Kawasaki Z1000 - Manual

EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations ofthe United States Environmental Protection Agency and California Air Resources Board. ...

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERALLAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOTEXCEEDING $10,000 PER VIOLATION. TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or renderi...

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop.However, it contains enough detail and basic in-formation to make it useful to the owner who de-sires to perform his own basic maintenance andrepair work. A basic knowledge of mechanics,the proper use...

NOTE ○ This note symbol indicates points of par- ticular interest for more efficient and con- venient operation. • Indicates a procedural step or work to bedone. ○ Indicates a procedural sub-step or how to dothe work of the procedural step it follows. Italso precedes the text of a NOTE.Indicates a c...

GENERAL INFORMATION 1-1 1 General Information Table of Contents Before Servicing ..................................................................................................................... 1-2 Model Identification................................................................................

1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra-tions, photographs, cautions, and detailed descriptions ...

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 disassembledand clean the parts in order prior to assembly. Storage of Removed Parts After all the parts including subass...

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 deformationwhich can lead to malfunction. If the specified tighteningsequence is not indicated, tighten the fasteners alternatingdiagon...

GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con-tact area. Be sure to maintain proper alignment and usesmooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ...

1-6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro-tate the crankshaft to positive direction (clockwise viewedfrom output side). Electrical Wires A two-color wire is ide...

GENERAL INFORMATION 1-7 Model Identification ZR1000–A1 Left Side View: ZR1000–A1 Right Side View:

1-8 GENERAL INFORMATION General Specifications Items ZR1000–A1 ∼ Dimensions: Overall length 2 080 mm (81.9 in.) Overall width 770 mm (30.3 in.) Overall height 1 055 mm (41.5 in.) Wheelbase 1 420 mm (55.9 in.) Road clearance 145 mm (5.7 in.) Seat height 820 mm (32.3 in.) Dry mass 198 kg (410.1 lb) Cu...

GENERAL INFORMATION 1-9 General Specifications Items ZR1000–A1 ∼ Lubrication system Forced lubrication (wet sump with cooler) Engine oil: Type API SE, SF or SGAPI SH or SJ with JASO MA Viscosity SAE10W-40 Capacity 3.8 L (4.0 US qt) Drive Train: Primary reduction system: Type Gear Reduction ratio 1.7...

1-10 GENERAL INFORMATION General Specifications Items ZR1000–A1 ∼ Tail/brake light 12 V 0.5/3.8 W (LED)(US, CA, Cal) 12 V 0.5/5W (LED) Alternator: Type Three-phase AC Rated output 24 A/ 14 V @5 000 r/min (rpm) Specifications are subject to change without notice, and may not apply to every country.(A...

GENERAL INFORMATION 1-11 Technical Information – Air Inlet System Subthrottle Control System The ZR1000–A1 ∼ employs large bore throttle bodies to increase power output. However, sudden changes in throttle opening can cause hesitation and jerky throttle response with a single butterflyvalve in a lar...

1-12 GENERAL INFORMATION Technical Information – Air Inlet System Operation The subthrottle control system consists of the subthrottle valve, subthrottle valve actuator with a stepping motor built in it, ECU, and subthrottle sensor. The subthrottle valve is built in the each throttlebody. The subthr...

GENERAL INFORMATION 1-13 Technical Information – New Ignition Interlock Sidestand Outline The New Ignition Interlock Sidestand System applied to ZR1000–A1 models that cannot function if gears are engaged and/or the sidestand is not lifted upward even though clutch lever pulled in, whichdiffers from ...

1-14 GENERAL INFORMATION Technical Information – Tail/Brake Lights Employing LED Outline This model employs a tail/brake light containing 21 Light Emitting Diodes (LED). The LED emits luminous beams over a longer life span than those emitted from a traditional electric heated bulb(more than 5 times ...

GENERAL INFORMATION 1-15 Technical Information – Tail/Brake Lights Employing LED The emitting color differs according to the materials of semi-conductors. Materials of Semi-Conductor and Emitting Color Materials of Semi-Conductor Emitting Color GaAsP,GaAlAs Red GaP Green GaN Blue Ga: Gallium As: Ars...

1-16 GENERAL INFORMATION Technical Information - KLEEN (KAWASAKI LOW EXHAUST EMISSION SYSTEM) Since the emission regulations become more severe, Kawasaki has adopted a type of simplified KLEEN, which have no catalyst protection system, according to each regulation of different countries. The muffler...

GENERAL INFORMATION 1-17 Unit Conversion Table Prefixes for Units: Prefix Symbol Power mega M × 1 000 000 kilo k × 1 000 centi c × 0.01 milli m × 0.001 micro µ × 0.000001 Units of Mass: kg × 2.205 = lb g × 0.03527 = oz Units of Volume: L × 0.2642 = gal (US) L × 0.2200 = gal (imp) L × 1.057 = qt (US)...

PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance Table of Contents Periodic Maintenance Chart .............. 2-2 Torque and Locking Agent ................. 2-4 Specifications .................................... 2-9 Special Tools ..................................... 2-11 Periodic Maintenance Procedu...

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. FREQUENCY Whichever 1 000 km * ODOMETERREADING comes (600...

PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever 1 000 km * ODOMETERREADING comes (600 mile) first 6 000 km → (4 000 mile) ↓ 12 000 km( 7 500 mile) 18 000 km(12 000 mile) 24 000 km(15 000 mile) 30 000 km(20 000 mile) 36 000 km(24 000 mile) OPERATION Every Clutch-adjust † • • •...

2-4 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: L: Apply a non-permanent locking agent tothe threads. G: Apply grease ...

PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Water pump drain bolt 11 1.1 95 in·lb Water pipe bolts 11 1.1 95 in·lb in/outlet Thermostat housing ground bolt 7 0.7 61 in·lb Thermostat bracket bolt 7 0.7 61 in·lb Radiator upper bolts 7 0.7 61 in·lb Radiator...

2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Engine Lubrication: Oil filler plug 1.5 0.15 13 in·lb Engine drain plug 20 2.0 14.5 Oil filter (cartridge type, P/No.16097–1070) 26 2.7 20 R, EO Oil filter (cartridge type, P/No.16097–0002) 31 3.2 23 R, EO Oil ...

PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Wheels/Tires: Front axle clamp bolt 34 3.5 25 Front axle 127 13 94 Rear axle nut 127 13 94 Final Drive: Engine sprocket nut 127 13 94 MO Engine sprocket cover bolts 9.8 1.0 87 in·lb Engine sprocket cover damper...

2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Handlebar lower clamp nuts 34 3.5 25 Handlebar switch housing screws 3.4 0.35 30 in·lb Frame: Footpeg holder bolts 34 3.5 25 Muffler mounting bolts 29 3.0 22 Side stand bolt 44 4.5 33 Side stand switch bolt 8.8...

PERIODIC MAINTENANCE 2-9 Specifications Item Standard Service Limit Fuel System: Throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Idle speed 1 100 ± 50 r/min (rpm) Bypass screws (turn out) 2 ± 1/4 (for reference) – – – Engine vacuum 32.7 ± 1.333 kPa (245 ± 10 mm Hg) Air cleaner element Paper filte...

2-10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Air pressure: (when cold) Front Up to 180 kg (396 lb) load: 250 kPa (2.5 kgf/cm², 36 psi) – – – Rear Up to 180 kg (396 lb) load: 290 kPa (2.9 kgf/cm², 41 psi) – – – Final Drive: Drive chain slack 20 ∼ 30 mm (0.8 ∼ 1.2 in.) – – – Dr...

PERIODIC MAINTENANCE 2-11 Special Tools Steering Stem Nut Wrench:57001–1100 Jack:57001–1238 Oil Filter Wrench:57001–1249 Pilot Screw Adjuster, C:57001–1292 Hand Tester:57001–1394 Spark Plug Wrench (Owner’s Tool):92110–1132

2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Fuel Hose and Connection Inspection ○ The fuel hoses are designed to be used throughout themotorcycle’s life without any maintenance, however, if themotorcycle is not properly handled, the high pressure in-side the fuel line...

PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Throttle Control System Inspection Throttle Grip Play Inspection • Check the throttle grip free play [A].If the free play is incorrect, adjust the throttle cable (seebelow). Throttle Grip Free Play Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) • Check...

2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Throttle Bore Cleaning • Check the throttle bore for cleanliness as follows: ○ Remove the throttle body assy (see Fuel System (DFI)chapter). ○ Check the main throttle valves and throttle bores [A] forcarbon deposits by opening the main valves...

PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Engine Vacuum Synchronization Inspection NOTE ○ These procedures are explained on the assumption thatthe inlet and exhaust systems of the engine are in goodcondition. • Situate the motorcycle so that it is vertical. • Remove the fuel tank (se...

2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the fuel tank (see Fuel System (DFI) chapter). • Start the engine and warm it up thoroughly. • Check the idle speed. Tachometer [A] If the idle speed is out of the specified range, adjust it. CAUTION Do not measure the idle speed by...

PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures If any one vacuum measurement is out of the standardmeasurement after synchronization, adjust the bypassscrews [A]. Front [B] Special Tool - Pilot Screw Adjuster, C: 57001-1292 • Adjust the lowest vacuum between #1 and #2 to the high-est of #...

2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Back out the same number of turns counted when firstturned in. This is to set the screw to its original position. NOTE ○ A throttle body has different “turns out” of the bypassscrew for each individual unit. When setting the bypassscrew, us...

PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Air Cleaner Element Cleaning NOTE ○ In dusty areas, the element should be cleaned morefrequently than the recommended interval. ○ After riding through rain or on muddily roads, the ele-ment should be cleaned immediately. WARNING If dirt or du...

2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Clean the element by tapping it lightly to loosen dust. • Blow away the remaining dust by applying compressedair [A] from the outside to the inside (from the clean sideto the dirty side). • Visually inspect the element for no tears or no br...

PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures ○ Disconnect the hoses from the separator, and remove theseparator [A] from the motorcycle left side. Front [B] ○ Visually inspect the separator for cracks and other dam-age.If the separator has any cracks or damage, replace it witha new one....

2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the fuel tank (see Fuel System (DFI) chapter). • Remove the radiator cap [A] in two steps. First turn thecap counterclockwise to the first stop. Then push and turnit further in the same direction and remove the cap. ○ The coolant wil...

PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures • Loosen the air bleeder bolt [A] on the thermostat housing. Front [B] • Replenish the coolant into the radiator until the coolantbegins to flow out the air bleeder bolt hole (that is, all theremaining air is forced out). • Tap the radiator h...

2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted whenthe engine is cold (at room temperature). • Remove: Lower Fairings (see Frame chapter)Pickup Coil CoverCylinder Head Cover (see Cylinder Head Cover Re-moval) •...

PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Valve Clearance Adjustment • To change the valve clearance, remove the camshaftchain tensioner, camshafts and valve lifters. Replace theshim with one of a different thickness. NOTE ○ Mark and record the valve lifter and shim locations sothey ...

2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE 1. Measure the clearance (when engine is cold).2. Check present shim size.3. Match clearance in vertical column with present shim size in horizontal column.4. Install the shim specified where the l...

PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. Measure the clearance (when engine is cold).2. Check present shim size.3. Match clearance in vertical column with present shim size in horizontal column.4. Install the shim specified where the...

2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Clutch Adjust Inspection • Pull the clutch lever just enough to take up the free play[A]. • Measure the gap between the lever and the lever holder.If the gap is too wide, the clutch may not release fully. Ifthe gap is too narrow, the c...

PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Engine Lubrication System Engine Oil Change • Situate the motorcycle so that it is vertical after warmingup the engine. • Remove the engine drain plug [A] to drain the oil. ○ The oil in the oil filter can be drained by removing the filter(see...

2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheels/Tires Tire Inspection As the tire tread wears down, the tire becomes more sus- ceptible to puncture and failure. An accepted estimate isthat 90 % of all tire failures occur during the last 10 % oftread life (90 % worn). So it is false ...

PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Air Pressure Inspection/Adjustment • Remove the air valve cap. • Measure the tire air pressure with an air pressure gauge[A] when the tires are cold (that is, when the motorcyclehas not been ridden more than a mile during the past 3hours).Adj...

2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Tighten both chain adjuster locknuts securely. • Tighten the axle nut. Torque - Rear Axle Nut: 127 N·m (13 kgf·m, 94 ft·lb) • Turn the wheel, measure the chain slack again at the tight-est position, and readjust if necessary. • Insert a new...

PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures • Rotate the rear wheel to inspect the drive chain for dam-aged rollers, and loose pins and links.If there is any irregularity, replace the drive chain.Lubricate the drive chain if it appears dry. • Stretch the chain taut by hanging a 98 N (1...

