Kawasaki Z750 - Manual

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 ZR750–J1 Left Side View: ZR750–J1 Right Side View:

1-8 GENERAL INFORMATION General Specifications Items ZR750–J1 Dimensions: Overall length 2 080 mm (81.9 in.) Overall width 780 mm (30.7 in.) Overall height 1 055 mm (41.5 in.) Wheelbase 1 425 mm (56.1 in.) Road clearance 165 mm (6.5 in.) Seat height 815 mm (32.1 in.) Dry mass 195 kg (430.0 lb) Curb ...

GENERAL INFORMATION 1-9 General Specifications Items ZR750–J1 Viscosity SAE 10W-40 Capacity 3.8 L (4.0 US qt) Drive Train: Primary reduction system: Type Gear Reduction ratio 1.714 (84/49) Clutch type Wet multi disc Transmission: Type 6-speed, constant mesh, return shift Gear ratios: 1st 2.571 (36/1...

1-10 GENERAL INFORMATION Technical Information – Air Inlet System Subthrottle Control System The ZR750–J1 employs large bore throttle bodies to increase power output. However, sudden changes in throttle opening can cause hesitation and jerky throttle response with a single butterflyvalve in a large ...

GENERAL INFORMATION 1-11 Technical Information – Air Inlet System Operation The subthrottle control system consists of the subthrottle valve, subthrottle valve actuator with a stepping motor built in it, ECU, and subthrottle sensor. The subthrottle valve is built in the each throttlebody. The subthr...

1-12 GENERAL INFORMATION Technical Information – New Ignition Interlock Sidestand Outline The New Ignition Interlock Sidestand System applied to ZR750–J1 models that cannot function if gears are engaged and/or the sidestand is not lifted upward even though clutch lever pulled in, whichdiffers from t...

GENERAL INFORMATION 1-13 Technical Information – Tail/Brake Lights Employing LED Outline This model employs a tail/brake light containing 21 Light Emitting Diodes (LED). The LED emits luminous beams over a longer life span than those emitted from a traditional electric heated bulb(more than 5 times ...

1-14 GENERAL INFORMATION 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...

GENERAL INFORMATION 1-15 Technical Information – KAWASAKI LOW EXHAUST EMISSION SYSTEM Since the emission regulations become more severe, Kawasaki has adopted a type of simplified KAWASAKI LOW EXHAUST EMISSION SYSTEM (KLEEN), which have no catalyst protection sys-tem, according to each regulation of ...

1-16 GENERAL INFORMATION 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 ................. 2-5 Specifications .................................... 2-10 Special Tools ..................................... 2-12 Periodic Maintenance Proced...

2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. Periodic Inspection: FREQUENCY Whichever comes first * OD...

PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever comes first * ODOMETER READING km × 1000 (mile × 1000) 1 6 12 18 24 30 36 See INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) Page Engine stop switch operation year • • • — Fuel system (DFI): Air cleaner element - clean # •...

2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart Periodic Replacement Parts: FREQUENCY Whichever comes first * ODOMETER READING km × 1000 (mile × 1000) 1 12 24 36 48 See CHANGE/REPLACE ITEM Every (0.6) (7.5) (15) (24) (30) Page Brake hoses 4 years • 2–36 Brake fluid (front and rear) 2 years • • 2...

PERIODIC MAINTENANCE 2-5 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: AL: Tighten the two clamp bolts alternatelytwo times to ensure even ti...

2-6 PERIODIC MAINTENANCE 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 Thermostat housing ground bolt 7.0 0.70 61 in·lb Thermostat bracket bolt 7.0 0.70 61 in·lb Radiator upper bolts 7.0 0.70 61 in·lb Radiator ...

PERIODIC MAINTENANCE 2-7 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 oil drain bolt 20 2.0 14 Oil filter 31 3.2 23 EO, R Holder mounting bolt 76 7.8 56 EO Oil pan bolts 11 1.1 95 in·lb Oil pipe holder bolts 13 1.3 113 ...

2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Tie-rod locknuts 6.9 0.70 61 in·lb Neutral switch 15 1.5 11 Wheels/Tires: Front axle clamp bolt 34 3.5 25 Front axle 108 11 80 Rear axle nut 108 11 80 Final Drive: Engine sprocket nut 125 13 92 MO Engine sprock...

PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Handlebar lower clamp nuts 34 3.5 25 Switch housing screws 3.5 0.36 31 in·lb Front fork clamp bolts (Upper) 20 2.0 14 Front fork clamp bolts (Lower) 20 2.0 14 AL Frame: Footpeg bracket bolts 34 3.5 25 L Side st...

2-10 PERIODIC MAINTENANCE 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 29.7 ±1.333 kPa (225 ±10 mmHg) – – – Air cleaner eleme...

PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Air pressure: (when cold) Front Up to 180 kg (397 lb) load: 250 kPa (2.5 kgf/cm², 36 psi) – – – Rear Up to 180 kg (397 lb) load: 290 kPa (2.9 kgf/cm², 42 psi) – – – Final Drive: Drive chain slack 25 ∼ 35 mm (1.0 ∼ 1.4 in.) – – – Dr...

2-12 PERIODIC MAINTENANCE 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):92110–1146

PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Fuel System (DFI) Fuel Hose and Connection Inspection ○ The fuel hoses are designed to be used throughout themotorcycle’s life without any maintenance, however, if themotorcycle is not properly handled, the high pressure in-side the fuel line...

2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Throttle Control System Inspection Throttle Grip Play Inspection • Check the throttle grip free play [A].If the free play is incorrect, adjust the throttle cable. Throttle Grip Free Play Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) • Check that the t...

PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Idle Speed Inspection • Start the engine and warm it up thoroughly. • With the engine idling, turn the handlebar to both sides.If handlebar movement changes the idle speed, thethrottle cables may be improperly adjusted or incorrectlyrouted or...

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 • Remove the fuel tank (see Fuel System (DFI) chapter). • Remove the fuel tank bracket bolts and bracket [A]. • Remove: Air Cleaner Duct Holder Screws [A] • Remove the air cleaner duct holder [B] backward. • Clean the element by tapping it li...

2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cooling System Radiator Hose and Connection Inspection ○ The high pressure inside the radiator hose can causecoolant to leak [A] or the hose to burst if the line is notproperly maintained. Visually inspect the hoses for signsof deterioration....

PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • When filling the coolant, choose a suitable mixture ratioby referring to the coolant manufacturer’s directions. CAUTION Soft or distilled water must be used with the an-tifreeze in the cooling system.If hard water is used in the system, it ...

2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Top End Air Suction Valve Inspection • Remove the air suction valve (see Engine Top End chap-ter). • Visually inspect the reeds for cracks, folds, warps, heatdamage or other damage.If there is any doubt as to the condition of the reeds...

PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures ○ When positioning #4 piston TDC at the end of thecompression stroke: Inlet valve clearance of #2 and #4 cylindersExhaust valve clearance of #3 and #4 cylindersMeasuring Valve [A] ○ When positioning #1 piston TDC at the end of thecompression ...

