreshing charge (initial charge). the electrolyte container out of the vinyl bag.
ELECTRICAL SYSTEM 16-25 Battery the seal cap [A] tightly into the filler ports until the seal • Fit caps are at the same level as the top of the battery. NOTE ○Do not hammer. Press down evenly with both hands. CAUTION Once you installed the seal caps after filling the battery, never remove it, nor add any water or electrolyte.
16-26 ELECTRICAL SYSTEM Battery Precautions 1) No need of topping–up No topping–up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seat cap to add water is very dangerous. Never do that. 2) Refreshing charge If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification (see the this chapter).
ELECTRICAL SYSTEM 16-27 Battery Interchange The sealed battery can fully display its performance only when combined with the proper vehicle electric system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped with a sealed battery. Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original equipment, the sealed battery’s life will be shortened.
16-28 ELECTRICAL SYSTEM Battery Terminal Voltage: 11.5 ∼ less than 12.6 V Standard Charge 0.9 A × 5 ∼ 10 h Quick Charge 4.0 A × 1.0 h Battery Terminal Voltage (V) [A] Charge Time (h) [B] CAUTION If possible, do not quick charge. If the quick charge is done due to unavoidable circumstances, do standard charge later on. Terminal Voltage : less than 11.5 V Charging Method : 0.9 A × 20 h NOTE ○Increase the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially.
ELECTRICAL SYSTEM 16-29 Charging System Alternator Cover Removal • Remove: Left Frame Cover (see Frame chapter) Clamp (open) [A] Alternator Lead Connector [B] a suitable container under the alternator cover [A], • Place and remove the cover bolts [B]. • Pull the alternator cover outside. Alternator Cover Installation silicone sealant to the alternator lead grommet and • Apply crankcase halves mating surface [A] on the front and rear sides of the cover mount.
16-30 ELECTRICAL SYSTEM Charging System Stator Coil Installation a non-permanent locking agent to the threads of • Apply the stator coil bolts and tighten them. Torque - Stator Coil Bolts: 11 N·m (1.1 kgf·m, 95 in·lb) the alternator • Secure tighten the bolt. lead with a holding plate, and ○Apply a non-permanent locking agent to the threads of the plate bolt. Torque - Alternator Lead Holding Plate Bolt: 11 N·m (1.
ELECTRICAL SYSTEM 16-31 Charging System the starter gear [A]. • Install Again, • there. clean the crankshaft tapered portion [B] and dry the woodruff key [C] securely in the slot in the crank• Fit shaft before installing the alternator rotor. the alternator rotor [A] while turning [B] the starter • Install clutch gear [C]. the washer [A] so that the chamfer side [B] faces • Install outward. NOTE ○Confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque.
16-32 ELECTRICAL SYSTEM Charging System a thin coat of molybdenum disulfide grease to the • Apply shaft [A], and install it and starter idle gear [B]. the alternator cover (see Alternator Cover Installa• Install tion). Alternator Inspection There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all.
ELECTRICAL SYSTEM 16-33 Charging System • If there is more resistance than shown in the table, or no hand tester reading (infinity) for any two leads, the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced. Using the highest resistance range of the hand tester, measure the resistance between each of the black leads and chassis ground.
16-34 ELECTRICAL SYSTEM Charging System the 1st step regulator circuit test: •○Do Connect the test light and the 12 V battery to the regulator/rectifier as shown. ○Check BK1, BK2, and BK3 terminal respectively. If the test light turns on, the regulator/rectifier is defective. Replace it. If the test light does not turn on, continue the test. the 2nd step regulator circuit test: •○Do Connect the test light and the 12 V battery in the same manner as specified in the "Regulator Circuit Test–1st Step".
ELECTRICAL SYSTEM 16-35 Charging System Charging Voltage Inspection the battery condition (see Battery section). • Check up the engine to obtain actual alternator operating • Warm conditions. the seats (see Frame chapter). • Remove Check that the ignition switch is turned off, and connect • the hand tester [A] to the battery terminals [B]. Special Tool - Hand Tester: 57001–1394 [A] the engine, and note the voltage readings at various • Start engine speeds with the headlight turned on and then turned off.
16-36 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 2. To Starter Circuit Relay 3. Alternator 4. Regulator/Rectifier 5. Joint Connector C 6. Battery 12 V 8 Ah 7. Main Fuse 30 A 8.