2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Apply oil to the sides of the rollers so that oil will penetrateto the rollers and bushings. Apply the oil to the O-rings sothat the O-rings will be coated with oil. • Wipe off any excess oil. Oil Applied Areas [A]O-ring [B] Brakes Brake Pa...

PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures If it does not, adjust and inspect the brake light switch. • While holding the switch body, turn the adjusting nut [A]to adjust the switch. CAUTION To avoid damaging the electrical connections in-side the switch, be sure that the switch body ...

2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Inspection (Visual Inspection) • Disassemble the front and rear master cylinders. • Check that there are no scratches, rust or pitting on theinner wall [A] of each master cylinder and on the outsideof each piston [B].If a mast...

PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Level Inspection • Check that the brake fluid level in the front brake reservoir[A] is above the lower level line [B]. NOTE ○ Hold the reservoir horizontal by turning the handlebarwhen checking brake fluid level. If the fluid level is lower t...

2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Level the brake fluid reservoir. • Remove the reservoir cap and diaphragm. • Remove the rubber cap from the bleed valve [A] on thecaliper. • Attach a clear plastic hose [B] to the bleed valve, and runthe other end of the hose into a contain...

PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedalis transmitted directly to the caliper for braking action. Air,however, is easily compressed. When air enter...

2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Bleed the brake line and the caliper: ○ Repeat this operation until no more air can be seen com-ing out into the plastic hose.1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A]. 2. Quickly open and close [B] ...

PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures WARNING When working with the disc brake, observe the pre-cautions listed below. 1. Never reuse old brake fluid.2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types an...

2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Suspension Front Fork Oil Leak Check • Visually inspect the front forks [A] for oil leakage, scoringor scratches on the outer surface of the inner tubes.Replace or repair any defective parts, if necessary. Rear Shock Absorber Oil Leak Check •...

PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Steering Steering Inspection • Lift the front wheel off the ground using the jack. Special Tool - Jack: 57001–1238 • With the front wheel pointing straight ahead, alternatelytap each end of the handlebar. The front wheel shouldswing fully lef...

2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Adjust the steering. Special Tool - Steering Stem Nut Wrench: 57001–1100 [B] If the steering is too tight, loosen the stem nut [A] a fractionof a turn.If the steering is too loose, tighten the stem nut a fractionof a turn. NOTE ○ Turn the s...

PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures • Unscrew the thermostat bracket bolt [A]. ○ If removing the spark plug #2 or #3. • Disconnect: Stick Coil Connectors [A] • Pull out the stick coil #1 [B]. • Take out the camshaft position sensor connector [C] fromthe bracket. • Pull out the ...

2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Clean the spark plug, preferably in a sandblasting device,and then clean off any abrasive particles. The plug mayalso be cleaned using a high-flash point solvent and a wirebrush or other tool.If the spark plug center electrode [A] and/or si...

PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures General Lubrication Lubrication • Before lubricating each part, clean off any rusty spots withrust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○ Whenever the vehicle...

2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Nut, Bolt, and Fastener Tightness Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also,check to see that each cotter pin is in place and in goodcondition. NOTE ○ For the engine fasteners, check the tightness of t...

FUEL SYSTEM (DFI) 3-3 Exploded View Clifornia Evaporative Emission Control System 1. Canister2. Separator3. Right fitting of throttle body #24. Right fitting of throttle body #35. Canister purge hose (green) 6. Fuel return hose (left, red)7. Fuel tank breather hose (right, blue)8. Separator breather...

3-8 FUEL SYSTEM (DFI) DFI Parts Location DFI: DFI Parts (this chapter) 8. ECU Fuse 15A 19. Turn Signal Relay F: Front 9. ECU (DFI) 20. Subthrottle Sensor (DFI) 1. Water temperature 10. Stick Coils 21. Main Throttle Sensor (DFI) Sensor (DFI) 11. Throttle Body Assy 22. Ignition Switch 2. Inlet Air Pre...

FUEL SYSTEM (DFI) 3-15 DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealedbattery as its power source. Do not use any other batteryexcept for a 12 V sealed battery as a pow...

3-18 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○ The DFI part connectors [A] have seals [B], including theECU. • Join the connector and insert the needle adapters (specialtool) [C] inside the seal [B] from behind the connector untilthe adapter reaches the terminal. Special Tool - Needle Adapt...

FUEL SYSTEM (DFI) 3-19 Troubleshooting the DFI System • Pull each connector [A] apart and inspect it for corrosion,dirt, and damage.If the connector is corroded or dirty, clean it carefully. If itis damaged, replace it. Connect the connectors securely. • Check the wiring for continuity. ○ Use the wi...

3-20 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○ There are two ways to inspect the DFI system. One isvoltage Check Method and the other is Resistance CheckMethod. (Voltage Check Method) ○ This method is conducted by measuring the input voltage[B] to a sensor [A] first, and then the output vol...

FUEL SYSTEM (DFI) 3-21 Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptomsthe rider has encountered. ○ Try to find out exactly what problem occurred under exactly what condit...

3-22 FUEL SYSTEM (DFI) Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ al...

3-24 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meantsimply as a rough guide to assist the troubleshooting for some of the more common difficulties. ○ The ECU may be involved in the DFI electric...

3-26 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) Piston ring /groove clearance excessive Inspect and replace (see chapter 5). Cylinder head gasket damaged Replace (see chapter 5). Cylinder head warped Inspect and replace (see chapter 5). No valve ...

3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Too low fuel pressure Inspect fuel line and fuel pump (see chapter 3). Water temperature sensor trouble Inspect and replace (see chapter 3). Inlet air temperature sensor trouble Inspect and replace ...

FUEL SYSTEM (DFI) 3-33 Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosisterminal. User Mode: The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator when DF...

3-34 FUEL SYSTEM (DFI) Self-Diagnosis • To enter the self-diagnosis dealer mode 2, open [B] andground [A] the lead more than five times [F] within 2 sec-onds [C] after the lead is first grounded, and then keep itgrounded continuously [D] for more than 2 seconds. ○ Count the blinks of the LED light t...

3-36 FUEL SYSTEM (DFI) Self-Diagnosis How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the FI indicator LED light as shownbelow. ○ Read 10th digit and unit digit as the FI indicator LED light blinks. ○ When there are a number of problems, all the service co...

FUEL SYSTEM (DFI) 3-37 Self-Diagnosis Service Code Table Service Code FI Indicator LED Light Problems 11 Main throttle sensor malfunction, wiring open or short 12 Inlet air pressure sensor malfunction, wiring open orshort 13 Inlet air temperature sensor malfunction, wiring openor short 14 Water temp...

3-38 FUEL SYSTEM (DFI) Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI or the ignitionsystem parts have troubles. Service Codes Parts Output Signal Usable Range or Criteria Backups by ECU 11 Main Throttle Sensor Main Throttle SensorOutput Voltage0....

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 atthe factory.Never drop the sensor, especially on a hard surface.Such a shock to the se...

FUEL SYSTEM (DFI) 3-41 Main Throttle Sensor (Service Code 11) Output Voltage Inspection • Measure the output voltage at the main throttle sensorin the same way as input voltage inspection, Note thefollowing. • Disconnect the main throttle sensor (gray) [A] and con-nect the harness adapter [B] betwee...

3-42 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the main throttle sensor connector. • Connect a digital meter [A] to the main throttle sensorconnector [B]. • Measure the main throttle sensor resistance. Main Throttle Se...

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...

3-44 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Output Voltage Inspection NOTE ○ The output voltage changes according to the local at-mospheric pressure. • Measure the output voltage at the ECU in the same wayas input voltage inspection. Note the following. Inlet Air Pressure Sens...

FUEL SYSTEM (DFI) 3-45 Inlet Air Pressure Sensor (Service Code 12) ○ Turn the ignition switch ON. ○ Measure the inlet air pressure sensor output voltage fromvarious vacuum readings, while pulling the handle of thefork oil level gauge. ○ Check the inlet air pressure sensor output voltage, usingthe fo...

FUEL SYSTEM (DFI) 3-47 Inlet Air Pressure Sensor (Service Code 12) Pv = 55 ∼ 86 cmHg Vv: Inlet Air Pressure Sensor Output Volt- age (V) (Digital Meter Reading) ID: Idling TO: Throttle Full Open Pv: Throttle Vacuum Pressure (absolute) ST: Standard of Sensor Output Voltage (v) Ps: Standard Atmospheric...

3-48 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface.Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal). • Disconnect the connector [A] from the inlet air tempera-t...

FUEL SYSTEM (DFI) 3-49 Inlet Air Temperature Sensor (Service Code 13) Sensor Resistance Inspection • Remove the inlet air temperature sensor (see this sec-tion). • Suspend the sensor [A] in a container of machine oil sothat the heat-sensitive portion is submerged. • Suspend a thermometer [B] with th...

3-50 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface.Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal). • Drain the coolant about 200 mL (6.76 US oz). • Disconnect the...

FUEL SYSTEM (DFI) 3-51 Water Temperature Sensor (Service Code 14) A. ECU D. Water Temperature Sensor V. Coolant Temperature Gauge in Tachometer Sensor Resistance Inspection • Remove the water temperature sensor (see this section). • Refer to the Electrical System chapter for water temper-ature senso...

3-52 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) CAUTION Never drop the sensor, especially on a hard surface.Such a shock to the sensor can damage it. NOTE ○ The atmospheric pressure sensor is the same part asthe inlet air pressure sensor except that the inlet airpressure sensor ...

FUEL SYSTEM (DFI) 3-53 Atmospheric Pressure Sensor (Service Code 15) Output Voltage Inspection • Measure the output voltage at the ECU in the same wayas input voltage inspection. Note the following. Digital Meter [A]ECU Connector [B] Atmospheric Pressure Sensor Output Voltage Connections to ECU Mete...

3-54 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) Va: Atmospheric Pressure Sensor Output Voltage (v) ST: Standard of Sensor Output Voltage (v) UR: Usable Range of Sensor Output Voltage (v) H: Altitude (m or feet) A. ECUE. Atmospheric Pressure Sensor

FUEL SYSTEM (DFI) 3-55 Crankshaft Sensor (Service Code 21) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has atthe time of self-diagnosis. If the engine cannot be started,the self-diagnosis system does not detect dynamic condi-tion of the...

3-56 FUEL SYSTEM (DFI) Camshaft Position Sensor (Service Code 23) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has atthe time of self-diagnosis. If the engine cannot be started,the self-diagnosis system does not detect dynamic condi-tion...

FUEL SYSTEM (DFI) 3-57 Speed Sensor (Service Code 24, 25) Speed Sensor Removal/Installation • See the Switches and Sensors section in the ElectricalSystem chapter. Speed Sensor Inspection • See the Switches and Sensors section in the ElectricalSystem chapter. Input Voltage Inspection NOTE ○ Be sure ...

3-58 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) • Disconnect the speed sensor connector [A] and connectthe harness adapter [B] between the harness connectorand speed sensor connector. Engine Sprocket Cover [C] • Connect a digital meter to the harness adapter leads. Special Tool - Throttle ...

FUEL SYSTEM (DFI) 3-59 Vehicle-down Sensor (Service Code 31) Removal CAUTION Never drop the down-sensor, especially on a hardsurface. Such a shock to the sensor can damage it. • Remove: Connection and Vehicle-down Sensor [A]Bolts and Washers [B]Front [C] Installation • The UP mark [A] of the sensor ...

3-60 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) • Turn the ignition switch OFF. • Remove the sensor. • Connect a digital volt meter [A] to the connector with nee-dle adapter set [B]. Special Tool - Needle Adapter Set: 57001–1457 Vehicle-down Sensor Output Voltage Connections to Sensor M...

3-62 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Subthrottle Sensor Removal/Adjustment CAUTION Do not remove or adjust the subthrottle sensor [A]since it has been adjusted and set with precision atthe factory.Never drop the sensor, especially on a hard surface.Such a shock to the sensor c...

3-64 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the subthrottle sensor connector. • Connect a digital meter [A] to the subthrottle sensor con-nector [B]. • Measure the subthrottle sensor resistance. Throttle Sensor Resist...

FUEL SYSTEM (DFI) 3-67 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [A]since it has been adjusted and set with precisionat the factory.Never drop the actuator , especially on a hard sur-face. Such a shock to the ...

3-68 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove the throttle body assy (see Throttle Body AssyRemoval). • Connect the peak voltage adapter [A] and a digital meter[B] to ...

FUEL SYSTEM (DFI) 3-69 FI Indicator LED Light Inspection Flow Chart

3-70 FUEL SYSTEM (DFI) FI Indicator LED Light LED Light Inspection • Remove the meter unit (see Electrical System chapter). • Using two auxiliary leads, supply battery power to the FIindicator LED light [A]. 12 V Battery [B] FI Indicator LED Light Check Connector: Meter Connector [C] (disconnected) ...