2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Slide the dust cover [A] at the clutch cable lower end outof place. • Loosen both adjusting nuts [B] at the clutch cover as faras they will go. • Pull the clutch outer cable [C] tight and tighten the adjust-ing nuts against the cover [D]. •...

PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures NOTE ○ Although 10W-40 engine oil is the recommended oilfor most conditions, the oil viscosity may need to bechanged to accommodate atmospheric conditions inyour riding area. Oil Filter Change • Drain the engine oil (see Engine Oil Change). •...

2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tread Depth Front: Standard: 3.4 mm (0.13 in.) Service Limit: 1 mm (0.04 in.) 1.6 mm (0.06 in.) (AT, CH, DE) Rear: Standard: 5.8 mm (0.23 in.) Service Limit: 2 mm (0.08 in.) (Up to 130 km/h (80 mph)) 3 mm (0.12 in.) (Over 130 km/h (80 mph)) W...

PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Final Drive Drive Chain Slack Inspection NOTE ○ Check the slack with the motorcycle setting on its sidestand. ○ Clean the chain if it is dirty, and lubricate it if it appearsdry. • Check the wheel alignment (see Wheel Alignment Inspec-tion). ...

2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Bend the cotter pin [A] over the nut. WARNING If the rear axle nut is not securely tightened or thecotter pin is not installed, an unsafe riding condi-tion may result. Drive Chain Wear Inspection • Remove: Chain Cover Screws [A]Chain Cover ...

PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Drive Chain Lubrication • If a special lubricant is not available, a heavy oil such asSAE 90 is preferred to a lighter oil because it will stay onthe chain longer and provide better lubrication. • If the chain appears especially dirty, clean ...

2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures If it does not, adjust and inspect the brake light switch. • While holding the switch body, turn the adjusting nut [A]to adjust the switch. CAUTION To avoid damaging the electrical connections in-side the switch, be sure that the switch body ...

PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Master Cylinder Inspection (Visual Inspection) • Remove the master cylinders (see Brakes chapter). • Disassemble the front and rear master cylinders. • Check that there are no scratches, rust or pitting on theinner wall [A] of each master cyl...

2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid 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 leve...

PERIODIC MAINTENANCE 2-33 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...

2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedalis transmitted directly to the caliper for braking action. Air,however, is easily compressed. When air enter...

PERIODIC MAINTENANCE 2-35 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] ...

2-36 PERIODIC MAINTENANCE 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...

PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Suspension Front Fork Oil Leak Check • Visually inspect the front forks [A] for oil leakage, scoringor scratches on the inner surface of the inner tubes.Replace or repair any defective parts, if necessary. Rear Shock Absorber Oil Leak Check •...

2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Bend the claw washer tabs [A]. • Remove the steering stem locknut [B] and claw washer[C]. • 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 tu...

PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Electrical System Spark Plug Inspection • Remove: Fuel Tank (see Fuel System (DFI) chapter) • Unscrew the thermostat bracket bolt [A]. • Disconnect: Water Temperature Sensor Connector [B]Left Switch Housing Connector [C] ○ If removing the spa...

2-40 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 suitable tool.If the spark plug center electrode [A] ...

PERIODIC MAINTENANCE 2-41 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...

2-42 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...

3-8 FUEL SYSTEM (DFI) DFI Parts Location DFI: DFI Parts (this chapter) 1. Water temperature Sen- sor (DFI) 2. Inlet Air Pressure Sensor (DFI) 3. Injectors (DFI)4. Fuel Pump (DFI)5. Inlet Air Temperature Sensor (DFI) 6. Sealed Battery7. Junction Box8. ECU Fuse 15 A9. ECU (DFI) 10. Stick Coils 11. Thr...

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

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 seals [B] from behind the connectoruntil the adapter reaches the terminal. Special Tool - Needle Adap...

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 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 ...

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 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 ma...

3-26 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) Cylinder, piston worn Inspect and replace (see chapter 5). Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapter 5).Piston ring/groove clearance excessive Inspect and rep...

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 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 t...

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 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 pr...

FUEL SYSTEM (DFI) 3-37 Self-Diagnosis Service Code Table 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 ...

3-38 FUEL SYSTEM (DFI) Self-Diagnosis Backups 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 V...

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) then Pv = Pl – Pg For example, suppose the following data is obtained: Pg = 8 cmHg (vacuum gauge reading) Pl = 70 cmHg (barometer reading) Vv = 3.2 V (digital volt meter reading) then Pv = 70 – 8 = 62 cmHg (abs) Plot this Pv (62 cmHg...

3-46 FUEL SYSTEM (DFI) 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 Pv: Throttle Vacuum Pressure (absolute) TO: Throttle Full Open Ps: Standard Atmospheric Pressure (abso- lute) ST: Standard of Sen...

FUEL SYSTEM (DFI) 3-47 Inlet Air Temperature Sensor (Service Code 13) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface.Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal). • Disconnect the connector [A] from the inlet air tempera-t...

3-48 FUEL SYSTEM (DFI) 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...

FUEL SYSTEM (DFI) 3-49 Water Temperature Sensor (Service Code 14) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface.Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal). • Drain the coolant (see Cooling System chapter). • Disconnect ...

3-50 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) A. ECU D. Water Temperature Sensor V. Coolant Temperature Gauge in Tachometer Sensor Resistance Inspection • Remove the water temperature sensor (see this section). • Refer to the Electrical System chapter for water temper-ature senso...

FUEL SYSTEM (DFI) 3-51 Atmospheric Pressure Sensor (Service Code 15) CAUTION Never drop the sensor, especially on a hard surface.Such a shock to the sensor can damage it. NOTE ○ The atmospheric pressure sensor is the same part asthe inlet air pressure sensor except that the inlet airpressure sensor ...

3-52 FUEL SYSTEM (DFI) 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...

FUEL SYSTEM (DFI) 3-53 Atmospheric Pressure Sensor (Service Code 15) Va: Atmospheric Pressure Sensor Output Voltage (v) ST: Standard of Sensor Output Voltage (v) H: Altitude (m or feet) UR: Usable Range of Sensor Output Voltage (v) A. ECUE. Atmospheric Pressure Sensor

3-54 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has atthe time of self-diagnosis. If the engine cannot be started,the self-diagnosis system does not detect dynamic condi-tion of the...

FUEL SYSTEM (DFI) 3-55 Camshaft Position Sensor (Service Code 23) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has atthe time of self-diagnosis. If the engine cannot be started,the self-diagnosis system does not detect dynamic condi-tion...

3-56 FUEL SYSTEM (DFI) 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 ...

FUEL SYSTEM (DFI) 3-57 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 ...

3-58 FUEL SYSTEM (DFI) 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 [B] Installation • The UP mark [A] of the sensor should face upward. T...

FUEL SYSTEM (DFI) 3-61 Subthrottle Sensor (Service Code 32) Subthrottle Sensor Removal/Adjustment CAUTION Do not remove or adjust the subthrottle sensor [A]since it has been adjusted and set with precision atthe factory.Never drop the sensor, especially on a hard surface.Such a shock to the sensor c...