ELECTRICAL SYSTEM 16-37 Ignition System WARNING The ignition system produces extremely high voltage. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running. This is to prevent ECU (Electrical Control Unit) damage. Do not install the battery backwards. The negative side is grounded.
16-38 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Installation the crankshaft sensor lead correctly (see Cable, • Route Wire, and Hose Routing in Appendix chapter). • Tighten: Torque - Crankshaft Sensor Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) silicone sealant [A] to the crankshaft sensor lead • Apply grommet and crankcase halves mating surface on the front and rear sides of the crankshaft sensor cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 56019–120 the clamps [A] direction as shown.
ELECTRICAL SYSTEM 16-39 Ignition System Crankshaft Sensor Inspection • Remove: Right Frame Cover (see Frame chapter) • Crankshaft Sensor Lead Connector [A] Set the hand tester to the × 100 Ω range and connect (+) lead to the yellow/black lead and (–) lead to the black lead in the connector. Special Tool - Hand Tester: 57001– 1394 If there is more resistance than the specified value, the coil has an open lead and must be replaced.
16-40 ELECTRICAL SYSTEM Ignition System Timing Rotor Removal the crankshaft sensor cover (see Crankshaft • Remove Sensor Removal) the timing rotor [A]. •○Remove Holding the timing rotor with the flywheel & pulley holder [B] and remove the bolt [C]. Special Tool - Flywheel & Pulley Holder : 57001–1343 Timing Rotor Installation the rotor to the crankshaft. • Fit • Tighten the rotor bolt. Torque - Timing Rotor Bolt : 39 N·m (4.
ELECTRICAL SYSTEM 16-41 Ignition System Camshaft Position Sensor Inspection • Remove: Fuel Tank (see Fuel System (DFI) chapter) • Camshaft Position Sensor Lead Connector [A] (disconnect) Set the hand tester to the × 10 Ω range and connect it to the yellow and black leads in the connector. Special Tool - Hand Tester: 57001–1394 If there is more resistance than the specified value, the sensor coil has an open lead and must be replaced.
16-42 ELECTRICAL SYSTEM Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Removal the fuel tank (see Fuel System (DFI) chapter). • Remove Remove the thermostat bracket bolt [A]. • Disconnect: • Water Temperature Sensor Connector [B] Left Switch Housing Connector [C] ○If removing the stick coil #2 or #3. the stick coil connectors [A]. • Disconnect Pull the stick coil #1 [B] off the spark plug.
ELECTRICAL SYSTEM 16-43 Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection the stick coils (see this chapter). • Remove Measure the primary winding resistance [A] as follows. •○Connect the hand tester between the coil terminals. ○Set the tester to the × 1 Ω range, and read the tester. the secondary winding resistance [B] as follows. •○Measure Connect the tester between the plug terminal and (–) coil terminal. ○Set the tester to the × 1 kΩ range and read the tester.
16-44 ELECTRICAL SYSTEM Ignition System WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. the ignition switch and the engine stop switch ON. • Turn Pushing the starter button, turn the engine 4 ∼ 5 seconds • with the transmission in neutral to measure the primary • peak voltage. Repeat the measurements 5 times for one stick coil. Stick Coil Primary Peak Voltage Standard: 88 V or more the test for the other stick coil.
ELECTRICAL SYSTEM 16-45 Ignition System Interlock Operation Inspection • Remove: Seats (see Frame chapter) Junction Box (see this chapter) ○Do not disconnect the connectors. 1st Check Measure the terminal voltage of the G/BK lead in the junction box connector [A] in accordance with the following procedure. ○Insert the needle adapter [B] in the Green/Black lead terminal. ○Set the tester [C] to the 25 V DC range, connect it to the needle adapter and frame ground [D].
16-46 ELECTRICAL SYSTEM Ignition System IC Igniter Inspection ○The IC Igniter is built in the ECU [A]. to the Interlock Operation Inspection, Ignition • Refer System Troubleshooting chapter and Fuel System (DFI) chapter for ECU Inspection.