FUEL SYSTEM (DFI) 3-71 ECU CAUTION Never drop the ECU, especially on a hard surface.Such a shock to the ECU can damage it. ECU Identification ○ Most countries have their own regulations, so each ECUhas different characteristic. So, do not confuse ECU’swith each other and use only the ECU’s for your ...

3-72 FUEL SYSTEM (DFI) ECU If the rubber protector [A] is removed, install it. ECU [B] ECU Power Supply Inspection • Visually inspect the terminals [A] of the ECU connectors.If the connector is clogged with mud or dust, blow it offwith compressed air.Replace the main harness if the terminals of the ...

FUEL SYSTEM (DFI) 3-73 ECU • Check the ECU power source voltage with a digital meter[A]. ○ Position the terminal in accordance with terminal numbersof ECU connectors [B] in this chapter figure. Battery [C] ECU Power Source Inspection Meter between Terminal 13 (W/Y) and Connections: Battery (–) Termi...

3-74 FUEL SYSTEM (DFI) DFI Power Source ECU Fuse Removal • Refer to the Electrical System chapter for the ECU fuseremoval. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system todetermine the cause, and then replace it with a new fuseof proper amperage. • Refer to the Elect...

FUEL SYSTEM (DFI) 3-75 Fuel Line Fuel Pressure Inspection NOTE ○ This inspection can determine which trouble the DFIsystem has, mechanical or electrical trouble. ○ It is preferable to measure the fuel pressure while run-ning the motorcycle just when trouble occurred in orderto know symptom well. ○ B...

3-76 FUEL SYSTEM (DFI) Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure with the engine idling. Fuel Pressure (idling) Standard: 310 kPa (3.2 kgf/cm², 46 psi) NOTE ○ The gauge needle will fluctuate. Read the pressure atthe average of the maximum and minimum indications. If ...

FUEL SYSTEM (DFI) 3-77 Fuel Line • Open the fuel tank cap [A] to lower the pressure in thetank. Front [B] • Be sure to place a piece of cloth around the fuel pumpoutlet hose. • Remove the fuel pump outlet hose [A] from the fuel pump[B] and the delivery pipe [C] (see Fuel Pump Removal). Front [D] WAR...

3-78 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur-face. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explo-sive under certain conditions. Make sure the areais well-ventilated and free from any s...

FUEL SYSTEM (DFI) 3-79 Fuel Pump • Replace the fuel pump gasket [A] with a new one. • Check that the fuel pump (–) terminal [A] and band [B] arein place. Front [C] • Apply a non-permanent locking agent to the threads ofthe fuel pump bolts. • Tighten the fuel pump bolts to a snug fit, following theti...

3-80 FUEL SYSTEM (DFI) Fuel Pump • Connect the hand tester (25 V DC) to the fuel pump con-nector [A] with needle adapter set. Front [B] Special Tools - Hand Tester: 57001–1394 Needle Adapter Set: 57001–1457 ○ Measure the operating voltage with the engine stopped,and with the connector joined. • Turn...

FUEL SYSTEM (DFI) 3-81 Fuel Pump Fuel Pump Relay Removal CAUTION Never drop the relay, especially on a hard surface.Such a shock to the relay can damage it. • Remove the seat cover (see Frame chapter). • Remove the fuel pump relay [A] from the tongue of thestorage compartment. • Disconnect the conne...

3-82 FUEL SYSTEM (DFI) Fuel Injectors Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Audible Inspection • Start the engine. • Apply the tip of a screwdriver [A] to the injector [C]. Putthe grip end onto your ear, and listen whether the injectoris clicking or not. ○ A so...

3-84 FUEL SYSTEM (DFI) Fuel Injectors Injector Signal Test • Prepare two test light sets with male terminals as shown. Rating of Bulb [A]: 12 V × 3 ∼ 3.4 W Terminal Width [B]: 1.8 mm (0.071 in.)Terminal Thickness [C]: 0.8 mm (0.031 in.) CAUTION Do not use larger terminals than specified above. Alarg...

FUEL SYSTEM (DFI) 3-85 Fuel Injectors Injector Resistance Inspection • Remove the fuel tank (see Fuel Tank Removal). • Disconnect the connector from the injector [A] (see Throt-tle Body Assy Disassembly/Assembly). • Measure the injector resistance with the hand tester [B]. Front [C] Special Tool - H...

3-86 FUEL SYSTEM (DFI) Fuel Injectors • Check the injector fuel line for leakage as follows: ○ Connect a commercially available vacuum/pressurepump [A] to the nipple of the delivery pipe [B] with ahigh-pressure fuel hose [C] (both ends connected withthe clamps [D]) as shown. Torque - Fuel Hose Clamp...

FUEL SYSTEM (DFI) 3-87 Fuel Injectors A. ECUK. 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 Relaye. Joint Connector C f. Sealed Battery j. Joint Connector B k. Main Fuse 30 A

3-88 FUEL SYSTEM (DFI) Throttle Grip and Cables Throttle Grip Play Inspection/Adjustment • Refer to the Throttle Control System Inspection in the Pe-riodic Maintenance chapter. Choke Lever Operation ○ Do not use the choke lever except when the engine has astarting difficulty like in cold weather (10...

FUEL SYSTEM (DFI) 3-89 Throttle Body Assy Idle Speed Inspection/Adjustment • Refer to the Idle Speed Inspection in the Periodic Main-tenance chapter . Throttle Bore Cleaning • Refer to the Throttle Control System Inspection in the Pe-riodic Maintenance chapter. Engine Vacuum Synchronization Inspecti...

3-90 FUEL SYSTEM (DFI) Throttle Body Assy • Loosen: Throttle Assy Holder Clamp Bolts [A]Air Cleaner Duct Clamp Bolts [B] Special Tool - Carburetor Drain Plug Wrench, Hex 3: 57001–1269 • Remove: Right and Left Side Covers (see Frame chapter)Coolant Reserve Tank (see Coolant Change in the Peri-odic Ma...

FUEL SYSTEM (DFI) 3-91 Throttle Body Assy • Remove the bolt [A] and the throttle cable plate [B] fromthe throttle body front side. • Remove the throttle cable lower ends from the throttlepulley. • Remove: Choke Cable Upper End (From choke lever)Choke Cable Lower End [A]Throttle Body #2 [B] • After r...

3-92 FUEL SYSTEM (DFI) Throttle Body Assy • Apply a thin coating of grease to the throttle cable upperends. • Install the upper ends of the throttle cables in the grip (seeThrottle Body Assy Removal). • Fit the projection [A] of the right switch housing into thehole [B] of the handlebar (front view)...

FUEL SYSTEM (DFI) 3-93 Throttle Body Assy CAUTION Never drop the injector, especially on a hard sur-face. Such a shock to the injector can damage it. • Pull out [A] the injectors along with the delivery pipe [B].If necessary, remove the injectors from the delivery pipe.Replace the O-rigs of the indi...

3-94 FUEL SYSTEM (DFI) Air Cleaner Element Removal/Installation • Refer to the Air Cleaner Element Cleaning in the PeriodicMaintenance 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 ...

FUEL SYSTEM (DFI) 3-95 Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explo-sive under certain conditions. Make sure the areais well-ventilated and free from any source of flameor sparks; this includes any appliance with a pilotlight. Do not smoke. Turn the ignition s...

3-96 FUEL SYSTEM (DFI) Fuel Tank • Be sure to place a piece of cloth [A] around the fuel hosepump outlet joint [B]. • While pinching the hose joint locks [C] with fingers, pullthe joint out along the delivery pipe. Front [D] WARNING Be prepared for fuel spillage; any spilled fuel mustbe completely w...

FUEL SYSTEM (DFI) 3-97 Fuel Tank Fuel Tank Installation • Note the above WARNING (see Fuel Tank Removal). • Route the hoses correctly (see Appendix chapter). • Check that the rubber dampers [A] are on the frame andthe fuel tank. Front [B] • Check that the dampers [A] are in place on the fuel tankas ...

3-98 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank and Cap Inspection • Visually inspect the gasket [A] on the tank cap for anydamage.Replace the gasket if it is damaged. • Check to see if the water drain pipe [B] and fuel breatherpipe [C] in the tank are not clogged. Check the tank capbreather also.If they...

FUEL SYSTEM (DFI) 3-99 Evaporative Emission Control System Parts Removal/Installation WARNING Gasoline is extremely flammable and can be ex-plosive under certain conditions. Turn the ignitionswitch OFF. Do not smoke. Make sure the area iswell-ventilated and free from any source of flameor sparks; th...

3-100 FUEL SYSTEM (DFI) Evaporative Emission Control System Separator Operation Test WARNING Gasoline is extremely flammable and can be ex-plosive under certain conditions. Turn the ignitionswitch OFF. Do not smoke. Make sure the area iswell-ventilated and free from any source of flameor sparks; thi...

COOLING SYSTEM 4-7 Special Tool Bearing Driver Set:57001–1129 Bearing Driver:57001–382 Kawasaki Bond (Silicone Sealant):56019–120

4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the left side cover (see Frame chapter). • Visually inspect the coolant [A] in the reserve tank. Front [B] If whitish cotton-like wafts are observed, aluminum partsin the cooling system are corroded. If the coolant isbrown, iron or...

COOLING SYSTEM 4-9 Coolant Pressure Testing • Remove the fuel tank (see Fuel System (DFI) chapter). • Remove the radiator cap, and install a cooling systempressure tester [A] on the filler neck [B]. NOTE ○ Wet the cap sealing surfaces with water or coolant toprevent pressure leaks. • Build up pressu...

4-10 COOLING SYSTEM Water Pump Water Pump Removal • Refer to Oil Pump Removal in the Engine Lubrication Sys-tem chapter. Water Pump [A]Front [B] Water Pump Installation • Refer to Oil Pump Installation in the Engine LubricationSystem chapter. Water Pump Inspection • Check the drainage outlet passage...

COOLING SYSTEM 4-11 Water Pump • Be sure to replace the mechanical seal, oil seal, and O-ring with new ones because these parts will be damagedby removal. • Apply plenty of high temperature grease to the oil seallips. • Apply oil to the outer circumference of the oil seal. • Press the oil seal [A] i...

4-12 COOLING SYSTEM Radiator Radiator Removal WARNING The radiator fan is connected directly to the bat-tery. The radiator fan may start even if the ignitionswitch is off. NEVER TOUCH THE RADIATOR FANUNTIL THE RADIATOR FAN CONNECTOR IS DIS-CONNECTED. TOUCHING THE FAN BEFORE THECONNECTOR IS DISCONNEC...

COOLING SYSTEM 4-13 Radiator • If necessary, remove: Radiator Fan Mounting Bolts [A]Radiator Fan [B] Radiator Inspection • Check the radiator core.If there are obstructions to air flow, remove them.If the corrugated fins [A] are deformed, carefullystraighten them.If the air passages of the radiator ...

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 toprevent pressure leaks. • Watching the pressure gauge, pump the pressure testerto build up the pressure until the relief valve opens: thegauge needl...

COOLING SYSTEM 4-15 Thermostat Thermostat Removal • Remove: Coolant : Drain about 200 mLFuel Tank (see Fuel System (DFI) chapter)Thermostat Bracket Bolt [A]Water Temperature Sensor Connector [B]Three Water Hoses [C] • Remove the thermostat housing [D]. Front [E] • Remove the screws [A], take off the...

4-16 COOLING SYSTEM Thermostat • To check valve opening temperature, suspend the ther-mostat [A] in a container of water and raise the tempera-ture of the water. ○ The thermostat must be completely submerged and mustnot touch the container sides or bottom. Suspend an ac-curate thermometer [B] in the...

COOLING SYSTEM 4-17 Hose and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend-ing direction. Avoid sharp bending, kinking, flattening ortwisting. • Run the hoses in accordance with the Cable, Wire, andHose Routing section in the Appendix chapter. • Wet the internal...

4-18 COOLING SYSTEM Radiator Fan Switch, Water Temperature Sensor CAUTION The fan switch or the water temperature sensorshould never be allowed to fall on a hard surface.Such a shock to their parts can damage them. Radiator Fan Switch Removal • Drain the coolant (see Coolant Change in the PeriodicMa...

ENGINE TOP END 5-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Coolant Drain Plug (Cylinder) 10 1.0 87 in·lb 2 Exhaust pipe manifold holder nuts 17 1.7 12 3 Muffler body clamp bolts 17 1.7 12 4 Muffler body mounting bolts and nuts 34 35 25 5 Crankshaft sensor cover bolts 11 1.1 95 in...

5-8 ENGINE TOP END Special Tools and Sealant Compression Gauge:57001–221 Valve Spring Compressor Assembly:57001–241 Piston Pin Puller Assembly:57001–910 Valve Seat Cutter, 45° - 27.5:57001–1114 Valve Seat Cutter, 45° - 32:57001–1115 Valve Seat Cutter, 32° - 28:57001–1119 Valve Seat Cutter, 32° - 30:...