3-62 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Output Voltage Inspection • Remove the throttle body assy (see Throttle Body AssyRemoval). • Measure the output voltage at the subthrottle sensor inthe same way as input voltage inspection. Note the fol-lowing. • Disconnect the subthrottle ...

FUEL SYSTEM (DFI) 3-63 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...

3-66 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [A]since it has been adjusted and set with precisionat the factory.Never drop the actuator , especially on a hard sur-face. Such a shock to the ...

FUEL SYSTEM (DFI) 3-67 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 ...

3-68 FUEL SYSTEM (DFI) FI Indicator LED Light Inspection Flow Chart

FUEL SYSTEM (DFI) 3-69 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) ...

3-70 FUEL SYSTEM (DFI) ECU CAUTION Never drop the ECU, especially on a hard surface.Such a shock to the ECU can damage it. ECU Removal • Remove: Seats (see Frame chapter)Junction Box [A] • Take the ECU [A] out along with the harness. • Disconnect the ECU lead connectors [B]. ECU Installation • Conne...

FUEL SYSTEM (DFI) 3-71 ECU • With the ECU connectors [A] connected, check the fol-lowing ground lead for continuity with the ignition switchOFF, using a tester and needle adapter set. ECU Grounding Inspection 26, 50, or 51 (BK/Y)Terminal ←→ Battery (–) Terminal: 0 Ω Engine Ground ←→ Battery (–) Term...

3-72 FUEL SYSTEM (DFI) ECU ECU Power Source Circuit A. ECUS. ECU Main Relay T. Ignition Switch a. ECU Fuse 15 Ad. Starter Relaye. Joint Connector C f. Sealed Battery j. Joint Connector B k. Main Fuse 30 A

FUEL SYSTEM (DFI) 3-73 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...

3-74 FUEL SYSTEM (DFI) 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...

FUEL SYSTEM (DFI) 3-75 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 ...

3-76 FUEL SYSTEM (DFI) Fuel Line • Open the fuel tank cap [A] to lower the pressure in thetank. • 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] WARNING Be pr...

FUEL SYSTEM (DFI) 3-77 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...

3-78 FUEL SYSTEM (DFI) 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...

FUEL SYSTEM (DFI) 3-79 Fuel Pump • Connect the hand tester (25 V DC) to the fuel pump con-nector [A] with needle adapter set. Special Tools - Hand Tester: 57001–1394 Needle Adapter Set: 57001–1457 ○ Measure the operating voltage with the engine stopped,and with the connector joined. • Turn the ignit...

3-80 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Relay Removal CAUTION Never drop the relay, especially on a hard surface.Such a shock to the relay can damage it. • Remove the seat cover (see Frame chapter). • Remove the fuel pump relay [A] from the tongue of thestorage compartment. • Disconnect the conne...

FUEL SYSTEM (DFI) 3-81 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...

FUEL SYSTEM (DFI) 3-83 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...

3-84 FUEL SYSTEM (DFI) 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]. Special Tool - Hand Tester...

FUEL SYSTEM (DFI) 3-85 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...

3-86 FUEL SYSTEM (DFI) 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

FUEL SYSTEM (DFI) 3-87 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...

3-88 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main-tenance chapter. Engine Vacuum Synchronization Inspection/ Adjustment • Refer to the Engine Vacuum Synchronization Inspectionin the Periodic Maintenance chapter. High Altitude Pe...

FUEL SYSTEM (DFI) 3-89 Throttle Body Assy • Loosen: Throttle Assy Holder Clamp Bolts [A]Air Cleaner Duct Clamp Bolts [B] • Remove: Right and Left Side Covers (see Frame chapter)Coolant Reserve Tank (see Cooling System in the Peri-odic Maintenance chapter)Crankcase Breather HoseRight and Left Air Cle...

3-90 FUEL SYSTEM (DFI) 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] • After removing the throttle...

FUEL SYSTEM (DFI) 3-91 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. • Fit the projection [A] of the right switch housing into thehole [B] of the handlebar. • Turn the throttle grip and make sure that...

3-92 FUEL SYSTEM (DFI) 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 the injectors along with the delivery pipe [A].If necessary, remove the injectors from the delivery pipe.Replace the O-rigs of the indicato...

FUEL SYSTEM (DFI) 3-93 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 ...

3-94 FUEL SYSTEM (DFI) 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...

FUEL SYSTEM (DFI) 3-95 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. WARNING Be prepared for fuel spillage; any spilled fuel mustbe completely wiped up im...

3-96 FUEL SYSTEM (DFI) Fuel Tank • Insert the pump outlet hose joint [A] straight onto the de-livery pipe [B] until the hose joint clicks [C]. Front [D] • Push and pull [A] the hose joint [B] back and forth morethan two times and make sure it is locked and doesn’tcome off. When the hose joint is cor...

COOLING SYSTEM 4-1 4 Cooling System Table of Contents Exploded View ........................................................................................................................ 4-2 Coolant Flow Chart ...........................................................................................

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

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

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 the Oil Pump Removal in the Engine LubricationSystem chapter. Water Pump Installation • Refer to the Oil Pump Installation in the Engine Lubrica-tion System chapter. Water Pump Inspection • Check the drainage outlet passage [A] at the bott...

COOLING SYSTEM 4-11 Water Pump • Take the oil seal [A] out of the housing [B] with a hook [C]. Water Pump Housing Assembly CAUTION Do not reuse the mechanical seal and oil seal. • Apply high temperature grease to the oil seal lips [A]. • Press the new oil seal into the housing with a bearingdriver [...

4-12 COOLING SYSTEM Radiator Radiator and Radiator Fan 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 THECONNE...

COOLING SYSTEM 4-13 Radiator Radiator and Radiator Fan Installation • Installation is the reverse of removal. • Install the radiator bracket collars [A] as shown. Rubber Damper [B]30 ∼ 40° [C] Radiator [D]Bracket [E] • Tighten: Torque - Radiator Lower Bolts [F]: 7.0 N·m (0.70 kgf·m, 61 in·lb) Radiat...

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 • Drain the coolant (see Cooling System in the PeriodicMaintenance chapter). • Remove: Fuel Tank (see Fuel System (DFI) chapter)Thermostat Bracket Bolt [A]Ground Lead [B]Water Temperature Sensor Connector [C]Three Water Hoses [D] • Remove the thermos...

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 Hoses 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. • Install the cla...

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 Cooling System in the PeriodicMa...

ENGINE TOP END 5-1 5 Engine Top End Table of Contents Exploded View ................................... 5-2 Specifications .................................... 5-6 Special Tools and Sealant ................. 5-8 Clean Air System ............................... 5-10 Air Suction Valve Removal............

ENGINE TOP END 5-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Coolant drain plug (cylinder) 9.8 1.0 87 in·lb 2 Exhaust pipe manifold holder nuts 17 1.7 12 3 Muffler body clamp bolt 17 1.7 12 4 Muffler body mounting bolt 30 3.0 22 5 Crankshaft sensor cover bolts 11 1.1 95 in·lb 6. &#...