ELECTRICAL SYSTEM 16-47 Ignition System
16-48 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Spark Plugs 5. Stick Coils 6. Side Stand Switch 7. Crankshaft Sensor 8. Camshaft Position Sensor 9. Throttle Sensor 10. Neutral Switch 11. Junction Box 12. Ignition Fuse 10 A 13. Starter Lockout Switch 14. Diode 15. ECU Main Relay 16. ECU Fuse 15 A 17. Vehicle-down Sensor 18. Main Fuse 30 A 19. Battery 12 V 8 Ah 20. ECU (Electrical Control Unit) 21. Joint Connector A 22.
ELECTRICAL SYSTEM 16-49 Electric Starter System Starter Motor Removal CAUTION Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. back the rubber cap [A]. • Slide • Remove the starter motor terminal nut [B]. the mounting bolts [A]. • Remove Pull out the starter motor [B]. • Starter Motor Installation CAUTION Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor.
16-50 ELECTRICAL SYSTEM Electric Starter System ○The brush plate [A] and brushes come off with the right -hand end cover [B]. the terminal locknut [A] and terminal bolt [B], and • Remove then remove the brush with the brush plate [C] from the right-hand end cover. Starter Motor Assembly the brush plate and brushes [A], and then put the • Install armature [B] among the brushes. • Install the O-rings [A] as shown.
ELECTRICAL SYSTEM 16-51 Electric Starter System the line [A] marked on the yoke with the through bolt • Align hole [B]. Brush Inspection the length [A] of each brush. • Measure If any is worn down to the service limit, replace the carbon brush holder assembly [B] and the terminal bolt assembly [C]. Starter Motor Brush Length Standard: 12 mm (0.47 in.) Service Limit: 8.5 mm (0.33 in.
16-52 ELECTRICAL SYSTEM Electric Starter System NOTE ○Even if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with the hand tester. If all other starter motor and starter motor circuit components check good, but the starter motor still does not turn over or only turns over weakly, replace the starter motor with a new one. Brush Lead Inspection the × 1 Ω hand tester range, measure the resis• Using tance as shown.
ELECTRICAL SYSTEM 16-53 Electric Starter System the hand tester [A] and 12 V battery [B] to the • Connect starter relay [C] as shown. Special Tool - Hand Tester: 57001–1394 If the relay does not work as specified, the relay is defective. Replace the relay. Testing Relay Tester Range: Criteria: × 1 Ω range When battery is connected → 0 Ω When battery is disconnected → ∞ Ω Electric Starter Circuit 1. Ignition Switch 2. Joint Connector D 3. Engine Stop Switch 4. Starter Button 5. Junction Box 6.
16-54 ELECTRICAL SYSTEM Lighting System This models adopt the daylight system and have a headlight relay in the junction box. In these models, the headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off. The headlight will go out momentarily whenever the starter button is pressed and come back on when the button is released.
ELECTRICAL SYSTEM 16-55 Lighting System the projection [A] of the bulb in the hollow [B] of the • Fit headlight. • Install the hook [C]. the dust cover [A] with the arrow mark upward onto the • Fit bulb [B] firmly as shown. • Good [C] Bad [D] Arrow Mark [E] After installation, adjust the headlight aim (see this chapter). Headlight Removal/Installation • Remove: Fairing (see Frame chapter) Disconnect the headlight connectors [A]. •○For the european model disconnect the city light connector.
16-56 ELECTRICAL SYSTEM Lighting System City Light Bulb Replacement (European Model) the fairing (see Frame chapter). • Remove • Pull out the socket [A] together with the bulb. • Pull the bulb [A] out of the socket. CAUTION Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage then the specified valve. • Replace the bulb with a new one.
ELECTRICAL SYSTEM 16-57 Lighting System Headlight/Tail Light Circuit (CA, AS) Headlight/Tail Light Circuit (Other than CA, AS) AS: Australia CA: Canada 1. Ignition Switch 2. Meter Ground 3. Alternator 4. Headlight Diodes 5. Taillight Fuse 10 A 6. Headlight Fuse 10 A 7. Junction Box 8. High Beam Indicator Light (LED) 9. Joint Connector D 10. City Light (European Model) 11. Headlight (High) 12. Headlight (Low) 13. Joint Connector A 14. Dimmer Switch 15. Passing Button 16. Main Fuse 30 A 17.