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 ClampAir Suction Valve Cover [D]Air Suction Valve Air Suction Valve Installation • Install the air suction valve [A] s...

ENGINE TOP END 5-11 Clean Air System Vacuum Switch Valve Test • Remove: Fuel Tank (see Fuel System (DFI) chapter)Vacuum Switch Valve • Connect a vacuum gauge [A] and syringe [B] or fork oillevel gauge to the vacuum hoses as shown. Special Tool - Fork Oil Level Gauge: 57001–1290 Air Flow [C] • Gradua...

5-12 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal • Remove: Fuel Tank (see Fuel System (DFI) chapter)Vacuum Switch Valve and HosesStick Coils (see Electrical System chapter)Air Suction Valve Covers [A] • Remove the cylinder head cover bolts [A] and take off thecover. Cylinder Head ...

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 positiononce it moves out to take up camshaft chain slack.Observe all the rules listed below:When removing the tension...

ENGINE TOP END 5-15 Camshaft, Camshaft Chain Camshaft Removal • Remove: Fuel Tank (see Fuel System (DFI) chapter)Stick Coils (see Electrical System)Cylinder Head Cover (see Cylinder Head Cover Re-moval)Pickup Coil Cover • Position the crankshaft at #1, 4 piston TDC. [A] TDC mark for #1, 4 Pistons[B]...

5-16 ENGINE TOP END Camshaft, Camshaft Chain • Apply engine oil to all cam parts and journals. • If a new camshaft is to be used, apply a thin coat of molyb-denum disulfide grease to the cam surfaces. NOTE ○ The exhaust camshaft has a 030 EX mark [A] and theinlet camshaft has a 030 IN mark [B]. Be c...

ENGINE TOP END 5-17 Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear • Remove: Camshaft Chain GuideCamshaft Cap • Cut strips of plastigage to journal width. Place a stripon each journal parallel to the camshaft installed in thecorrect position. • Measure each clearance between the camshaft journ...

5-18 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Chain Removal • Split the crankcase (see Crankshaft/Transmission chap-ter). • Remove the camshaft chain [A] from the crankshaftsprocket.

ENGINE TOP END 5-19 Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Seats (see Frame chapter)Fuel Tank (see Fuel System (DFI) chapter)Stick CoilsSpark Plugs Owners Tool - Spark Plug Wrench, He...

5-20 ENGINE TOP END Cylinder Head Cylinder Head Removal • Drain the coolant (see Cooling System chapter). • Remove: Exhaust Pipes (see Exhaust Pipe Removal)Coolant Drain Bolt [A] (cylinder) • Remove: Cylinder Head Cover (see Cylinder Head Cover Re-moval)Camshaft Position Sensor (see Electrical Syste...

ENGINE TOP END 5-21 Cylinder Head • Install: Front Camshaft Chain Guide [A]O-ring [B]Collar [C] • Tighten: Torque - Front Camshaft Chain Guide Bolt (Upper) [D]: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Camshaft Chain Guide Bolt (Lower) [E]: 12 N·m (1.2 kgf·m, 104 in·lb) • Install: Rear Camshaft Chain Guid...

5-22 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Engine Top End in the Periodic Maintenancechapter. Valve Clearance Adjustment • Refer to the Engine Top End in the Periodic Maintenancechapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the valv...

ENGINE TOP END 5-23 Valves Valve Guide Installation • Apply oil to the valve guide outer surface before installa-tion. • Heat the area around the valve guide hole to about 120 ∼ 150 °C (248 ∼ 302 °F). • Drive the valve guide in from the top of the head using thevalve guide arbor. The flange stops th...

5-24 ENGINE TOP END Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B]and valve seat [C]. ○ Measure the outside diameter [D] of the seating patternon the valve seat.If the outside diameter is too large or too small, repair...

ENGINE TOP END 5-25 Valves Seat Cutter Operation Care: 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for otherpurposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. 3. Do not fai...

5-26 ENGINE TOP END Valves • Measure the outside diameter of the seating surface witha vernier caliper.If the outside diameter of the seating surface is too small,repeat the 45° grind until the diameter is within the spec-ified range. Widened Width [A] of engagement by machining with45° cutterGround...

ENGINE TOP END 5-27 Valves If the seat width is too wide, make the 60° [A] grind de-scribed below.If the seat width is within the specified range, lap the valveto the seat as described below. • Grind the seat at a 60° angle until the seat width is withinthe specified range. ○ To make the 60° grind, ...

ENGINE TOP END 5-29 Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal)Water Hose [A] • Remove the cylinder [B]. Cylinder Installation NOTE ○ If a new cylinder is used, use new piston ring. • Install the pins [A] and new cylinder gasket [B]. • Apply engine oil to t...

5-30 ENGINE TOP END Cylinder, Pistons • Remove the piston pins. Special Tool - Piston Pin Puller Assembly: 57001–910 [A] • Remove the pistons. • Carefully spread the ring opening with your thumbs andthen push up on the opposite side of the ring [A] to removeit. • Remove the 3-piece oil ring with you...

ENGINE TOP END 5-31 Cylinder, Pistons NOTE ○ If a new piston is used, use new piston ring. • Install the piston with its hollow facing forward. • Fit a new piston pin snap ring into the side of the pistonso that the ring opening [A] does not coincide with the slit[B] of the piston pin hole. ○ Apply ...

5-32 ENGINE TOP END Cylinder, Pistons Piston Ring Groove Width • Measure the piston ring groove width. ○ Use a vernier caliper at several points around the piston. Piston Ring Groove Width Standard Service Limit Top [A] 0.83 ∼ 0.85 mm 0.93 mm (0.0327 ∼ 0.0335 in.) (0.037 in.) Second [B] 0.82 ∼ 0.84 ...

ENGINE TOP END 5-33 Throttle Body Holder Throttle Body Holder Installation • Be sure to install the O-rings [A]. • Install the clamps [B] as shown and so that its hole fit onthe projection [C] of the holder. • Tighten: Torque - Throttle Body Holder Bolts [D]: 12 N·m (1.2 kgf·m, 104 in·lb) Throttle B...

5-34 ENGINE TOP END Muffler WARNING To avoid a serious burn, do not remove the mufflerswhen the engine is still hot. Wait until the mufflerscool down. Muffler Body Removal • Remove: Muffler Body Clamp Bolts [A]Muffler Body Mounting Bolts [B]Muffler Body [C] Exhaust Pipe Removal • Remove: Muffler Bod...

ENGINE TOP END 5-35 Muffler ○ Install the muffler body clamp bolts as shown. [L] Upper Side[M] Inside[N] Connection Part Detail • Thoroughly warm up the engine, wait until the enginecools down, and retighten all the bolts and nuts.

CLUTCH 6-1 6 Clutch Table of Contents Exploded View ........................................................................................................................ 6-2 Specifications ...............................................................................................................

6-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) - - - Clutch: Clutch plate assembly 48.4 ∼ 49.0 mm (1.91 ∼ 1.93 in.) - - - Friction plate thickness 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) 2.4 mm (0.094 in.) Friction and steel plate warp 0.2 mm (0.00...

6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch Adjust Inspection in the Periodic Main-tenance chapter. Clutch Lever Free Play Adjustment • Refer to the Clutch Adjust Inspection in the Periodic Main-tenance chapter. Cable Removal • Slide the dust cover [A] a...

CLUTCH 6-7 Clutch Cover Clutch Cover Removal • Remove: Engine Oil (drain, see Engine Oil Change section in thePeriodic Maintenance chapter)Clutch Cable Lower End [A]Clutch Cover Mounting Bolts [B]Clutch Cable Bracket [C] • Turn the release lever [A] toward the rear as shown, andremove the clutch cov...

6-8 CLUTCH Clutch Cover • Fit the spring [A] as shown. [B] Viewed from Rear[C] Release Shaft[D] Clutch Cover Clutch Cover Disassembly • Remove: Oil Seal [A]Needle Bearings • Remove: Circlip [A] Special Tool - Inside Circlip Pliers [B]: 57001–143 • Remove: Oil Level Gauge [C] Clutch Cover Assembly • ...

CLUTCH 6-9 Clutch Clutch Removal • Remove: Engine Oil (drain, see Engine Oil Change section in thePeriodic Maintenance chapter)Clutch Cover (see Clutch Cover Removal)Clutch Spring Bolts [A]Clutch SpringsClutch Spring Plate [B] (with thrust bearing and pusher[C]) • Remove: Friction Plates, Steel Plat...

6-10 CLUTCH Clutch ○ Install the spacer [A] so that the tapered side [B] facesinward. ○ Install the washer [A] so that the OUT SIDE mark facesoutward. ○ 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 6-11 Clutch • Apply molybdenum disulfide grease to the pusher ends[A] and install the pusher [B]. • Apply engine oil to the needle bearing [C] and install it. • Install the washer [D]. • Align the mark [A] of the clutch spring plate [B] with thegroove [C] of the clutch hub. • Install the clut...

6-12 CLUTCH Clutch Clutch Plate Assembly Adjustment • Inspect the clutch plate assembly length, and then re-place the steel plate(s) which brings the length within thespecified range. • Remove: Spring BoltsSpring HoldersSpringsSpring Plate • Replace the following steel plate(s). Part No. Thickness 1...

ENGINE LUBRICATION SYSTEM 7-1 7 Engine Lubrication System Table of Contents Exploded View ........................................................................................................................ 7-2 Engine Oil Flow Chart...................................................................

ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Oil filler plug 1.5 0.15 13 in·lb 2 Engine drain plug 20 2.0 14.5 3 Oil filter (cartridge type, P/No. 16097–1070) 26 2.7 20 EO, R 3 Oil filter (cartridge type, P/No. 16097–0002) 31 3.2 23 EO, R 4 Oil cooler mou...

7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart

ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart 1. Camshaft Oil Passage2. Oil Passage Hole in Alternator Rotor Bolt3. Starter Clutch Oil Passage Hole4. Main Oil Passage5. Crankshaft Oil Passage6. Oil Filter7. Oil Cooler8. Oil Pressure Switch9. Oil Pipe 10. Oil Pump 11. To Drive Shaft 12. Oil Pip...

7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil: Type API SE, SF or SGAPI SH or SJ with JASO MA Viscosity SAE 10W-40 Capacity: 3.1 L (3.3 US gt) (when filter is not removed)3.3 L (3.5 US gt) (when filter is removed)3.8 L (4.0 US gt) (when engine is completely dry) Level Between...

ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²:57001–164 Oil Pressure Gauge Adapter, PT3/8:57001–1233 Kawasaki Bond (Silicone Sealant):56019–120 Oil Filter Wrench:57001–1249

7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri-orated, or contaminated engine oil will causeaccelerated wear and may result in engine or trans-mission seizure, accident, and injury. Oil Level Inspection • Check that the engine oil level...

ENGINE LUBRICATION SYSTEM 7-9 Oil Pan Oil Pan Removal • Remove: Engine Oil (drain, see Periodic Maintenance chapter)Muffler (see Engine Top End chapter)Oil Pan Bolts [A]Oil Pan [B] ○ Remove the oil pipe [A], oil pressure relief valve [B] andoil screen [C] as necessary. Oil Pan Installation • Clean t...

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 • Check to see if the valve [A] slides smoothly when push-ing it in with a wooden ...

ENGINE LUBRICATION SYSTEM 7-11 Oil Pump Oil Pump Removal • Drain: Coolant (see Periodic Maintenance chapter)Engine Oil (see Periodic Maintenance chapter) • Remove: Water Hose [A]Water Pipe Fitting Bolts [B]Water Pipes [C] • Remove: Water Pump Cover Bolts [A]Clamp [B]Water Pump Cover [C] • Remove: Wa...

7-12 ENGINE LUBRICATION SYSTEM Oil Pump • Fit the pin [A] of the oil pump cover [B] into the hole [C] inthe crankcase. • Install: Pins [A]Water Pump Body [B] • Install: Impeller [A] and Bolt [B] • Tighten: Torque - Water Pump Impeller Bolt: 10 N·m (1.0 kgf·m, 87 in·lb) • Install: Pins [C]Water Pump ...

ENGINE LUBRICATION SYSTEM 7-13 Oil Pump Oil Pump Drive Gear Removal • Remove: Clutch (see Clutch chapter)Oil Pan (see Oil Pan Removal)Circlip [A] and Washer [B]Oil Pump Drive Gear [C] Oil Pump Drive Gear Installation • Apply molybdenum disulfide oil solution to the journal por-tions [A] on the oil p...