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: Vacuum Switch Valve (see Vacuum Switch Valve Re-moval) • 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] • Gradually ra...

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: Cylinder Head Cover (see Cylinder Head Cover Re-moval)Pickup Coil Cover • Position the crankshaft at #1, 4 piston TDC. TDC mark [A] for #1, 4 PistonsTiming Mark (crankcase halves mating surface) [B] • Remove: Camshaft Chain Tens...

5-16 ENGINE TOP END Camshaft, Camshaft Chain • Position the crankshaft at #1, 4 piston TDC. • Pull the tension side (exhaust side) [A] of the chain tautto install the chain. • Engage the camshaft chain with the camshaft sprocketsso that the timing marks on the sprockets are positionedas shown. ○ The...

ENGINE TOP END 5-17 Camshaft, Camshaft Chain If any clearance exceeds the service limit, measure thediameter of each camshaft journal with a micrometer. Camshaft Journal Diameter Standard: 23.950 ∼ 23.972 mm (0.9429 ∼ 0.9438 in.) Service Limit: 23.92 mm (0.942 in.) If the camshaft journal diameter i...

5-18 ENGINE TOP END 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 Owner’s Tool - Spark Plug Wrench, 1...

ENGINE TOP END 5-19 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...

5-20 ENGINE TOP END Cylinder Head • Install: Front Camshaft Chain Guide [A]O-ring [B]Collar [C] • Tighten: Torque - Front Camshaft Chain Guide Bolt (Upper) [D]: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Camshaft Chain Guide Bolt (Lower) [E]: 12 N·m (1.2 kgf·m, 104 in·lb) • Install the removed parts (see ap...

ENGINE TOP END 5-21 Valves Valve Clearance Inspection • Refer to the Engine Top End in the Periodic Maintenancechapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the valve lifter and shim. ○ Mark and record the valve lifter and shim locations so theycan be instal...

5-22 ENGINE TOP END 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 the ...

ENGINE TOP END 5-23 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...

5-24 ENGINE TOP END Valves Seat Cutter Operation Care: 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for 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...

ENGINE TOP END 5-25 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...

5-26 ENGINE TOP END 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, ...

5-28 ENGINE TOP END Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal)Water Hose [A] • Remove the cylinder [B]. Cylinder Installation NOTE ○ If a new cylinder is used, use new piston ring. • Install the dowel pins [A] and new cylinder gasket [B]. • Apply engine oi...

ENGINE TOP END 5-29 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...

5-30 ENGINE TOP END Cylinder, Pistons NOTE ○ If a new piston is used, use new piston ring. • Install the piston with its marking 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. ...

ENGINE TOP END 5-31 Cylinder, Pistons Piston Ring, Piston Ring Groove Wear • Check for uneven groove wear by inspecting the ring seat-ing.The rings should fit perfectly parallel to groove surfaces.If not, replace the piston and all the piston rings. • With the piston rings in their grooves, make sev...

5-32 ENGINE TOP END Cylinder, Pistons Piston Ring End Gap • Place the piston ring [A] inside the cylinder, using the pis-ton to locate the ring squarely in place. Set it close to thebottom of the cylinder, where cylinder wear is low. • Measure the gap [B] between the ends of the ring with athickness...

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]: 13 N·m (1.3 kgf·m, 113 in·lb) Throttle B...

5-34 ENGINE TOP END Muffler WARNING To avoid a serious burn, do not remove the mufflerwhen the engine is still hot. Wait until the mufflercool down. Muffler Body Removal • Remove: Muffler Body Clamp Bolt [A]Muffler Body Mounting Bolt [B] • Pull the muffler body backward. Exhaust Pipe Removal • Remov...

ENGINE TOP END 5-35 Muffler ○ Install the muffler body clamp bolt as shown. Upper Side [H]Outside [I] • 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 37.7 ∼ 38.3 mm (1.48 ∼ 1.51 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...

CLUTCH 6-5 Special Tool and Sealant Clutch Holder:57001–1243 Kawasaki Bond (Silicone Sealant):56019–120

6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment • Refer to the Clutch in the Periodic Maintenance chapter. Cable Removal • Slide the dust cover [A] at the clutch cable lower end outof pla...

CLUTCH 6-7 Clutch Lever and Cable Clutch Lever Adjustment The adjuster has 5 positions so that the clutch lever posi- tion 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 holder. ○ The distance fr...

6-8 CLUTCH Clutch Cover Clutch Cover Removal • Remove: Engine Oil (drain, see Engine Lubrication System in thePeriodic Maintenance chapter)Clutch Cable Lower End [A]Clutch Cover Mounting Bolts [B] • Turn the release lever [A] toward the rear as shown, andremove the clutch cover [B]. About 90° [C] Cl...

CLUTCH 6-9 Clutch Cover • Fit the spring [A] as shown. Viewed from Rear [B]Release Shaft [C]Clutch Cover [D] Clutch Cover Disassembly • Remove: Oil Seal [A]Needle Bearings • Remove: Circlip [A]Oil Level Gauge [B] Clutch Cover Assembly • Replace the needle bearings and oil seal with new ones. NOTE ○ ...

6-10 CLUTCH Clutch Clutch Removal • Remove: Engine Oil (drain, see Engine Lubrication System 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], spring and washer) • Remove: Frictio...

CLUTCH 6-11 Clutch ○ Install the spacer [A] so that the tapered side [B] facesinward. ○ Install the washer [A] so that the OUTSIDE 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 - C...

6-12 CLUTCH Clutch • Apply molybdenum disulfide grease to the pusher ends[A] and install the bearing [B], pusher [C], spring [D] andwasher [E] in the clutch spring plate [F]. ○ Apply engine oil to the needle bearing. • Install the clutch spring plate, springs and spring holders,and tighten the clutc...

CLUTCH 6-13 Clutch Clutch Plate, Wear, Damage Inspection • Visually inspect the friction and steel plates for signs ofseizure, overheating (discoloration), or uneven wear. • Measure the thickness of each friction plate [A] at severalpoints.If any plates show signs of damage, or if they have wornpast...

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 oil drain bolt 20 2.0 14 3 Oil filter 31 3.2 23 EO, R 4 Holder mounting bolt 76 7.8 56 EO 5 Oil pan bolts 11 1.1 95 in·lb 6 Oil pipe holder bolts 13 1.3 113 in·lb L 7 ...

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 Pressure Switch8. Oil Pipe9. Oil Pump 10. To Drive Shaft 11. Oil Pipe 12. To Output...

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 Oil Filter Wrench:57001–1249 Kawasaki Bond (Silicone Sealant):56019–120

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 Engine Lubrication System in thePeriodic Maintenance chapter)Exhaust Pipe Assy and Muffler Body (see Engine TopEnd chapter)Oil Pan Bolts [A]Oil Pan [B] Oil Pan Installation • Clean the oil screen [A]. • Install th...

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 Cooling System in the Periodic Mainte-nance chapter)Engine Oil (see Engine Lubrication System in the Peri-odic Maintenance chapter) • Remove: Water Pipe Bolts [A]Water Pipes [B] • Remove: Water Pump Cover Bolts [A]Clamp [...