16-58 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit CA: Canada model MY: Malaysia model 1. Joint Connector D 2. Meter Unit 3. Right Turn Signal Indicator Light (LED) 4. Left Turn Signal Indicator Light (LED) 5. Front Right Turn Signal Light 6. Front Left Turn Signal Light 7. Joint Connector A 8. Frame Ground 9. Hazard Button 10. Turn Signal Switch 11. Meter Ground 12. Turn Signal Relay 13. Junction Box 14.
ELECTRICAL SYSTEM 16-59 Lighting System and turn the bulb [A] counterclockwise and remove • Push it. the new bulb [A] by aligning its upper and lower pins • Insert [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise. ○Turn the bulb about 15°. For the Canadian Model: Unscrew the screw [A]. • • Unscrew the screws [A]. and turn the bulb [A] counterclockwise and remove • Push it.
16-60 ELECTRICAL SYSTEM Lighting System the new bulb [A] by aligning its upper and lower pins • Insert [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise. Turn Signal Relay Inspection • Remove: Seats (see Frame chapter) Upper Seat Cover (see Frame chapter) Turn Signal Relay [A] one 12 V battery and turn signal lights as indi• Connect cated in the figure, and count how may times the lights flash for one minute.
ELECTRICAL SYSTEM 16-61 Lighting System • Unscrew the bolts [A]. the mounting screws [A]. • Unscrew Remove the tail/brake light (LED) [B]. •○Pull out the mount portion [C]. Tail/Brake Light (LED) Installation • Tighten the tail/brake light mounting screws. Torque - Tail/Brake Light Mounting Screws: 1.2 N·m (0.
16-62 ELECTRICAL SYSTEM Radiator Fan System Fan System Circuit Inspection the lead connector [A] from the radiator fan • Disconnect switch. an auxiliary wire [A], connect the radiator fan switch • Using leads. If the fan rotates, inspect the fan switch. If the fan does not rotate, inspect the following. Leads and Connectors Main Fuse and Fan Fuse Fan Motor Fan Motor Inspection the fuel tank (see Fuel System (DFI) chapter). • Remove the 2-pin connector [A] in the fan motor leads.
ELECTRICAL SYSTEM 16-63 Radiator Fan System Radiator Fan Circuit 1. Radiator Fan 2. Radiator Fan Switch 3. Joint Connector A 4. Joint Connector D 5. Meter Ground 6. Frame Ground 7. Joint Connector B 8. Junction Box 9. Fan Fuse 15 A 10. Main Fuse 30 A 11.
16-64 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Unit Removal • Remove: Fairing (see Frame chapter) Slide • [B]. the dust cover [A] and remove the wiring connector the meter unit by taking off the mounting screws • Remove [C] with the washers. CAUTION Place the meter or gauge so that the face is up. If a meter or gauge is left upside down or sideways for any length of time, it will malfunction.
ELECTRICAL SYSTEM 16-65 Meter, Gauge, Indicator Unit Electronic Combination Meter Unit Inspection • Remove the meter unit [A].
16-66 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit MODE AND RESET BUTTON Operation Check: Connect the 12 V battery and terminals in the same manner as specified in the "Liquid Crystal Display (LCD) Segments Check". Check that the display change to the ODO, TRIP, and CLOCK displays each time the MODE button [A] is pressed. ○If the fuel level gauge flashed, display change to ODO, TRIP, CLOCK and FUEL. If the display function does not work, replace the meter assembly. • • the clock mode.
ELECTRICAL SYSTEM 16-67 Meter, Gauge, Indicator Unit the HOUR setting mode, press the RESET button to • Ineffect the MINUTE setting mode. ○The minute display flashes on the display. • Press the MODE button to set the minute. the MINUTE setting mode, press the RESET button to • Inreturn to the HOUR/MINUTE setting mode. the MODE button to complete the time setting • Press process. ○The clock starts counting the seconds as soon as the MODE button is pressed. the ODO mode.
16-68 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit the oscillator is not available, the speedometer can be • Ifchecked as follows. ○Install the meter unit. ○Raise the rear wheel off the ground, using the jack. ○Turn on the ignition switch. ○Rotate the rear wheel by hand. ○Check that the speedometer shows the speed. If the speedometer does not work, check the speed sensor electric source voltage and speed sensor. The electric source voltage and speed sensor are normal, replace the meter assembly.