7-14 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Removal • Drain: Coolant (see Periodic Maintenance chapter)Engine Oil (see Periodic Maintenance chapter) • Remove: Oil Filter (see Periodic Maintenance chapter)Water Hose [A]Oil Cooler Mounting Bolt [B] and WasherOil Cooler [C] and Water Hose Oil ...

ENGINE LUBRICATION SYSTEM 7-15 Oil Pressure Measurement Oil Pressure Measurement • Remove the oil passage plug, and attach the adapter [A]and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001–164 Oil Pressure Gauge Adapter, PT 3/8: 57001–1233 • Start the engine and wa...

7-16 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal • Remove: Engine Oil (drain, see Periodic Maintenance chapter)Switch Cover [A]Switch Terminal [B]Oil Pressure Switch [C] Oil Pressure Switch Installation • Apply silicone sealant to the threads of the oil pressureswitch a...

ENGINE REMOVAL/INSTALLATION 8-1 8 Engine Removal/Installation Table of Contents Exploded View ........................................................................................................................ 8-2 Special Tools ......................................................................

ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal • Support the rear part of the swingarm with a stand [A]. • Squeeze the brake lever slowly and hold it with a band[A]. WARNING Be sure to hold the front brake when removing theengine, or the motorcycle may fall over. It could...

8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Radiator Hose Clamp [A] (Loosen)Radiator Hose [B]Oil Cooler Water Hose Clamp [C] (Loosen)Oil Cooler Water Hose [D]Radiator Bolt [E] (Loosen)Radiator Bracket Bolt [F] • Disconnect Crankshaft Sensor Lead Connector (see Electrical Sy...

ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation • Using the Hexagon Wrench, turn the adjusting collar [A]counter clockwise to mark the gap between the engineand flame adjusting collar. • Remove the drive chain [A] from the output shaft [B]. • Down the rear portion of the engine a little ...

ENGINE REMOVAL/INSTALLATION 8-11 Engine Removal/Installation ○ Ninth, temporarily install: Front Engine Bracket [A]Front Right Engine Mounting Bolt [B] ○ Tenth, tighten the rear bracket bolts. Torque - Rear Engine Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) ○ Eleventh, tighten securely: Middle Engin...

CRANKSHAFT/TRANSMISSION 9-1 9 Crankshaft/Transmission Table of Contents Exploded View ................................... 9-2 Specifications .................................... 9-6 Special Tools and Sealant ................. 9-8 Crankcase Splitting............................ 9-9 Crankcase Splittin...

CRANKSHAFT/TRANSMISSION 9-9 Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal/Installationchapter). • Set the engine on a clean surface and hold the enginesteady while parts are being removed. • Remove: Crankshaft Sensor (see Electrical System chapter)Clutch (see Clutch...

9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Apply liquid gasket to the breather plate mating surface[A] 1 to 1.5 mm (0.04 to 0.06 in.) thick, and then installthe breather plate. Sealant - Three Bond: 1207B • Apply a non-permanent locking agent to the threads andtighten the bolts [A]. Torque -...

CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting • Apply liquid gasket [A] to the mating surface of the lowercrankcase half. Sealant - Kawasaki Bond (Silicone Sealant): 92104–1063 CAUTION Do not apply liquid gasket around the crankshaftmain bearing inserts, and oil passage holes. • Fit the lower cra...

9-12 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft [A]. Crankshaft Installation CAUTION If the crankshaft, bearing inserts, or crankcasehalves are replaced with new ones, select the bear-ing inserts ...

CRANKSHAFT/TRANSMISSION 9-13 Crankshaft and Connecting Rods • Apply molybdenum disulfide grease [A] to the outer sur-face of the upper insert and the inner surface of the con-necting rod big end. • Apply molybdenum disulfide oil [B] to the inner surfacesof upper and lower bearing inserts. ○ The moly...

9-14 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods (1) Bolt Length Measurement Method • Be sure to clean the bolts, nuts, and connecting rodsthoroughly with a high-flash point solvent, because thenew connecting rods, bolts, and nuts are treated with ananti-rust solution. WARNING Clean the b...

CRANKSHAFT/TRANSMISSION 9-15 Crankshaft and Connecting Rods (2) Rotation Angle Method If you don’t have a point micrometer, you may tighten thenuts 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 aret...

9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Bend • Remove the connecting rod big end bearing inserts, andreinstall the connecting rod big end cap. • Select an arbor [A] of the same diameter as the connect-ing rod big end, and insert the arbor through the connect-ing ro...

CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert/Crankpin Wear • Measure the bearing insert/crankpin [B] clearance withplastigage [A]. ○ Tighten the big end nuts to the specified torque (see Con-necting Rod Installation). NOTE ○ Do not move the connec...

9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Big End Inside Diameter Marks None 38.000mm ∼ 38.008mm (1.4961 ∼ 1.4964 in.) 38.009 ∼ 38.016 mm (1.4964 ∼ 1.4967 in.) Big End Cap [A]Connecting Rod [B]Weight Mark, Alphabet [C]Diameter Mark (Around Weight Mark) [D]: “ ” or no...

CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods Crankshaft Main Bearing Insert/Journal Wear • Using a plastigage (press gauge) [A], measure the bear-ing insert/journal [B] clearance. NOTE ○ Tighten the crankcase bolts to the specified torque (seeCrankcase Assembly). ○ Do not turn the cra...

9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Measure the main bearing inside diameter, and mark theupper 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 torqu...

CRANKSHAFT/TRANSMISSION 9-21 Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal and Installation inthe Electrical System chapter. Starter Motor Clutch Assembly • Be sure to install the one-way clutch [A] so that its flange[B] fits in the holder rec...

9-22 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal • Mark [A] the position of the shift lever [B] on the shift shaftso that it can be installed later in the same position. • Remove: Shift Lever Bolt [C]Shift Lever • Remove: Footpeg Bracket Bolts [A]Muffler Mounting Bolt [B]Footpeg Bracket...

CRANKSHAFT/TRANSMISSION 9-23 Transmission • Install the footpeg bracket [A]. • Apply a non-permanent locking agent to the footpegbracket bolts [B]. • Tighten: Torque - Footpeg bracket Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Muffler Mounting Bolt and Nut [C]: 29 N·m (3.0 kgf·m, 22 ft·lb) • Install the sh...

9-24 CRANKSHAFT/TRANSMISSION Transmission • Remove: Gear Positioning Lever Bolt [A]Gear Positioning Lever [B], Collar and spring External Shift Mechanism Installation • Install the gear positioning lever [A] as shown. Spring [B]Collar [C]Bolt [D] • Tighten: Torque - Gear Positioning Lever Bolt: 12 N...

CRANKSHAFT/TRANSMISSION 9-25 Transmission Transmission Shaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the drive shaft [A] and output shaft [B]. Transmission Shaft Installation • Check to see that the set pins [A] and set rings [B] are inplace. • Install the drive shaft and o...

9-26 CRANKSHAFT/TRANSMISSION Transmission • Remove the ball bearing [A] from each shafts. Special Tools - Bearing Puller: 57001–135 [B] Bearing Puller Adapter: 57001–317 [C] • Discard the bearing. Transmission Shaft Assembly • Apply engine oil to the sliding surfaces on the transmis-sion shafts, gea...

9-28 CRANKSHAFT/TRANSMISSION Transmission 1. 1st Gear2. 2nd Gear3. 3rd Gear4. 4th Gear5. 5th Gear6. 6th (Top) Gear7. Toothed Washer, 31 mm (1.22 in.) 8. Thrust Washer, 30 mm (1.18 in.) 9. Circlip 10. Circlip 11. Bushing 12. Bushing13. Needle Bearing14. Needle Bearing15. Bearing Outer Race16. Steel B...

CRANKSHAFT/TRANSMISSION 9-29 Transmission Shift Drum and Fork Installation • Install the shift rods [A], noting the groove position. Therods are identical. • Position the one with shortest ears [B] on the drive shaftand place the pin in the center groove in the shift drum[C]. ○ The two forks [D] on ...

9-30 CRANKSHAFT/TRANSMISSION Transmission Shift Fork/Gear Groove Wear • Measure the thickness of the shift fork ears [A], and mea-sure the width [B] of the gear grooves.If the thickness of a shift fork ear is less than the servicelimit, the shift fork must be replaced. Shift Fork Ear Thickness Stand...

WHEELS/TIRES 10-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Front axle clamp bolt 20 2.0 15 2 Front axle 127 13 94 3 Rear axle nut 127 13 94 G: Apply grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.

10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims): Rim runout: Axial - - - TIR 0.5 mm (0.020 in.) Radial - - - TIR 0.8 mm (0.031 in.) Axle runout/100 mm (3.94in.) TIR 0.05 mm (0.0020 in.) or less TIR 0.2 mm (0.008 in.) Wheel balance 10 g (0.35 US oz) or less - - - Balance we...

10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Brake Caliper Mounting Bolts [A] • Loosen: Right Side Axle Clamp Bolt [A]Axle [B] • Raise the front wheel off the ground. Special Tool - Jack: 57001–1238 • Pull out the axle to the right and drop the front wheel outof the forks. CAUTION D...

WHEELS/TIRES 10-7 Wheels (Rims) • Tighten the axle. Torque - Front Axle: 127 N·m (13 kgf·m, 94 ft·lb) • Before tightening the clamp bolt on the right front fork leg,pump the front fork up and down 4 or 5 times to allow theright front fork leg to seat on the front axle. NOTE ○ Put a block in front of...

10-8 WHEELS/TIRES Wheels (Rims) • Remove: Caliper Mounting Bolts [A]Caliper [B] • Remove the drive chain [A] from the rear sprocket towardthe left. • Move the rear wheel back and remove the wheel from therear caliper. • Remove the rear wheel. CAUTION Do not lay the wheel on the ground with the discf...

WHEELS/TIRES 10-9 Wheels (Rims) • Bend the cotter pin [A] over the nut [B]. WARNING If the rear axle nut is not securely tightened or thecotter pin is not installed, an unsafe riding condi-tion may result. • Adjust the drive chain slack after installation (see FinalDrive chapter). • Check the rear b...

10-10 WHEELS/TIRES Wheels (Rims) Axle Inspection • Visually inspect the front and rear axle for damages.If the axle is damaged or bent, replace it. • Place the axle in V blocks that are 100 mm (3.94 in.) [A]apart, and set a dial gauge [B] on the axle at a pointhalfway between the blocks. Turn [C] th...

WHEELS/TIRES 10-11 Wheels (Rims) (b) When the tire is on the rim. • Pry [A] the balance weight off the rim flange using a reg-ular tip screwdriver as shown in the figure. ○ Insert a tip of the screwdriver between the tire bead [B]and weight blade [C] until the end of the tip reaches theend of the we...

10-12 WHEELS/TIRES Wheels (Rims) • When required total weight exceeds 20 g (0.71 US oz), in-stall balance weight at both sides of rim flange as shown. Weight Selection: g (US oz) Required Total Weight: g (US oz) One Side [A] Other Side [B] 20 (0.71) 10 (0.35) 10 (0.35) 30 (1.06) 20 (0.71) 10 (0.35) ...

WHEELS/TIRES 10-13 Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection/Adjustment in the Pe-riodic Maintenance chapter. Tire Inspection • Refer to the Tire Inspection in the Periodic Maintenancechapter. Tire Removal • Remove: Wheel (see Front Wheel Removal, Rear Wheel Re-...

10-14 WHEELS/TIRES Tires • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal with a soapand water solution or rubber lubricant, and pull [B] thevalve stem [A] through the rim from the inside out until itsnaps into place. CAUTION Do not use engine oil or petroleum distil...

WHEELS/TIRES 10-15 Tires • Check to see that the rim lines [A] on both sides of the tiresidewalls 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 ...

10-16 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheel, and take out the following. CollarsCoupling (out of rear hub)Grease SealsCirclips • Use the bearing remover to remove the hub bearings [A]. CAUTION Do not lay the wheel on the ground with the discfacing down. This can damage or w...

11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the PeriodicMaintenance chapter. Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the PeriodicMaintenance chapter. Wheel Alignment Inspection/Adjustment • Refer to the ...

11-8 FINAL DRIVE Drive Chain • Set plate holder (A) [A] and plate holder (B) [B] on thebody. • Fit plate holder (A) to link plate. • Turn pin holder by hand until plate holder (B) touches theother link plate. • Turn pin holder by wrench clockwise until two pins of linkcome into groove of plate holde...

FINAL DRIVE 11-9 Drive Chain • Turn wrench clockwise until tip of riveting pin hits of linkpin. • Rivet it. • Some work for the other link pin. • After staking, check the staked area of the link pin forcracks. • Measure the outside diameter [A] of the link pin and linkplates outside width [B]. Link ...

11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove: Speed Sensor [A] ConnectorEngine Sprocket Cover Bolts [B]Engine Sprocket Cover [C] with Speed Sensor • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer. NOTE ○ When loosening the engine sprocket ...