7-12 ENGINE LUBRICATION SYSTEM Oil Pump • Install: Pins [A]Water Pump Body [B] • Install: Impeller [A], Washer and Bolt [B] • Tighten: Torque - Water Pump Impeller Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install: Pins [C]Water Pump Cover and Bolts Torque - Water Pump Cover Bolts: 11 N·m (1.1 kgf·m, 95...

ENGINE LUBRICATION SYSTEM 7-13 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...

7-14 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal • Remove: Engine Oil (drain, see Engine Lubrication System in thePeriodic Maintenance chapter)Switch Cover [A]Switch Terminal [B]Oil Pressure Switch [C] Oil Pressure Switch Installation • Apply silicone sealant to the thr...

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

8-4 ENGINE REMOVAL/INSTALLATION Special Tool Engine Mount Nut Wrench:57001–1450

ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal • Support the rear part of the swingarm with a stand. • 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 couldcaus...

ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Remove the middle and lower engine mounting nuts [A]and bolts. • Remove: Rear Engine Bracket Bolts [B]Rear Engine Bracket [C] • Using the nut wrench [A], loosen the locknut [B]. Special Tool - Engine Mount Nut Wrench: 57001–1450 • Using t...

ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation ○ Tenth, temporarily install: Front Engine Bracket [C]Right Upper Engine Mounting Bolt [A]Front Engine Bracket Bolts [B] ○ Eleventh, tighten the right upper engine mounting bolt. ○ Lastly, tighten the front engine bracket bolts. Torque - Ri...

CRANKSHAFT/TRANSMISSION 9-1 9 Crankshaft/Transmission Table of Contents Exploded View ................................... 9-2 Specifications .................................... 9-6 Special Tools and Sealant ................. 9-9 Crankcase Splitting............................ 9-10 Crankcase Splitti...

9-8 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Shift fork guide pin diameter 6.9 ∼ 7.0 mm 6.8 mm (0.272 ∼ 0.276 in.) (0.268 in.) Shift drum groove width 7.05 ∼ 7.20 mm 7.3 mm (0.278 ∼ 0.283 in.) (0.287 in.)

9-10 CRANKSHAFT/TRANSMISSION 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 Clutc...

CRANKSHAFT/TRANSMISSION 9-11 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 -...

9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Apply liquid gasket [A] to the mating surface of the lowercrankcase half. Sealant - Kawasaki Bond (Silicone Sealant): 92104–1066 CAUTION Do not apply liquid gasket around the crankshaftmain bearing inserts, and oil passage holes. • Fit the lower cra...

CRANKSHAFT/TRANSMISSION 9-13 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 ...

9-14 CRANKSHAFT/TRANSMISSION 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...

CRANKSHAFT/TRANSMISSION 9-15 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...

9-16 CRANKSHAFT/TRANSMISSION 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...

CRANKSHAFT/TRANSMISSION 9-17 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...

9-18 CRANKSHAFT/TRANSMISSION 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...

CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods • Measure the connecting rod big end inside diameter, andmark each connecting rod big end in accordance with theinside diameter. • Tighten the connecting rod big end nuts to the specifiedtorque (see Connecting Rod Installation). NOTE ○ The ...

9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Runout • Measure the crankshaft runout.If the measurement exceeds the service limit, replace thecrankshaft. Crankshaft Runout Standard: TIR 0.02 mm (0.0008 in.) or less Service Limit: TIR 0.05 mm (0.0020 in.) Crankshaft Main Bear...

CRANKSHAFT/TRANSMISSION 9-21 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...

9-22 CRANKSHAFT/TRANSMISSION Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal and Installation inthe Electrical System chapter. Starter Motor Clutch Inspection • Remove: Alternator Cover (see Electrical System chapter)Starter Idle Gear • Turn the...

CRANKSHAFT/TRANSMISSION 9-23 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]Footpeg Bracket [B] • Remove the bolt [A...

9-24 CRANKSHAFT/TRANSMISSION Transmission • Install the footpeg bracket [A]. • Tighten: Torque - Footpeg Bracket Bolts [B]: 34 N·m (3.5 kgf·m, 25 ft·lb) • Install the shift lever [A], aligning the mark (previouslymarked). • Tighten: Torque - Shift Lever Bolt: 6.9 N·m (0.70 kgf·m, 61 in·lb) • Install...

CRANKSHAFT/TRANSMISSION 9-25 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...

9-26 CRANKSHAFT/TRANSMISSION 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...

CRANKSHAFT/TRANSMISSION 9-27 Transmission • Remove the ball bearing [A] from each shafts. Special Tools - Bearing Puller: 57001–135 [B] Bearing Puller Adapter: 57001–317 [C] • Discard the bearing. Transmission Shaft Assembly • Apply engine oil to the bushings, ball bearings and shafts. • Install the...

9-30 CRANKSHAFT/TRANSMISSION Transmission Shift Drum and Fork Removal • Remove: Lower Crankcase Half (see Crankcase Splitting)Transmission ShaftsExternal Shift Mechanism (see External Shift Mecha-nism Removal)Bolt [A] and Screw [B]Shift Drum Bearing Holder [C] • Pull out the shift rods [D], and take...

CRANKSHAFT/TRANSMISSION 9-31 Transmission Shift Fork Bending • Visually inspect the shift forks, and replace any fork that isbent. A bent fork could cause difficulty in shifting, or allowthe transmission to jump out of gear when under power. 90° [A] Shift Fork/Gear Groove Wear • Measure the thicknes...

WHEELS/TIRES 10-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Front axle clamp bolt 34 3.5 25 2 Front axle 108 11 80 3 Rear axle nut 108 11 80 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/ TIR 0.05 mm (0.0020 in.) or less TIR 0.2 mm 100 mm (3.94 in.) (0.008 in.) Wheel balance 10 g (0.35 oz.) or less – – – Balance we...

10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Brake Caliper Mounting Bolts [A] • Loosen the front axle clamp bolt [A]. • Remove the front 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 ...

WHEELS/TIRES 10-7 Wheels (Rims) • Tighten the front axle. Torque - Front Axle: 108 N·m (11 kgf·m, 80 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 fr...

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. 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 brake...

10-10 WHEELS/TIRES Wheels (Rims) Axle Inspection • Remove the front and rear axles. • 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 pointhalf...

WHEELS/TIRES 10-11 Wheels (Rims) CAUTION When removing the balance weight, do not touchthe brake disc. The disc could be damaged.Do not tap the screwdrivers. The rim could be dam-aged. Balance Weight Installation • Check if the weight portion has any play on the clip.If it does, discard it. WARNING ...

10-12 WHEELS/TIRES Tires Air Pressure Inspection • Refer to the Air Pressure Inspection in the Periodic Main-tenance chapter. Tire Inspection • Refer to the Tire Wear Inspection in the Periodic Mainte-nance chapter. Tire Removal • Remove: Wheel (see Front Wheel Removal, Rear Wheel Re-moval)Disc(s)Va...