ELECTRICAL SYSTEM 16-69 Meter, Gauge, Indicator Unit Water Temperature Meter Check: Connect the 12 V battery and terminals in the same manner as specified in the "Liquid Crystal Display (LCD) Segments Check". Connect the variable rheostat [A] to the terminal [8] as shown. Check that the number of segments matches the resistance value of the variable rheostat. • • • Resistance Temperature Warning Value (Ω) Meter Indicate – [A] – 209.8 50°C (122°F) [B] – 69.1 80°C (176°F) [B] – 21.
16-70 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Fuel Level Gauge Inspection: Connect the 12 V battery and terminals in the same manner as specified in the “Liquid Crystal Display (LCD) Segments Check”. Connect a variable rheostat [A] to terminal [4] and [9] as shown. Check that the number of segment [B] matches the resistance value of the variable rheostat. • • • Resistance (Ω) 0 ∼ 16.5 Number of Segments F 6 11.5 ∼ 34.5 5 26.5 ∼ 52.5 4 41.5 ∼ 70.5 3 56.5 ∼ 88.5 71.
ELECTRICAL SYSTEM 16-71 Meter, Gauge, Indicator Unit the oscillator is not available, the tachometer can be • Ifchecked as follows. ○Connect the 12 V battery and terminals in the same man- ner as specified in the "Liquid Crystal Display (LCD) Segments Check". ○Using an auxiliary wire, quick open and connect the terminal [1] to the terminal [7] repeatedly. ○Then the tachometer segment [A] should flick [B]. If the segment does not flick, replace the meter assembly.
16-72 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Right and Left Turn Signal Indicator Light (LED): For Right Turn Signal Indicator Light (LED) Battery Positive (+) Terminal to Terminal [13] For Left Turn Signal Indicator Light (LED) Battery Positive (+) Terminal to Terminal [14] High Beam Indicator Light: Battery Positive (+) Terminal to Terminal [15] each LED lights does not go on, replace the meter as• Ifsembly.
ELECTRICAL SYSTEM 16-73 Meter, Gauge, Indicator Unit Meter Circuit 1. Right Turn Signal Indicator Light (LED) 2. High Beam Indicator Light (LED) 3. Neutral Indicator Light (LED) 4. Oil Pressure Warning Indicator Light (LED) 5. FI Indicator Light (LED) 6. Odometer/Trip Meter/ Clock/Fuel Indicator 7. Water Temperature Gauge 8. Fuel Level Gauge 9. Tachometer 10. Speedometer 11. Meter Light (LED) 12. Left Turn Signal Indicator Light (LED) 13. Meter Unit 14. Joint Connector D 15. Frame Ground 16.
16-74 ELECTRICAL SYSTEM Switches and Sensors Brake Light Timing Inspection • Refer to the Brakes in the Periodic Maintenance chapter. Brake Light Timing Adjustment • Refer to the Brakes in the Periodic Maintenance chapter. Switch Inspection a hand tester, check to see that only the con• Using nections shown in the table have continuity (about zero ohms). ○For the handlebar switches and the ignition switch, refer to the tables in the Wiring Diagram.
ELECTRICAL SYSTEM 16-75 Switches and Sensors • Remove the fan switch [A]. the switch [A] in a container of coolant so that • Suspend the temperature–sensing projection and threaded portion • are submerged. Suspend an accurate thermometer [B] in the coolant so that the sensitive portions are located in almost the same depth. NOTE ○The switch and thermometer must not touch the container sides or bottom.
16-76 ELECTRICAL SYSTEM Switches and Sensors the sensor [A] in a container of coolant so that • Suspend the temperature-sensing projection [E] and threaded por- • tion [E] are submerged. Suspend an accurate thermometer [B] in the coolant. NOTE ○The sensor and thermometer must not touch the container side or bottom. the container over a source of heat and gradu• Place ally raise the temperature of the coolant while stirring the coolant gently.
ELECTRICAL SYSTEM 16-77 Switches and Sensors • Remove: Bolts [A] Speed Sensor Cover • Remove: Bolt [A] • Take out the speed sensor [B]. the speed sensor connector [A] with the battery • Connect [B], 10 kΩ resistor [C] and hand tester [D] as shown. • Set the tester to the DC 25 V range. Special Tool - Hand Tester: 57001–1394 [A] each side of the speed sensor surface with the • Trace screw driver. ○Then the tester indicator should flick [B].