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 discfacing down. This can damage or warp the disc.Place blocks under the wheel so that the disc doesnot touch the ground. • Remove the re...

11-12 FINAL DRIVE Sprocket, Coupling • Replace the grease seal with a new one. • Press in the grease seal so that the seal surface is flushwith the end of the hole. ○ Apply high temperature grease to the grease seal lips. Special Tool - Bearing Driver Set : 57001–1129 Coupling Installation • Grease ...

FINAL DRIVE 11-13 Sprocket, Coupling Sprocket Wear Inspection • Visually inspect the engine and rear sprocket teeth forwear and damage.If the teeth are worn as illustrated, replace the sprocket,and inspect the drive chain wear (see Drive Chain WearInspection). [A] Worn Tooth (Engine Sprocket)[B] Wor...

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 alignthe number with the arrow mark [B] on the lever holde...

BRAKES 12-9 Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end,and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach thecaliper [C] from the disc. CAUTION Do not loosen the caliper assembly bolts [D]. Takeout only the caliper mounting bolts ...

12-10 BRAKES Calipers Caliper Installation • Install the caliper and brake hose lower end. ○ Replace the washers on each side of hose fitting with newones. • Tighten: Torque - Caliper Mounting Bolts (Front): 25 N·m (2.5 kgf·m, 18 ft·lb) Caliper Mounting Bolts (Rear): 25 N·m (2.5 kgf·m, 18 ft·lb) Bra...

BRAKES 12-11 Calipers WARNING To avoid serious injury, never place your fingers orpalm in front of the piston. If you apply compressedair into the caliper, the piston may crush your handor fingers. ○ Pull out the pistons by hand. • Remove the dust seals [A] and fluid seals [B]. • Remove the bleed va...

12-12 BRAKES Calipers • Replace the fluid seals [A] with new ones. ○ Apply brake fluid to the fluid seals, and install them intothe cylinders by hand. • Replace the dust seals [B] with new ones if they are dam-aged. ○ Apply brake fluid to the dust seals, and install them intothe cylinders by hand. •...

BRAKES 12-13 Calipers Rear Caliper Assembly • Clean the caliper parts except for the pads. CAUTION For cleaning the parts, use only disc brake fluid,isopropyl alcohol, or ethyl alcohol. • Install the bleed valve and rubber cap. Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) • Replace the fluid...

12-14 BRAKES Calipers Caliper Piston and Cylinder Damage • Visually inspect the piston [A] and cylinder surfaces.Replace the caliper if the cylinder and piston are badlyscores or rusty. Front Caliper [B]Rear Caliper [C] Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper ho...

BRAKES 12-15 Brake Pads Front Brake Pad Removal • Remove: Mounting Bolts [A] • Remove: Pad Pin Bolt [A]Pad Spring [B]Brake Pads [C] Front Brake Pad Installation • Push the caliper pistons in by hand as far as they will go. • Apply silicone grease to the stopper ring [A]. • Install: Brake PadsPad Spr...

12-16 BRAKES Brake Pads Rear Brake Pad Installation • Push the caliper piston in by hand as far as it will go. • Install: Brake PadsPad PinClip • Install the caliper (see Caliper Installation). WARNING Do not attempt to drive the motorcycle until a fullbrake pedal is obtained by pumping the brake pe...

BRAKES 12-17 Master Cylinder Front Master Cylinder Removal • Disconnect the front brake light switch connectors [A]. • Remove the banjo bolt [B] to disconnect the brake hosefrom the master cylinder [C] (see Brake Hose Removal/In-stallation). • Remove the rear view mirror (see Steering chapter). • Un...

12-18 BRAKES Master Cylinder Rear Master Cylinder Removal • Unscrew the brake hose banjo bolt [A] on the master cylin-der (see Brake Hose Removal/Installation). • Pull off the reservoir hose lower end [B], and drain thebrake fluid into a container. • Loosen the master cylinder mounting bolts [C] lig...

BRAKES 12-19 Master Cylinder Rear Master Cylinder Disassembly NOTE ○ Do not remove the push rod clevis for master cylinderdisassembly since removal requires brake position ad-justment. • Remove the rear master cylinder (see Rear Master Cylin-der Removal). • Slide the dust cover on the push rod out o...

12-20 BRAKES Brake Disc Brake Disc Removal • Remove the wheel (see Wheels/Tires chapter). • Unscrew the mounting bolts, and take off the disc. Brake Disc Installation • Install the brake disc on the wheel so that the marked side[A] faces out. • Apply a non-permanent locking agent to the threads ofth...

BRAKES 12-21 Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level in the Periodic Maintenancechapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte-nance chapter. Brake Line Bleeding • Refer to the Brake Line Bleeding in the Periodic Mainte-nance ch...

12-22 BRAKES Brake Hose Brake Hose Removal/Installation CAUTION Brake fluid quickly ruins painted or plastic sur-faces; any spilled fluid should be completely wipedup immediately with wet cloth. • When removing the brake hose, take care not to spill thebrake fluid on the painted or plastic parts. • ...

SUSPENSION 13-1 13 Suspension Table of Contents Exploded View ........................................................................................................................ 13-2 Specifications ....................................................................................................

SUSPENSION 13-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Rear shock absorber nuts (upper and lower) 34 3.5 25 2 Swingarm pivot shaft nut 127 13 94 3 Swingarm pivot shaft locknut 98 10 72 4 Rocker arm nut 34 3.5 25 5 Tie-rod nuts 59 6.0 43 G: Apply or add grease.

13-8 SUSPENSION Front Fork Rebound Damping Force Adjustment (Only Right Fork Leg) • To adjust the rebound damping force, turn the rebounddamping adjuster [A] on top of the right front fork leg tothe desired position. ○ The standard adjuster setting for the average-build riderof 68 kg (150 lb) with n...

SUSPENSION 13-9 Front Fork Front Fork Removal (each fork leg) • Remove: Front Wheel (see Wheels/Tires chapter.)Front Fender (see Frame chapter.)Windshield and Bracket (see Frame chapter.)Inner Cover (see Frame chapter.)Fairing and Bracket (see Frame chapter.) Loosen the upper fork clamp bolts [A] an...

13-10 SUSPENSION Front Fork Fork Oil Change • Remove the front fork (see Front Fork Removal). ○ Turn the spring preload adjuster [A] counterclockwise untilthe fully position. • Unscrew the top plug [B] out of the inner tube. • Avoiding the pins [A], set the front fork spring compressorset [B] on the...

SUSPENSION 13-11 Front Fork • Drain the fork oil into a suitable container. • Remove the fork spring [A]. ○ Pump the piston rod [B] up and down at least ten times toexpel the oil from the fork. • Hold the fork tube upright, press the inner tube and thepiston rod all the way down. • Pour in the type ...

13-12 SUSPENSION Front Fork Oil Level (fully compressed, without spring) Standard: Right fork leg 62 ± 2 mm (2.44 ± 0.08 in.) Left fork leg 47 ± 2 mm (1.85 ± 0.08 in.)(from the top of the outer tube) NOTE ○ Fork oil level may also be measured using the fork oillevel gauge. Special Tool - Fork Oil Le...

SUSPENSION 13-13 Front Fork • Check the O-ring on the top plug and replace it with a newone if damaged. • For the right fork leg, check the distance [C] between thebottom end [A] of the top plug and rebound damping ad-juster [B] with a pair of vernier caliper. [C] 20 mm (0.79 in.) • Holding the top ...

13-14 SUSPENSION Front Fork ○ Holding the inner tube [A] by hand, pull the outer tube [B]several times to pull out the outer tube. • Remove the inner tube guide bushing [A], outer tubeguide bushing [B], washer [C], oil seal [D] from the innertube. Front Fork Assembly • Replace the following parts wi...

SUSPENSION 13-15 Front Fork • Install the cente ring plate on the cylinder unit. • Insert the cente ring plate and cylinder unit as a set intothe inner tube. Cylinder Unit [A] and Center Ring Plate [C] for Right ForkLegCylinder Unit [B] and Center Ring Plate [C] for Left ForkLeg • Hold the front for...

13-16 SUSPENSION Front Fork Spring Tension • Since a spring becomes shorter as it weakens, check itsfree length [A] to determine its condition.If the spring of either fork leg is shorter than the servicelimit, it must be replaced. If the length of a replacementspring and that of the remaining spring...

SUSPENSION 13-17 Rear Shock Absorber Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebounddamping adjuster [A] to the desired position. ○ The standard adjuster setting for an average-build riderof 68 kg (150 lb) with no passenger and no accessories3/4 turns out of ...

13-18 SUSPENSION Rear Shock Absorber Special Tools - Hook Wrench: 57001–1539 [A] Spring Adjustment Adjuster Damping Position Force Setting Load Road Speed 193.4 mm Weak Soft Light Good Low (7.61 in.) ↑ ↑ ↑ ↑ ↑ ↑ ↓ ↓ ↓ ↓ ↓ ↓ 183.4 mm Strong Hard Heavy Bad High (7.22 in.) Rear Shock Absorber Removal •...

SUSPENSION 13-19 Rear Shock Absorber • Remove the shock absorber [A] from upside. Rear Shock Absorber Installation • Tighten: Torque - Rear Shock Absorber Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear Shock Absorber Inspection • Remove the rear shock absorber. • Visually inspect the following items. Smoot...

13-20 SUSPENSION Swingarm Swingarm Removal • Remove the muffler bodies (see Engine Top End chapter.) • Raise the rear wheel off the ground with jack. Special Tool - Jack: 57001–1238 • Remove: Rear Wheel (see Wheels/Tires chapter.)Chain Cover (see Final Drive chapter.)Mud Guard (see Frame chapter.)Br...

SUSPENSION 13-21 Swingarm Swingarm Installation • Apply plenty of grease to the ball bearing, needle bearingsand grease seals, and add plenty of grease to the greasenipple. • Install the collars [A]. ○ Place the right collar [A] on the stopper [B] inside theframe [C]. • Insert the pivot shaft into t...

13-22 SUSPENSION Swingarm • Remove the ball bearing and needle bearings. Special Tool - Oil Seal and Bearing Remover: 57001–1058 [A] Swingarm Bearing Installation • Apply plenty of grease to the ball bearing and needlebearings. • Install the needle bearings so that the manufacturer’smarks face in. •...

SUSPENSION 13-23 Tie-Rod, Rocker Arm Tie-Rod Removal • Remove the muffler bodies (see Engine Top End chapter.) • Remove the side stand (see Frame chapter.) • Using the jack, raise the rear wheel off the ground. Special Tool - Jack: 57001–1238 • Squeeze the brake lever slowly and hold it with a band[...

STEERING 14-1 14 Steering Table of Contents Exploded View ........................................................................................................................ 14-2 Special Tools .........................................................................................................

14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Windshield and Bracket (see Frame chapter.)Inner Cover (see Frame chapter.)Fairing and Bracket (see Frame chapter.)Front Wheel (see Wheels/Tires chapter.)Handlebar (see Handlebar Removal.)Steering Stem Head Bolt PlugSteering Stem Head ...

STEERING 14-7 Steering Stem • To remove the bearing outer races [C] pressed into thehead pipe [B], insert a bar [A] into the recesses [D] of headpipe, and applying it to both recess alternately hammer itto drive the race out. NOTE ○ If either steering stem bearing is damaged, it is recom-mended that...

14-8 STEERING Steering Stem • Apply grease the lower ball bearing [A] and install it ontothe stem. • Apply grease to the upper ball bearing [B] and inner race[C]. • Install the stem [A] through the head pipe and install theball bearing [B] and inner race [C] on it. • Install the stem cap [D] and ste...

14-10 STEERING Handlebar Handlebar Removal • Remove: Clutch Lever Assembly [A]Left Handlebar Switch Housing [B]Front Brake Master Cylinder [C]Right Handlebar Switch Housing [D]Handlebar Holder Bolts [E] • Remove the handlebar holders [F] and then pull out thehandlebar [G]. • Remove the cotter pins [...

STEERING 14-11 Handlebar Rear View Mirrors Removal • Loosen the lower hexagonal area [A] for tightening to re-move the rear view mirror from the holder. CAUTION Do not force to tighten and/or loosen the upperhexagonal area (Adapter) [B] with a pair of span-ners. Disassembly of this area is Not Avail...

FRAME 15-1 15 Frame Table of Contents Exploded View ........................................................................................................................ 15-2 Seats .......................................................................................................................

FRAME 15-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Footpeg holder bolts 34 3.5 25 2 Muffler mounting nuts 29 3.0 22 3 Side stand bolt 44 4.5 33 4 Side stand switch bolt 8.8 0.9 78 in·lb G: Apply grease.