WHEELS/TIRES 10-13 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...

10-14 WHEELS/TIRES 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 ...

WHEELS/TIRES 10-15 Hub Bearing Hub Bearing Removal • Remove the wheel, and take out the following. CollarsCoupling (out of rear hub)Grease SealsCirclip • 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 wa...

FINAL DRIVE 11-1 11 Final Drive Table of Contents Exploded View ........................................................................................................................ 11-2 Specifications ..................................................................................................

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. Drive Chain Wear Inspection • Refer to the Drive Chai...

FINAL DRIVE 11-7 Drive Chain Drive Chain Replacement • Remove: Chain Cover (see Drive Chain Removal)Engine Sprocket Cover (see Engine Sprocket Removal) EK JOINT TOOL #50Body [A]Handlebar [B]Cutting & Riveting Pin [C]For Cutting [D]For Riveting [E]Plate Holder (A) [F]Plate Holder (B) [G]Gauge [H]...

11-8 FINAL DRIVE Drive Chain • Replace the link pin, link plate and grease seals. • Apply grease to the link pins [A] and grease seals [B] [C]. • Engage the drive chain on the engine and rear sprockets. • Insert the link pins in the drive chain ends. • Install the grease seals [C]. • Install the lin...

FINAL DRIVE 11-9 Drive Chain • Turn pin holder until riveting pin touches link pin. • 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] ...

11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove: Speed Sensor Connector [A]Engine Sprocket Cover Bolts [B]Engine Sprocket Cover [C] with Speed Sensor • 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 t...

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). Worn Tooth (Engine Sprocket) [A]Worn To...

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. • Unscrew the banjo bolt and remove the brake hoses [D]from the caliper (see Brake Hose Remova...

12-10 BRAKES Calipers Front Caliper Disassembly • Remove: Front Caliper (see Caliper Removal)Brake Pads and Springs (see Brake Pad Removal) • Using compressed air, remove the pistons. ○ Cover the piston area with a clean, thick cloth [A]. ○ Blow compressed air [B] into the hole for the banjo bolt to...

BRAKES 12-11 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. •...

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

BRAKES 12-13 Calipers Caliper Piston and Cylinder Damage • Visually inspect the piston [E] and cylinder surfaces.Replace the caliper if the cylinder and piston are badlyscores or rusty. Fluid Seal [A]Dust Seal [B]Rubber Boot [C]Front Caliper [J]Rear Caliper [K] Caliper Holder Shaft Wear The caliper ...

12-14 BRAKES Brake Pads Front Brake Pad Removal • Remove the caliper from the disc. • Draw out the holder shaft pin [A], and take off the holdershaft [B]. • Remove the pad [C] on the piston side. • Push the holder [D] towards the piston, and remove thepad of the other side [E] from the holder shaft ...

BRAKES 12-15 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). • Unscrew the clamp bolts [A], and take off the master cyl...

12-16 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 12-17 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...

12-18 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 12-19 Brake Fluid Brake Fluid Level Inspection • Refer to the Brakes in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brakes in the Periodic Maintenance chapter. Brake Line Bleeding • Refer to the Brakes in the Periodic Maintenance chapter.

12-20 BRAKES Brake Hose Brake Hose Removal/Installation CAUTION Brake fluid quickly ruins painted or plastic 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 13-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Front fork clamp bolts (Upper) 20 2.0 14 2 Front fork clamp bolts (Lower) 20 2.0 14 AL 3 Front fork top plugs 25 2.5 18 4 Front fork bottom Allen bolts 30 3.1 22 L 5 Front axle clamp bolt 34 3.5 25 6. Right fork leg7. Left f...

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 108 11 80 3 Swingarm pivot shaft locknut 98 10 72 4 Rocker arm nut 34 3.5 25 5 Tie-rod bolts 59 6.0 43

13-8 SUSPENSION Front Fork Front Fork Removal • Remove: Front Wheel (see Tires/Wheels chapter)Front Fender (see Frame chapter)Fairing (see Frame chapter) Loosen the handlebar bolt, upper fork clamp bolt and forktop plug before-hand if the fork leg is to be disassembled. NOTE ○ Loosen the top plug af...

SUSPENSION 13-9 Front Fork • Hold the outer tube vertically in a vise and compress thefork completely. • Wait until the oil level stabilizes. • Use the fork oil level gauge [A] to measure the distancebetween the top of the inner tube to the oil level. Special Tool - Fork Oil Level Gauge: 57001–1290 ...

13-10 SUSPENSION Front Fork • Remove the cylinder unit [A], washer, and the spring [B]from the inner tube. • Remove the following from the top of the outer tube: Dust Seal [A]Retaining Ring [B] • Separate the inner tube [A] from the outer tube [B]. NOTE ○ From the compressed state, firmly pull down ...

SUSPENSION 13-11 Front Fork Front Fork Assembly • Check the top plug O-ring and replace it with a new one. • Replace the following parts with new ones: Retaining Ring [A]Dust Seal [B]Oil Seal [C]Inner Guide Bushing [D]Outer Guide Bushing [E]Fork Bottom Allen Bolt Gasket [F] • Install the guide bushi...

13-12 SUSPENSION Front Fork Inner Tube/Outer Tube Inspection • Visually inspect the inner tube [A] and repair any nicks orrust by using an oil stone.If the damage is not repairable, replace the inner tube.Since damage to the inner tube damages the oil seal slip,replace the oil seal whenever the inne...

SUSPENSION 13-13 Rear Shock Absorber Rebound Damping Force Adjustment • Turn the damper adjuster [A] to adjust the rebound damp-ing. ○ Align the numbered mark [B] of the adjuster. ○ The standard adjuster setting for average-build rider of68 kg (150 Ib) with no passenger and no accessories isposition...

13-14 SUSPENSION Rear Shock Absorber • Remove: Lower Shock Absorber Nut [A]Lower Shock Absorber Bolt [B] • Remove: Upper Shock Absorber Nut [A]Upper Shock Absorber Bolt [B] • Remove the shock absorber [A] from upside. Rear Shock Absorber Installation • Tighten: Torque - Rear Shock Absorber Nuts: 34 ...

SUSPENSION 13-15 Swingarm Swingarm Removal • Raise the rear wheel off the ground with jack. Special Tool - Jack: 57001–1238 • Remove: Chain Cover (see Final Drive chapter)Mud Guard (see Frame chapter)Brake Hose Clamp [A]Rear Wheel (see Wheels/Tires chapter) Lower Shock Absorber Nut and Bolt [A]Upper...

13-16 SUSPENSION Swingarm Swingarm Installation ○ Place the collar [A] on the stopper [B] inside the frame [C]. • Insert the pivot shaft into the frame from the right side. • Tighten the pivot shaft so that the clearance [D] betweenthe collar and the frame come to zero mm. • Tighten: Torque - Swinga...

SUSPENSION 13-17 Swingarm Swingarm Bearing Installation • Install the needle bearings so that the manufacturer’smarks face in. • Install the ball bearing so that the manufacturer’s marksfaces out. Special Tool - Bearing Driver Set: 57001–1129 [A] Swingarm Bearing, Sleeve Inspection CAUTION Do not re...