16-78 ELECTRICAL SYSTEM Switches and Sensors Fuel Level Sensor Inspection • Remove: Fuel Tank (see Fuel System (DFI) chapter) Open the clamps [A]. • Remove: • Bolts [B] Fuel Level Sensor [C] that the float moves up and down smoothly without • Check binding. It should go down under its own weight. If the float does not move smoothly, replace the sensor. Float in Full Position [A] Float in Empty Position [B] Float Arm Stoppers [C] 105.2 ∼ 112.2 mm (4.142 ∼ 4.417 in.) from the Sensor Base Line [D] 33.6 ∼ 40.
ELECTRICAL SYSTEM 16-79 Switches and Sensors the test light [A] (12 V 3.4 W bulb a socket with • Connect leads) and the 12 V battery [B] to the fuel level sensor connector [C]. Connections: Battery (+) → 12 V 3.4 W Bulb (one side) 12 V 3.4 W Bulb (other side) → Blue Lead Terminal Battery (–) → BK/Y Lead Terminal If the test light turn on, the reverse switch is defective. Replace the fuel level sensor. • Remove: Fuel Level Sensor (see Fuel Level Sensor Inspection) Connect (12 V 3.
16-80 ELECTRICAL SYSTEM Junction Box The junction box [A] has fuses [B], relays, and diodes. The relays and diodes can not be removed. Junction Box Fuse Circuit Inspection the seats (see Frame chapter). • Remove • Remove the junction box [A]. off the connectors [A] from the junction box [B]. • Pull Make all connector terminals are clean and tight, and • none ofsurethem have been bent. Clean the dirty terminals, and straighten slightly–bent terminals.
ELECTRICAL SYSTEM 16-81 Junction Box Starter Circuit/Headlight Relay Inspection the junction box (see Junction Box Fuse Circuit • Remove Inspection). conductivity of the following numbered terminals • Check by connecting the hand tester and one 12 V battery to the junction box as shown. ○Refer to the Junction Box Internal Circuit. If the tester does not read as specified, replace the junction box.
16-82 ELECTRICAL SYSTEM Junction Box Diode Circuit Inspection the junction box. • Remove • Check conductivity of the following pairs of terminals. Diode Circuit Inspection Tester Connection 13-8, 13-9, 12-11, 12-14, 15-14, 16-14 The resistance should be low in one direction and more than ten times as much in the other direction. If any diode shows low or high in both directions, the diode is defective and the junction box must be replaced.
ELECTRICAL SYSTEM 16-83 Fuse 30 A Main Fuse Removal • Remove: Right Side Cover (see Frame chapter) • 30 A Main Fuse Connector [A] Pull out the main fuse [B] from the starter relay with needle nose pliers. Junction Box Fuse Removal the seats (see Frame chapter). • Remove the hook to lift up the lid [A]. • Unlock Pull the [B] straight out of the junction box with nee• dle nosefuses pliers.
16-84 ELECTRICAL SYSTEM Fuse Fuse Inspection the fuse (see Fuse Removal). • Remove the fuse element. • Inspect If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit.
APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing .............................................................................................. Troubleshooting Guide ...........................................................................................................
17-2 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Fixes by the left side clamp of the tank. 2. Run the tank drain hose under the bracket for the side cover. 3. Air cleaner drain hose 4. Cooling reserve tank hose (Run the hose inside the under ring.) 5. Fuel tank drain hose 6. Fixes by the swingarm clamp 7. Fuel level sensor 8. Fixes by the right side clamps two places of the tank. 9. Run the lead outside the frame. 10.
17-4 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Clutch cable 2. Meter ground 3. Clamp (Ignition switch connector) 4. Ignition switch connector 5. Inlet air pressure sensor 6. To ignition coil 7. Fan motor connector (Connect the connector on the inlet air pressure sensor.) 8. Clamp 9. To fuel pump 10. To fuel level gauge and fuel reserve switch 11. To pickup coil and oil pressure switch 12. Band 13. Main harness 14. Starter relay 15. To rear brake switch 16. Connect the battery negative cable and battery. 17.