FRAME 15-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Windshield screws 0.35 ∼ 0.50 0.035 ∼ 0.050 3 ∼ 4 in·lb 2 Front fender bolts 3.9 0.4 34.7 in·lb L

FRAME 15-7 Seats Rear Seat Removal • Insert the ignition switch key into the seat lock [A], turningthe key counterclockwise, pulling up on the rear of theseat [B], and pulling the seat backward. WARNING The muffler surface is hot once the engine has beenstarted. When operating the seat lock be caref...

15-8 FRAME Side Covers Side Cover Removal • Remove the bolt [A]. • Pull the side cover [B] evenly outward to clear the stop-pers. Side Cover Installation • Insert the tabs [A] into the holes [B]. • Install the bolt.

FRAME 15-9 Fairings Windshield Removal • Remove: Bolts [A]Windshield [B] Windshield Installation • Windshield Installation is the reverse of removal. Torque - Windshield Screw: 0.35 ∼ 0.50 N·m (0.035 ∼ 0.050 kgf·m, 3 ∼ 4 in·lb) Inner Cover Removal • Remove: Inner Cover Screws [A] (both side)Inner Co...

15-10 FRAME Fairings • Remove: Fairing Mounting Bolts [A] (both side)Headlight Connectors Fairing Installation • Fairing installation is the reverse of removal. Faring Bracket Removal • Remove: Fairing (see Fairing Removal)Turn Signal Lights (see Electrical System chapter)Meter Unit [A] (see Electri...

FRAME 15-11 Seat Covers Seat Cover Removal • Remove: SeatsScrews [A] • Push the central pin, and then remove the quick rivets [A]. • Pull the front portions [A] of the seat cover outside [B],and then remove the seat cover backward. Seat Cover Installation • Installation is reverse of removal. • Put ...

15-12 FRAME Mud Guard Mud Guard Removal • Remove: Chain Cover (see Final Drive chapter)Bolt [A]Clamp [B] • Lift up the mud guard [A], and then pull it out backward. Mud Guard Installation • Put the projections [A] into the grommets [B].

FRAME 15-13 Fenders Front Fender Removal • Remove: Brake Hose Clamps [A]Bolts [B] (both side) • Remove the front fender [C]. Front Fender Installation • Install the brake hose clamps to the front fender holes. Rear Fender Rear Removal • Remove: SeatsSeat CoverCanister (California model only)Diodes [...

15-14 FRAME Fenders • Remove: Quick Rivets [A]Rear Fender Rear [B] Rear Fender Rear Installation • Put the projection [A] into the hole [B]. • Put the projections [A] into the holes [B]. • Installation is reverse of removal.

FRAME 15-15 Frame Cover Frame Cover Removal • Remove: Bolts [A]Frame Cover [B] (both side)

15-16 FRAME Battery Case Battery Case Removal • Remove: SeatsSeat CoverRear Fender AssySide CoversBatteryLeft Side Screw [A] (with reserver tank) • Pull out the battery case [B] backward [C]. Battery Case Installation • Put the battery case attachments [A] at the projections [B]on the frame.

FRAME 15-17 Side Stand Side Stand Removal • Raise the rear wheel off the ground with the stand. • Remove: Muffler (both side)Exhaust pipeSide Stand Switch Bolt [A]Side Stand Switch [B]Spring [C] Side Stand Nut [D]Side Stand Bolt [E]Side Stand [F] Side Stand Installation • Apply grease to the sliding...

15-18 FRAME Frame Frame Inspection • Visually inspect the frame for cracks, dents, bending, orwarp. ○ If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causingan accident. If the frame is bent, dented, cracked,or warped, replace it.

ELECTRICAL SYSTEM 16-1 16 Electrical System Table of Contents Parts Location.................................... 16-3 Exploded View ................................... 16-4 Specifications .................................... 16-10 Special Tools and Sealant ................. 16-11 Wiring Diagram (U.S...

16-2 ELECTRICAL SYSTEM Fan Motor Inspection ................... 16-63 Meter, Gauge, Indicator Unit.............. 16-65 Meter Unit Removal ..................... 16-65 Meter, Gauge Disassembly .......... 16-65 Electronic Combination Meter Unit Inspection .......................... 16-66 Switches and S...

ELECTRICAL SYSTEM 16-3 Parts Location [A] Starter Lockout Switch[B] Camshaft Position Sensor[C] Radiator Fan Switch[D] Starter Motor[E] Alternator[F] Speed Sensor[G] Neutral Switch[H] Side Stand Switch [I] Water Temperature Sensor[J] Battery[K] Junction Box[L] Front Brake Light Switch[M] Stick Coils...

ELECTRICAL SYSTEM 16-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Meter mounting screws 1.2 0.12 11 in·lb 2 Tail/brake light mounting screws 1.2 0.12 11 in·lb 3 License plate light mounting screws 1.2 0.12 11 in·lb 4 Front brake light switch screw 1.2 0.12 11 in·lb 5 Starter locknut...

ELECTRICAL SYSTEM 16-7 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Water temperature sensor 25 2.5 18 SS 2 Spark plugs 13 1.3 115 in·lb 3 Alternator lead holding plate bolts 11 1.1 95 in·lb L 4 Starter motor mounting bolts 11 1.1 95 in·lb 5 Stator motor coil bolts 11 1.1 95 in·lb 6 A...

ELECTRICAL SYSTEM 16-9 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Regulator/rectifier bolts 6.9 0.7 62 in·lb 2 Fuel level sensor bolts 6.9 0.7 62 in·lb 3 Side stand switch bolt 8.8 0.9 78 in·lb 4 Neutral switch 15 1.5 11 5 Speed sensor bolt 6.9 0.7 62 in·lb L 6 Speed sensor cover bo...

16-20 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob-serve all the rules below. ○ Do not reverse the battery lead connections. This willburn out the diodes on the electrical parts. ○ Always check battery condit...

16-22 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying,etc.If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion,dirt, and damage.If the connector is corroded or dirty, clean it...

ELECTRICAL SYSTEM 16-23 Battery Battery Removal CAUTION Do not disconnect the battery cables or any otherelectrical connections when the ignition switch isON, as this could damage the ECU (Electronic Con-trol Unit).Never reverse the connections of the battery, thiscould damage the ECU. • Remove: Sea...

ELECTRICAL SYSTEM 16-25 Battery • Fit the seal caps [A] tightly into the filler ports until the sealcaps 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 bat-tery, never remove it, nor...

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 sealingplug to add water is very dangerous. Never do that. 2) Refreshing charge If an engine will not start, a horn sounds ...

ELECTRICAL SYSTEM 16-27 Battery Interchange The sealed battery can fully display its performance only when combined with a proper vehicle electric system.Therefore, replace the sealed battery only on a motorcyclewhich was originally equipped with the sealed battery. Be careful, if a sealed battery i...

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 chargeis done due to unavoidable circumstances, do stan-dar...

ELECTRICAL SYSTEM 16-29 Charging System Alternator Cover Removal • Remove: Frame Cover Bolts [A]Left Frame Cover [B] Clamp (open) [A]Alternator Lead Connector [B] ○ For California model, remove the separator. • Place a suitable container under the alternator cover [A],and remove the cover bolts [B]....

16-30 ELECTRICAL SYSTEM Charging System Stator Coil Installation • Apply a non-permanent locking agent to the stator coilbolts and tighten it. Torque - Stator Coil Bolts: 11 N·m (1.1 kgf·m, 95 in·lb) • Secure the alternator lead with a holding plate, andtighten the bolt. ○ Apply a non-permanent lock...

ELECTRICAL SYSTEM 16-31 Charging System • Install the starter gear [A]. • Again, clean the crankshaft tapered portion [B] and drythere. • Fit the woodruff key [C] securely in the slot in the crank-shaft before installing the alternator rotor. • Install the alternator rotor [A] while turning [B] the ...

16-32 ELECTRICAL SYSTEM Charging System • Apply a thin coat of molybdenum disulfide grease to theshaft [A], and install it and starter idle gear [B]. • Install the alternator cover (see Alternator Cover Installa-tion). Alternator Inspection There are three types of alternator failures: short, open (...

ELECTRICAL SYSTEM 16-33 Charging System If there is more resistance than shown in the table, or nohand tester reading (infinity) for any two leads, the statorhas an open lead and must be replaced. Much less thanthis resistance means the stator is shorted, and must bereplaced. • Using the highest res...

16-34 ELECTRICAL SYSTEM Charging System • Do the 1st step regulator circuit test: ○ Connect the test light and the 12 V battery to the regula-tor/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 tes...

ELECTRICAL SYSTEM 16-35 Charging System Charging Voltage Inspection • Check the battery condition (see Battery section). • Warm up the engine to obtain actual alternator operatingconditions. • Remove the seats (see Frame chapter). • Check that the ignition switch is turned off, and connectthe hand t...

16-36 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch2. To Starter Circuit Relay3. Alternator 4. Regulator/Rectifier5. Joint Connector C6. Battery 12 V 8 Ah 7. Main Fuse 30A8. Load

ELECTRICAL SYSTEM 16-37 Ignition System WARNING The ignition system produces extremely high volt-age. Do not touch the spark plugs or stick coilswhile the engine is running, or you could receivea severe electrical shock. CAUTION Do not disconnect the battery cables or any otherelectrical connections...

16-38 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Installation • Route the crankshaft sensor lead correctly (see Cable,Wire, and Hose Routing in Appendix chapter). • Tighten: Torque - Crankshaft Sensor Bolts: 5.9 N·m (0.6 kgf·m, 53 in·lb) • Apply silicone sealant [A] to the crankshaft sensor...

ELECTRICAL SYSTEM 16-39 Ignition System Crankshaft Sensor Resistance: 375 ∼ 565 Ω • Using the highest resistance range of the tester, measurethe resistance between the crankshaft sensor leads andchassis ground.Any tester reading less than infinity ( ∞ ) indicates a short, necessitating replacement o...

16-40 ELECTRICAL SYSTEM Ignition System Camshaft Position Sensor Removal • Remove: Fuel Tank (see Fuel System (DFI) chapter)Camshaft Position Sensor Lead Connector [A] (discon-nect) ○ Push the tongue [B] upside and take out the connectorfrom the bracket. • Remove: Camshaft Position Sensor Bolt [A]Ca...

ELECTRICAL SYSTEM 16-41 Ignition System Camshaft Position Sensor Peak Voltage Inspection • Remove: Fuel Tank (see Fuel System (DFI) chapter)Camshaft Position Sensor Lead Connector [A] (discon-nect) • Set the hand tester [B] to the 10 V DC range. • Connect the peak voltage adapter [C] to the hand tes...

16-42 ELECTRICAL SYSTEM Ignition System • Remove the stick coil harness [A] from the bracket. • Remove: Stick Coil Connector #4 [B] (disconnect)Stick Coil #4 [C]Stick Coil Connector #3 [D] (disconnect) • Disconnect: Water Temperature Sensor Connector [A]Left Switch Housing Connector [B] • Pull the m...

ELECTRICAL SYSTEM 16-43 Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection • Remove the stick coils (see this chapter). • Measure the primary winding resistance [A] as follows. ○ Connect the hand tester between the coil terminals. ○ Set the tester to the × 1 Ω range, ...

16-44 ELECTRICAL SYSTEM Ignition System WARNING To avoid extremely high voltage shocks, do nottouch the spark plugs or tester connections. • Turn the ignition switch and the engine stop switch ON. • Pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measure...

ELECTRICAL SYSTEM 16-45 Ignition System Interlock Operation Inspection • Remove: Seats (see Frame chapter)Junction Box (see this chapter) ○ Do not disconnect the connectors. 1st Check • Measure the terminal voltage of the G/BK lead in the junc-tion box connector [A] in accordance with the followingp...

16-46 ELECTRICAL SYSTEM Ignition System IC Igniter Inspection ○ The IC Igniter is built in the ECU [A]. • Refer to the Interlock Operation Inspection, IgnitionSystem Troubleshooting Chapter and Fuel System (DFI)chapter for ECU Inspection.

16-48 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Ignition Switch2. Engine Stop Switch3. Starter Button4. Spark Plugs5. Stick Coils6. Side Stand Switch7. Crankshaft Sensor8. Camshaft Position Sen- sor 9. Throttle Sensor 10. Neutral Switch 11. Junction Box 12. Ignition Fuse 10A13. St...

ELECTRICAL SYSTEM 16-49 Electric Starter System Starter Motor Removal CAUTION Do not tap the starter motor shaft or body. Tappingthe shaft or body could damage the motor. • Remove the mounting bolts [A]. • Pull out the starter motor [B]. • Slide back the rubber cap [A]. • Remove the starter motor te...

16-50 ELECTRICAL SYSTEM Electric Starter System ○ The brush plate [A] and brushes come off with theright–hand end cover [B]. • Remove the terminal locknut [A] and terminal bolt [B], andthen remove the brush with the brush plate [C] from theright–hand end cover. Starter Motor Assembly • Install the b...