13-18 SUSPENSION Tie-rod, Rocker Arm Tie-rod Removal • 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[A]. • Remove: Lower Rear Shock Absorber Bolt and Nut [A]Up...

STEERING 14-5 Steering Steering Inspection • Refer to the Steering in the Periodic Maintenance chapter. Steering Adjustment • Refer to the Steering in the Periodic Maintenance chapter.

14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Inner Cover (see Frame chapter)Fairing and Bracket (see Frame chapter)Front Wheel (see Wheels/Tires chapter)Handlebar (see Handlebar Removal)Steering Stem Head Bolt PlugSteering Stem Head Bolt [A] and WasherFront Fork Clamp Bolts (Lowe...

STEERING 14-7 Steering Stem Stem, Stem Bearing Installation • Replace the bearing outer races with new ones. • Apply grease to the outer races, and drive them into thehead pipe at the same time. Special Tool - Bearing Driver Set: 57001–1129 [A] • Replace the bearing inner races and oil seal with new...

14-8 STEERING Steering Stem • Install the claw washer [A] so that its bent side [B] facesupward, and engage the bent claws with the grooves ofstem locknut [C]. • Hand tighten the stem locknut until it touches the clawwasher. • Tighten the stem locknut clockwise until the claws arealigned with the gr...

STEERING 14-9 Handlebar Handlebar Removal • Remove: Handlebar Holder PlugsClutch Lever Assembly [A]Left Handlebar Switch Housing [B]Front Brake Master Cylinder [C]Right Handlebar Switch Housing [D]Handlebar Holder Bolts [E] • Remove the handlebar holder [F] and then pull out thehandlebar. • Remove t...

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 bracket bolts 34 3.5 25 L 2 Side stand bracket bolts 49 5.0 36 3 Side stand bolt 44 4.5 33 4 Side stand switch bolt 8.8 0.90 78 in·lb G: Apply grease. L: Apply a non-permanent locking agent.

FRAME 15-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Front fender bracket bolts 8.8 0.90 78 in·lb L 2 Front fender bolts 3.9 0.40 35 in·lb

FRAME 15-7 Seats Rear Seat Removal • Insert the ignition switch key into the seat lock [A], turningthe key clockwise, pulling up on the rear of the seat [B],and pulling the seat backward. Rear Seat Installation • Slip the rear seat hooks [A] into the hollow-cubic bracket[B] on the frame. • Insert th...

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 Inner Cover Removal • Remove: Inner Cover Screws [A] and WashersInner Cover [B] Inner Cover Installation • Fit the projection [A] on the inner cover [B] into the hole[C] in the fairing. • Install the washers and inner cover screws. Fairing Removal • Remove: Fairing Mounting Bolts...

15-10 FRAME 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 ...

FRAME 15-11 Mud Guard Mud Guard Removal • Remove: Chain Cover (see Final Drive chapter)Bolt [A]Clamp [B] • Lift up the mud guard [A], and then pull it out backward. Mud Guard Installation • Put the projections [A] into the grommets [B].

15-12 FRAME Fenders Front Fender Removal • Remove: Front Wheel (see Wheels/Tires chapter)Brake Hose ClampsFront Reflector Bolts [A]Bolts [B] (both side) • Remove the front fender [C]. Front Fender Installation • Apply a non-permanent locking agent to the threads ofthe bracket bolts. • Tighten: Torqu...

FRAME 15-13 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.

15-14 FRAME Frame Cover Frame Cover Removal • Remove: Bolts [A]Frame Cover [B] (both side)

FRAME 15-15 Battery Case Battery Case Removal • Remove: SeatsSeat CoverRear Fender AssySide CoversBatteryReserver Tank Screws • Pull out the battery case [A] backward. Battery Case Installation • Put the battery case attachments [A] at the projections [B]on the frame.

15-16 FRAME Side Stand Side Stand Removal • Raise the rear wheel off the ground with the stand. • Remove: Side Stand Switch Bolt [A]Side Stand Switch [B]Spring [C] Side Stand Nut [D]Side Stand Bolt [E]Side Stand [F] Side Stand Installation • Apply grease to the sliding area [B] of the side stand [A]...

FRAME 15-17 Rear View Mirrors 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 ...

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 ......................................................................................

16-2 ELECTRICAL SYSTEM Spark Plug Installation ...................................................................................................... 16-44 Spark Plug Inspection ....................................................................................................... 16-44 Spark Plug G...

ELECTRICAL SYSTEM 16-3 Parts Location 1. Starter Lockout Switch2. Camshaft Position Sen- sor 3. Radiator Fan Switch4. Starter Motor5. Alternator6. Speed Sensor7. Neutral Switch8. Side Stand Switch 9. Water Temperature Sen- sor 10. Battery 11. Junction Box 12. Front Brake Light Switch13. Stick Coils1...

ELECTRICAL SYSTEM 16-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Meter mounting screws 1.2 0.12 10 in·lb 2 Tail/brake light mounting screws 1.2 0.12 10 in·lb 3 License plate light mounting screws 1.2 0.12 10 in·lb 4 Front brake light switch screw 1.0 0.10 9 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 1.3 113 in·lb 3 Alternator lead holding plate bolt 11 1.1 95 in·lb L 4 Starter motor mounting bolts 11 1.1 95 in·lb 5 Stator coil bolts 11 1.1 95 in·lb 6 Alternat...

ELECTRICAL SYSTEM 16-9 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Regulator/rectifier bolts 6.9 0.70 61 in·lb 2 Fuel level sensor bolts 6.9 0.70 61 in·lb 3 Side stand switch bolt 8.8 0.90 78 in·lb L 4 Neutral switch 15 1.5 11 5 Speed sensor bolt 6.9 0.70 61 in·lb L 6 Speed sensor co...

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 cap [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 seat capto add water is very dangerous. Never do that. 2) Refreshing charge If an engine will not start, a horn sounds weak...

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

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: Left Frame Cover (see Frame chapter)Clamp (open) [A]Alternator Lead Connector [B] • Place a suitable container under the alternator cover [A],and remove the cover bolts [B]. • Pull the alternator cover outside. Alternator Cov...

16-30 ELECTRICAL SYSTEM Charging System Stator Coil Installation • Apply a non-permanent locking agent to the threads ofthe stator coil bolts and tighten them. 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 n...

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 30 A8. 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 (0.60 kgf·m, 52 in·lb) • Apply silicone sealant [A] to the crankshaft senso...

ELECTRICAL SYSTEM 16-39 Ignition System Crankshaft Sensor Inspection • Remove: Right Frame Cover (see Frame chapter)Crankshaft Sensor Lead Connector [A] • Set the hand tester to the × 100 Ω range and connect (+) lead to the yellow/black lead and (–) lead to the black leadin the connector. Special To...