17-6 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Run the main harness through lower and right side of the thermostat. 2. Frame ground (with thermostat bracket) 3. Ignition switch connector 4. Meter ground 5. Engine harness 6. Water temperature sensor 7. Inlet air pressure sensor 8. Clamp 9. To pickup coil and oil pressure switch 10. To fuel level gauge and fuel reserve switch 11. To fuel pump 12. Regulator/rectifier 13. Run the lead through the inside of the pipe. 14. Speed sensor 15. To side stand switch 16.
17-8 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Tail light 2. Clamp 3. Atmospheric pressure sensor 4. To ECU fuse 5. Junction Box 6. To self-diagnosis indicator terminal 7. Pickup coil and oil pressure switch 8. Fuel pump 9. Fuel level gauge and fuel reserve switch 10. To inlet air temperature sensor 11. Fan motor connector 12. Inlet air pressure sensor 13. Water temperature sensor 14. Engine harness 15. Meter ground 16. Ignition switch lead 17. Frame ground (with thermostat) 18.
17-10 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Clamp the position of branch harness and front right turn signal light lead. 2. Run the meter harness into the hole of cover. 3. Meter 4. Set the cover to cover all of the connector. 5. Clamp the right and left switch housing lead and front left turn signal light lead. 6. To left switch housing 7. To front left turn signal light 8. To right switch housing 9. Headlight high and low 10. Running position light 11.
17-12 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Clamp 2. Brake hose 3. Run the brake hose through the inside of the reservoir hose. 4. Tight the bolt to the specified torque with the stopper (for turning prevention) applied. 5. Seat lock 6.
17-14 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Cam sensor lead (Run the lead between the convex area of cap center and bolt head to secure the coupler.) 2. Fan switch horn lead 3. Cap 4. Clutch cable (Run the cable through forward the water hose.) 5. Air suction valve 6. Water hose (Thermostat – Radiator) 7. Water hose (Head – Thermostat) 8. Inlet air pressure sensor 9. Vacuum hose (Run the vacuum hose under the throttle cable to connect with the inlet air pressure sensor.) 10.
17-16 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Bend the bracket as shown to secure the lead. 2. Bend the bracket. 3. Install the lead upward. 4. Pickup coil and oil pressure switch (Run the cable through inner side from the starter lead.) 5. Install the exterior of the lead with staking area facing downward. 6. Battery negative cable (Run the cable through under the cross pipe.) 7. Starter lead (Run the lead through outside of engine bracket and under the cross pipe.) 8.
17-18 APPENDIX Troubleshooting Guide NOTE ○Refer to the Fuel System chapter for most of DFI trouble shooting guide. ○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties.
APPENDIX 17-19 Troubleshooting Guide Air cleaner duct loose Compression low: Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head warped Cylinder head gasket damaged Valve spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface) Other: IC igniter in ECU trouble Throttle body assy not synchronizing E
17-20 APPENDIX Troubleshooting Guide Engine load faulty: Clutch slipping Engine oil level too high Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate: Engine oil level too low Engine oil poor quality or incorrect Gauge incorrect: Water temperature gauge broken Water temperature sensor broken Coolant incorrect: Coolant level too low Coolant deteriorated Wrong coolant mixed ratio Cooling system component incorrect: Radiator fin damaged Radiator clogged Thermostat trouble R
APPENDIX 17-21 Troubleshooting Guide Engine mount loose Crankshaft bearing worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain, sprocket, guide worn Air suction valve damaged Vacuum switch valve damaged Alternator rotor loose Catalytic converter melt down due to muffler overheating (KLEEN) Abnormal Drive Train Noise: Clutch noise: Clutch damper weak or damaged Clutch housing/friction plate clearance excessive Clutch housing gear worn Wrong installation of outside friction plat
17-22 APPENDIX Troubleshooting Guide Rear shock adjustment too soft Front fork, rear shock absorber spring weak Rear shock absorber oil leaking Brake Doesn’t Hold: Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in master cylinder Master cylinder scratched inside Battery Trouble: Battery discharged: Charge insufficient Battery faulty (too low terminal voltage) Battery lead making poor contact Load excessive (
MODEL APPLICATION Year Model 2004 ZR750–J1 Beginning Frame No. JKAZRDJ1□4A000001 ZR750J–000001 JKAZR750JJA000001 □:This digit in the frame number changes from one machine to another. Part No.