ELECTRICAL SYSTEM 16-51 Electric Starter System • Align the line [A] marked on the yoke with the through bolthole [B]. Brush Inspection • Measure the length [A] of each brush.If any is worn down to the service limit, replace the carbonbrush holder assembly [B] and the terminal bolt assembly[C]. Star...

16-52 ELECTRICAL SYSTEM Electric Starter System NOTE ○ Even if the foregoing checks show the armature to begood, it may be defective in some manner not readilydetectable with the hand tester. If all other starter motorand starter motor circuit components check good, butthe starter motor still does n...

ELECTRICAL SYSTEM 16-53 Electric Starter System • Connect the hand tester [A] and 12 V battery [B] to thestarter relay [C] as shown. Special Tool - Hand Tester: 57001–1394 If the relay does not work as specified, the relay is defec-tive. Replace the relay. Testing Relay Tester Range: × 1 Ω range Cri...

16-54 ELECTRICAL SYSTEM Lighting System This models adopt the daylight system and have a head- light relay in the junction box. In these models, the head-light does not go on when the ignition switch and the enginestop switch are first turned on. The headlight comes on afterthe starter button is rel...

ELECTRICAL SYSTEM 16-55 Lighting System Headlight Bulb Replacement • Remove: Headlight Connector [A]Headlight Bulb Dust Cover [B] • Remove: Hook [A]Headlight Bulb [B] CAUTION When handling the quartz–halogen bulb, nevertouch the glass portion with bare hands. Alwaysuse a clean cloth. Oil contaminati...

16-56 ELECTRICAL SYSTEM Lighting System • Fit the dust cover [A] with the arrow mark upward onto thebulb [B] firmly as shown. Good [C]Bad [D]Arrow Mark [E] • After installation, adjust the headlight aim (see this chap-ter). Headlight Removal/Installation • Remove: Fairing (see Frame chapter) • Disco...

ELECTRICAL SYSTEM 16-57 Lighting System • Pull the bulb [A] out of the socket [B]. CAUTION Do not turn the bulb. Pull the bulb out to preventdamage to the bulb. Do not use bulb rated forgreater wattage then the specified valve. • Replace the bulb with a new one.

16-58 ELECTRICAL SYSTEM Lighting System Headlight/Tail Light Circuit (US, CA, AS) Headlight/Tail Light Circuit (Other than US, CA, AS) US: United States of AmericaCA: Canada AS: Australia 1. Ignition Switch2. Meter Ground3. Alternator4. Headlight Diodes5. Taillight Fuse 10A6. Headlight Fuse 10A 7. J...

ELECTRICAL SYSTEM 16-59 Lighting System Turn Signal Light Circuit US: U.S.A. modelCA: Canada model MY: Malaysia model 1. Joint Connector D2. Meter Unit3. Right Turn Signal Indicator Light (LED)4. Left Turn Signal Indicator Light (LED)5. Front Right Turn Signal Light6. Front Left Turn Signal Light7. ...

16-60 ELECTRICAL SYSTEM Lighting System • Push and turn the bulb [A] counterclockwise and removeit. • Insert the new bulb [A] by aligning its upper and lower pins[B] with the upper and lower grooves [C] in the socket, andturn the bulb clockwise. ○ Turn the bulb about 15° degrees. For the U.S.A. and ...

ELECTRICAL SYSTEM 16-61 Lighting System • Insert the new bulb [A] by aligning its upper and lower pins[B] with the upper and lower grooves [C] in the socket, andturn the bulb clockwise. CAUTION The front turn signal/running position lights usea vibration resistant bulb. Replacement of the front turn...

16-62 ELECTRICAL SYSTEM Lighting System • Unscrew the bolts [A]. • Loosen the bolts [B]. • Unscrew the mounting screws [A]. • Remove the tail/brake light (LED) [B]. ○ Pull out the mount portion [C]. Tail/Brake Light (LED) Installation • Tighten the tail/brake light mounting screws. Torque - Tail/Bra...

ELECTRICAL SYSTEM 16-63 Radiator Fan System Fan System Circuit Inspection • Disconnect the lead connector [A] from the radiator fanswitch. • Using an auxiliary wire [A], connect the radiator fan switchleads.If the fan rotates, inspect the fan switch.If the fan does not rotate, inspect the following....

16-64 ELECTRICAL SYSTEM Radiator Fan System Radiator Fan Circuit 1. Radiator Fan2. Radiator Fan Switch3. Joint Connector A4. Joint Connector D 5. Meter Ground6. Frame Ground7. Joint Connector B8. Junction Box 9. Fan Fuse 10A 10. Main Fuse 30A 11. Battery 12 V 8 Ah

ELECTRICAL SYSTEM 16-65 Meter, Gauge, Indicator Unit Meter Unit Removal • Remove: Wind Sealed (see Frame chapter) • Slide the dust cover [A] and remove the wiring connector[B]. • Remove the meter unit by taking off the mounting screws[C] with the washers. CAUTION Place the meter or gauge so that the...

16-66 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Electronic Combination Meter Unit Inspection • Remove the meter unit [A]. [1] Ignition [10] Battery (+) [2] Fuel Reserve Switch [11] Oil Pressure Warning [3] Unused Indicator Light (LED) [4] Fuel Level Sensor Ground (–) [5] Neutral Indicator Light...

ELECTRICAL SYSTEM 16-67 Meter, Gauge, Indicator Unit MODE AND RESET BUTTON Operation Check: • Connect the 12 V battery and terminals in the same man-ner as specified in the "Liquid Crystal Display (LCD) Seg-ments Check". • Check that the display change to the ODO, TRIP, andCLOCK displays eac...

ELECTRICAL SYSTEM 16-69 Meter, Gauge, Indicator Unit • If the oscillator is not available, the speedometer can bechecked 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 speed...

16-70 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Water Temperature Meter Check: • Connect the 12 V battery and terminals in the same man-ner as specified in the "Liquid Crystal Display (LCD) Seg-ments Check". • Connect the variable rheostat [A] to the terminal [8] asshown. • Check that t...

ELECTRICAL SYSTEM 16-71 Meter, Gauge, Indicator Unit Fuel Level Gauge Inspection: • Connect the 12 V battery and terminals in the same man-ner as specified in the “Liquid Crystal Display (LCD) Seg-ments Check”. • Connect a variable rheostat [A] to terminal [4] and [9] asshown. • Check that the numbe...

16-72 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • If the oscillator is not available, the tachometer can bechecked as follows. ○ Connect the 12 V battery and terminals in the same man-ner as specified in the "Liquid Crystal Display (LCD) Seg-ments Check". ○ Using an auxiliary wire, quic...

ELECTRICAL SYSTEM 16-73 Meter, Gauge, Indicator Unit Right and Left Turn Signal Indicator Light (LED): For Right Turn Signal Indicator Light (LED)Battery Positive (+) Terminal to Terminal [13] For Left Turn Signal Indicator Light (LED)Battery Positive (+) Terminal to Terminal [14] High Beam Indicato...

16-74 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Circuit 1. Right Turn Signal Indicator Light (LED)2. High Beam Indicator Light (LED)3. Neutral Indicator Light (LED)4. Oil Pressure Warning Indicator Light (LED)5. FI Indicator Light (LED)6. Odometer/Trip Meter/Clock/Fuel Indicator7. Water T...

ELECTRICAL SYSTEM 16-75 Switches and Sensors Brake Light Timing Inspection • Refer to the Brakes in the Periodic Maintenance chapter. Brake Light Timing Adjustment • Refer to the Brakes in the Periodic Maintenance chapter. Switch Inspection • Using a hand tester, check to see that only the con-necti...

16-76 ELECTRICAL SYSTEM Switches and Sensors • Disconnect the connector [A]. • Remove the fan switch [B]. • Suspend the switch [A] in a container of coolant so thatthe temperature–sensing projection and threaded portionare submerged. • Suspend an accurate thermometer [B] in the coolant sothat the se...

ELECTRICAL SYSTEM 16-77 Switches and Sensors • Suspend the sensor [A] in a container of coolant so thatthe temperature-sensing projection [E] and threaded por-tion [E] are submerged. • Suspend an accurate thermometer [B] in the coolant. NOTE ○ The sensor and thermometer must not touch the con-tainer...

16-78 ELECTRICAL SYSTEM Switches and Sensors • Remove: Bolts [A]Speed Sensor Cover • Remove: Bolt [A] • Take out the speed sensor [B]. • Connect the speed sensor connector [A] with the battery[B], 10 k Ω resistor [C] and hand tester [D] as shown. • Set the tester to the DC 25 V range. Special Tool -...

ELECTRICAL SYSTEM 16-79 Switches and Sensors Fuel Level Sensor Inspection • Remove: Fuel Tank (see Fuel System (DFI) chapter) • Open the clamps [A]. • Remove: Bolts [B]Fuel Level Sensor [C] • Check that the float moves up and down smoothly withoutbinding. It should go down under its own weight.If th...

16-80 ELECTRICAL SYSTEM Switches and Sensors • Connect the test light [A] (12 V 3.4 W bulb a socket withleads) and the 12 V battery [B] to the fuel level sensorconnector [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 Le...

ELECTRICAL SYSTEM 16-81 Junction Box The junction box [A] has fuses [B], relays, and diodes. The relays and diodes can not be removed. Junction Box Fuse Circuit Inspection • Remove the seats (see Frame chapter). • Remove the junction box [A]. • Pull off the connectors [A] from the junction box [B]. ...

16-82 ELECTRICAL SYSTEM Junction Box Starter Circuit/Headlight Relay Inspection • Remove the junction box (see Junction Box Fuse CircuitInspection). • Check conductivity of the following numbered terminalsby connecting the hand tester and one 12 V battery to thejunction box as shown. ○ Refer to the ...

ELECTRICAL SYSTEM 16-83 Junction Box Diode Circuit Inspection • Remove the junction box. • 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 morethan ten times as...

16-84 ELECTRICAL SYSTEM Fuse 30A Main Fuse Removal • Remove: Right Side Cover (see Frame chapter)30A Main Fuse Connector [A] • Pull out the main fuse [B] from the starter relay with needlenose pliers. Junction Box Fuse Removal • Remove the seats (see Frame chapter). • Unlock the hook to lift up the ...

APPENDIX 17-1 17 Appendix Table of Contents Cable, Wire, and Hose Routing .............................................................................................. 17-2 Troubleshooting Guide ...........................................................................................................

APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Fixes by the left side clamp of the tank.2. Tank drain hose passes the side cover installation under the bracket.3. Air cleaner drain hose4. Fuel tank drain hose5. Cooling reserve tank hose6. Fixes by the swingarm clamp7. Fuel level sensor8. Fixes by th...

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 connector4. Meter ground (with thermostat)5. Engine harness (Connect the harness on the cross pipe.)6. Water temperature sens...

17-20 APPENDIX Troubleshooting Guide NOTE ○ Refer to the Fuel System chapter for mostof DFI trouble shooting guide. ○ This is not an exhaustive list, giving everypossible cause for each problem listed. Itis meant simply as a rough guide to assistthe troubleshooting for some of the morecommon difficu...

APPENDIX 17-21 Troubleshooting Guide Air cleaner duct loose Compression low: Spark plug looseCylinder head not sufficiently tightened down No valve clearanceCylinder, piston wornPiston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessiveCylinder head warpedCylinder head ...

17-22 APPENDIX Troubleshooting Guide Muffler overheating: For KLEEN, do not run the engine even if with only one cylinder misfiring or poorrunning (Request the nearest service fa-cility to correct it) For KLEEN, do not push-start with a dead battery (Connect another full-chargedbattery with jumper c...

APPENDIX 17-23 Troubleshooting Guide Abnormal Engine Noise: Knocking: IC igniter in ECU troubleCarbon built up in combustion chamberFuel poor quality or incorrectSpark plug incorrectOverheating Piston slap: Cylinder/piston clearance excessiveCylinder, piston wornConnecting rod bentPiston pin, piston...

17-24 APPENDIX Troubleshooting Guide Handling and/or Stability Unsatisfactory: Handlebar hard to turn: Cable routing incorrectHose routing incorrectWiring routing incorrectSteering stem nut too tightSteering stem bearing damagedSteering stem bearing lubrication inade- quate Steering stem bentTire ai...

MODEL APPLICATION Year Model Beginning Frame No. 2003 ZR1000–A1 JKAZRCA1 □ 3A000001 ZRT00A–000001JKAZRT00AAA000001 2004 ZR1000–A2 JKAZRCA1 □ 4A015001 JKAZRT00AAA015001ZRT00A–015001 □ :This digit in the frame number changes from one machine to another. Part No.99924-1310-03 Printed in Japan