16-40 ELECTRICAL SYSTEM Ignition System Timing Rotor Removal • Remove the crankshaft sensor cover (see CrankshaftSensor Removal) • Remove the timing rotor [A]. ○ Holding the timing rotor with the flywheel & pulley holder[B] and remove the bolt [C]. Special Tool - Flywheel & Pulley Holder : 5...

16-42 ELECTRICAL SYSTEM Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Removal • Remove the fuel tank (see Fuel System (DFI) chapter). • Remove the thermostat bracket bolt [A]. • Disconnect: Water Temperature Sensor Connector [B]Left Switch Housing Connector [C] ○ If removin...

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 10 A13. S...

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. • Slide back the rubber cap [A]. • Remove the starter motor terminal nut [B]. • Remove the mounting bolts [A]. • Pull out the sta...

16-50 ELECTRICAL SYSTEM Electric Starter System ○ The brush plate [A] and brushes come off with the right-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 ...

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 • Fit the projection [A] of the bulb in the hollow [B] of theheadlight. • Install the hook [C]. • 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 (...

16-56 ELECTRICAL SYSTEM Lighting System City Light Bulb Replacement (European Model) • Remove the fairing (see Frame chapter). • Pull out the socket [A] together with the bulb. • Pull the bulb [A] out of the socket. CAUTION Do not turn the bulb. Pull the bulb out to preventdamage to the bulb. Do not...

ELECTRICAL SYSTEM 16-57 Lighting System Headlight/Tail Light Circuit (CA, AS) Headlight/Tail Light Circuit (Other than CA, AS) AS: Australia CA: Canada 1. Ignition Switch2. Meter Ground3. Alternator4. Headlight Diodes5. Taillight Fuse 10 A6. Headlight Fuse 10 A7. Junction Box 8. High Beam Indicator ...

16-58 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit CA: Canada model MY: Malaysia model 1. Joint Connector D2. Meter Unit3. Right Turn Signal Indica- tor Light (LED) 4. Left Turn Signal Indicator Light (LED) 5. Front Right Turn Signal Light 6. Front Left Turn Signal Light 7. Joint Conn...

ELECTRICAL SYSTEM 16-59 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°. For the Canadian Model: • U...

16-60 ELECTRICAL SYSTEM 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. Turn Signal Relay Inspection • Remove: Seats (see Frame chapter)Upper Seat Cover (see Frame chapter)Turn Signal Re...

ELECTRICAL SYSTEM 16-61 Lighting System • Unscrew the bolts [A]. • 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/Brake Light Mounting Screws...

16-62 ELECTRICAL SYSTEM 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....

ELECTRICAL SYSTEM 16-63 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 15 A 10. Main Fuse 30 A 11. Battery 12 V 8 Ah

16-64 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Unit Removal • Remove: Fairing (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 fac...

ELECTRICAL SYSTEM 16-65 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...

16-66 ELECTRICAL SYSTEM 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...

16-68 ELECTRICAL SYSTEM 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...

ELECTRICAL SYSTEM 16-69 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...

16-70 ELECTRICAL SYSTEM 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...

ELECTRICAL SYSTEM 16-71 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...

16-72 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Right and Left Turn Signal Indicator Light (LED): For Right Turn Signal Indicator Light (LED)Battery Positive (+) Terminal to Terminal [13] For Left Turn Signal Indicator Light (LED)Battery Positive (+) Terminal to Terminal [14] High Beam Indicato...

ELECTRICAL SYSTEM 16-73 Meter, Gauge, Indicator Unit Meter Circuit 1. Right Turn Signal Indica- tor Light (LED) 2. High Beam Indicator Light (LED) 3. Neutral Indicator Light (LED) 4. Oil Pressure Warning In- dicator Light (LED) 5. FI Indicator Light (LED)6. Odometer/Trip Meter/ Clock/Fuel Indicator ...

16-74 ELECTRICAL SYSTEM Switches and Sensors Brake Light Timing Inspection • Refer to the Brakes in the Periodic Maintenance chapter. Brake Light Timing Adjustment • Refer to the Brakes in the Periodic Maintenance chapter. Switch Inspection • Using a hand tester, check to see that only the con-necti...

ELECTRICAL SYSTEM 16-75 Switches and Sensors • Remove the fan switch [A]. • 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 sensitive portions are located in ...

16-76 ELECTRICAL SYSTEM 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...

ELECTRICAL SYSTEM 16-77 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 -...

16-78 ELECTRICAL SYSTEM Switches and Sensors Fuel Level Sensor Inspection • Remove: Fuel Tank (see Fuel System (DFI) chapter) • Open the clamps [A]. • Remove: Bolts [B]Fuel Level Sensor [C] • Check that the float moves up and down smoothly withoutbinding. It should go down under its own weight.If th...

ELECTRICAL SYSTEM 16-79 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...

16-80 ELECTRICAL SYSTEM Junction Box The junction box [A] has fuses [B], relays, and diodes. The relays and diodes can not be removed. Junction Box Fuse Circuit Inspection • Remove the seats (see Frame chapter). • Remove the junction box [A]. • Pull off the connectors [A] from the junction box [B]. ...

ELECTRICAL SYSTEM 16-81 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 ...

16-82 ELECTRICAL SYSTEM 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...

ELECTRICAL SYSTEM 16-83 Fuse 30 A Main Fuse Removal • Remove: Right Side Cover (see Frame chapter)30 A Main Fuse Connector [A] • Pull out the main fuse [B] from the starter relay with needlenose pliers. Junction Box Fuse Removal • Remove the seats (see Frame chapter). • Unlock the hook to lift up th...

16-84 ELECTRICAL SYSTEM Fuse Fuse Inspection • Remove the fuse (see Fuse Removal). • Inspect the fuse element.If it is blown out, replace the fuse. Before replacing ablown fuse, always check the amperage in the affectedcircuit. If the amperage is equal to or greater than thefuse rating, check the wi...

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. Run the tank drain hose under the bracket for the side cover.3. Air cleaner drain hose4. Cooling reserve tank hose (Run the hose inside the under ring.)5. Fuel tank drain hose6. Fixes by the swingarm clamp7. F...

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 ground5. Engine harness6. Water temperature sensor7. Inlet air pressure sensor8. Clamp9. To pickup coil and...

17-18 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...

17-20 APPENDIX Troubleshooting Guide Engine load faulty: Clutch slippingEngine oil level too highEngine oil viscosity too highDrive train troubleBrake dragging Lubrication inadequate: Engine oil level too lowEngine oil poor quality or incorrect Gauge incorrect: Water temperature gauge brokenWater te...

17-22 APPENDIX Troubleshooting Guide Rear shock adjustment too softFront fork, rear shock absorber spring weakRear shock absorber oil leaking Brake Doesn’t Hold: Air in the brake linePad or disc wornBrake fluid leakageDisc warpedContaminated padBrake fluid deterioratedPrimary or secondary cup damage...

MODEL APPLICATION Year Model Beginning Frame No. 2004 ZR750–J1 JKAZRDJ1 □ 4A000001 ZR750J–000001JKAZR750JJA000001 □ :This digit in the frame number changes from one machine to another. Part No.99924-1323-01 Printed in Japan